Question Bank With Solution: Manufacturing Process-I

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI
Questionbankwithsolution

3rd
semester
1
QUESTION BANK WITH
SOLUTION
Manufacturing Process-I
B.E. III Semester
Mechanical Engineering
By
Prof. Naresh R. Tawale
H.O.D (Mechanical)
Nagpur Institute Of Technology, Nagpur

3rd
semester
2
STUDYOFSINGLEPOINTCUTTINGTOOL

3rd
semester
3
UNITI
Q1 Explain the tool geometry of single point cutting tool used on lathe with neat
sketches?
Classificationofcuttingtools:Allthecuttingtoolsusedinmetalcuttingcanbebroadly
classifiedas:
Single point tools, i.e., those having only one cutting edge; such as lathe tools, shaper
tools,planertools,boringtools,etc.
Multipoint tool, i.e. those are having more than one cutting edge; such as milling
cutters, drills, broaches, grinding wheels etc. These tools may, for the sake of analysis,
be considered as consisting of a number of single point tools each forming a cutting
edge.Thecuttingtoolscanalsobeclassifiedaccordingtothemotionas:
a) Linearmotiontoolslathe,boring,broaching,planning,shapingtools,etc.
b) Rotarymachinetoolsmillingcutters,grindingwheels,etc.
c) LinearandRotarytoolsdrills,boringtools,boringheads,etc.
Important terms: Before proceeding further, it would be advisable to be acquainted
withafewimportanttermsrelatedtotheGeometryofsinglepointtools.(SeeFig)

Fig1.1differentpartsofsinglepointcuttingtool
1. Shank. It forms the body of a solid tool and it is this part of the tool which is
grippedinthetoolholder.

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2. Face.Itisthetopsurfaceoftoolbetweentheshankandpointofthetool.Inthe
cuttingactionthechipsflowalongthissurfaceonly.
3. Point.Itisthewedgeshapedportionwherethefaceandflankofthetoolmeet.It
is cutting part of tool. It is also called nose, particularly in case of round nose
tools.
4. Flank. Portion of tool which faces the work is term as flank. It is the surface
adjacenttoandbelowthecuttingedgewhentoolliesinahorizontalposition.
5. Base. It is actually the bearing surface of the tool on which it is held in a tool
holderorclampeddirectlyinatoolpost.
6. Heel. It is the curved portion at the bottom of tool where the base and flank of
thetoolmeet,asshowninFig1.
7. Noseradius.Ifthecuttingtip(nose)ofasinglepointtoolcarriesasharpcutting
pointthecuttingtipisweak.Itis,therefore,highlystressedduringtheoperation
mayfailorlosecuttingabilitysoonandproducesmarksonthemachinedsurface.
Inordertopreventtheseharmfuleffectsthenoseisprovidedwitharadiuscalled
noseradius.Itenablesgreaterstrengthofthecuttingtip,aprolongtoollifeanda
superior surface finish on the work piece. Also as the value of this radius
increases,ahighercuttingspeedcanbeused.Butifitistoolargeitmayleadto
chatter.Soabalancehastobemaintained.Itsvaluenormallyraisesfrom0.4mm
to1.6mmdependingonseveralfactorslikedepthofcut,amountoffeed,typeof
cutting,typeoftool(solidorwithinsert),etc.
Principlesanglesofsinglepointtools:Thedifferentanglesprovidedonsinglepoint
tools play a significant role in successful and efficient machining of metals. The
thoroughstudyofthesetoolsanglesisthereforemustthemainanglesprovidedon
these tools are shown in Fig 5.4 and the average values of these cutting different
metalsaregiveninchapter6.

3rd
semester
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Fig1.2Principlesanglesofsinglepointofcuttingtools
1. Rakeangle.Itistheangleformbetweenthefaceoftoolandplaneparalleltoits
base. If this inclination is towards the inclination it is known as back rake or top
rake. When it is towards the side of tool it is called the side rake. These rake
angles guide the chips away from cutting edge thereby reducing the chip
pressure on face and increasing the keenness of the tool so that less power is
required for cutting. It is important to note that an increased rake angle will
reduced the strength of cutting edge. With the result, the tools used for cutting
hard metals are given smaller rake angles whereas those used for softer metals
containlargerrakes.
Negative rake. The rake angles described above are called positive rake angles.
When no rake is provided on the tool, it is said to have a zero rake. When the
faceoftoolissogroundthatitslopesupwardfromthepointitissaidtocontain
a negative rake. It obviously reduces the keenness of the tool and increases the
strength of the cutting edge. Such a rake is usually employed on carbide tipped
tools when they are used for machining extra hard surfaces, hardened steel
partsandfortakingintermittentcuts.Atoolwithnegativerakewillhavealarger
lip angle, resulting in a stronger tool. Another advantage of negative rake,
particularlyincaseoftippedtoolsisthatthetendencyofthechippressureisto
pressthetipagainstthebodyofthetool.Thisisobviously,afavorablefactorfor
tippedtools.Thevalueofnegativetakeothesetoolsnormallyvaryfrom5to10
degree.
2. Lip angle. The angle between the face and the flank of the tool is known as lip
angle. It is also sometimes called the angle of keenness of the tool. Strength of
thecuttingedgeorpointofthetoolisdirectlyaffectedbythisangle.Largerthe

3rd
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lip angle stronger will be the cutting edge and viceversa. It would be observed
that since the clearance angle remains practically constant in all the cases, this
anglevariesinverselyastherakeangle.Itisonlyforthisreasonthatwhenharder
metals are to be machined, i.e., a stronger tool is required, the rake angle is
reducedandconsequentlythelipangleisincreased.Thissimultaneouslycallsfor
reducedcuttingspeeds,whichisadisadvantage.Thelipangleis,therefore,kept
as low as possible without making the cutting edge weak, that it becomes
unsuitableforcutting.
3. Clearance angle. It is the angle formed by the front or side surfaces of the tool
which are adjacent and below the cutting edge when the tool is held in a
horizontal position. It is the angle between one of these surfaces and a plane
normaltothebaseofthetool.Whenthesurfaceconsideredforthispurposeisin
frontoftool,i.e.,justbelowthepoint,theangleformediscalledfrontclearance
andwhenthesurfacebelowthesidecuttingedgeisconsideredtheangleformed
is known as side clearance angle. The purpose of providing front clearance is to
allow the tool to cut freely without rubbing against the surface of the job, and
thatofthesideclearancetodirectthecuttingthrusttothemetalareaadjacent
tothecuttingedge.
4. Relief angle. It is the angle formed between the flank of the tool and a
perpendicularlinedrawnfromthecuttingpointtothebaseofthetool.
5. Cuttingangle.Thetotalcuttingangleofthetoolistheangleformedbetweenthe
toolfaceandlinethroughthepoint,whichisatangenttothemachinedsurface
of the work at that point. Obviously, its correct value will depend upon the
positionofthetoolinwhichitisheldinrelationtotheaxisofiob.
Q2 What are the various tool materials? Explain desirable properties of cutting tool
materials?
Various cutting tool materials have been used in industry for different applications. A
number of developments have occurred in the 20 th century thanks to aerospace and
nuclear programmer. A large variety of cutting tool materials has been developed to
cater to the variety of materials used in this programme. The important characteristics
ofacuttingtoolmaterialare:

3rd
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i) Higher hardnessthan that of the workpiece material being machined, so that it
canbepenetratingintotheworkmaterial.
ii) Hot hardness, which is the ability of the material to retain its hardness at
elevated temperatures in view of the high temperatures existing in the cutting
zone. This requirement becomes more and more stringent with the increasing
emphasisonhighercuttingspeedstobolsterproductivity.
iii) Wear resistance The chip tool and chip work interfaces are exposed to such
severeconditions,thatadhesiveandabrasionwearisverycommon.Thecutting
tool material should, therefore, have high abrasion resistance to improve the
effectivelifeoftool.
iv) Toughnessthe tool, even though is hard, should have enough toughness to
withstand the impact loads that come in the beginning of the cut or to force
fluctuationsduetoimperfectionsintheworkmaterial.Thisrequirementisgoing
tobemoreusefulforinterruptedcutting,forexamplemilling.
v) Low frictionthe coefficient of friction between chip and tool should be low,
whichwouldallowlowerwearratesandbetterchipflow.
vi) Better thermal characteristicsSince a lot of heat is generated at the cutting
zone, it is necessary that the tool material should have higher thermal
conductivity to dissipate this heat in the shortest time, otherwise the tool
temperaturewillbecometoohighthusreducingitslife.Allthesepropertiesmay
notbefoundinasingletoolmaterial.Acomparisonoftheseveralofthecutting
tool materials is presented in Table 2.3. Improvements in tool materials have
beentakingplaceoverthepastcenturytogiveusbettercuttingperformance.
Q3Explainthenecessityofacoolantinmachininganditsproperties?
Cutting fluids sometimes referred to as lubricants or coolants are liquid and gases
appliedtothetoolandworkpiecetoassistinthecuttingoperations.
PurposeofCuttingFluids:Cuttingfluidsareusedforthefollowingpurposes:
1. To cool the tool. Cooling the tool is necessary to prevent metallurgical damage
andtoassistindecreasingfrictionatthetoolchipinterfaceandatthetoolwork
piece interface. Decreasing friction means less power required to machine and
moreimportantincreasedtoollifeandgoodsurfacefinish.Thecoolingactionof

