▪ Drilling is a metal cutting process

carried out by a rotating cutting tool

to make circular holes in solid
materials.

▪ Hole is generated by the rotating

cutting tool known as drill bit which
exerts a large force on the work,
clamped on the table or support.

Depending on application, different

types of drill bits are available. The most
commonly used drill bit is the twist drill.
▪ Drilling machines are manufactured in different types and sizes
according to the type of operation, amount of feed, depth of cut,
spindle speeds, method of spindle movement and the required
accuracy.
▪ There are mainly seven types of Drilling Machine. They are:
1. Portable Drilling Machine
2. Sensitive Drilling Machine/Pillar Drill/Bench Drill
3. Upright Drilling Machine
4. Radial Drilling Machine
5. Gang Drilling Machine
6. Multiple Spindle Drilling Machine
7. Deep Hole Drilling Machine
In case of playback issues, please visit this link:
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Note: This content was collected from YouTube for ease of understanding and IUT does not hold any copyright.
▪ Drill bits are cutting tools used to remove material
to create holes, almost always of circular cross-
section. Land

Margin Margin
Width

Flutes
– Helps to form the geometry of the tip.
– Allows oil and coolant to reach to the cutting edges.
– Allows chips to come out from the drilled hole.
 Heel Chisel Edge

Cutting
Lip
 TWIST DRILL
▪ The most common drill bits are twist drills in case of
working with wood, steel and other non ferrous
materials
▪ Twist drills have three parts
▪ Body: consisting of two or more spiral grooves called
flutes. Flutes serve as channels through which chips
are withdrawn from hole and coolant gets to cutting
edges.
▪ Point: a wide variety of geometry are used, but
typically have a point angel of 118°.
▪ Shank: a straight or tapered section where the drill is
clamped.
Point Angle:

What would happen if drill bits do not have point angle?

Depending on Helix/rake angle,
twist drill generally fall into
three categories:
– Regular/Standard Spiral Drill
– Slow Spiral Drill
– Fast Spiral Drill
Regular Spiral Drills
– 28° to 32° helix angle, together with
a point angle of ~118°,
– Regular spiral is found on most
general purpose drills and cobalt
drills.
– Used in a wide variety of drilling
applications. Suitable for drilling
steel and cast iron.
Slow Spiral Drills Fast Spiral Drills
– 12° to 22° helix angle — are available with a – 34° to 38° helix angle — are available with a
point angle of 118° for cutting brass and point angle of ~100°
bronze and with a point angle of 90° for – For softer ferrous and non-ferrous (such as
cutting plastics materials. Aluminum alloys, Copper etc.) materials
– Used in materials producing broken chips producing stringy (wiry) chips.
such as brass or bronze, or cast iron. – Provides greater lifting power for chips, but are
– Are stronger, but have less lifting power for weaker.
chips. – Generally used in deep holes.
– Generally limited to shallow holes.

13
▪ The two most common types are:
1. HSS (High Speed Steel) drill
2. Carbide- tipped drills

▪ Other types are:

Solid Carbide drill, TiN coated drills, carbide coated masonry
drills, parabolic drills, split point drill
▪ Drills and similar tools with
parallel shanks are held in a
drill chuck

▪ By rotating the outer sleeve,

the jaws can be opened and
closed.

▪ To ensure maximum grip, the

chuck should be tightened
using the correct size of chuck
key. This prevents the drill from
spinning during use

Drill bit is only gripped in place of the shank

▪ The different methods used for holding drill in a drill
spindle are:

▪ By directly fitting in the spindle hole.

