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Machining: A subtractive
process used to get desired
shape, size, and finish by
removing surplus material in
the form of chips by a cutting
tool and by providing suitable
relative motion between the
workpiece and cutting tool
Cutting tool: removes excess
material through direct
mechanical contact
M a c h i n e t o o l : p r o v i d e s
necessary relative motion
between the work-piece and
tool
What is it?
Machini Generatrix
ng
(cutting)
Process
Directrix
(feed)
P l a n a r Shapin S t r a i g h t S t r a i g h t
Surface
g
, Line
Line
Planing
Cylindrica Turning Circular
l
Straight
Line
P l a n a r Milling
Surface
Straight
Line
Circular
I. I. T.
Turning
v Step Turning
v Taper Turning
v Form Turning
v Contour Turing
Facing
Necking
Parting-Off
Boring
v Counter-Boring
v C o u n t e r Sinking
Shaping
Planing
Using MULTI-Point
Cutting Tools
Milling
Drilling
Reaming
Knurling
Tapping
Hobbing
Broaching
Sawing
Using ABRASIVES
as Cutting Tools
Grinding
Honing
Lapping
Super-Finishing
Polishing
Buffing
I. I. T.
Tailstock
Bed
Schematic Diagram of an Engine Lathe
MI-102: Manufacturing Techniques
I. I. T.
Carriage
assembly
C a r r i a g e
a s s e m b l y
provides the
means for
mounting and
moving cutting
tools.
C a r r i a g e
a s s e m b l y
consists of
carriage, cross
slide, compound
rest, tool post
I. I. T.
Feed rod
provides
t
h
e
powered
movemen
t of the
carriage
and cross
slide for
automatic
movement
of tool
used in
t u r n i n g Leadscrew
operation for cutting threads, a leadscrew is
used to provide automatic
movement to carriage.
Example: A 14 x
48 Lathe
designates that
the swing is 14
in. and the
maximum
distance
between centers
is 48 in.
Engine lathe,
Speed lathe,
Tool room lathe,
Turret lathe,
Automatic lathe,
Numerical control lathe
Type of
lathes
ENGINE LATHE
Most frequently used in
manufacturing
They are heavy duty
machine tools with all the
components have power
drive for all tool
movements except on
compound rest.
Most engine lathes are
equipped with chip pans
and a built-in coolant
circulating system.
SPEED LATHE
Speed lathes usually
h a v e o n l y a
headstock, a
tailstock, and a
simple tool post
Usually three or four
speeds
Mainly used for wood
turning, polishing,
or metal spinning
Spindle speeds up to
4000 rpm.
MI-102: Manufacturing Techniques
I. I. T.
Turret lathe
RAM TYPE
SADDLE
TYPE
Primary difference is
in mounting and size
of two types.
Ram type is light,
less rigidity and so
for small jobs using
fine cuts
Saddle type heavy,
more rigid, large
jobs and heavy cuts
RAM TYPE
Operation
of
Turning is the process of Machining external
lathe
cylindrical and conical surfaces.
Straight turning: for producing cylindrical shapes
Taper turning: for producing conical shapes
Facing: making edges square and clear
Chamfering: slightly tapering and rounding off of
edges
Threading: for producing threads
Drilling: for creating /producing hole
Boring: for enlarging hope and correcting shape
Parting off or necking: separating or making square
groove
Knurling: making impression for firm gripping
Reaming: finishing purpose
Straight/cylindrical turning
Orthogonal turning
Oblique turning
TAPER TURNING
Cutting tool is fed at an angle to the axis
of rotation producing an external/
internal conical surface.
Tapers generally specified in degrees of
included angle between the sides (or rate
of change in diameter along the length
mm/mm)
FOUR Methods for Taper turning:
Swiveling the Compound Rest: Only for
Short and steep Tapers
Taper turning attachment: for fine taper-ness
less than 0.5mm/mm
Setting over tailstock: low taper in long jobs
NC lathe with programmed both movements of
movement of tool
MI-102: Manufacturing Techniques
I. I. T.
Taper turning
attachment
C r o s s
slide is
made free
and tool
is moved
with help
o
f
attachme
nt at an
angle
Contour turning
The tool follows a contour
creating a contoured form on
the turned part instead of
parallel to the axis. Cross slide
is made free to follow the path
of contour.
FORM TURNING
Cutting edge of Tool has a Specific
Form or Shape and is fed radially
inward towards the axis of rotating
work piece.
FACING
Cutting tool is fed radially inwards
(at 90 w.r.t. the axis of rotation) into
the rotating work piece.
End facing: facing by tool moving
radially outward from the center
Shoulder facing: facing the stepped
cylindrical work piece
Chamfering
The tool is fed radially inward
used to cut an angle on the
corner of the cylinder,
forming a chamfer to avoid
sharp edges.
Parting off & necking
Tool is fed perpendicular to
the rotational axis
Necking is a making partial
cutoff
MI-102: Manufacturing Techniques
I. I. T.
DRILLING
The tool (Drill) mounted on the
tailstock of the engine lathes
is fed by hand against a
rotating work piece along the
axis of lathe.
BORING
Tool mounted to tailstock is
fed parallel to the lathe axis
after giving suitable depth of
cut
I. I. T.
REAMING
I t i s s e m i - f i n i s h i n g
operation that enlarges
an existing hole. Tool is
rotated and fed along
rotational axis.
knurling
Roughening the surface of work
piece for better gripping.
No machining operation only coldforming takes place
Process involves pressing of
two hardened rolls against the
rotating work piece with sufficient
force to form impression (the knurl)
like raised diamond pattern.