3rd
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8
thefluidsisbydirectcarryingawayoftheheatdevelopedbyplasticdeformation
of shear plane and that due to friction. Hence, a high filmcoefficient for heat
transfer is necessary for a good coolant. For cooling ability, water is very
effective, but is objectionable for corrosiveness and lack of friction reducing
wear.
2. To cool the workpiece. The role of cutting fluid in cooling the workpiece is to
preventitsexcessivethermaldistortion.
3. To lubricate and reduce friction. (a) The energy or power consumption in
removing metal is reduced: (b) abrasion or wear on the cutting tool is reduced
thereby increasing the life of the tool; (c) by virtue of lubrication, less heat is
generated and the tool, therefore, operates at lower temperatures with the
tendency to extend tool life; and (d) chips are helped out of the flutes of drills,
tapes, dies, saws, broaches, etc. An incidental improvement in the cutting
operation is that builtup edge will be reduced which, in turn, will decrease
friction at the toolworkpiece area and contribute toward a cooler tool. It is
important to give the optimum cooling effect and lubrication condition in metal
cutting.
4. Toimprovesurfacefinish.
5. To protect the finished surface from corrosion. To protect the finished surface
from corrosion, especially in cutting fluids made up of a high percentage of
water, corrosion inhibitors are effective in the form of sodium nitrate or
triethanolamine.
6. Tocausechipsbreakupintosmallpartsratherthanremainaslongribbonswhich
arehotandsharpanddifficulttoremovefromworkpiece.
7. To wash the chips away from the tool. This is particularly desirable to prevent
foulingofthecuttingtoolwiththeworkpiece.
PropertiesofCuttingFluids:Acuttingfluidsshouldhavethefollowingproperties:
1. Highheatabsorptionforreadilyabsorbingheatdeveloped.
2. Goodlubricatingqualitiestoproducelowcoefficientoffriction.
3. Highflashpointsoastoeliminatethehazardoffire.
4. Stabilitysoasnottooxideintheair.
5. Neutralsoasnottoreactchemically.
6. Odorlesssoasnottoproduceanybadsmellevenwhenheated.
7. Harmlesstotheskinoftheoperators.

3rd
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8. Noncorrosivetotheworkonthemachine.
9. Transparencysothatthecuttingactionoftoolmaybeobserved.
10. Lowviscositytopermitfreeflowofliquid.
11. Lowpricedtominimizeproductioncost.
Choiceofcuttingfluids:Thechoiceofcuttingfluiddependsuponthefollowingfactors.
1. Typeofoperation
2. Therateofmetalremoval
3. Materialoftheworkpiece
4. Materialofthetool
5. Surfacefinishrequirement
6. Costofcuttingfluids
Q4Whatismachinabilityofmetal?Whatfactorsaffectthemachinability?
Machinability:Machinabilityofamaterialgivestheideaofthecasewithwhichitcanbe
machined.Theparametersgenerallyinfluencingthemachinabilityofamaterial:
1. Physicalpropertiesofthematerial.
2. Mechanicalpropertiesofthematerial.
3. Chemicalcompositionofthematerial.
4. Microstructureofthematerial.
5. Cuttingconditions.
Since this property (machinability) of the material depends on various variable
factors,itisnotpossibletoevaluatethesameintermsofprecisenumericalvalues,
butasarelativequantity.Thecriteriaofdeterminingthesamemaybeasfollows:
1. Toollife.Thelongerthetoollifeitenablesatagivencuttingspeedthebetter
isthemachinability.
2. Surfacefinish.Itisalsodirectlyproportional,i.e..,thebetterthesurfacefinish
thehigheristhemachinability.
3. Power consumption Lower power consumption per unit of metal removed
indicatesbettermachinability.
4. Cutting forcesThe lesser the amount of cutting force required for the
removalofacertainvolumeofmetalorthevolumeofmetalremovedunder
standardcuttingforcesthehigherwillbethemachinability.
1
NAGPUR
10
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3rd
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ductilematerialswhenhowcuttingspeedsareusedandadequatelubricationisnot
provided. This causes excessive friction between the chip and tool face, leading to
thefractureofthechipintosmallsegments.Thiswillalsoresultinexcessivewearon
the tool and a poor surface finish on the workpiece. Other factors responsible for
promotingthe production of discontinuouschips are smallerrake angle on the tool
andtoomuchdepthofcut.
1) Continuouschip.

Fig1.4continuouschip
As is evident from the name, the presence of separated segmental elements is
totally eliminated in this case. This type of chip is produced while machining a
ductile material, like mild steel, under favorable cutting conditions, such as high
cutting speed and minimum friction between the chip and the tool face. If
otherwise, it will break and from the segment chip. The friction at the Chiptool
interface can be minimized by polishing the tool face and adequate use of
coolant.Also,withdiamondstoolsthefrictionisless.Thebasisoftheproduction
ofacontinuouschipisthecontinuousplasticdeformationofthemetalaheadof
thetool,thechipmovingsmoothlyupthetoolface.Otherfactorsresponsiblefor
promotingitsproductionarebiggerrakeangle,finerfeedandkeencuttingedge
ofthetool.

3rd
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2) Continuouschipwithbuiltupedge:

Fig1.5Continuouschipwithbuiltupedge
Suchachipisusuallyformedwhilemachiningductilematerialwhenhighfriction
existsatthechiptoolinterface.Theupwardflowingchipexertspressureonthe
tool face. The normal reaction N
R
of the chip on tool face is quite high, and is
maximumatthecuttingedgeornoseofthetool.Thisgivesrisetoanexcessively
high temperature and the compressed metal adjacent to the tool nose gets
weldedtoit.Thechipisalsosufficientlyhotandgetsoxidizedasitcomesofthe
tool and turns blue in color. The extra metal welded to the nose or point of the
tooliscalledbuiltupedge.Thismetalishighlystrainhardenedandbrittle.With
the result as the chip flows of the tool, the built of edge is broken and carried
away with chip while the rest of it adheres to the surface of the work piece,
makingitrough.Duetothebuiltupedgetherackangleisalsoalteredandsois
thecuttingforce.Thecommonfactorsresponsibleforpromotingtheformation
ofbuiltofedgearelowcuttingspeedexcessivefeed,smallrakeangleandlackof
lubricant.
Adverseeffectsofbuiltupedgeformation:
a) Roughsurfacefinishontheworkpiece.
b) Fluctuatingcuttingforce,causingthevibrationincuttingtool.
c) Chancesofcarryingawaysomematerialfromthetoolbythebuiltupsurface,
producingcrateronthetoolfaceandcausingtoolwear.
For avoiding the formation of built up edge the following precaution are
required.

3rd
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i) Thecoefficientoffrictionatthechiptoolinterfaceshouldbeminimizedby
means of polishing the tool face and adequate supply of coolant the
operation.
ii) Therakeangleshouldbekeptlarge.
iii) High cutting speeds and low feeds should be employed because at high
speed the strain of the weld becomes low. Similarly at very high
temperaturealsothestrainoftheweldbecomeslow.
Q6writesshortnoteson
i) Effectofcuttingspeed,feedanddepthofcutontoollife
EffectofcuttingspeedOutofalltheabovefactorsthemaximumeffectontoollifeisof
cuttingspeed.Thetoollifevariesinverselyasthecuttingspeed,i.e.,higherthecutting
speedthesmallerthetoollife.Generally,thereductionintoollifecorrespondingtoan
increaseincuttingspeedisparabolic,asshowninfig3.BasedonpioneerworkofF.W.
Taylor,therelationshipbetweencuttingspeedandtoollifecanbeexpressedas:
.
Fig1.6Curveshowingparabolicreductionintoollifewiththeincreaseincuttingspeed.
VTn=C
V=Cuttingspeed(m/min)
T=Toollife(minutes)

3rd
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N=Anexponents,whosevaluelargelydependsonthematerialofthetool,calledtool
life index. Up to a certain extent, its value is also influenced by some other variables
liketoolmaterial,cuttingconditions,etc.
C = A constant, called machining constant, which is numerically equal to the cutting
speedinmetersperminutethatwouldgiveatoollifeofoneminute.

Fig1.7Cuttingspeedtoollifecurvesfordifferenttoolmaterials.
Forallpracticalpurposestheaveragevaluesofexponentnforcommontoolmaterials
canbetakenas:
n=0.1to0.15forhighspeedsteeltools
=0.2to0.5forcementedcarbidetools
=0.6to1.0forceramictools
Formeasuringtoollifethetoolsareoperatedatdifferentcuttingspeedstofailureand
the results recorded. If the relationship between different cutting speeds and the
correspondingtoolslivesareplottedonlogloggraph,straightlinesobtainedasshown
inFig.1.7whichrevealthatthetoollifedecreaseswiththeincreaseincuttingspeed.
Feedanddepthofcut
Feed rate and depth of cut are the other important cutting variables which also effect
the tool life appreciably. An increase in the feed rate and depth of cut has a similar
effect i.e., reduction in tool life, as is experienced by the tool when cutting speed is
increased. However, the effect is not to severe as produced in the latter case. The

3rd
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differentvariable,cuttingspeed,toollife,feedrateanddepthofcutareinterrelatedas
giveninthefollowingimpericalformula:
257
V=m/min
T0.19xf0.36xt0.30
Where,V=Cuttingspeedinm/min
T=Toollifeinminutes
f=Feedratinmm/min
and,t=Depthofcutinmm
For a given tool life the relationship among the other variables is also given by the
followingimpericalformula:
C
V=
Faxtb
Where,V=Cuttingspeedin(m/min)forthegiventoollife
f=Feedratinmm/min
t=Depthofcutinmm
C=Aconstant
Theexpressionaandbof(f)and(t)willdependuponthemechanicalproperties
of the workpiece material. From the expressionabove it is quite clear that if the
toollifeisconsideredasconstantthecuttingspeed(V)willdecreaseifthefeedrate(f)
anddepthofcut(t)areincreased.