▪ By using drill sleeve

▪ By using drill socket

▪ By using drill chuck

▪ To remove a shank from the spindle, a taper key known
as a drill drift is used
▪ The drift is inserted through a slot in the spindle

Strike here
to remove

Most modern machines

have a built-in drift
▪ Common operations performed in a drilling machine
are:
▪ Drilling
▪ Reaming
▪ Boring
▪ Counter boring
▪ Countersinking
▪ Tapping
In case of playback issues, please visit this link:
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Note: This content was collected from YouTube for ease of understanding and IUT does not hold any copyright.
Through-holes: drill exits the opposite side of work
Blind-holes: drill does not exit on opposite side of work

Figure: Two hole types: (a) through-hole, and (b) blind hole
Used to improve surface
finish while slightly
enlarging the hole
▪ It is a process of smoothing the surface of drilled holes with a
tool.
▪ Tool is called as reamer.
▪ Initially a hole is drilled slightly smaller in size.
▪ Drill is replaced by reamer.
▪ A reamer enters the workpiece axially and enlarges an
existing hole to the diameter of the tool.
▪ A reamer is a multi-point tool that has many flutes, which may
be straight or in a helix.
▪ Reaming removes a minimal amount of material and is often
performed after drilling to obtain both a more accurate
diameter and a smoother internal finish.
▪ It is a process carried on a
drilling machine to increase
the size of an already
drilled hole

▪ Initially a hole is drilled to

the nearest size and using a
boring tool the size of the
hole is increased.
▪ This process involves increasing
the size of a hole at only one end.
▪ Cutting tool will have a small
cylindrical portion called pilot to
guide it straight into the existing
hole.
▪ Counter boring is often performed
after drilling to provide space for
the head of a fastener, such as a
bolt, to sit flush with the workpiece
surface.
▪ This is an operation of making
the end of a hole into a conical
shape.
▪ Countersinking is performed
after drilling to provide space
for the head of a fastener, such
as a screw, to sit flush with the
workpiece surface.
▪ Process of cutting internal
threads with a thread tool
called as tap.

▪ Tap is a fluted threaded tool

used for cutting internal
thread
 Used to provide
internal screw
threads on an
existing hole

The tool is
called a tap

Figure: Tapping
IENG 475: Computer-Controlled
36 10/28/2021
Manufacturing Systems
Clamping set
used when drilling round bar
Cutting Speed (v)
▪ The peripheral speed of the drill
v = *D*N where
D = diameter of the drill
N = rotational speed of the drill in rpm

Feed Rate (f)

▪ The movement of drill along the axis

Depth of Cut (d)

▪ The distance from the machined surface to the drill axis
d=D/2
Material Removal Rate (MRR)

It’s the volume of material removed by the drill per unit time
MRR = ( D2 / 4) * f * N mm3 / min

Machining Time (t)

It depends upon the length (l) of the hole to be drilled , to the Speed (N) and
feed (f) of the drill
t = L / f N min
In case of playback issues, please visit this link:
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Note: This content was collected from YouTube for ease of understanding and IUT does not hold any copyright.
 Basics of Lathe
Machine Operations
Mechanical and Production Engineering Department (MPE)
Islamic University of Technology (IUT)
 Introduction
➢ Lathe is a machine, which removes the metal
from a piece of work to the required shape &
size.
❖Lathe is called “Mother of Machine Tools“
❖ Works with Cylindrical job-piece.

➢ Turning Operation: It is an operation done by

Lathe Machine.
▪ Machine Tool – LATHE
▪ Job-piece (also called work-piece) – is given
rotary motion
▪ Cutting Tool – is given linear motion
The Lathe
Resources explaining different parts of a lathe machine:

1. https://youtu.be/1e6L6Gk0RbI
2. https://learnmechanical.com/lathe-machine/
Close view
 Lathe parts
Tool-post
➢ Fitted on top slide
and carries the
cutting-tool and the
cutting-tool holder.
Lathe parts
◼ Tool holders
➢ Used for holding cutting
tool bits.
➢ Available in Right hand,
left hand and straight
configuration.
◼ Cutting Tools
➢ Can be made of “High
Speed Steel” held in
tool holders.
➢ Can be also Ceramic
(Tungsten Carbide) bits
held directly in tool-
post.
 Chucks
Chucks hold the work-piece tightly so that it doesn’t come out during any
Lathe operation.

Three jaw chuck Four Jaw chuck

 Centers

Headstock center Tailstock center

(Live Centre) (Dead Centre)

Workpiece
Turning Parameters
1. Cutting Speed v
2. Feed f
3. Depth of Cut d
Cutting speed: The Peripheral Speed of Workpiece
past the Cutting Tool

 DN D = Diameter (mm)
v= m/min N = Revolutions per Minute
1000 (rpm)

Feed:
The distance the tool advances for every
rotation of workpiece (mm/rev).

