ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

UNIT-6 MILLING AND GRINDING

Milling is a process of removing excess material from the w/p with a rotating cutting tool called milling cutter. The milling cutter is a multipoint cutting tool with cutting teeth formed on the circumference or on the end face or on the both. With suitable speed and multi cutting edges, material can be removed at a faster rate and also fine surface finish can be produced. Milling process is used for producing flat, contoured or helical surfaces for cutting threads, slots, toothed gears etc. Princi le !" milling: Milling works on the principle, that when a w/p is fed slowly against a multi point cutter, revolving at high speed, material can be removed. s the w/p moves against the tool, each tooth of the cutter removes metal from the surface of the w/p to produce the desired shape.

U Milling !r c!n#enti!n$l milling: !f the w/p is fed in the direction opposite to that of the rotating cutter, the process is called up milling. Clim% milling !r &!'n milling: !f the w/p is fed in the same direction as that of the rotating cutter, it is called down milling or climb milling.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

UP MILLING DO(N MILLING COMPARISON )ET(EEN UP AND DO(N MILLING UP MILLING The w/p is fed in the direction opposite to that of the rotating cutter. Thickness of the chip is minimum at the beginning of the cut and reaches maximum when the cut ends. The cutting force is directed upwards and this tends to lift the w/p from the table. #ence greater clamping force is necessary. $hips get accumulated at the cutting %one .These chips interfere with the revolving cutter, thereby impairing the surface finish. DO(N MILLING The w/p is fed in the same direction as that of the rotating cutter. Thickness of the chip is maximum at the beginning of the cut and reaches to the minimum when the cut ends. The cutting force acts downwards, that keeps the w/p firmly on the table. There by permitting lesser clamping forces. $hips do not interfere with the revolving cutter as they are disposed easily by the cutter .#ence there is no damage to the surface finish.

&ifficult for efficient cooling since the 'fficient cooling can be achieved since the cutter rotates in upward direction carrying coolant can easily reach the cutting %one. away the coolant from the cutting %one. (sed for machining hard surfaces such as (sed for finishing operation and small castings and forging. works. CLASSIFICATION OF M*M ". a. #ori%ontal or plain M.M b.)ertical M.M SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

$olumn and knee type . A!.IT P" e *

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y " c.(niversal M.M *. +ixed bed type M.M ,. -laner Type M.M .. /pecial purpose M.M

HORI+ONTAL M*M The machine consists of ". )$,e- The base forms the foundation of the m/c upon which all the other parts are mounted. *. C!lumn: is a vertical hollow casting that houses main drive and the spindle. ,. .nee: 0nee can slide up and down on the vertical guide ways provided on the front face of the column. 0nee is actuated by means of an elevating screw .0nee supports the saddle. .. S$&&le- supports the work table and can be moved hori%ontally on the guide ways provided on the upper face of the knee. 1. S in&le: is a hollow shaft supported by the column. The spindle obtains the power from the motor and transmits it to the arbor. The arbor carries the cutter and rotates about a hori%ontal axis. 2. (!r/ t$%le: rests on the saddle and can be moved at right angles to the movement of the saddle. The work table is provided with T3slots for holding the w/p. 4. O#er $rm: is mounted on the column, supports the yoke, which in turn supports the free end of the arbor. OPERATION: !n operation, the w/p is raised against the rotating cutter to give the re5uired depth of cut. The table is moved in a hori%ontal plane to give feed to the w/p.#ori%ontal M.M are used to obtain grooves,slots,keyways,gear teeth etc.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

HORI+ONTAL M*M 0ERTICAL M*M The machine consists of ". )$,e- The base forms the foundation of the m/c upon which all the other parts are mounted. *. C!lumn: is a vertical hollow casting that houses main drive and the spindle. ,. .nee: 0nee can slide up and down on the vertical guide ways provided on the front face of the column. 0nee is actuated by means of an elevating screw .0nee supports the saddle. .. S$&&le- supports the work table and can be moved hori%ontally on the guide ways provided on the upper face of the knee. 1. (!r/ t$%le: rests on the saddle and can be moved at right angles to the movement of the saddle. The work table is provided with T3slots for holding the w/p. 2. S in&le: spindle head is fixed to the vertical column. The spindle head may be either fixed, sliding, swivel head type or it may be a combination of the last two. !n sliding type, the spindle can be moved up and down to perform operations like grooving, slotting, facing etc. The swivel head type is used to work on angular surfaces. 6enerally )ertical M.M is used to perform end milling and face milling operations.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