3rd
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ii) ToolSignature(ASAsystem)
Thetermtoolsignatureortooldesignationisusedtodenoteastandardizedsystemof
specifyingtheprincipaltoolanglesofasinglepointcuttingtool.Somecommonsystems
usedfortooldesignationortoolnomenclaturearethefollowing:
1. American (or ASA) System. It declines the principal angles like side rake, back
rake; nose etc., without any reference to their locations with regard to the
cuttingedge.Assuch,thissystemofnomenclaturedoesnotgiveanyinclination
ofthetoolbehaviorwithregardtoflowofchipduringthecuttingoperation.The
threereferenceplanesadaptedfordesignatingdifferenttoolanglesaresimilarto
those used in conventional machine drawing, i.e., XX, YY and ZZ, the last one
containingthebaseoftoolandthetwoplanesbeingnormaltothisplane,aswell
as mutually perpendicular. Thus, this system is a coordinate system of tool
nomenclature.
2. British system. This system, according to BS 1886 1952, defines the maximum
rate.ThevarioustoolparametersinthissystemareindicatedintheorderofBack
rake,Siderake,Endreliefangle,Sidereliefangle,Endcuttingangle,Sidecutting
edgeangle,andNoseradius.
3. Continental systems. This category of tool nomenclature systems includes the
GermanorDINSystem(DIN6581),RussianSystem(OCTBKC6897and6898)and
Czechoslovakian System (CSN1226). The various tool parameters in these
systemsarespecifiedwithreferencetothetoolreferenceplanes.
4. International systems. It is an internationally adopted system, developed
recently. It incorporates the salient features of tool nomenclature of different
systemsinit.
It is a method of identification of tool angles standardized by the American Standards

Association (ASA), according to which seven important elements compromise the
signatureofthesinglepointcuttingtoolandarestatedinthefollowingangle.
Backrakeangle,Siderakeangle,Sidereliefangle,Endcuttingangle,
Sidecuttingedgeangle,andNoseradius.Itisusedtoomitthesymbolfordegreesand
mm,simplystartingthenumericalvalueofeachelement.Forexampleatoolhavingtool
signaturesas10.10,6,6,8,8,2willhavethefollowingangles.
Backrakeangle=10
Siderakeangle=10
1
NAGPUR
17
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3rd
semester
18
4. By a clamp type breaker in which a thincarbide plate or clamp is brazed or
screwedonthefaceofthetool.
Effective control of the chip, as it moves across the face of the tool, may also be
achievedbyproperselectionoftoolangel,feed,depthofcutandcuttingfluidsused.
A large positive front rake gives rise to a looser chip formation, which flows down
the face of tool, and away from the workpiece, leaving the newly cut surface
unscratched. A small positive or negative side rake has the effect of decreasing the
radiusatwhichthechipcoils.Hencethetendencytoproduceshort,easilymanaged
chip. Slightly increased feed gives a thickerchip which breaks more quickly. A small
depthofcutwithafinefeedallowsthechiptoformintocomparativelysmallpieces
or direct it into swarf tray. The use of a good stream of coolant that acts as a
quenching medium causes the hot chip to become harder and break into small
pieces.
iii) Machinabiityindex:
As mentioned in the previous article, the machinabiity of a material is

relative quantity. The machinabilites of different materials are compared
to in terms of their machinabiity indexes. For this purposes machinabiity
indexes are compared. The machinabiity index of this steel is taken
asd100. For computing the machinabiity index of any other material the
followingrelationshipisused:
Machinabiityindex(%)
Cuttingspeedofmetalfor20min.toollife
=x100
Cuttingspeedofstandardfreecuttingsteelfor20min.toollife
But,thisisonlyonemethodsusedfordeterminingmachinabilityratingsofdifferent
materials. The selection of a suitable criterion or method for evaluating the
machinability will depend upon the type of cutting operation. For example, a
comparisonbetweenthecuttingforcesrequiredformachiningaparticularmaterial
andthoserequiredforastandardmaterialmayformthebasisofevaluatingrelative
1
NAGPUR
19
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Fig.1.9O
OF TECHNOL
Similarly, a
gcertainm
ons may als
fail to pro
and,hence
ideringtha
nability inde
entativema
Mach
(%)
steel
25
5565
70
mean by o
weenthese
astohow
6(b)show
rk, in whi
nalcutting
Orthogonal
LOGY
Questionb
compariso
materialwit
so form a b
ovide stand
e,notconsi
tthemach
ex for som
achinability
hinability in
5
oblique and
twometho
thesetwo
wsthediffer
ich the to
andobliqu
bankwiths
on between
hthatobta
basis for ev
dard ratings
ideredvery
inabilityind
e materials
yindexfors
ndex Mate
Red
Alum
Mag
d orthogon
odsisclearl
cuttingme
rencebetw
ool remain
(b)Obl
uecuttingp
olution
n the rate
ainedwith
valuating m
s due to th
yreliable.
dexforfree
s given in T
somemate
erial
brass
minumalloy
nesiumallo
nal cutting?
yillustrated
ethodsdiffe
weentheset
ns stationa
liquecuttin
processesin
Manufacturin
of wear on
astandard
machinabilit
he involvem
ecuttingste
Table 1. as
rials.
Mac
(%)
ys
oys
150
300
500
? How do t
dinFigs.6
erwhiletur
twometho
ary and th
ng
nplanning.
ngprocessI
n a cutting
materialu
ty. Howeve
ment of sev
eelis100%
represent
hinability i
1500
2000
hey differ f
(a)and6(b
rningajob
dsasapplie
he work p
3rd
semeste
tool
nder
er, all
veral
%the
ative
ndex
from
b).In
on a
edto
piece
er

3rd
semester
20
Basically in Orthogonal cutting, the cutting edge of the tool remains at right angles to
the direction of cutting velocity [Fig. 1.9 (a) or work feed, Fig. 1.9 (b)]. This type of
cuttingisalsoasknownastwodimensionalcutting.Inobliquecutting,thecuttingedge
ofthetoolisinclinedatanacuteanglewiththedirectionofthetoolfeedorworkfeed,
the chip being disposed of at a certain angle. This type of cutting is also called three
dimensional cutting. The main features of the two types of cutting are summarized as
below:
Orthogonalcutting
1. Thecuttingedgeofthetoolremainsnormaltothedirectionoftoolfeedorwork
feed.
2. Thedirectionofthechipflowvelocityisnormaltothecuttingedgeofthetool.
3. The angle of inclinationt of the cutting edge of the tool with the normal to the
velocityVtiszero.
4. Thechipflowangle,i.e.,theanglebetweenthedirectionofchipflowandthe
normaltothecuttingedgeofthetool,measuredintheplaneofthetoolfaceis
zero.
5. Thecuttingedgeislongerthanthewidthofthecut.
The last condition may not be fulfilled in some cases. It is then called semi
orthogonalorrestrictedorthogonalcutting.
Obliquecutting
1. The cutting edge of the tool always remains inclined at an acute angle to the
directionoftoofeedorworkfeed.
2. The direction of the chip flow velocity is at angle with the normal to the
cuttingedgeofthetool.Theangleisknownaschipflowangle.
3. The cutting edge of the tool is inclined at angle t with the normal to the
directionoftoolfeedorworkfeed.i.e.,thevelocityVt.
4. Three mutually perpendicular components of cutting forces act at the cutting
edgeofthetool.
5. Thecuttingedgemayormaynotbelongerthanthewidthofthecut.
2
NAGPUR
21
A
o
d
o
p
Orthogo
Theproc
1. O
R INSTITUTE
Aninterestin
ut in wor
iscussionso
f its simpl
rinciplesof
onalandob
cessofmet
Orthogonal
(a) O
Fig.1.10Or
OF TECHNOL
ngfeature
rkshops is
onmetalcu
licity. How
forthogona
liquecuttin
talcuttingis
cutting,and
rthogonal
thogonalan
LOGY
Questionb
tonoteher
through o
uttingwillb
ever, it wo
alcuttingar
ng:
sdividedin
d
ndoblique
bankwiths
rewillbeth
oblique cu
beintheco
ont matte
reequallya
ntothefollo
2
(b)Obliq
cuttingpro
olution
hatmostof
utting meth
ontextofo
er much si
applicableto
owingtwom
2.Obliquec
que
ocessesintu
Manufacturin
fthemetal
hod, but a
orthogonalc
nce most
oobliquec
mainclasse
cutting.
urning.
ngprocessI
lcuttingca
all our fur
cuttingbec
of the gen
utting.
es:
3rd
semeste
rried
rther
cause
neral
er

3rd
semester
22
LATHEMACHINEANDITSOPERATIONS

3rd
semester
23
UNITII
Q1 with block diagram explains the working of a lathe machine mentioning various
directionsinwhichthecuttingtoolcanmove.
Q2 Name the various methods available for taper turning on a lathe machine. Explain
Setovermethodwithaneatsketch.
Q3Whyfeedmechanismisusedinlathe?Describetheworkingoffeedmechanism.
Q4ExplaininbrieftheApronmechanismwithneatsketch?
Q5whatistheuseofbackgear?Explaintheuseofbackgear?
Q6ExplainthreadscuttingoperationonLathemachine
Q7Writesshortnoteson:
I) Latheoperations.
II) Timeestimationforturningoperation.
III) Carriage
IV) Dialchasingindicator
V) Lathesizeanditsspecification

3rd
semester
24
Q1 with block diagram explains the working of a lathe machine mentioning various
directionsinwhichthecuttingtoolcanmove.