Depth of Cut:
Perpendicular distance between machined surface
and uncut surface of the Workpiece.
d = (D1 – D2)/2 (mm)
Material Removal Rate
MRR
Volume of material removed in one
revolution. MRR =  D d f mm3
• Job makes N revolutions/min
MRR =  D d f N (mm3/min)
◼ In terms of v MRR is given by
MRR = 1000 v d f (mm3/min)
Typical Operations
Done By Lathe
◼ Turning ◼ Chamfering
◼ Facing ◼ Taper turning
◼ Grooving ◼ Drilling
◼ Parting ◼ Threading
 Turning ..
Cylindrical job-piece: 1) Excess Material is
removed to reduce Diameter.
2) a depth of cut of 1 mm will reduce diameter
by 2 mm.
Workpiece
Cutting
speed Depth of cut (d)
N
Machined
surface
Chuck Feed Chip
Tool
Depth of cut
 Facing ..
◼ It means to machine end of job-piece  produces
smooth surface; reduces the length of job-piece by a
little.
◼ We use Turning Tool.
◼ Feed: in direction perpendicular to workpiece axis
◆ Length of Tool Travel = radius of workpiece.

◼ Depth of Cut: in direction parallel to workpiece axis.

Chuck Workpiece
d
Machined
Face
Cutting
speed Depth of
cut
Tool Feed
 Grooving
◼ Produces a Groove on workpiece
◼ Shape of tool  shape of groove
◼ Carried out using Grooving Tool

Shape produced
by form tool Groove

Feed or Grooving
Form tool depth of cut tool
 Parting

Tool is fed radially

into rotating
work at some
location to cut
off end of part,
or provide a
groove
Chamfering

Cutting edge
cuts an
angle on the
corner of the
cylinder,
forming a
"chamfer"
 Taper Turning
◼ Taper:

D1 − D2
tan  =
2L 90°
D1  D2

B  C

A L

Methods
◼ Form Tool
◼ Swiveling Compound Rest
◼ Taper Turning Attachment
◼ Simultaneous Longitudinal and Cross Feeds
 Taper Turning
By Form Tool
Workpiece Taper


Form Direction
Straight of feed
cutting edge tool
 Taper Turning
By Compound Rest
Dog
Mandrel Tail stock quill

Tail stock

Face plate Direction of feed

Tool post & Compound rest
Tool holder Slide
Compound rest
Cross slide  Hand crank
Threading
Pointed form tool
is fed linearly
across surface of
rotating workpart
parallel to axis of
rotation at a large
feed rate, thus
creating threads
 Drilling
Drill – cutting tool – held in
Tailstock – feed from Tailstock.
Quill
Drill clamp moving
quill
Tail stock
Feed
Tail stock clamp
 Example
A mild steel rod having 50 mm diameter and 500 mm
length is to be turned on a lathe. Determine the
machining time to reduce the rod to 45 mm in one
pass when cutting speed is 30 m/min and a feed of
0.7 mm/rev is used.

Given data: D = 50 mm, Lj = 500 mm v = 30 m/min, f

= 0.7 mm/rev
Substituting the values of v and D in
 DN
v= m/min
1000 N = 191 rpm
Machining time: Lj
t= min
f N
◼ t = 500 / (0.7191)
= 3.74 minutes
 Example
◼ A 150 mm long 12 mm diameter stainless steel rod is to
be reduced in diameter to 10 mm by turning on a lathe
in one pass. The spindle rotates at 500 rpm, and feed is
0.4 mm/rev. Calculate the cutting speed, material
removal rate and the time required for machining the
steel rod.
Given data: Lj = 150 mm, D1 = 12 mm, D2 = 10
mm, N = 500 rpm  DN
Using Equation → → → v = 1000 m/min
v = 12500 / 1000
= 18.85 m/min.
depth of cut = d = (12 – 10)/2 = 1 mm
From Equation : MRR =  D d f N
MRR = 3.142120.41500 = 7538.4
L
mm3/min t = j min
f N
t = 150/(0.4500) = 0.75 min.
 Example
◼ Determine the angle at which the compound
rest would be swiveled for cutting a taper on a
work-piece having a length of 150 mm and
outside diameter 80 mm. The smallest diameter
on the tapered end of the rod should be 50 mm
and the required length of the tapered portion
is 80 mm.
◼ Given data: D1 = 80 mm, D2 = 50 mm, Lj = 80
mm (with usual notations)
tan  = (80-50) / 280
or  = 10.620
The compound rest should be swiveled at 10.62o
 Process sequence
From raw material of 175 mm length and 60
mm diameter a workpiece is to be made which
has been specified in the given figure

