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MACHINE
ABSTRACT
INTRODUCTION
The project work subject is one, in which actually we are leaning the
theoretical concepts in practical way. Also the practical experience is one
of the aims of this subject. For a developing industry these operating
performed and the parts or components produced should have its minimum
possible production cost, then only the industry runs profitably. There are a
number of units having used in industries for various purposes.
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of
circular cross-section in solid materials. The drill bit is a rotary cutting tool,
often multipoint. The bit is pressed against the workpiece and rotated at
rates from hundreds to thousands of revolutions per minute. This forces the
cutting edge against the workpiece, cutting off chips from what will
become the hole being drilled.
Exceptionally, specially-shaped bits can cut holes of non-circular crosssection; a square cross-section is possible.
Process
Drilled holes are characterized by their sharp edge on the entrance side and
the presence of burrs on the exit side (unless they have been removed).
Also, the inside of the hole usually has helical feed marks.
Drilling may affect the mechanical properties of the workpiece by creating
low residual stresses around the hole opening and a very thin layer of
highly stressed and disturbed material on the newly formed surface. This
causes the workpiece to become more susceptible to corrosion at the
stressed surface.A finish operation may be done to avoid the corrosion.Zinc
Center punching
Constraining the position of the drill bit using a drill jig with drill
bushings
Spot drilling
The purpose of spot drilling is to drill a hole that will act as a guide for
drilling the final hole. The hole is only drilled part way into the workpiece
because it is only used to guide the beginning of the next drilling process.
Center drilling
The purpose of center drilling is to drill a hole that will act as a center of
rotation for possible following operations. Center drilling is typically
performed using a drill with a special shape, known as a center drill.
Deep hole drilling
Deep hole drilling is defined as a hole depth greater than five times the
diameter of the hole. These types of holes require special equipment to
maintain the straightness and tolerances. Other considerations are
roundness and surface finish.
Deep hole drilling is generally achievable with a few tooling methods,
usually gun drilling or BTA drilling. These are differentiated due to the
coolant entry method (internal or external) and chip removal method
(internal or external). Using methods such as a rotating tool and counter-
a rotary motion similar to a twist drill; however, the bits are designed with
bearing pads that slide along the surface of the hole keeping the drill bit on
center. Gun drilling is usually done at high speeds and low feed rates.
Trepanning
Trepanning is commonly used for creating larger diameter holes (up to
915 mm (36.0 in)) where a standard drill bit is not feasible or economical.
Trepanning removes the desired diameter by cutting out a solid disk similar
to the workings of a drafting compass. Trepanning is performed on flat
products such as sheet metal, granite (curling stone), plates, or structural
members like I-beams. Trepanning can also be useful to make grooves for
inserting seals, such as O-rings.
Microdrilling
Microdrilling refers to the drilling of holes less than 0.5 mm (0.020 in).
Drilling of holes at this small diameter presents greater problems since
coolant fed drills cannot be used and high spindle speeds are required. High
spindle speeds that exceed 10,000 RPM also require the use of balanced
tool holders.
drilling technologies are still at a research stage. It is the case of the selfmaintained vibrations drilling: the eigen frequency of the tool is used in
order to make it naturally vibrate while cutting; vibrations are selfmaintained by a mass-spring system included in the tool holder. Other
works use a piezoelectric system to generate and control the vibrations.
These systems allow high vibration frequencies (up to 2 kHz) for small
magnitude (about a few microns); they particularly fit drilling of small
holes. Finally vibrations can be generated by mechanical systems
the
frequency is given by the combination of the rotation speed and the number
of oscillation per rotation (a few oscillations per rotation), the magnitude is
about 0.1 mm.
This last technology is a fully industrial one (example: SineHoling
technology of MITIS). Vibration drilling is a favoured solution in order to
face issues like deep hole drilling, multi-material stacks drilling
(aeronautics) or dry drilling (without lubrication). Generally it allows
increasing the reliability and the control of the drilling operation.