Fig2.1BlockDiagramofalathemachineshowingvariousparts.
Fromthefig2.1theheadstockisattheleftendofthebedandisfixedonthebedandis
houses the power source, the power transmission, the gear box and the spindle. The
spindle is hollow and is should be sufficiently rigid to provide accurate rotary motion
andmaintainsaccuratealignmentwiththelatheaxis.ThelivecenterfitsintotheMorse
tapperinthespindleholeforthepurposeoflocatingtheworkpieceaxis.Themaingear
boxprovidesthenecessaryspindlespeedconsideringtherangeofmaterialtobeturned
inthelathe.Theheadstockalsohousesthefeedgearboxtoprovidevariousfeedrates
andthreadcuttingranges.
The tail stock is towards the right end on the bed which provides the tail stock spindle
forthepurposeoflocatingthelongcomponentsbytheuseofcenters.Thetailstockis
movableontheinnerguidewaysprovideonthebedtoaccommodatedifferentlength
of the work piece .It also serves the purpose of holding tools such as twist drill, center
drill,reameretc.formakingandfinishingholesinthecomponentswhicharelocatedin
thelinewiththeaxisofrotation.

3rd
semester
25
The third major element in the lathe mechanism is the carriage which provides the
necessary longitudinal motion to the cutting tool to generate the necessary surface.
Thisalsohousesthecrosssliderforgivingthemotion(crossfeed)tothecuttingtoolin
a direction perpendicular to the axis of rotation, the compound slide, which provide
auxiliary slide to get the necessary special motion for specific surface generation and
toolpostwhichallowsmountingofthecuttingtool.
Themotionofthespindlemotoriscommunicatedtoacarriagethroughtheleadscrew.
Engamentoftheleadscrewwiththecarriageisthroughtheuseofthehalfnut.Though
theleadscrewcanbeusedforfeedingthecuttingtoolinadirectionparalleltotheaxis
of rotation, many a times a separate feed rod is provided for this function. The main
reason is that the lead screw is more accurate and is sparingly used only for thread
cutting,suchthatitmaintainsitsaccuracy.Forroutingfeeding,thefeedrodisused.

Fig2.2
Alargeno.ofsurfacescanbegeneratedbytherelativemotionbetweentheworkpiece
andthecuttingtool.Theshapeofthecuttingtoolisalsoresponsibleforthegeneration
ofaparticularshapesurface.Thecombinationoftwomotioni.e.
1) Primary motion of the tool or the work piece constitutes the Cutting speed which
causestherelativemotionbetweentheworkpieceandthecuttingtoolsuchthatthe

3rd
semester
26
faceofthetoolapproachthematerialtobecut.Usuallytheprimarymotionconsumes
mostofthecuttingpower.

Fig2.3Generationofacylindricalsurfacebysinglepointcuttingtool.
2)Thesecondarymotionistheonewhichfeedsthetoolrelativelypasttheworkpiece.
The combination of the primary and the secondary motion is responsible for the
generationofthedesiredsurface.
Planesurfacegenerationinshaping:
Plane surfaces can be generated when the work piece or the tool reciprocates for the
primarymotionwithoutanyrotation.Withthemultipointtoolgenerallyplanesurfaces
aregenerated.Inthissituationacombinationofformingandgeneratingisusedtogeta
varietyofcomplexsurfaceswhichareotherwiseimpossibletogetthroughsinglepoint
tool operation. Some typical examples are spur gear hobbing and spiral milling of
formedcavities.

3rd
semester
27
fig.no.2.8Generatingaflatsurfacewithalinearmotionofasinglepointcuttingtool
Q2Namethevariousmethodsavailablefortaperturningonalathemachine.Explain
Setovermethodwithaneatsketch.
Variousmethodsareusedfortapperturningonajob.Themostcommonontheseare
thefollowing:
1. TailstockSetOvermethod
2. Byswivelingthecompoundrest
2
NAGPUR
28
3. U
4. U
5. B
1. T
Whe
butt
angle
betw
1) The j
and two
angleto
2)Anal
theorigi
Outoft
clamping
boththe
position
part is t
operato
be shifte
stock, fa
graduati
Therequ
Onrefer
x=L
R INSTITUTE
Usingtheta
Usingaform
Bycombing
TAILSTOCK
n tapper tu
thetipofth
eofinclinat
womethod
ob revolve
o centers, w
thecenter
lternativem
inalpositio
hetwothe
gboltofth
efrontand
byapred
to be obta
r and if the
ed towards
acing the he
ionsasteel
uiredamou
rringtofig2
Lsin
OF TECHNOL
pperturnin
morbroadn
alongitudi
SETOVERM
urning is pe
hetoolshou
tionshould
sforaccom
Fig.2.9Tap
s in a posit
while the t
rlineofthe
methodcan
nandmove
tailstockm
etailstock
rearendo
determined
ained on th
e same is to
s the opera
ead stock h
rulecanbe
untoftailst
2.9itwillbe
LOGY
Questionb
ngattachme
nosetool
nalandcro
METHOD
erformed a
uldmoveat
beequalt
mplishingth
perturningb
tion, i.e. in
tool moves
job.
nbetoshift
ethetoolp
methoduti
kisloosened
fthetailst
amountof
he tail stoc
o be obtain
ator. Gradu
help in adju
eusedfort
tocksetove
eseenthat
bankwiths
ent
ossfeedina
at that time
taninclinat
o i.e.hal
heserelative
bytailstock
perfect ali
along the
tthecente
paralleltoth
lizesthese
d.Then,by
tock,thede
fsetover.
ck side the
nedon the
uations pro
usting the r
thispurpose
ercanbeca
t
olution
aspeciallat
e the work
tiontothe
lfofthetot
emovemen
ksetover
ignment wi
straight lin
rlineofthe
heaxisofth
econdmeth
ymeansoft
eadcenter
Ifthelarge
e center wi
head stock
ovided on t
required se
e.
alculatedas
Manufacturin
the.
rotates an
centeraxis
taltappera
nts.
ith the hea

ne which is
eworkata
hespindle.
hod.Forthi
thesetscre
isshiftedfr
erdiameter
ill be shifte
k side the d
the flat sur
t over. In a
sfollows:
ngprocessI
d the tool
softhejob.
angle.There
ad stock sp
s inclined a
anangle f
sthenuto
ew,provide
romtheori
rofthetap
ed towards
dead center
rface of the
absence of
3rd
semeste
feed
.This
ecan
indle
at an
from
fthe
edon
ginal
pered
s the
r will
e tail
such
er

3rd
semester
29
Foraverysmallangle itcanbesafelyconsideredthat:
sin tan
x=Ltan
Dd
But,tan canalsobetaken=(consideringtriangleEFGorKLM)
2l
Ddtotaltaper
Therefore,x=L=Totallengthx
2l 2xTaperlength
Wherex=requiredsetoverinmm
D=largerdia.Inmm
d=smalldia.inmm
L=Totallengthofworkinmm
L=lengthoftaperedportioninmm
Incasethejobistobetaperedoveritsfulllength,lwillbeequalto=L.Therefore,the
setoverwillbegivenby:
Dd TotalTaper
x==
2 2
2.BYSWIVELLINGTHECOMPOUNDREST:
Steepandshortexternaltapercaneasilybeturnedinlathebyswivelingthecompound
rest on the carriage through an angle which is equal to half the total included angle of
the taper. The compound rest carries swivel plate under it. It is screwed to the cross
slide by means of a bolt and nut. The graduations on its periphery are in degrees. For
swiveling the compound rest the swivel plates is unscrewed and then rotated, along
with the compound rest, through the required angle. The graduations on the swivel
plateshelpinsettingthecompoundrestatthedesiredinclination.Toolisthenfeedby
handbyrotatingthecompoundresthandscrew.Therequiredinclinationiscalculated
bytheformula:
3
NAGPUR
30
ta
3.BYUS
Itisave
As the
anywhe
withdiff
Itiscap
maximu
mm.
R INSTITUTE
Fig.2.1
D
an =
2L
SINGTHET
erysuitable
attachmen
re along th
ferentman
pableoftur
m,andthe
OF TECHNOL
10turningt
d
TAPERTU
methodof
nt travels a
he length of
ufacturers
rningallcla
maximum
LOGY
Questionb
taperswive
RNINGATT
ftaperturn
along with
f the job. A
haveacom
assesoftap
lengthoft
bankwiths
elingthecom
TACHMENT
ningwhich
the saddl
All the tape
mmonprinc
persofwhic
hetaperth
olution
mpoundre
T:
providesa
e, it is po
er attachme
ipleofwork
chthetotal
atcanbet
Manufacturin
st
verywider
ossible to t
ents though
king.
lincludeda
urnedinon
ngprocessI
rangeofta
turn the p
h vary in de
angleis16
0
nesettingis
3rd
semeste
pers.
paper
esign
0
asa
s235
er
3
NAGPUR
31
CONSTR
The atta
guide pl
work.Gu
theaxis
slide p
lockingl
WORKIN
First,th
ways. A
calibrate
thisang
angle
the sadd
blockB
lineofm
R INSTITUTE
RUCTION:
achment co
late G whic
uideplateG
ofthewor
provided w
everandis
NG:
hecrosssli
A graduated
edindegre
le.Thisme
withthece
dle, the gui
isconnecte
movement,
OF TECHNOL
Fig
onsists of a
ch can be
Gcarriesa
k.Guidepla
with a tie T
sfreetoslid
deisdiscon
d scale is p
ees.Thehal
ans,thegu
enterlineo
ide block B
edtothecr
thatisana
LOGY
Questionb
.2.11Useof
bracket at
swung and
slotwhich
ateGcarrie
at its rear
dealonggu
nnectedfro
provided o
lftaperang
uideplateis
ofthebrack
B will slide a
rossslidei
angle tot
bankwiths
ftaperturn
ttached to
d set at a d
canbeswu
esaslotS,f
r. Block B i
ideplateth
omthesadd
n the brac
gle( )isca
ssetinsuc
ket.Thus,w
along the c
twillguide
theaxisoft
olution
ningattachm
the rear si
desired incl
ungandset
fittedwith
is connecte
hroughthe
dlesothat
cket, as sho
lculatedan
hawaytha
whenthelo
center line
ethetoolto
thejob.
Manufacturin
ment
de of the b
lination to
tatadesire
aslidingbl
ed to this t
slotS.
itisfreeto
own in dia
ndtheguid
atitscente
ongitudinal
of the guid
otravelpa
ngprocessI
bed. It carr
the axis of
edinclinatio
ockB.thec
tie through
omovealon
agram, whic
eplateiss
erlinemake
feedisgive
de plate. As
ralleltoits
3rd
semeste
ries a
f the
onto
cross
h the
ngits
ch is
etat
esan
ento
s the
own
er