20
Threading

50 40 Dia

50 40 50

20 Dia
 Process sequence

A possible sequence for producing the

component would be:

◼ Turning (reducing completely to 50 mm)

◼ Facing (to reduce the length to 160 mm)
◼ Step turning (reducing from 50 mm to 40
mm)
◼ Thread cutting
◼ Grooving
 PowerPoint to accompany

Welding
Principles and Practices
Third Edition
Sacks and Bohnart

Shielded
Metal Arc
Welding

1
Copyright © The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
 What is Arc Welding?
The process of joining metal to metal with the help of an electric current (arc) is called
arc welding. The power supply for the electric current is transferred between a welding
electrode (or a “metal stick”) and the base metal, creating an “arc” (creates an intense
heat of around 6500°F), that melts the metals upon contact. This process requires
intense heat, and after the metals have cooled, a metallurgical bond is created.

There are many different types of arc welding,

from manual to semi-automatic to fully
automated, but all require an electrode and an
electric current to bond two metals, which
creates an arc upon contact.
 Equipments for Arc Welding
Equipments:
• A welding generator (D.C.) or Transformer (A.C.)
• Two cables- one for work and one for electrode, cable connectors
• Earthing Clams
• Electrode holder
• Electrode
• Protective shield
• Gloves
• Steel Wire brush
• Chipping hammer
• Goggles
• Tong (for catching hot work piece)
• Aprons, sleeves, etc.
 Electric Power Supply For Arc
Welding
DC vs. AC Currents
The electric power supply for arc welding can come from either a direct (DC) or alternating (AC) current.

Direct current (DC) arc welding is often used in stick welding (will learn about it in the upcoming slides)
and lower-voltage cases, and is generally preferred over AC. This is because the DC current uses electrons
that flow steadily in one direction, creating a smoother and more stable arc.

Alternating current (AC) arc welding has greater volatility in the electrons, as they change direction
constantly. AC current is usually a secondary choice in welding, but can be helpful in some instances, like
when a stronger current is needed to prevent the arc from blowing out or for transmitting electricity over
large distances.
 Types of Arc Welding
This process can be categorized into two different types; consumable and non-consumable
electrode methods:

Consumable Electrode Methods: Non-Consumable Electrode Methods:

• *MIG (Metal Inert Gas) Welding. • TIG (Tungsten Inert Gas) welding
*MAG (Metal Active Gas) Welding. • PAW (Plasma Arc Welding)
Both MIG and MAG are a type of
GMAW (Gas Metal Arc Welding).
• Shielded Metal Arc Welding (SMAW)
/ Stick Welding / Manual Metal Arc
Welding
• FCAW (Fluxed Cored Arc Welding)
• Submerged Arc Welding (SAW)
• Electro-Slag Welding (ESW)
• Arc Stud Welding (SW)
Shielded Metal Arc Welding
(SMAW)
In this process the arc is struck between the metal
rod (flux coated electrode) and the work piece,
both the rod and work piece surface melt to form
a weld pool. Simultaneous melting of the flux
coating on the rod will form gas, and slag, which
protects the weld pool from the surrounding
atmosphere. This is a versatile process ideal for
joining ferrous and non-ferrous materials with a
range of material thicknesses in all positions.

Weld Pool / Weld

Puddle: The
localized volume of
molten metal in a
weld prior to its
solidification as
weld metal.

