MODULE-2 IME-22ESC144

MACHINE TOOLS AND OPERATIONS

INTRODUCTION: Several metal cutting operations are carried out to produce a mechanical part
of required shape and size. The metal cutting operations may be carried out either manually by
using hand tools such as chisels, files, saws etc. using metal cutting machines. When machines
perform the metal cutting operations by the cutting tools mounted on them, they are called machine
tools.
Definition- Machine tool: Machine tool is a power driven machine to produce a product by
removing the excess material using a cutting tool. It holds both work-piece (i.e. the one which has
to be machined) and the cutting tool, the one which is used to separate/remove material stock from
the work piece. Machining operation is done by relative motions between the tool and the work-
piece.

Examples-Lathe, Drilling, Milling machine, Grinding machine, Shaper

Definition – Machining: Machining is a process in which a material is cut to a desired final

shape and size by a controlled material-removal process. The processes that have this common
theme are collectively called subtractive manufacturing. Machining utilizes machine tools

LATHE MACHINE:
A lathe is a machine tool which turns cylindrical material. It is said to be the mother of all the
machine tools. The lathe is the oldest of all machine tools and the most basic tool used in industries.
Definition-Lathe: A lathe is defined as a machine tool is primarily used to produce circular
objects and is used to remove excess material by forcing a cutting tool against a rotating work piece.
Lathes are also called turning machines, since the work piece is turned or rotated between two
centers: the live center and dead center.
Since it is so versatile, that almost all the machining operations which are performed on other
machine tools like, drilling, grinding, shaping, milling etc., can be performed on it.

Working principle of lathe:

Generally a circular job is between the live center and the dead center. The head stock spindle
provides the power to rotate the job with a chuck or catch plate. A single point tool is held on the
tool post with the cutting edge at the level of the spindle axis and close to the job at its
circumference. Cutting action is obtained by tool movement perpendicular to the axis of rotation
(depth of cut) and simultaneously moving it parallel to the axis of rotation (feed) along the job. For
a set depth of cut, the carriage is moved from right to the left, the tool is feed from the job and the
carriage is moved back to the initial position. Depth of cut is set and the feed is given as explained.

Cylindrical surface - Turning

Flat surface - Facing Tapered surface – Taper Turning

Basically three types of surface can be produced: Cylindrical, Flat & Taper
Cylindrical surface: Tool moves parallel to the axis of rotation of the workpiece.
Flat surface: Tool moves perpendicular to the axis of rotation of the workpiece.
Taper surface: Tool moves at an angle to the axis of rotation of the workpiece.

Lathe Operations

1. Cylindrical Turning
2. Facing
3. Knurling

1. Cylindrical Turning

Turning is the removal of metal from the outer diameter of a rotating cylindrical work piece.
Turning is used to reduce the diameter of the work piece, usually to a specified dimension. The
workpiece is held rigidly and rotated between the two centers: live center and dead center. The
cutting tool is fed against the revolving work piece in a direction parallel to the lathe axis so as to
produce a cylindrical surface.

Cylindrical turning can be done through rough turning and finish turning. In rough turning, the
excess material is removed rapidly by giving a deep depth of cut and a high feed rate. Whereas in
finish turning, excess material is removed by giving light depth of cut and small feed.

2. Facing

Facing is defined as an operation performed on the lathe to generate either flat surfaced or shoulders
at the end of the work piece. In facing operation, the direction of feed given is perpendicular to the
axis of the lathe. The work piece is held in the chuck and the facing tool is fed either from outer
edge of the work piece progressing towards the center or vice versa. The cutting tool is held by a
tool holder in a tool post.
3. Knurling

Knurling is the process of embossing a required shaped pattern on the surface of the work piece.
This diagram shows the knurling tool pressed against a piece of circular work piece. The lathe is
set, so that the chuck revolves at a low speed. The knurling tool is pressed against the rotating work
piece and pressure is slowly increased until the tool produces a pattern on the work piece.
Sometimes more than one pass may be required to get a deep cut. Depending on the knurling tool
selected, a variety of knurled patterns can be produced.
 DRILLING MACHINE

Definition - Drilling Machine: It is a machine tool which is used to drill the holes
on the components or workpiece with the help of drill bits. The drill bits is a Multi-point
cutting tool.

Working principle of a drilling machine

This sketch should be
drawn.

This sketch NEED

NOT to be drawn. It
is only for reference
 1. Base (Bed): It carries the entire weight of the machine, and transfer the weight to the
ground. At the top of the base, there are some slots provided to support large jobs.

2. Vertical column: It is mounted over the base. It is made of cast iron and is very rigid so
that it can carry the load of the arm as well as a drill head.