Work holding
devices
Mandrel
Mandrel:
holding hollow
shape w/p
machining of
faces
for
disc
for
side
Collet
tool steels
high speed steel (hss)
cemented carbides
coated carbides
ceramics
cermets (ceramic material in a metallic binder)
polycrystalline diamond (pcd) and (CBN)
I. I. T.
Geometry of
single point
cutting tool
I. I. T.
I. I. T.
COUNTER-BORING:
Making of INTERNAL STEPPED HOLE in
which a Lager Diameter Follows a
Smaller Diameter Partially into the
Hole
COUNTER-SINKING:
Similar to Counter-Boring, Except
that the Step in the Hole is Cone
Shaped for Flat-Head Screws and
Bolts.
CENTERING or CENTER-DRILLING:
D r i l l i n g o f a S t a r t i n g H o l e t o
Accurately Establish its Location for
Subsequent Drilling.
TYPICAL SEQUENCE of
OPERATIONS in a
HOLE MAKING
I. I. T.
I. I. T.
DRILLING MACHINE
Drilling is Most Commonly Performed on a Drill Press.
MAIN
TYPE
Applications
4. GANG
MAIN
TYPE
Applications, Designation
BENCH TYPE
Milling
Milling is a machining operation in which a workpart is fed past a rotating cylindrical tool called
milling cutter is multi point cutting tool.
In milling axis of rotation of the cutting tool is
perpendicular to the direction of feed.
While in drilling, the cutting tool is fed in a
direction parallel to its axis of rotation.
HORIZONTAL TYPE
VERTICAL TYPE
TYPES of PERIPHERAL or
PLAIN MILLING
(b) slot milling (slotting): the (b) partial face milling: the
width of the cutter is less than the cutter overhangs the work on
work-piece width. very thin cutter only one side.
can be used to mill narrow slots or to
cut a work-part in two, called saw
milling.
(d) straddle milling: the same as (d) profile milling: this is a form
side milling, only cutting takes of end milling in which the outside
place on both sides of the work.
periphery of a flat part is cut.
I. I. T.
TYPES of PERIPHERAL
according to the rotation
direction of the cutter two types:
(e) up or conventional: the
direction of motion of the cutter
is opposite to the feed direction.
(f) down or climb milling: the (f) surface contouring: a balldirection of cutter motion is in nose cutter is fed back and forth
the feed direction
across the work along a curvilinear
path at close intervals to create a
3-dimensional surface form.
I. I. T.
DIFFERENCES
UP Milling
The direction of motion of
the cutter is opposite to the
feed direction.
It is milling against the
feed."
Cutting force direction is
tangential to the periphery of
the cutter which tends to lift
the work piece as the cutter
exits the material.
DOWN Milling
The direction of cutter
motion is in the feed
direction
It is milling with the feed."
Cutting force direction is
downward, tending to hold
the work against the
milling machine table.
I. I. T.
Type
(a) column and
knee type
(general purpose)
Applications
for slab, side, or straddle milling.
well suited for face and end
milling operations
for milling to produce twist
drills), milling cutters, and helical
gear teeth, etc.
I. I. T.
Milling cutter
Milling cutters are classified on the basis of
methods of mounting and direction of rotation.
Method of mounting
arbor cutters have a center hole for mounting on
an arbor.
shank cutters have either a tapered or a straight
shank.
vtapered shanks cutters can be mounted
directly in the milling machine spindle.
vstraight shank cutters are held in a chuck.
MI-102: Manufacturing Techniques
I. I. T.
GRINDING
Grinding is a finishing process using abrasives (i.e. Al2O3,
SiC, B4C, Diamond, CBN, etc.) bonded in form of Wheel
operating at Very High Surface Speeds.
Similar to the Milling, Cutting in grinding can be either the
Periphery or the Face of the Grinding Wheel.
Face
Periphery
MI-102: Manufacturing Techniques
I. I. T.
I. I. T.
I. I. T.
Surface Grinding
Surface Grinding for Plain Flat Surfaces.
Workpiece is Normally Held in a Horizontal Orientation.
Peripheral Grinding:
Performed using
Periphery of the
Grinding Wheel
r o t a t i n g t h e
Horizontal Axis,
Cylindrical Grinding
Used for Rotational Parts.
Cylindrical Grinding Operations can be Divide into TWO Basic Types:
(A) External Cylindrical Grinding; (B) Internal Cylindrical
Grinding.
I. I. T.
APPLICATIONS:
Parts Include Axles, Crankshafts, Spindles, Bearings and
Bushings, and Rolls for Rolling Mills
Centerless Grinding
The Workpiece is NOT Held Between Centers so Reduction in
Work Handling Time therefore for High volume Production.
EXTERNAL Centerless Grinding: Consists of Two Wheels
v Grinding Wheel: Rotating at Surface Speeds of 1200 to
1800 m/min.
v Regulating Wheel: Rotating at Lower Speeds and is Inclined
at a Slight Angle to Control through Feed of the Work
I. I. T.
TOOL GRINDERS
MI-102: Manufacturing Techniques
GRINDING WHEEL
Grinding Wheel is Usually Disk-shaped and is
Precisely Balanced for High Rotational Speeds.
A Grinding Wheel Consists of Abrasive Particles held by
Bonding Material in position.
Parameters of the Grinding Wheel used for
designation:
(1) Type of Abrasive Particle Material,
(2) Size of Abrasive Particles,
(3) Bonding Material,
(4) Wheel Grade,
(5) Wheel Structure
All these parameters affect Desired Performance of
Grinding in terms of surface roughness and metal
removal rate i.e. rate of cutting.
I. I. T.
I. I. T.
as per spacing
An Open Structure has large Air Gaps than the Abrasives and
reverse is true for dense structure.
Bond
A Dense Structure is One in
Material
which P is Relatively Small, And
p
Pg is Larger.
I. I. T.
I. I. T.
New scheme