ME2252.Notes.www.Chennaiuniversity.net[1]

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ME 2252 MANUFACTURING TECHNOLOGY II

II year Mechanical Engg. B-Sec
Notes on Lesson
UNIT I : THEORY OF METAL CUTTING
Material removal process
Types of machine tools
Turning machines
Drilling machines
Boring machines
Milling machines
Grinding machines
Shaping and planing machines
Gear cutting machines
Unconventional machining machines
Special machines like automats, copy turning machines, reaming ,

copy milling machines, centreless grinding machine, broaching
machine etc.
Chip formation
Discontinuous chip
Continuous chip
Continuous chip with built-up edge
Orthogonal cutting
Mechanics of orthogonal cutting
Merchants cutting force circle
Orthogonal cutting with shear plane
Strain and strain rate in orthogonal cutting
Free ebooks, Notes,Important Questions & study materials online
www.chennaiuniversity.net
Requirement of a cutting tool material

Cutting tool materials
Carbon tool steels
High speed steel
Cast cobalt alloys
Cemented carbides
Coated carbides
Ceramics
Diamond
Cubic boron nitride(CBN)
Tool wear
Flank wear
Crater wear
Diffusion wear
Tool life
Taylors tool life equation
Surface finish
Ideal surface finish in turning
Cutting fluids
Function of a cutting fluid

o Cooling action
o Lubricating action
Types of cutting fluid
Water based emulsions
Straight mineral oils
Mineral oils with additives
UNIT II : CENTRE LATHE AND SPECIAL PURPOSE LATHES

Centre lathe constructional features
Head stock
Tail stock
Bed
Carriage
Feed rod
Lead screw
Feed change gear box
Lathe specifications
Distance between centers
Swing over the bed
Swing over the cross slide
Horse power of the motor
Number of speeds
Number of feeds
Cutting tools
Cutting tool geometry

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
o Nose radius
Types of tools
Parting tool
Turning tool
Right hand turning tool
Left 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
Lathe operations
Turning
Facing
Knurling
Parting
Drilling
Boring
Taper turning methods
Form tool method
Compound rest method
Tailstock set over method
Using taper turning attachment
Thread cutting method
Special attachments
Copy turning attachment
Radius turning attachment
Machining time and power estimation
Capstan And Turret Lathe

The principle parts are
Bed
Head stock
Cross slide and saddle
The turret saddle and auxiliary slide
Comparison of capstan and turret lathe

S.No.
1.
Capstan lathe
Turret lathe
Short slide since the saddle is Saddle moves along the bed, thus
clamped on the bed in position.
allowing the turret to be of large

size.
2.
Light duty machine, generally for Heavy duty machine, generally for
components whose diameter is less components with large diameters
than 50mm.
3.
as 200mm.
Too much overhang of the turret Since the turret slides on the bed,
when it is nearing cut.
there is no such difference.
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
Number of spindles and work positions
Type
Single spindle automates
Cutting off
Swiss type
Automatic screw machine
Special type
Multiple spindles automates
Cutting off bar
Drilling, forming, cutting off bar
Bar
Special type
UNIT-III : RECIPROCATING AND MILLING MACHINES
Shaper
The main parts of shaper are
Base
Column
Table
Ram
Tool head assembly- tool feed handle, tool slide, apron, clapper box, tool
holder
Specifications
Stroke length
Length and width of table
Number of ram double strokes per minute
Motor horse power
Range of ram speeds
Planer
The main parts of planer are
Bed
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
Types Of Milling Machine
Column and knee type

o Horizontal
o Vertical
o Universal
o Turret type
Production type
o Simplex
o Duplex
o Triplex
Planomillers
Special type
o Rotary table
o Drum type
o Copy milling
o Keyway milling
o Spline shaft milling machine
Horizontal Milling Machine

The basic parts of the horizontal milling machine are
Base
Column
Knee
Saddle
Table
Arbor
Over-arm
Spindle
8
Specifications
The maximum length of longitudinal, cross and vertical travels of the table
and its dimensions
Main drive motor power
Number of spindle speeds
Distance from spindle nose to table surface
Milling cutters
Based on construction
Solid
Inserted tooth type
Based on mounting
Arbor mounted
Shank mounted
Nose mounted
Based on rotation
Right hand rotation
Left hand rotation
Based on helix
Right hand helix
Left hand helix
Plain milling cutters

Side and face milling cutters
Slitting saw
Special form cutters
End mills
Methods of milling
Upmilling (conventional milling)
Down milling (climb milling)
Hole making operations

The types of hole making operations performed on these holes are
Drilling
Boring
Reaming
Counter sinking
Counter boring
Tapping
Universal Drilling Machine(Radial Drilling Machine)