3. Work Table: It is attached to the column and holds the machine vice thereby, the
workpiece is fixed in the machine vice to carry out the drilling operation. The table can
move up and down and can be locked to the column.

4. Drill head: On one side of the arm a drill head is mounted. A drill chuck is mounted over
it. A V-types belt is provided to transfer the power from the motor to the pulley and from
pulley, the mechanical power is transferred to the drill head.

5. Spindle: A spindle is a rotating shaft which holds the cutting tool.

Working: When the motor is turned on, the stepped pulley mounted on it also rotates. A V
belt transmits this power to another stepped pulley located on the other end and is inverted
to increase or decrease the speed of the rotational motion. As the pulley rotates, the spindle
also rotates which in turn rotates the drill bit which makes the holes on the component placed
in the machine vice.

Drilling Operations

1. Drilling
2. Boring
3. Reaming

1. Drilling
 It is the operation of producing cylindrical holes in a solid objects by means of a revolving
tool called drill bit. Initially the center of the hole is marked by two cross lines, and a center punch
is used to highlight the center. The hole is generated by the sharp edges of the rotating drill bit that
is forced to move against the rigidly clamped work piece. The chips get curled and escapes through
the helical grooves (flutes) provided in the drill bit.
A drilled hole will have the rough size of the required hole and needs further sizing and
finishing operations.

2. Boring

Boring is a hole enlarging operation performed on a previously drilled hole using an adjustable
cutting tool having only one cutting edge. This operation is performed when a drill bit of the
required dimension is not available. In such case, a hole is first drilled to the nearest dimension, and
then a single point cutting tool is fastened and adjusted to a boring bar to enlarge the size of the
existing hole to the required dimension.

In addition to enlarging a previously drilled hole, boring operation corrects the hole location
and out-of-roundness, if any, as the tool can be adjusted to remove more metal from one side of the
hole than the other. While boring, the tool is rotated at speeds slower than that of reaming.

3. Reaming
 Reaming is the operation of finishing a previously drilled hole to bring it to a more exact size
and to improve the surface finish of the hole. The operation is carried out using a multi tooth
revolving tool called reamer, which consists of a set of parallel straight cutting edges along the
length of the cylindrical body.

While reaming, the speed of the spindle is reduced to nearly half that of the drilling. The
material is removed in small amounts, and hence the surface of the drilled hole is finished with high
accuracy. The amount of material to be removed should not exceed 0.125mm.

MILLING MACHINE
Definition of milling:

It is a process of shaping work materials mounted on a movable worktable by feeding the work
material against a multipoint rotating cutter to perform the cutting operation.
A milling machine can be used for producing flat, angular or curved surfaces, for cutting threads,
gears, slots etc.

Definition -Milling machine: -

A milling machine is a power operated machine tool in which the work piece is mounted on moving
table is machined to various shapes when moved under a revolving serrated cutter.
PRINCIPLE OF MILLING

The milling cutter is mounted on a rotating shaft known as arbor. The work piece which is
mounted on the table can be fed slowly against the rotating cutter. The workpiece can be fed in two
different directions with respect to cutter rotation.
In up milling process, the workpiece is fed in the direction opposite to that of the rotating
cutter.
In down milling, the workpiece is fed in the same direction as that of the rotating cutter.
Comparison Up milling Vs Down milling

Working of milling machine

This sketch should be

drawn.
 This sketch NEED
NOT to be drawn. It
is only for reference

The main part of machine is base, Column, Knee, Saddle, Table, Overarm, Arbor Support and
Elevating Screw.
Base: It gives support and rigidity to the machine and also acts as a reservoir for the cutting fluids

Column: The column is mounted vertically on the base. The column is box shaped and houses all
the driving mechanisms for the spindle and table feed.

Knee: The knee is a rigid casting mounted on the front face of the column. The knee moves
vertically along the guide ways and this movement enables to adjust the distance between the cutter
and the job mounted on the table by operating the elevating screw provided below the knee.

Saddle: The saddle rests on the knee The saddle moves transversely, i.e., crosswise (in or out) on
guide ways provided on the knee.
Table: The table rests on guide ways in the saddle and provides support to the work. The table
carriers T-slots which accommodate the clamping bolt for fixing the work. The worktable and hence
the job fitted on it is given motions in three directions:

a). Vertical (up and down) movement provided by raising or lowering the knee.

b). Cross (in or out) or transverse motion provided by moving the saddle in relation to knee.

c). Longitudinal (back and forth) motion provided by hand wheel fitted.
Working:

The work piece is mounted on the table with the help of suitable fixtures. The desired contour,
feed and depth of cut for the job are noted down. A suitable milling cutter for the specified job is
selected and mounted on the arbor. The knee is raised till the cutter just touches the work-piece. It
can be moved in X and Y- directions in the horizontal plane on the saddle. In operation, the tool
runs at high speed, and the work table, saddle and the knee, moved to give specified feed and depth
of cut. The table is moved in horizontal plane to perform desired operation.

