Production Processes
Production Processes
of Bihar
Department of Science & Technology
Government Polytechnic Vaishali
PRODUCTION PROCESS
Semester-IV (Mechanical Engineering)
Unit -1
CNC Lathe & Part Programming
by
Prof. Jitendra Kumar
Lecturer ,Department of Mechanical
Engineering
CONTENTS
• POWERPOINT PRESENTATION
• NOTES
• EXAMPLES
• ASSIGNMENTS
Learning Objectives
Students will be able to:
• Maintenance is difficult
CNC Machine Tool
DNC
• Direct Numerical Control is a system that uses a
central computer to control several machines at the
same time
• Distributed Numerical Control (DNC): the central
computer downloads complete programs to the CNC
machines, which can be workstations or PCs, and can
get the information for the machine operations.
• The speed of the system is increased, large files can
be handled and the number of machine tools used is
expanded.
13
Distributed numerical control (DNC)
• In early 1980s, Distributed numerical control (DNC)
comes into picture.
• Now, many CNC machines together with robots,
programmable logic controllers, and other computer-
based controllers have been integrated into DNC
systems to make automated manufacturing systems
possible.
DNC
Configuration-1
15
DNC Configuration-2
Components of DNC
• Central computer
• Bulk memory for storing programs
• Communication network
• CNC machines
Advantages of DNC
• Greater computational capability and
flexibility
• Central computer and bulk memory, which
stores the NC programs.
• Shop floor control
• Establishes the framework for evolution of
future automation, CIM
Satellite Computers
• Satellite computers are minicomputers
and they serve to take some of the burden
of central computer, Each satellite
computer control several machine tools.
Control Systems possible in CNC
Machine
• Point to point mode:
Point-to-point straight line
mode
Co-ordinate system
• All the machine tool use Cartesian Co-ordinate system.
• The first axis to be identified is the Z – axis, This is
followed by X and Y axes respectively.
G17 XY Plane
G18 XZ Plane
G19 YZ Plane
Table of Important G codes
Code Meaning Format
G20/G70 Inch Unit
G21/G71 Metric Unit
G28 Automatic Return to Reference
Point
G40 Cutter compensation cancel
G41 Cutter compensation left N__G41D__
G42 Cutter compensation right N__G42D__
Start (0,0)
Linear interpolation: G01
• G01:
– linear interpolation at feed speed.
G91 G0l X200.0 Y100.0 F200.0
Y
G91: End
incremental 100.0
coordinates
Start 200.0 X
Circular interpolation: G02, G03
• G02, G03:
– For circular interpolation, the tool destination and the circle
center are programmed in one block
– G02 is clockwise interpolation, G03 is counterclockwise
interpolation
G 02 R
G 17 X __ Y __ F __;
G 03 I __ J __
G 02 R
G 18 X __ Z __ F __;
G 03 I __ K __
G 02 R
G 19 Y __ Z __ F __;
G 03 J __ K __
End point Circle center, radius
Circular interpolation: G02, G03
X R=-50mm
End Specify R with
sign before it:
180° +R
R=50mm >180° -R
Start
Y
• Specify Center with I, J, K
End
– I, J, K are the incremental
distance from the start of
X the arc;
– Viewing the start of arc
Start as the origin, I, J, K have
j positive or negative signs.
Center
i
Circular interpolation: G02, G03
N0010 G92 X200.0 Y40.0 Z0 ;
N0020 G90 G03 X140.0 Y100.0 I -60.0 F300;
;
N0030 G02 X120. 0 Y60.0 I- 50.0 G92:
Or To define working
N0010 G92 X200.0 Y40.0 Z0 ; coordinate
N0020 G90 G03 X140.0 Y100.0 R60.0 F300 ;
N0030 G02 X120.0 Y60.0 R50.0 ;
G90: absolute Y
coordinates 10 R50
0
60 R60
40
X
O 90 120 140 200
Circular interpolation: G02, G03
PRODUCTION PROCESS
Semester-IV (Mechanical Engineering)
Unit -2
Drilling
by
Prof. Jitendra Kumar
Lecturer ,Department of Mechanical
Engineering
CONTENTS
• POWERPOINT
PRESENTATION
• NOTES
• EXAMPLES
• QUESTION BANK
Learning Objectives
Students will be able to:
Drilling Terminology
Numerical Problems
Drilling
• Drilling is a operation that cuts cylindrical holes.
DRILLIN
INTRODUCTION: A G machine
drilling
was primarily designed to a
hole, originate
but it can also
perform a No. of
similar operations. In a drilling
machin holes may be drilled
e at low
and quickly
cost. The hole is
generated by the rotating edge of a
cutting tool known as the drill
which exerts large force on the
work clamped on the table. The
cutting motion is provided by
rotating the drill and feeding is done
by giving rectilinear motion to the
drill in the
has two axial edges
cutting direction. Here the
called
drill
lips. used 91
TYPES OF DRILLING
(1) Portable drilling machine:
This type of D.M. can be operated with ease
anywhere in the work shop and is used for drilling
holes in work pieces in any position which cannot
be drilled in a standard D.M. The entire D.M.
including the motor is compact and small in size.
The max. size of the drill that can accommodate
is not more than 12 to 18 mm.
6
(2) Sensitive D.M. It is a small
machine designed for drilling
small holes at high speed in
light and small jobs. The
base of the machine may be
mounted on a bench or on
the floor.
