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Types of machine tools Turning machines Drilling machines Boring machines Milling machines Grinding machines
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Chip formation Discontinuous chip Continuous chip Orthogonal cutting
Mechanics of orthogonal cutting Merchants cutting force circle Orthogonal cutting with shear plane Strain and strain rate in orthogonal cutting
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Requirement of a cutting tool material Cutting tool materials Carbon tool steels High speed steel
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Cutting fluids o Cooling action Types of cutting fluid Straight mineral oils
Surface finish
o Lubricating action
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Tool life
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Bed Carriage Feed rod Lead screw Feed change gear box
Swing over the cross slide Horse power of the motor Number of speeds Number of feeds
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Cutting tool geometry o Nose radius
Cutting tools
o Back rake angle o Side rake angle o End relief angle o Side relief angle o End cutting edge angle o Side cutting edge angle
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Tail stock
Types of tools Parting tool Turning tool Right hand turning tool
Radius turning tool Thread cutting tool Chamfering tool Internal turning tool Inter facing tool Recess or groove making tool Internal threading tool
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Taper turning methods Form tool method Thread cutting method
Compound rest method Tailstock set over method Using taper turning attachment
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Capstan And Turret Lathe The principle parts are Bed Head stock Cross slide and saddle
S.No. 1.
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Capstan lathe
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Turret lathe allowing the turret to be of large size. as 200mm. there is no such difference. 5
Short slide since the saddle is Saddle moves along the bed, thus clamped on the bed in position.
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2. than 50mm. 3. when it is nearing cut.
Light duty machine, generally for Heavy duty machine, generally for components whose diameter is less components with large diameters
Too much overhang of the turret Since the turret slides on the bed,
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Automatic lathes
Classification
Automatic lathes may be classified based on their Size Type of blank machined Processing capacity Machining accuracy obtained Principle of operation design features
Special type
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Cutting off bar Bar Special type
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Tool head assembly- tool feed handle, tool slide, apron, clapper box, tool holder
Planer
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Table Columns or housing Cross rail Tool head Specifications Dimensions of the table Horizontal distance between the two vertical housings Length that the table can travel Height from top of the table to the top of cross rail Type of drive
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Base
o Turret type
Planomillers
o Keyway milling
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Horizontal Milling Machine Base Column Knee Saddle Table Arbor Over-arm Spindle
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Production type
o Universal
Specifications The maximum length of longitudinal, cross and vertical travels of the table and its dimensions Main drive motor power
Based on rotation
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Based on helix Left hand helix Plain milling cutters Side and face milling cutters Slitting saw Special form cutters End mills
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Right hand rotation Left hand rotation Right hand helix 9
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The types of hole making operations performed on these holes are Drilling Boring Reaming Counter sinking Counter boring Tapping
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Salient features
Provides movement of the spindle in three directions Several holes can be drilled on a work piece without moving the same.
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UNIT-IV : ABRASIVE PROCESS, SAWING, BROACHING AND GEAR CUTTING Grinding wheel specification and selection Abrasive types
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Metal Grade Soft Medium Hard Structure Open Medium Dense
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Synthetic resin Rubber Shellac 11
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Aluminium oxide
Wheel balancing
Wheel head
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Surface grinding machine Centreless grinding machine The main parts are Grinding wheel Regulating wheel
Horizontal spindle and reciprocating table Vertical spindle and reciprocating table Horizontal spindle and rotating table Vertical spindle and rotating table
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Honing
Honing is a low abrading process which uses bonded abrasive sticks for removing stock from metallic and non-metallic surfaces. The advantages of honing are Correction of geometrical accuracy Out of roundness Taper Axial distortion
Lapping
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Super finishing generally used for integrity
Super finishing is another abrasive process which utilizes either a bonded abrasive like honing for cylindrical surfaces or a cup wheel for flat surfaces. It is
Removing surface fragmentation Reducing surface stresses and burns and thus restoring surface
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Lapping is generally the final finishing operation done with loose abrasive grains.
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Dimensional accuracy
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Polishing and Buffing Polishing is done with a very fine abrasive in loose form smeared on the polishing wheel with the work rubbing against the flexible wheel. A very small amount of material is removed in polishing. In buffing the abrasive grains in a suitable carrying medium such as grease are applied at suitable intervals to the
high luster is generated on the buffed surface. The dimensional accuracy of the parts is not affected by polishing and buffing operations.
In this process a continuous moving belt with an abrasive is used for grinding the
being driven while the other remains idle. The workpiece is oscillated across the face of the abrasive belt to obtain a uniform belt wear and surface finish. Sawing machines
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Manual Power Band saw Vertical Horizontal Contour Circular saw
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surfaces. The abrasive belt is normally passed between two wheels with one
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Broaching Broaching is a multiple tooth cutting operation with the tool reciprocating similar to the sawing operations. The similarities end there, since in broaching the machining operation is completed in a single stroke as the teeth on the cutting tool called broach, are at a gradually increasing height corresponding to the feed per tooth of a milling cutter.
Broaching machines Push broaching machines Pull broaching machines Surface broaching machines
Gear cutting
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UNIT-V : CNC MACHINE TOOLS AND PART PROGRAMMING Numerical Control (N.C) It can be defined as a programmable automation in which the process is controlled by numbers, letters and symbols. Components of N.C o Program of instructions o Machine control unit o Machine tool
o Process planning o Part programming o Tape preparation o Tape verification o Production Components Of CNC A tape reader
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Micro or mini computer Machine tool Advantages Greater flexibility High productivity Good reliability Metric conversions Memory functions
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N.C. Procedure
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Tool function Preparatory functions Miscellaneous functions Program number Tool length compensation Cutter radius compensation Canned cycles
Preparing the part programs for CNC machine tools manually is a viable system for any kind of job. But the assistance of a computer is desirable for part
respect is the complexity of the work piece which makes manufal part programming a very difficult exercise. Close tolerance contouring to some
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APT language statements Geometry Motion Post processor auxiliary
mathematically defined, or through a set of points other than a circular arc, is an example requiring too many coordinate calculations making manual part programming too tedious to be practicable.
The complete APT part program consists of the following four types of
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Speed function