Milling Operations

1. Plain(Plane) milling
2. Slot milling

1. Plain(Plane) milling

The slab milling is the operation of producing flat, horizontal surface with a milling cutter whose
axis is parallel to the surface of the workpiece being machined. The process is carried out on a
horizontal milling machine with a cutter having straight or helical teeth formed on a periphery of a
cylindrical surface.
The cutter is mounted on the arbor, rotating at a suitable speed, while the workpiece is fed
against the cutter causing material to be removed from the workpiece.
A plain smooth surface can be produced with this process. Helical tooth cutter removes greater
amount of material and produces a smooth surface finish when compared to straight tooth cutters.
 2. Slot milling

Slot milling is the operation of producing slots like T-slots, plain slots, dovetail slots etc., in
worktable fixtures and other work holding devices. The operation may be performed using either
end milling cutter, T-slot cutter, dovetail cutter or side milling cutter. The type of cutter selected
depends on the shape of the slot to be produced.
Two separate milling cutters are required for milling T-slots. Initially a plain cutter is used
to cut the throat (open slot) starting from one end of the work piece to its other end. A T-slot milling
cutter is then used to cut the headspace to the desired dimensions. Similar procedure is followed for
cutting a dovetail slot, but a dovetail slot cutter is used in place of T-slot cutter.

Introduction to Advance Manufacturing Systems:

Computer Numerical Control (CNC)
What is a CNC Machine?
• Numerical control is a programmable automation in which process is controlled by
Numbers, Letters, and symbols.
 • CNC refers to a computer controller that accepts a program or a set of instructions and
stores it in the memory of the computer, which in turn controls the working of the machine
tool

Basic components of CNC system

(i) Input Devices: These are the devices which are used to input the part program in the CNC
machine. There are three commonly used input devices and these are punch tape reader, magnetic
tape reader and computer.
(ii) Machine Control Unit (MCU): It is the heart of the CNC machine. It performs all the
controlling action of the CNC machine, the various functions performed by the MCU are
It reads the coded instructions fed into it.
It decodes the coded instruction.
It implements interpolation (linear, circular and helical) to generate axis motion commands.
It feeds the axis motion commands to the amplifier circuits for driving the axis mechanisms.
It receives the feedback signals of position and speed for each drive axis.
It implements the auxiliary control functions such as coolant or spindle on/off and tool change.
(iii) Machine Tool: A CNC machine tool always has a slide table and a spindle to control of the
position and speed.
The machine table is controlled in X and Y axis direction and the spindle is controlled in the Z
axis direction.
(iv) Driving System: The driving system of a CNC machine consists of amplifier circuits, drive
motors and ball lead screw.
The MCU feeds the signals (i.e. of position and speed) of each axis to the amplifier circuits.
The control signals are than augmented (increased) to actuate the drive motors.
And the actuated drive motors rotate the ball lead screw to position the machine table.
v) Feedback System: This system consists of transducers that act as sensors. It is also called a
measuring system.
It contains position and speed transducers that continuously monitor the position and speed of the
cutting tool located at any instant.
The MCU receives the signals from these transducers and it uses the difference between the
reference signals and feedback signals to generate the control signals for correcting the position
and speed errors.
(vi) Display Unit: A monitor is used to display the programs, commands and other useful data of
CNC machine

Advantages of CNC Machines

1. Higher productivity
2. Higher precision
3. Does not require a skilled operator
4. Improved automation
5. Repeatability & reliability
6. Flexibility
7. Motion control
8. Increased machine utilization

Applications of CNC

Aerospace Industries: The machining of metal aircraft components occurs at the highest level of
precision. This is highly essential for safety-critical applications.

Automotive industries: Uses CNC milling machine for both prototyping and production.

Military and Defense Industries: The ability of CNC machines to provide on-demand replacement
parts and upgraded components are particularly useful in this industry.

Electronics Industries: CNC machining also helps in the prototyping and production of consumer
electronics.
Health care sector: The tight tolerances afforded by CNC machining are essential to the high
performance of machined medical components. CNC machinable medical parts include surgical
instruments, electronic enclosures, orthotics, and implants.

Oil and Gas Industry: This sector leverage the uses of CNC machines for precise, reliable parts
such as pistons, cylinders, rods, pins, and valves.

3D Printing

Will be given later