7
(3) Upright D.M.: This is designed for
handling medium sized W.P. It is
similar to a S.D.M. but is heavier
and larger than S.D.M.and is power
supplie with feed
dArrangement.
a) Round Column Section (or) Pillar D.M.:
It consists of round column and a round
table. The table can be moved up and
down on the column for
accommodating heights. The
W.P. of different table may be
rotated
360o about its own centre. The max.
size of the hole that can be drilled is
not more than 50mm.
94
(4) Radial D.M: It is intende for drilling medium
large and heavy W.P.dIt consists to a heavy, roun
of
vertical column mounted on a large base. The d
column supports a radial arm which can be raised
and lowered to accommodate work pieces of
difference heights The arm may be swung around
to any position over the work bed. The drill head
containing mechanism for rotating and feeding the
drill is mounted on the radial arm and can be
moved horizontally on the guide ways and clamped
at any desired position. This can be further
classified as
9
(a) Plain RDM.:- It has the movements explained
above.
10
(5) Gang D.M.: When a No. of
single spindle D.M.
columns are placed side
by side on a
commo base havea
n worktable,
commo
In a G.D.M. 4 to 6 spindles
n,
may be mounted side by side.
The speed and feed of
spindles are controlled
independently.
Specifications
1. Max.size ofdrill that the machine can operate,
2. Max. spindle travel
3. Table diameter / size
4. Morse taper No. of the drill spindle
5. No. of spindle speeds and feeds available.
6. Floor space required
7. Net wt. of the machine
Drills are
TERMINOLOGY
Tan
manufactured g
as: Shank
1. Straight
shank drills
Neck
(up to ϕ13.5
mm)
2. Taper shank
Drills (ϕ14.0mm
onwards) Body
Ti
p
Drill Chuck with Chuck
key
Morse taper is provided
on all drilling
accessories and inside
Drilling Machine
drilling machine
Spindle
spindle
Drift
107
Sleeve
DRILL GEOMETRY
Lip angle/ Tip Angle/ Point
Angle
Drill
Land: Land maintains the alignment of the drill so
that hole is straight and to the right size.
17
Helix angle: Angle formed b/w a plane containing
drill axis and the leading edge of land. Based on the
value of the angle the drills can be classified as
1)Slow spiral series: 12o to 22o - Used for brass,
bronze, CI that produce broken chips. They provide
less lifting power, but are stronger, used for shallow
holes. Also used in horizontal applications where
drill is not rotating.
2) Regular spiral series: 28o to 32o - most widely
used
3)Fast/High spiral series: 34o to 38o – Used for
softer ferrous and non-ferrous materials producing
long string like chips. They provide great lifting
power, but are weak, used for deep holes.
18
19
Lip angle: Angle formed b/w the cutting edges. Smaller
point angles results in lower effective rake. Effect of
change in effective rake is negligible on drill
performance. Less point angles generate wider and
thin chips. Higher point angles generate narrow and
thick chips. Increase in point angle increases the
cutting efficiency of the drill because most materials
are cut efficiently in the form of thick chips. Smaller
the point angle, longer is the lip length and hence
reduces load per unit length of the lip and helps in
resisting the wear caused by abrasive action during
machining of metals like C.I.
21
Clearance / Lip relief
Angle: Angle formed b/w
flank and a plane normal
to drill axis at the tip of
the drill. Large clearance
angles (80–120) are used
for ductile matls. to
compensate elastic
recovery. Small angles
(60–80) are used for
brittle matls.
22
Chip formation
of a drill
Cutting Speed in Drilling
• The cutting speed in drilling is the surface speed of
the twist drill.
D N
V m / min
1000
Drilling Time
• Time for drilling the hole
L
T , min
fN
MRR in Drilling
D
2
MRR fN ,
3
mm / m i n
4
Example
A hole with 40-mm diameter and 50-mm depth is to be
drilled in mild steel component. The cutting speed can
be taken as 65 m/min and the feed rate as 0.25 mm/
rev. Calculate the machining time and the material
removal rate.
QUESTION BANK
The rake angle in a drill (GATE-1996)
(a) Increases from centre to periphery
(b) decreases from centre to periphery
(c) Remains constant
(d) Is irrelevant to the drilling operation
IES - 1997
The rake angle in a twist drill
(a) Varies from minimum near the dead centre to a
maximum value at the periphery
(b) Is maximum at the dead centre and zero at the
periphery
(c) Is constant at every point of the cutting edge
(d) Is a function of the size of the chisel edge.
IES - 1992
A drill for drilling deep holes in aluminum should have
(a) High helix angle (b) Taper shank
(c) Small point angle (d) No lip
IES - 1992
Low helix angle drills are preferred for drilling holes in
(a) Plastics (b) Copper
(c) Cast steel (d) Carbon steel
GATE- 2002
The time taken to drill a hole through a 25 mm thick
plate with the drill rotating at 300 r.p.m. and moving at
a feed rate of 0.25 mm/revolution is
(a) 10 sec (b) 20 sec
(c) 60 sec (d) 100 sec
IES - 2002
The arm of a radial drilling machine is being raised at a
speed of 3.9 m/min by single start square threads of 6
mm pitch and 30 mm diameter. The speed of the
screw
(a) Is 650 rpm
(b) Is 180 rpm
(c) Is 130 rpm
(d) Cannot be determined as the data is insufficient
IES - 1992
A drill for drilling deep holes in aluminum should have
(a) High helix angle (b) Taper shank
(c) Small point angle (d) No lip
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