Material
Drilling in metal
High speed steel twist bit drilling into aluminium with methylated spirits
lubricant
Under normal usage, swarf is carried up and away from the tip of the drill
bit by the fluting of the drill bit. The cutting edges produce more chips
which continue the movement of the chips outwards from the hole. This is
successful until the chips pack too tightly, either because of deeper than
normal holes or insufficient backing off (removing the drill slightly or
totally from the hole while drilling). Cutting fluid is sometimes used to
ease this problem and to prolong the tool's life by cooling and lubricating
the tip and chip flow. Coolant may be introduced via holes through the drill
shank,
which
is
common
when
using
gun
drill.
When
flowing out along the fluting. A conventional drill press arrangement can be
used in oil-hole drilling, but it is more commonly seen in automatic drilling
machinery in which it is the workpiece that rotates rather than the drill bit.
In computer numerical control (CNC) machine tools a process called peck
drilling, or interrupted cut drilling, is used to keep swarf from detrimentally
building up when drilling deep holes (approximately when the depth of the
hole is three times greater than the drill diameter). Peck drilling involves
plunging the drill part way through the workpiece, no more than five times
the diameter of the drill, and then retracting it to the surface. This is
repeated until the hole is finished. A modified form of this process,
called high speed peck drilling or chip breaking, only retracts the drill
slightly. This process is faster, but is only used in moderately long holes
otherwise it will overheat the drill bit. It is also used when drilling stringy
material to break the chips.
Drilling in wood
Wood being softer than most metals, drilling in wood is considerably easier
and faster than drilling in metal. Cutting fluids are not used or needed. The
main issue in drilling wood is assuring clean entry and exit holes and
preventing burning. Avoiding burning is a question of using sharp bits and
the appropriate cutting speed. Drill bits can tear out chips of wood around
the top and bottom of the hole and this is undesirable in
fine woodworkingapplications.
The ubiquitous twist drill bits used in metalworking also work well in
wood, but they tend to chip wood out at the entry and exit of the hole. In
some cases, as in rough holes for carpentry, the quality of the hole does not
matter, and a number of bits for fast cutting in wood exist, including spade
bits and self-feeding auger bits. Many types of specialised drill bits for
boring clean holes in wood have been developed, including brad-point
bits, Forstner bits and hole saws. Chipping on exit can be minimized by
using a piece of wood as backing behind the work piece, and the same
technique is sometimes used to keep the hole entry neat.
Holes are easier to start in wood as the drill bit can be accurately positioned
by pushing it into the wood and creating a dimple. The bit will thus have
little tendency to wander.
Grinding Machines
Grinding Machines are also regarded as machine tools. A distinguishing
feature of grinding machines is the rotating abrasive tool. Grinding
machine is employed to obtain high accuracy along with very high class of
surface finish on the workpiece. However, advent of new generation of
grinding wheels and grinding machines, characterised by their rigidity,
power and speed enables one to go for high efficiency deep grinding (often
called as abrasive milling) of not only hardened material but also ductile
materials.
Conventional grinding machines can be broadly classified as:
(a) Surface grinding machine
(b) Cylindrical grinding machine
(c) Internal grinding machine
action at the same time and consequently a higher material removal rate
may be attained than for grinding with a peripheral wheel.
In principle the operation is same as that for facing on the lathe. This
machine has a limitation in accommodation of workpiece and therefore
does not have wide spread use. However, by swivelling the worktable,
concave or convex or tapered surface can be produced on individual
The concept of single pass deep grinding at a table speed much higher than
what is possible in a creep feed grinder has been technically realized in this
machine. This has been made possible mainly through significant increase
of wheel speed in this new generation grinding machine.
Cylindrical grinding machine
This machine is used to produce external cylindrical surface. The surfaces
may be straight, tapered, steps or profiled. Broadly there are three different
types of cylindrical grinding machine as follows:
1. Plain centre type cylindrical grinder
2. Universal cylindrical surface grinder
3. Centreless cylindrical surface grinder
Plain centre type cylindrical grinder
The machine is similar to a centre lathe in many respects. The workpiece is
held between head stock and tailstock centres. A disc type grinding wheel
performs the grinding action with its peripheral surface
Universal cylindrical surface grinder
Universal cylindrical grinder is similar to a plain cylindrical one except that
it is more versatile. In addition to small worktable swivel, this machine
provides large swivel of head stock, wheel head slide and wheel head
mount on the wheel head slide.