The weld pool must be carried along the joint in a consistent width and depth, and the motion used
to carry the weld pool has a direct effect on the quality of the weld bead.
Shielded Metal Arc Welding
(SMAW)

How does SMAW Work?

Working Animation Of SMAW Process

What is SMAW?
SMAW
 Tungsten Inert Gas Welding (TIG)
• Definition:
– In TIG welding, arc is formed
between a non-consumable
tungsten electrode and the
metal being welded.
– Gas is fed through the torch
to shield the electrode and
molten weld pool.
– A filler metal is normally used,
though some welds, known as
autogenous welds, or fusion
welds do not require it.
• Shielding Gases:
– Argon
– 2 to 5% Hydrogen What is TIG Welding?
– Helium
 Gas Metal Arc Welding (GMAW)
Gas metal arc welding, sometimes referred to by its subtypes Metal Inert Gas (MIG) and Metal Active Gas
(MAG) is a welding process in which an electric arc forms between a consumable wire electrode and the
workpiece metal, which heats the workpiece metal, causing them to fuse.
Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a commonly
used high filler metal deposition rate welding process. Wire is continuously fed from a spool. MIG welding
is therefore referred to as a semiautomatic welding process.

MIG vs MAG

Shielding Gases:
Inert (for MIG)
• Argon, Helium
Active (for MAG)
• 1 to 5% Oxygen,
3 to 25% CO2

What is MIG Welding?

 Weld Metal Protection

• During fusion welding, the molten metal in the weld

“puddle” is susceptible to oxidation
• Must protect weld puddle (or weld pool) from the
atmosphere
• Methods
– Weld Fluxes
– Inert/Active Gases
– Vacuum
More on SMAW
 1- The Electrode
• Is a consumable - it gets
melted during the welding
process
• Is composed of two parts
– Core Rod (Metal Filler)
▪ Carries welding current
▪ Becomes part of the weld
– Flux Coating
▪ Produces a shielding gas
▪ Forms a slag

13
 2 - Weld Puddle/Weld Pool

• As the core rod, flux

coating, and work pieces
heat up and melt, they
form a pool of molten
material called a Weld
Puddle or Weld Pool.

14
 3- Shielding Gas

• A shielding gas is
Shielding
4 Gas formed when the flux
coating melts.
3 • This protects the weld
2 puddle from the
atmosphere preventing
contamination during
the molten state

15
 4- Slag
• Slag is a combination of the flux
coating and impurities from the base
metal that float to the surface of the
weld.
• Slag quickly solidifies to form a solid
coating.
• The slag can be chipped away and
cleaned with a wire brush when hard.
16
 5-Travel Angle
• Also commonly called
Lead Angle
• The travel (lead) angle
20-30°
is the angle between the
electrode and the plane
perpendicular to the
weld axis

17
 SMAW Advantages

• Equipment less complex, more portable and

less costly
• Can be done indoors or outdoors, in any
location and any position
• Electrodes available to match properties and
strength of most base metals.
 SMAW Welding Circuit
• Current flows through
the electrode cable, to
the electrode holder,
through the electrode,
and across the arc
• On the work side of the
arc, the current flows
through the base
material to the work
clamp and back to the
welding machine
19
 Polarity Switch

• Electrode negative and electrode positive used

in d.c. welding
• DCEN (d.c. electrode negative)
– Electrode connected to negative terminal of power
source and work connected to positive terminal
• DCEP (d.c. electrode positive)
– Electrode connected to positive terminal of power
source and work connected to negative terminal
In AC, switch changes to either electrode positive
or electrode negative
 Metal Electrode Holders

• Device used for holding electrode

mechanically
• Conveys electric current Lenco dba NLC. Inc.

from welding cable to electrode

• Insulated handle protects hand from heat
• Made of metal with high electrical conductivity
and ability to withstand high temperatures
 Hand and Head Shields

• Bright light caused by electric arc contains two

kinds of invisible rays which injure eyes and
skin
– Ultraviolet
– Infrared
• Rays affect eyes within 50 feet;
and skin any distance within
20 feet Hand shield so person may hold
shield in front of face
Some more resources on
SMAW

How to Arc Weld

Stick Welding: How to Read the Puddle