3rd
semester
32
After every cut, the feed to the tool is given by moving the compound restwhich is
poisoned parallel to the cross slide, i.e. , at 90
0
to the axis of the job. The required
anglecaneasilybefoundoutfromtherelation:
Dd
Tan=alldimensionsareinmm
2L
Dd
=tan
1
(degrees)
2L
Or
Insometaperturningattachmentitwillbeobservedthatthebracketinsteadofhaving
graduationsindegreescarriesdivisionsinmm.insuchcaseswehavetofindoutno.of
mm divisions through which the guide plate should be swiveled instead of calculating
theangle .Thesedivisionscanbefoundoutfromtheformula:
Dd
M=xC
2L
Where, M = the required no. of mm divisions through which the guide plate is to be
swiveled.
D=Largerdia.Inmm
D=Smallerdia.Inmm
L=Lengthoftaperinmm
C=halfofthetotallengthofguideplateinmm.
ADVANTAGESOFUSINGATAPERTURNINGATTACHMENT:
1. Itssettingisveryeasyandcanbedoneveryquickly.
2. Itsusedoesnotcallfortoomuchofskillonthepartoftheoperator.
3. Accuratecanbereadilybeobtainedinasinglesetting.
3
NAGPUR
33
4. N
d
a
5. It
6. I
b
4.USIN
Very sho
cutting
causea
in cuttin
maximu
Q3 Wh
thewor
Thegea
reversin
R INSTITUTE
Normal set
uringtheo
lignmento
tisequallys
ts use enab
ecauselong
GAFORM
F
ort tapers c
edge of th
lotofvibra
ng. Therefo
m20mmle
y feed me
kingoffee
rmechanis
ng mechan
OF TECHNOL
up and al
operation,a
rthecomp
suitablefor
ble a bette
gitudinalpo
ORBROAD
ig.2.12Tap
can easily b
e tool is gr
ationsandc
ore while u
ength.Use
chanism (t
dmechanis
smoperate
ism. This i
LOGY
Questionb
ignment of
asinotherm
oundrestis
rexternala
r surface fi
owerfeeds
DNOSETOO
perturning
be turned
round to c
chatterbec
using this m
ofheavyan
tumbler rev
sm?
dbymeans
is used for
bankwiths
f the lathe
methodseit
stobeswiv
swellasin
nish and e
caneasily
OL:
byusingbr
with the fo
ontain half
ausethefu
method for
ndrigidtyp
versing mec
softhefee
r providing
olution
and its ma
therintwo
veled.
ternaltape
nsure an in
beemploye
roadnoset
orm or broa
f taper ang
ullcuttinge
turning ve
peoflathew
chanism) in
edreverse
g power fe
Manufacturin
ain part is
ocentersar
ers.
ncrease rate
ed
tool
ad nose to
gle Use of s
edgeofthe
ery short ta
willincrease
n used in l
leveriscall
eeds to the
ngprocessI
not distrib
ethrowno
e of produc
ol in which
such a too
toolisinvo
aper, say u
ethislimit.
athe? Desc
ledthetum
e carriage.
3rd
semeste
buted
utof
ction
h the
l will
olved
up to
cribe
mbler
The
er

3rd
semester
34
motionfromthespindletotheleadscrewortothefeedrodistransmittedthroughthis
mechanism.
Referfig

Fig.2.13Feedmechanismandchangegears
GearG
1
ismountedontherearendofthespindleS.thefeedmechanismconsistofthe
gears G
2
, G
3
and G
4
and is operated by means of feed reverse lever F. When the lever
operated from the center position to either the top or the bottom position one of the
gear G2 or G3 will mesh with the gear G1 where as these two gears always mesh with
each other mutually. Thus, it will be seen that in top position of the lever F motion is
transmitted from gear G1 to G4through gear G3 and gear G2 plays no role with the
resultthegearG4willhavethesamedirectionofrotationasthespindlefig(a).
Against this, in lower position of the lever F, motion from G1 is transmitted to G4
through G2and G3 respectively as shown in fig (b). This will enable G4 to rotate in a
directionoppositetothatofthespindleS.Itwillbeevidentthatwhentheleverwillbe
initscentralpositionneitherofgearsG2andG3willbemeshingwithG1andthusthe
feed mechanism will be disengaged. The above mechanism is usually enclosed in the
headstockexcepttheleverFwhichiskeptprojectingoutside.

3rd
semester
35
Onthesameend,astheabovemechanism,butoutsidetheheadstock,thereisanother
setofgearscalledChangegears.ThisconsistofgearsG5,G6,G7andG8.Etc.GearG5is
mounted on the same spindle as G4 and thus rotates at the same speed as the latter.
This transmits the motion to gear G8 through G6 and G7, which further transmit it to
the lead screw or the feed rod. These four gears are known as change gears for the
reasonthattheycanberemovedandreplacebytheothergearshavingdifferentnoof
teeth. A desired speed of lead screw or feed rod can be obtained by selecting the
suitablechangegearshavingpropernoofteeth.GearsG6andG7areusuallymounted
on the stud and are known as stud gears. A quadrant is provided and the stud can be
shifted along its straight slot to enable proper meshing of change gears. Also, this
quadrantcanbeswungverticallyalongtheslotPtoenablemeshingofgearG5andG6.
Whenpropermeshinghasbeenacquiredthequadrantislockedinposition.GearG8is
mounteddirectlyontheleadscrewonthoselatheswhichdonothaveafeedgearbox,
where it is mounted on the gear box driving shaft in those lathe which carry the gear
box.
Q4ExplaininbrieftheApronmechanismwithneatsketch?
Apron:
It is the hanging part in front of the carriage. It serves as housing for no of gear trains
through which power feed can be given to the carriage and cross slide. Also it carries
the clutch mechanism and split half nut. Out of these two, the former (clutch
mechanism) is used to transmit motion from the feed rod, whereas the latter, in
conjunctionwiththeleadscrew,movesthewholecarriageinthreadcutting.
ApronMechanism:
Throughthismechanismpowerfeedscanbegiventothecarriageandcrossslide.
Construction:
H is the hand wheel for providing the longitudinal hand feed to the carriage.H
1
is the
hand wheel for providing hand feed to the cross slide. Lever L
1
is for engaging or
disengaging the power feed to the carriage and cross slide. Star wheel S is operated
when power feed is to be engaged. Lever L
2
operates the split half nut N to engage or
disengagethesamefromleadscrewL.Disthechasingdialusedinthreadcutting.
3
NAGPUR
36
Insideth
rear end
Spindle
therack
bylever
gear G
3
free and
theGea
alwaysi
Spindle
Gear G
9
whichca
whenw
drawnin
the S
5
d
disengag
ofG
9
an
R INSTITUTE
heapronth
d and hand
S
2
carriesa
kprovideda
rL
1
.Thislev
with G
4
wh
d is not me
rG
2
.Spindl
nmeshwit
S
5
is just b
is not rigid
anbedraw
ewanttot
n.thisenab
riven by th
gethesame
dthetrans
Fig.2.1
OF TECHNOL
hereare5s
d wheel at
anothergea
atthefront
verhasthre
ich is moun
esh with an
leS
4
inadd
thgearG
6
w
below the s
dly secured
wninorpus
transmitth
bletempora
he lead scre
e,thestarw
missioniss
4Apronme
LOGY
Questionb
spindlesS
1
,
the front.
arG
7
atitsr
tofthelat
eeposition
nted on sp
y other gea
itiontogea
whichismo
spindle S
3
a
to S
5
. Clut
shedoutby
emotionfr
arilyrigidfa
ew through
wheelisro
stopped.
echanismu
bankwiths
,S
2
,S
3
,S
4
a
G
1
is in m
rearend,o
he.Spindle
s1,2and3
indle S
4
.In
ar. In posit
arG
4
carrie
ountedont
and it carrie
tch T is pro
yrotatingt
romthelea
asteningbe
h the worm
tatedinthe
useinlathe
olution
andS
5
.Spind
mesh with G
utsidethe
eS
3
carries
3.Inpositio
position 2
ion 3 i.e. to
esanotherg
hescrewed
es gear G
8
ovided at th
hespindle
adscrewto
etweenS
5
a
m W and ge
ereversed
Manufacturin
dleS
1
carrie
G
2
mounted
apron,whi
gearG
3
wh
on1i.e.low
i.e. the mid
op, the gea
gearG
5
atit
dspindleof
and G
9
wit
he rear end
bymeanso
othespindl
ndG
9
,with
ear G
9
. Wh
irectionto
ngprocessI
esgearG
1
a
d on spindl
chmeshes
hichisoper
west,iteng
ddle; Gear
ar G
3
mesh
tsrearend
fthecrosss
h the worm
d of this sp
ofstarwhe
eS
5
thesp
htheresult
hen we wan
pushthecl
3rd
semeste
atits
e S
2
.
with
rated
gages
G
3
is
with
.Itis
slide.
m W.
indle
eelS.
indle
that
nt to
lutch
er