S P IN D L EH E A D

C U T T E R W O R K T A B L E
S A D D L E

V E R T IC A LG U ID E W A Y S

H O R IZ O N T A L G U ID E W A Y S

K N E E

B A S E

0ERTICAL M*M MILLING OPERATIONSPLAIN MILLING OR SLA) MILLING7 !t is performed on #ori%ontal M.M.!t is the operation of producing plain hori%ontal surfaces parallel to the axis of the rotating cutter. -lain or slab milling cutter is used which has straight or helical teeth on the periphery of a cylindrical surface. En& Milling: 'nd milling is used for machining end surfaces, slots, and pockets. $utter used in end milling is '8& M!99 $(TT':. !t has teeth on the bottom face as well as the periphery and may have straight or helical flutes. Sl!t Milling: /lot milling is the operation of producing slots in work pieces. The slots can be of varied shapes such as plain, T3 slots, &ovetail slots etc.The cutter to be used is chosen according to the shape of the slot to be produced. Angul$r milling: is a process used for milling all types of an angular cuts, grooves and similar work. The faces of angular cutters may be the same or each face may be at different angle.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y " F!rm milling: is used to produce curved profiles and also convex, concave and spline etc.They may also be used for cutting gear teeth. Str$&&le milling: is a process in which a pair of side milling cutters is used for machining two parallel surfaces of a work piece simultaneously. Two or more cutters are mounted on an arbor with a distance spacer between them.

T3slot milling /lot milling

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

S eci"ic$ti!n, !" Uni#er,$l Milling m$c1ine Table overall si%e -ower traverse /ped range GRINDING 6rinding is a process of removing e2ce,, !" m$teri$l by the $%r$,i#e $cti!n of a r!t$ting '1eel on the surface of the work piece. !t is basically a "ini,1ing ! er$ti!n employed to produce a work piece of 1ig1 $ccur$c3 $n& ,ur"$ce "ini,1* SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En . A!.IT P" e 4

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

The Wheel used for grinding operation is known as grinding wheel. !t consists of sharp crystals called ;abrasives< that are held together by suitable bonding. Princi le !" Grin&ing 6rinding is a process in which the excess material is removed by the rubbing action of the abrasive particles. The process removes very little material in the form of fine chips when compared to that of drilling or milling process and this makes it to be called a finishing process.

A%r$,i#e,brasives are mineral crystals that act as cutting edges in a grinding wheel. The hardness of the crystals is much higher than that of the workpiece. brasives are of two types. 8atural abrasives rtificial abrasives 8atural abrasives: re available in nature. They include ". &iamond *. 'mery ,. $orundum .. /and stone 1. 6arnet mong

&iamond is a crystalline form of carbon, is the hardest material ever known. sharpening carbide and ceramic tools. /and stone or solid 5uart% is used for sharpening wood working tools.

natural abrasives, diamond is the most commonly used and is used extensively for

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y " 'mery and corundum are natural aluminium oxide and have a greater hardness and better abrasive action than 5uart%. 6arnet sand is a good abrasive, and a common replacement for silica sand in sand blasting. (se of natural abrasives is limited because they contain higher percentage of impurities and posses non > uniform properties.?#ardnss,toughness@. rtificial brasives: These are manufactured abrasives that are fre from impurities and posses properties better than those of natural abrasives. $ubic boron nitride?$A8@ luminium oxide? l*B,@ /ilicon $arbide ?/i$@ Aoron $arbide lso used as a

C)N: is used for grinding iron, steel alloys of iron and similar materials. mineral and a machining insert.

Aluminium !2i&e 4Al5O6@: !t is used for grinding alloy steel carbon steels etc.!t is also useful as refractory in the linings of special furnaces. Silic!n C$r%i&e: is a synthetic abrasive which is harder than aluminium oxide.$aborundum is a type of silicon carbide that is used to grind the surfaces of marble, stones and granite. )!r!n C$r%i&e- use in tool die fabrication, lapping and ultra sonic machining. SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En . A!.IT P" e C

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

)!n&ing M$teri$l,: is an adhesive substance that holds the abrasive particles together to form a grinding wheel. The most commonly used bonding materials are )itrified bond /ilicate bond :esinoid bond :ubber bond /hellac bond