This allows grinding of any taper on the workpiece. Universal grinder is
also equipped with an additional head for internal grinding.
Roll grinding is a specific case of cylindrical grinding wherein large
workpieces such as shafts, spindles and rolls are ground.
Crankshaft or crank pin grinders also resemble cylindrical grinder but are
engaged to grind crank pins which are eccentric from the centre line of the
shaft
Cam and camshaft grinders are essentially subsets of cylindrical grinding
machine dedicated to finish various profiles on disc cams and cam shafts.
The desired contour on the workpiece is generated by varying the distance
between wheel and workpiece axes. The cradle carrying the head stock and
tail stock is provided with rocking motion derived from the rotation of a
master cam that rotates in synchronisation with the workpiece. Newer
machines however, use CNC in place of master cam to generate cam on the
workpiece.
External centreless grinder
Boring
may be supported at one end (which works for both through holes
and blind
line-boring)
implies
the
A horizontal boring mill, showing the large boring head and the workpiece
sitting on the table.
Boring head on Morse taper shank. A small boring bar is inserted into one
of the holes. The head can be shifted left or right with fine gradation by a
screw, adjusting the diameter of the circle that the cutting tip swings
holes and counterbores are produced by moving the tool parallel to the axis
of workpiece rotation.
The four most commonly used workholding devices are the three-jaw
chuck, the four-jaw chuck, the collet, and the faceplate. The three-jaw
chuck is used to hold round or hex workpieces because the work is
automatically centered. On these chucks the runout faces limitations; on
late-model CNCs, it can be quite low if all conditions are excellent, but
traditionally it is usually at least .001-.003 in (0.025-0.075 mm). The fourjaw chuck is used either to hold irregular shapes or to hold round or hex to
extremely low runout (with time spent indicating and clamping each piece),
in both cases because of its independent action on each jaw. The face plate
is also used for irregular shapes. Collets combine self-centering chucking
with low runout, but they involve higher costs.
For most lathe boring applications, tolerances greater than 0.010 in
(0.25 mm) are easily held. Tolerances from there down to 0.005 in
(0.13 mm) are usually held without especial difficulty or expense, even in
deep holes. Tolerances between 0.004 in (0.10 mm) and 0.001 in
(0.025 mm) are where the challenge begins rising. In deep holes with
tolerances
this
tight,
the
limiting
factor
is
just
as
often
AC Power
supply
AC Motor
Spindle
Boring operation
Counter shaft
Drilling operation
workpiece
Grinding operation
CONSTRUCTIONAL DETAILS
S.No
Components
Quantity
Material
1.
Grinding wheel
100 mm
Carborandum
2.
Drill bit
15 mm
HSS
3.
Cutter
Mild steel
5.
Belt
and
arrangement
pulley 1
Mild steel
6.
Base plate
Mild steel
7.
Electric motor
WORKING PRINCIPLE
APPLICATIONS
The required
pressure is set and the operation is carried out. In automobile shops various
operations are required frequently Drilling, boring, reaming, grinding etc.
It is also used as a screw driver for tightening and loosening nuts and bolts.
It is used.
1. In automobile workshops
2. In small scale industries
3. In such places where frequent changes in operations are
required
4. In welding shops for grinding.
ADVANTAGES
The pneumatically operated multi purpose device has many
advantages. They are as follows:
Low cost, so it can be used in small scale industries.
Higher rate and quicker operations
A number of operations like (drilling), screw driving,
reaming etc., can be done.
The nuts and bolts can be tightened to a particular
pressure by operating the gate valve placed in the
control unit and the pressure gauge.
Both loosening and tightening is possible. Since there
is air flow in both directions.
DISADVANTAGES
1. Initial cost is high
2. Spindle rotation is pneumatic power, so this machine
having low torque
3. Need a separate compressor
CONCLUSION
With the idea on view, we have completed the project titled
DESIGN AND FABRICATION OF MULTIPURPOSE MACHINE
By means of this machine various operations can be performed using same
power. So this multipurpose device is used for various operations with a
less amount of investment.
This is one of the most reliable and simple machine in the machine
shop in which many number of operations can be done.
REFERENCES
1.
2.
Reference Guide
3.
4.
Machines, McGraw-Hill,
5.
Industry,
6.