3rd
semester
37
WORKING:
Whenhandfeedisrequiredtobegiventothecarriageorthecrossslide,leverL
1
isput
inposition2sothatthegearG
3
neitherengagedwithG
4
norwithG
2
.Whenpowerfeed
istobegiventothecarriage,leverL
1
isputinposition3sothatG
3
mesheswithG
8
and
G
2
simultaneously.StarwheelistightenedtoconnectG
9
withS
5
.Motionistransmitted
from the lead screw to the G
9
, through the worm and hence to S
5
and G
8
. It is further
transmitted to G
2
and hence G
7
, they being on the same spindle. G
7
meshes with the
fixed rack and, therefore, the carriage is moved. To give power feed to the cross slide
lever L
1
is put in position 1, so that the gear G
3
meshes with the G
4
. Now the
transmission of the motion from the lead screw is to the worm then to G
2
and G
8
and
finallytoG
3
throughG
4
andG
5
.
This mechanism is not capable of providing power feed to both lead screw and cross
slidesimultaneously.
Q5whatistheuseofbackgear?Explaintheuseofbackgear?
BackgearedHeadstock:
CONSTRUCTION:
The back geared head stock consist of a casing accommodating the main Spindle, the
threeorfourstepconepulleyandthebackgears.Theinternalmechanismofthistype
ofheadstockisshowninfig.Inthis,astepconepulleyismountedonthemainspindle,
whichcarriesaspurgearG
1
atitsoneendandapinionP
1
attheother.GearG
1
isfirmly
keyedtothespindlesothatitcanneverrevolvefree.Thespindlecarriesasleeveoverit
whichisaloosefit.Theconepulleyisfirmlysecuredtothissleeve.Also,thepinionP
1
is
firmlysecuredtothissleeve.ThisarrangementforcesthepinionP
1
torevolvewiththe
cone pulley under all conditions. A spring knob K engages the gear G
1
with the cone
pulley. The cone pulley is driven by means of a belt, through a countershaft, by an
electricmotor.Thisspindleenablesfourdifferentspeedofspindle.
Useofbackgears(WORKING):
The back is used for effecting reduction in spindle speeds, there by facilating a wider
rangeofspeeds.Thebackgearsaremountedonaneccentricshaftwhichisoperatedby
means of hand lever known as back gear engaging lever (L). The back gears consist of
spur gear G
2
(opposite pinionP
1
) and a pinion P
2
(opposite gear G
1
). When speed

3rd
semester
38
reductionisdesired,theknobispulledouttomaketheconepulleyfreeofgearG
1
and
hencethespindle.Thebackgearsareputintomeshwiththespindlegearsbypullingin
theeccentricshaft.Nowthesequenceoftransmissionofmotionandpowerissuchthat
the cone pulley is driven by the motor through the belt. With the result the pinion P
1
revolves.ThisbeinginmeshwithgearG
2
,transfersthemotiontolatterwhich,inturn,
revolves the eccentric shaft and hence the pinion P
2
.This, further being in mesh with
gearG
1
,transmitthemotiontothelatterandhencetotheSpindle.
Q6ExplainthreadscuttingoperationonLathemachine
PRINCIPLEOFTHRESDCUTTING:
Thread cuttingis oneof the important operations performed onlathe. Theprinciple of
thread cutting is to produce a helical groove on a cylindrical or conical surface by
feedingthetoollongitudinallywhenthejobisrevolvedbetweencentersorbyachuck.
Thelongitudinalfeedshouldbeequaltothepitchofthethreadtobecutperrevolution
of the work piece. The leadscrew of the lathe, through which the saddle receives its
traversing motion, has a definite pitch. A definite ratio between the longitudinal feed
androtationoftheheadstockshouldthereforebefoundoutsothattherelativespeed
of rotation of the work and the leadscrew will result in the cutting of a screw of a
desired pitch. This is affected by change gears arranged between the spindle and
theleadscreworbychangegearmechanismorfeedboxusedinamodernlathewhereit
providesawiderrangeoffeedandthespeedratiocanbeeasilyandquicklychanged.
THREADCUTTINGOPERATION:
In thread cutting operation the first step is to remove the excess material from the
workpiece to make its diameter equal to the major diameter of the screw thread.
Change gears of correct sizeare then fitted to theend of the bed between the spindle
and the leadscrew. The shape or form of the threads depends on the shape of the
cuttingtooltobeused.
Inametricthread,theincludedangleofthecuttingedgeshouldbegroundexactly60
0
.
The top of the tool nose should be set at the same height as the center of the
workpiece. A thread tool gauge is usually used against the turned surface to check the
cutting tool so that each face of the cutting tool may be equally inclined to the center

3rd
semester
39
lineoftheworkpiece.Thespeedofthespindleisreducedbyonehalftoonefourthof
the speed required for turning according to the type of the material being machined,
andthehalfnutisthenengaged.Thedepthofcutwhichusuallyvariesfrom0.05to0.2
mmisappliedbyadvancingthetoolperpendiculartotheaxisoftheworkoratanangle
equaltoonehalfoftheangleofthethread,and30
0
inthecaseofthemetricthread,by
swiveling the compound rest. Except when taking very light finishing cuts, the latter
methodissuperiortotheformerasit
1. Permitsthetooltohaveatoprake;
2. Permitscuttingtotakeplaceononeedgeofthetoolonly.
3. Allowthechipstoslideeasilyacrossthefaceofthetoolwithoutcrowding.
4. Reducescuttingstrainthatactsonthetool.
5. Reducesthetendencytocausethetooltodigin.
After the tool has produced a helical groove up to the end of the work this is quickly
withdrawnbytheuseofthecrossslide,thehalfnutdisengaged,andthetoolisbrought
back to the starting position to give a fresh cut. Before reengaging the half nut it is
necessary to ensure that the tool will follow the same path it has traversed in the
previouscut,otherwisethejobwillbespoiled.Severalcutsarenecessarybeforethefull
depth of thread is reached. Arising from this comes the necessary to pickup the
thread.
Cuttingrighthandandlefthandthreads:
When cutting the right hand threads the carriage must move towards the head stock,
for a left hand thread the carriage must moves from the headstock and toward the
tailstock.Thejobmovesasalways,intheanticlockwisedirectionwhenviewedfromthe
tailstock end. As previously mentioned the direction at which the carriage moves in
relationtothelatheheadstockiscontrolledbymeansofthetumblergearsorbevelgear
feedreversingmechanism.
Cuttingmultiplethreads:
In a piece of the work it is possible to have several separate and independent threads
runningalongit.Accordingly,theremaybesinglethreadedscrewandmultipleormulti
startthreadedscrew.Theindependentthreadsarecalledstarts.Foronecompleteturn

3rd
semester
40
round the screw when there is a movement of one threads the screw is called single
threaded screw but when there is a movement of more than one thread the screw is
called multi or multistar threaded screw.In the case of, a three startthread, for one
complete turns the thread advance three times as far as if it was a single thread. The
distancethemultiplescrewthreadadvancesalongitsaxisinoneturniscalledlead.
Thecalculationforthemultistartthreadareidenticalwiththoserequiredforasingle
start thread. The ratio depends upon the relationship between the pitch of the lead
screwofthemachine,andthelead,butnotthepitch,ofthethreadtobecut.
Thismaybewrittenas:
DriverPitch Leadofthescrewtobecut
=
DrivenPitch PitchoftheLeadscrew
The cutting procedure of multi start thread is similar to that of single start threads. In
multi start threads, circumference of the job should be divided equally in to as many
partastherearestartsonthethreads,andeverypartsordivisionofthecircumference
ofthejobbecomesthestartingpointforthenewthread.
Cuttingtaperedthread:
The surface is first turn taper to the required angle by any one of the taper turning
methodsdescribedbefore.Thethreadcuttingtoolisthensetperpendiculartothelathe
axis and not to the tapered surface. To produce an accurate thread a taper turning
attachmentisused.Thisisswiveledtobethehalftaperangle.Thethreadisfinishedin
theusualmanner.
Q8Writesshortnoteson:
I. Latheoperations:
The various operations have been performed on the lathe machine to generate the
desiredshape.
a) Turning:

3rd
semester
41
Turningisbyfarthemostcommonlyusedoperationinalathe.Inthis,theworkheldin
thespindleisrotatedwhilethetoolisfedpasttheworkpieceinadirectionparallelto
theaxisofrotation.Thesurfacethusgeneratedisacylindricalsurface.(fig4.1)
b) Facing:
Facing is an operation for generating flat surfaces in lathes. The feed, in this case, is
given in a direction perpendicular to the axis of revolution. The tool used should thus
have an approach angle suitable so that it would not interfere with the work piece
duringthetoolfeeding.
Also, the radius of work piece at the contact point of tool varies continuously, as the
tool approaches the center. Thus, the resultant cutting speed continuously varies in
facing, starting at the highest value at the circumference, to almost zero near the
center. Since the cutting action and the surface finish generated depend on the actual
cuttingspeedoftheworkpiece,duecartehastobetakenofthisfact.
c) Knurling:
Knurlingisametalworkingoperationdoneinalathe.Inthis,aknurlingtoolhavingthe
requisite serrations is forced on to the work piece material, thus deforming the top
layer, as shown in fig. this forms a top surface, which is rough and provides a proper
grippingsurface.
d) Parting:
Partingandgroovingaresimilaroperations.Inthis,aflatnosedtoolwouldplungercut
the work piece with a feed in the direction perpendicular to the axis of revolution, as
shown in fig. This operation is generally carried out for cutting off the part from the
parent material. When the tool goes beyond the center, the part would be severed.
Otherwise, a rectangular groove would be obtained. It is also possible, in similar
operation,touseaspecialformofatooltoobtainthespecificgrooveshape.
e) Drilling:
Drilling is the operation of making cylindrical holes into the solid material, as shown in
fig.AtwistDrillisheldinthequillofthetailstock,andisfedintotherotatingworkpiece
byfeedingthetailstockquill.Sincetheworkpieceisrotating,theaxisoftheholeiswell
maintained,evenwhenthedrillentersatanangleinitially.Thesameoperationcanalso

3rd
semester
42
be used for other hole making operations, such as center drilling, counter sinking, and
counter boring. This operation is limited to holes through the axis of rotation of the
ends.
f) Boring:
Boring is the operation of enlarging a hole already made by a single point boring tool
turnedasboringbar,asshowninfig.Theoperationissomewhatsimilartotheexternal
turning operation. In view of the internal operation, it is more restricted. The cutting
forcesexperiencedaresomewhatmorethantheexternaloperation.Also,thetoolused
is less rigid compared to tuning tool, and as a result, it cannot withstand the large
cuttingforces.Thus,theprocessparametersusedaresomewhatlowerthanthoseused
forturning.Boringisusedforgeneratinganaccurateholewithgoodsurfacefinish.
II. Timeestimationforturningoperation:
The total time in completing the job by machining will includes many factors such as
actual time taken in machining (cutting time), time required in setting of job, time
requiredinsettingoftoolortoolsandhandlingtime,etc.Themethodofcomputingthe
actualmachiningorcuttingtimeisgivenbelow:
Supposetheworkistobeturnedthroughthelengthoflmm
l
1
=thedistancerequiredforfeedingthetoolcrosswise,toincreasethedepthofcutin
mm.
l
2
=overtravelofthetoolinmmattheendoftheeachcut.
t=Depthofcutinmm.
f
1
=feedinmmperrevolution.
N=speedinrpmofthework.
n=totalnoofcutstakenforobtainingtherequireddiameterofthefeed.
L
1
=totaldistance,inmmthatthetooltravelsinthedirectionofthefeed.
Now,thedistancetravelbythetoolinthedirectionofthefeedinasinglecut
=l+l
1
+l
2
=L(say)

3rd
semester
43
Therefore,thetotaldistancesL
1
isgivenby:
L
1
=Lxnmm
Alsotheamountoffeed(f)perminuteisgivenby
f=f
1
xNmm
The Time T, in minutes, required for the tool to move through the complete length L
1
mmwillbecomputedbytheformula:
L
1
T=minutes
f
Lxn
=minutes
f
1
xN
III. Carriage:
Thelathecarriageservesthepurposeofthesupporting,guidingandfeedingthetool
against the job during the operation on the lathe. It consists of the following main
parts.

Fig.thecarriage

3rd
semester
44
a) Saddle:
It is the part of the carriage which slide along the bed ways and supports the
crossslide,compoundrestandtoolpost.
b) Crossslide:
Itismountedonthetopofthesaddleandalwaysmovesinadirectionnormaltothe
axis of the main spindle. It can either be operated by hand by means of the cross
feedscrew,ormaybegivenpowerfeedthroughtheapronmechanism.
c) Compoundrest:
It is also known as tool rest. It is also mounted on the cross slide and carries a
graduatedcircularbase,calledaswivelplate.Thelatterisgraduatedindegreesand
enables the former to swivel to any angle in a horizontal plane. The upper part,
known as compound slide, can be moved by means of the compound rest feed
screw.
d) Toolpost:
Itisatopmostpartofthecarriageanditisusedforholdingthetoolortoolholderin
position.
e) Apron:
Itisthehangingpartinfrontofthecarriage.Itservesashousingfornoofgeartrains
through which power feed can be given to the carriage and cross slide. Also it
carriestheclutchmechanismandsplithalfnut.Outofthesetwo,theformer(clutch
mechanism) is used to transmit motion from the feed rod, whereas the latter, in
conjunctionwiththeleadscrew,movesthewholecarriageinthreadcutting.
IV)Chasingdialorthreadindicator:
Thechasingdialisaspecialattachmentusedinmodernlathesforaccuratepicking
up of the thread. This dial indicates when to close the split or half nuts. This is
mounted on the right end of the apron. It consists of a vertical shaft with a worm
gearengagedwiththeleadscrew.Thetopofthespindlehasarevolvingdialmarked
withlinesandnumbers.Thedialturnswiththeleadscrewsolongthehalfnutisnot

3rd
semester
45
engaged.Ifthedialturns,thegraduationspassafixedreferenceline.Thehalfnutis
closed for all even threads when any line on the dial coincides with the reference
line. For all odd threads, the half nut is closed at any number line on the dial
determinedfromthecharts.Ifthepitchofthethreadtobecutisanexactmultiple
ofthepitchoftheleadscrew,thethreadiscalledeventhreadotherwisethethread
iscalledoddthread.
Incaseofdialtherulefordeterminingthedialdivisionis:
In the case of metric thread, the product of the pitch of the lead screw and the
number of the teeth on the worm wheel must be an exact multiple of the pitch of
the thread to be cut. In the case of the English threads, the product of the threads
per inch to be cut and the number of teeth on the worm wheel must be an exact
multiple of the number of threads per inch of the lead screw. For example, if the
pitch of the lead screw is6 mmand the worm wheelhas 15 teeth, the product will
be90,suchas1,1.25,1.5,2,2.25,3,3.75,4.5,6,7.5,9,10,15,30,45,90,maybe
pickupwhenanylineofthedialcoincidewiththereferenceline.Forpickingupthe
threadsofdifferentpitches,asetofwormwheelisusedtogivedesiredvalue.
V) Lathesizeanditsspecification:
In order to specify the lathe, the no. of parameters is used based on the specific
applications. The major elements used for specification should invariably be based
on the components that are manufactured in the lathe. The following are the basic
elementsgenerallyspecifiedforthecapabilityofthelathemachine.Fig
Distancebetweencenters:specifiesthemaximumlengthofthejobthatcanbe
turnedinthelathe.
Swing over the bed: specifies the maximum diameter of the job that can be
turnedinthelathemachine,generallyrestrictedtosmalllengthjobs.
Swing over the cross slide: specifies the maximum diameter of the job that can
be turned in the lathe machine with the job across the cross slide, which is
generallythecase

3rd
semester
46
Throughthe above gives the basic capacityof the machine as shown in fig. there are a
no. of other factors that should also be specified to fully describe the lathe machine.
Theyare:
Horsepowerofthemotor.
Cuttingspeedrange.
Feedrange.
Screwcuttingcapacity
Accuracyachievable
Spindlenosediameterandholesize.

3rd
semester
47
SHAPERMACHINESANDSLOTTINGMACHINES

3rd
semester
48
UnitIII
Q1 Explain with neat sketch crank and slotted lever mechanism used in shaper? Show how the Quick
returnoftoolisaccomplished.
Q2whatarethevariousshaperoperations?
Q3ExplainwithneatsketchWhitworthquickreturnmechanismusedinshaper?
Q4whatarevariouspartsandtheirfunctionsofslottermachine?
Q6ExplaininshortwithneatsketchtheHydraulicmechanisminshapermachine.
Q7Explainwithneatsketches:
i) Tablefeedmechanisminshaper.
ii) Q13describesinbriefthepuncherslotterandtoolroomslotter.
Q8Statethefunctionofthefollowingpartsofshaper.
i) Crossrail
ii) Clapperbox
iii) Toolhead
Q9whatarethevariouspartsandtheirfunctionsofshapermachine?
4
NAGPUR
49
Q1Exp
howthe
Ans cra
transmit
individu
bullgea
onthes
tothece
thecran
at a uni
within t
pivoted
the rock
rotatesc
willrota
in the s
Thus,th
ram.
R INSTITUTE
lainwithn
eQuickretu
ank and slo
ttedtothe
almotoror
rmaybech
stepconep
entreofthe
nkpin11is
form speed
he slotted
at15atits
ker arm is f
causingthe
ateonthec
lotted link
erotarym
OF TECHNOL
neatsketch
urnoftool
otted link
bullgear1
roverhead
hangedbyd
pulley.Bullg
ebullgear
fitted.Rota
d. Sliding b
link 9. The
sbottomen
forked and
ecrankpin
crankpinci
9 giving it
otionofth
LOGY
Questionb
crankand
isaccompl
mechanism
14through
lineshaftt
differentco
gear14isa
isradialslid
ationofthe
lock 12 wh
e slotted lin
ndattached
connected
torotatet
rcle,andat
a rocking m
ebullgear
bankwiths
slottedlin
ished.
m is as sho
thepinion
throughspe
ombination
alargegear
de16which
ebullgear
hich is mou
nk 9 which
dtothefra
d to the ra
heslidingb
tthesame
movement
isconverte
olution
nkmechani
own in fig.
1whichre
eedcontrol
ofgearing
rmounted
hcarriesas
willcauset
unted upon
h is also kn
ameofthe
m block 8
block12fas
timewillm
which is c
edtorecip
Manufacturin
ismusedin
The motio
eceivesitsm
lmechanism
forsimplys
withinthe
slidingbloc
thecrankp
the crank
own as the
column.Th
by a pin. A
stenedtot
moveupand
ommunicat
rocatingm
ngprocessI
nshaper?S
on or pow
motionfrom
m.Speedo
shiftingthe
column.Bo
ck10intow
pin11torev
pin 11 is f
e rocker ar
heupperen
As the bull
hecrankpi
ddownthe
ted to the
ovemento
3rd
semeste
Show
wer is
man
fthe
ebelt
olted
which
volve
fitted
rm is
ndof
gear
in11
eslot
ram.
fthe
er