0itri"ie& %!n&: This is the most commonly used bonding material. )itrified bond is made of clay and feldspar .The bond is strong, rigid, porous and not affected by fluids ?water, oil and acids@.6enerally =DE of the wheel is made up of vitrified bond. Silic$te %!n&- !t is made up of sodium silicate. !t is used in operations that generate less heat. /ilicate bonds are not strong as vitrified bonds. Re,in!i& %!n&- is made up of synthetic resin or a plastic that becomes hard after heating. This bond has a good strength and is more elastic than vitrified bond but resistance to heat and chemical action is low.:esinoid bond is the most fre5uently used bond next to vitrified bond. Ru%%er )!n&- is made up of natural or synthetic rubber. :ubber bonded wheels are denser than retinoid bond but are less heat resistant. :ubber bonds are used where a good surface finish with high dimensional accuracy is a primary re5uirement. !t is the most flexible bond. S1ell$c )!n&- This is a organic bond. !t has considerable strength and its elasticity is greater than other types of bond. Aut this bond is not suitable for heavy duty work. $lassification of grinding Machine: ". /urface grinding Machine #ori%ontal spindle 6.M )ertical /pindle 6.M SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En . A!.IT P" e "D

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

*. $ylindrical 6.M ,. $enterless 6 M .. /pecial 6 M 1. !nternal 6 M Sur"$ce grin&ing M$c1ine- / 6 M is mainly used for grinding flat surfaces, angular and irregular surfaces can also be finished. !t consists of a hori%ontal spindle carrying the grinding wheel and a reciprocating work table. The work piece can be directly clamped on the table or by means of a magnetic chuck. !n operation, the rotating grinding wheel is brought in contact with the surface of the work piece removes material in the form of fine grains. :eciprocating table gives the longitudinal feed to the work piece and vertical downward movement of the wheel gives the re5uired depth of cut.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

S PIN D L E r!" # !" w $ e e l ab ra%!& e' art!(le %

W )P

w o rk tab le

C3lin&ric$l Grin&ing M$c1ine is used for grinding external cylindrical surfaces that may be plain, tapered or contoured. !n operation, the cylindrical work piece is made to rotate between the two centers. /eparate motor is used to drive the headstock and the grinding wheel. The work table is made in two parts. The upper table carries the head stock and tailstock and can be swiveled by a small angle that enables to grind taper surfaces. The lower table mounted on the hori%ontal guide ways provides longitudinal movement for the upper table. !n operation, both the grinding wheel and the work piece are made to rotate in opposite direction. s the work piece reciprocates the grinding wheel comes in contact with the cylindrical surface of the workpiece.The abrasive action of the wheel removes material from the work piece in the form of fine chips.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y "

Centerle,, grin&ing- is used for grinding surfaces of work piece that cannot be held and rotated between centers. This process is primarily useful for grinding long, slender shafts or bars. Work piece is supported by the grinding wheel, regulating wheel and a work rest. The grinding operation is performed by the grinding wheel only. The function of the regulating wheel is to support the work piece while in operation. :egulating wheel carries a rubber bond and helps in the rotation of the work piece.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y " Aoth grinding wheel and regulating wheel rotate in the same direction. The work supports the work piece from the bottom.

rest

7ue,ti!n )$n/ ". 'xplain with a neat diagram the principle working of a milling machine. *. What is cylindrical grindingF 'xplain with a neat sketch. ,. What is millingF $lassify the different types of milling machines. SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En . A!.IT P" e ".

ACHARYA INSTITUTE OF TECHNOLOGY

DEPARTMENT AUTOMOBILE ENGINEERING

II SEMESTER ACADEMIC YEAR 2012-13

SUB: ELEMENTS OF MECHANICAL ENGINEERING Sub Code : 10EME24

St !!: SRINI"AS Y " .. 9ist and explain the various operations that can be performed on a milling machine. 1. 8ame the various abrasives and binding materials used in grinding wheel and explain each one of them. 2. 'xplain with a neat sketch working principle of center less grinding process. 4. 'xplain the principle of milling and draw a schematic sketch of a hori%ontal milling machine and label its parts. =. &istinguish between cylindrical grinding and surface grinding. C. 'xplain the following with sketches a@ (p milling b@ down milling c@ face milling "D. 'xplain and draw a schematic sketch of a vertical milling machine and label its parts. "". 'xplain the different types bonding of grinding wheels and the materials used.

SRINIVAS Y V. Asst. Prof. Dept. of AUTO. En

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