The main parts are
Base
Column
Radial arm
Drill head
Salient features
Provides movement of the spindle in three directions
Several holes can be drilled on a work piece without moving the same.
10
UNIT-IV : ABRASIVE PROCESS, SAWING, BROACHING AND GEAR

CUTTING
Grinding wheel specification and selection
Abrasive types
Aluminium oxide
Silicon carbide
Cubic boron carbide
Diamond
Grain size
Fine
Medium
Coarse
Vitrified
Silicate
Synthetic resin
Rubber
Shellac
Metal
Soft
Medium
Hard
Bond
Grade
Structure
Open
Medium
Dense
11
Grinding wheel types
Wheel balancing
Dressing and truing
Types of grinding machines
Cylindrical grinding
Surface grinding
Centreless grinding
Cylindrical Grinding Machine

The main parts are
Base
Tables lower and upper table
Head stock
Tail stock
Wheel head
Surface grinding machine
Horizontal spindle and reciprocating table
Vertical spindle and reciprocating table
Horizontal spindle and rotating table
Vertical spindle and rotating table
Centreless grinding machine

The main parts are
Grinding wheel
Regulating wheel
12
Types of feed in centreless grinding
Infeed
Through feed
End feed
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
Dimensional accuracy
Lapping
Lapping is generally the final finishing operation done with loose abrasive grains.
The process is employed to get
Extreme accuracy of dimension
Correction of minor imperfection of shape
Refinement of the surface finish
Close fit between mating surfaces
Super finishing
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
generally used for
Removing surface fragmentation
Reducing surface stresses and burns and thus restoring surface

integrity
Correcting inequalities in geometry

13
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
buffing wheel. Negligible amount of material is removed in buffing while a very
high luster is generated on the buffed surface. The dimensional accuracy of the
parts is not affected by polishing and buffing operations.
Abrasive belt grinding

In this process a continuous moving belt with an abrasive is used for grinding the
surfaces. The abrasive belt is normally passed between two wheels with one
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
The various types of sawing machines used are
Hack saw
Manual
Power
Band saw
Vertical
Horizontal
Contour
Circular saw
14
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
Continuous surface broaching machines
Gear cutting
Gear forming Vs Gear generation
Gear shaping
Gear hobbing
15
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
N.C. Procedure
o Process planning
o Part programming
o Tape preparation
o Tape verification
o Production
Components Of CNC
A tape reader
Micro or mini computer
Computer hardware interface and servo mechanism
Machine tool
Advantages
Greater flexibility
High productivity
Good reliability
Metric conversions
Memory functions
16
Manual part programming
Coordinate function
Feed function
Speed function
Tool function
Preparatory functions
Miscellaneous functions
Program number
Tool length compensation
Cutter radius compensation
Canned cycles
Computer assisted part programming

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
programming because of a variety of reasons. The first and foremost in this
respect is the complexity of the work piece which makes manufal part
programming a very difficult exercise. Close tolerance contouring to some
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.
APT language
The complete APT part program consists of the following four types of
statements
Geometry
Motion
Post processor
auxiliary
17

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ME 2252 MANUFACTURING TECHNOLOGY II

Material removal process

Types of machine tools

Shaping and planing machines

Gear cutting machines

Unconventional machining machines

Special machines like automats, copy turning machines, reaming ,

Continuous chip with built-up edge

Mechanics of orthogonal cutting

Merchants cutting force circle

Orthogonal cutting with shear plane

Strain and strain rate in orthogonal cutting

Free ebooks, Notes,Important Questions & study materials online

Requirement of a cutting tool material

Carbon tool steels

High speed steel

Cast cobalt alloys

Cubic boron nitride(CBN)

Taylors tool life equation

Ideal surface finish in turning

Function of a cutting fluid

Types of cutting fluid

Water based emulsions

Straight mineral oils

Mineral oils with additives

Free ebooks, Notes,Important Questions & study materials online

UNIT II : CENTRE LATHE AND SPECIAL PURPOSE LATHES

Feed change gear box

Distance between centers

Swing over the bed

Swing over the cross slide

Horse power of the motor

Cutting tool geometry

Free ebooks, Notes,Important Questions & study materials online

Right hand turning tool

Left hand turning tool

Radius turning tool

Thread cutting tool

Internal turning tool

Inter facing tool

Recess or groove making tool

Internal threading tool

Taper turning methods

Form tool method

Compound rest method

Tailstock set over method

Using taper turning attachment

Thread cutting method

Free ebooks, Notes,Important Questions & study materials online

Copy turning attachment

Radius turning attachment

Machining time and power estimation

Capstan And Turret Lathe

Cross slide and saddle

The turret saddle and auxiliary slide

Comparison of capstan and turret lathe

allowing the turret to be of large

there is no such difference.

Free ebooks, Notes,Important Questions & study materials online

Automatic lathes may be classified based on their

Type of blank machined

Machining accuracy obtained

Principle of operation design features