3rd
semester
50
Fig.3.1PrincipleofquickreturnmechanismFig.3.2QuickReturnMotion
Theprincipleofquickreturnmotionisillustratedinfig.whenthelinkisintheposition
PM,theramwillbeattheextremebackwardpositionofitsstroke,andwhenitisatPN,
and the extreme forward position the ram will have been reached. PM and PN are
showntangenttobecrankpincircle.Theforwardcuttingstroke,therefore,takesplace
when the crank rotates to the angle C
2
L C
1
. It is evident that the angle C
2
K C
1
made by
the forward or cutting stroke is greater than the angle C
2
L C
1
described by the return
stroke. The angular velocity of the crank pin being constant the return stroke is,
therefore, completed within a shorter time for which known as quick return motion.
The ratio between the cutting time and the return time may be determined by the
formula:
CuttingtimeC
2
KC
1
=
ReturntimeC
2
LC
1
Cuttingtimetoreturntimeratiousuallyvariesbetween2:1andthepracticallimitis3:2
Theonlydisadvantagelieswiththismechanismisthatthecuttingspeedandthereturn
speedisnotconstantthroughoutthesestroke.Itisminimumwhentherockerarmisat
thetwoextremitiesandthespeedismaximumwhentherockerarmisvertical.
Q2whatarethevariousshaperoperations?
AnsAshaperisaversatilemachinetoolprimarilydesignedtogenerateaflatsurfaceby
a single point cutting tool. But it may also be used to perform many other operations.
Thedifferentoperationswhichashapercanperformareasfollows:
1) Machininghorizontalsurface.
2) Machiningverticalsurface.
3) Machiningangularsurface
4) Cuttingslots,grooves,andkeyways
5) Machiningirregularsurfaces

3rd
semester
51
6) Machiningsplinesorcuttinggears.
Machininghorizontalsurface:
Fig.3.3Machininghorizontalsurface
Machininghorizontalsurfaceonaworkpiece.Ashaperismostlyusedtomachineaflat,
true surface on a work piece held in a vise or other holding devices. After the work is
properly held on the table, a planning tool is set in the tool post with minimum
overhang.Thetableisraisedtillthereisaclearanceof25to30mmbetweentooland
theworkpiece.Thelengthofstrokeshouldbenearly20mmlongerthantheworkand
thepositionofstrokeissoadjustedthatthetoolbeginstomovefromdistanceof12to
15mmbeforethebeginningofthecutandcontinuestomove5to8mmaftertheend
ofthecut.Propercuttingspeedandfeedisthenadjusted.Shortstrokesshouldbegiven
with slow speed. Both roughing and finishing cuts are performed to complete the job.
For roughing cut speed is decreased but feed and depth of cut increased. Depth cut is
adjustedbyrotatingthedownfeedscrewofthetoolhead.Theamountofdepthofcut
isadjustedbyamicrometerdial.Thedepthofcutforroughingworkusuallyrangesfrom
1.5to3mmwhilethefinishingworkitrangesfrom0.075to0.200mm.feedisadjusted

3rd
semester
52
aboutonehalfthewidthofthecuttingedgeofthetoolsothateachcutwilloverlapthe
lastcutgivingasmoothsurfacefinish.
Machiningverticalsurface:

Fig.3.4Machiningverticalsurface
1)Apron2)work
Machiningverticalsurfaceonaworkpiece.Averticalcutismadewhilemachiningthe
endofaworkpiece,squaringupablockorcuttingshoulder.Theworkismountedinthe
viseordirectlyonthetableandthesurfacetobemachinediscarefullyalignedwiththe
axisoftheram.Asidecuttingtoolissetonthetoolpostandthepositionandlengthof
stroke is adjusted. The vertical slide is set exactly at zero position and the apron is
swiveledinadirectionawayfromthesurfacebeingcut.Thisisnecessarytoenablethe
tool to move upwards andaway from thework during returnstroke. Thispreventsthe
side of the tool from dragging on the planed vertical surface during return stroke. The
downfeedisgivenbyrotatingthedownfeedscrewbyhand.Thefeedisabout0.25mm

3rd
semester
53
Givenattheendofeachreturnstroke.Bothroughingandfinishingcutsareperformed
tocompletethejob.
Machiningangularsurface:

Fig.3.5Machiningangularsurface
1)Work2)Apron3)Swivelingangle
Machining of an angular surface on a work piece. An angular cut is made at any angle
otherthanarightangletothehorizontalortotheverticalplane.Theworkissetonthe
table and the vertical slide of the tool head is swiveled to the requires angle either
towards left or towards right from the vertical position. The apron is then further
swiveled away from the work so that the tool will clear the work during return stroke.
The down feed is given by rotating the down feed screw. Angular surface can also be
machined in a universal shaper or by using a universal vise without swiveling the tool
head.
Cuttingslots,grooves,andkeyways:

3rd
semester
54

Fig.3.6Cuttingslots,grooves,andkeyways
1) Vise2)Tool3)Work 1)Toobit2)Work3)Vise
Withsuitabletoolsashapercanverycongenitallymachineslotsorgroovesonaworkor
cut external keyways on shafts and internal key ways on pulleys or gears. For cutting
slotsorkeywaysasquarenosetoolsimilartoapartingtoolisselectedillustratescutting
ofexternalkeywaysandcuttingofinternalkeywaysinshaper.Externalkeywaysarecut
on a shaft by first drilling ahole at the blind end of the keyways. The diameter of the
holes should be 0.5 to 0.8 mm oversize than the width of the keyway and the depth
shouldbeabout1.5mmlargerthanthedepthofthekeyway.Thisnecessarytoleavea
clearance on the tool at the end of the stroke. The length and position of stroke is
carefully adjusted so that the stroke will terminate exactly at the clearance hole. The
speedisreduceswhilecuttingakeyways.Internalkeywayiscutbyholdingthetoolon
special tool holder so that the tool post will not hit against the work at the end of the
stroke. The clapper block is locked in the clapper box to prevent the tool from lifting
duringreturnstroke.Lubricationisnecessaryontheworktopreventthecuttingedgeof
thetoolfromwearduetodragging.
Machiningirregularsurfaces:

3rd
semester
55

Fig.3.7Machiningirregularsurfaces
A shaper can also produce a contoured surface i.e. a convex or concave surface of
combination of any of the above surface. To produce a small contoured surface a
forming tool is used. If the curve is sufficiently large, power cross feed in conjunction
withamanualdownfeedissoadjustedthatthetoolwilltracetherequiredcontour.If
thecounterhastoomanyupsanddownsboththefeedsareoperatedbyhand.Around
nose tool is selected for machining irregular surfaces. For a shallow cut the apron may
besettheverticalbutifthecurveisquitesharp,theapronisswiveledtowardsrightor
leftawayfromthesurfacetobecut.Machiningofaconcavesurfaceusingaroundnose
tool.
Machining splines or cutting gears: By using and index centre, illustrated in gear or
equally,spacedsplinemaybecut.Theworkismountedbetweentwocentersandspline
iscutsimilartothecuttingofakeyway.Afterthefirstsplineiscut,theworkisrotated
throughapredeterminedamountbyusingtheindexplateandindexpin.Theperiphery
of a gear blank is divided, and equally spaced grooves are cut by using an index plate
havingproperholecircles.Whilecuttinggearaformedtoolisused.
Q3ExplainwithneatsketchWhitworthquickreturnmechanismusedinshaper?
AnsWhitworthquickreturnmechanismissimplelinediagramofthemechanism.The
bullgearmountedonlargefixedpinuponwhichitisfreetorotate.Thecrankplate4is
pivotedessentiallyuponthefixedpinat5.Fittedonthefaceofthebullgearisthecrank
5
NAGPUR
56
pin 2 on
provided
connect
rotatea
circle of
point5w
willrota
moveme
reciproc
W
butwhe
been re
backwar
complet
position
time tak
returnm
T
closer o
position
Q4wha
AnsThe
1) B
2) C
R INSTITUTE
F
n the top
donthecra
s the crank
taconstan
f a reduce A
withavaria
ateinacirc
ent of the r
catingofthe
Whenthep
enthepinis
ached. Wh
rdposition
ted when t
tothebac
ken by the
motionisob
helengtho
r away fro
ofpin7on
atarevario
edifferent
Base
Column
OF TECHNOL
FIG.3.8Whi
of is moun
ankplate4
k plate by a
ntspeedthe
A2 and slid
ableangula
leandrota
ram similar
erampasse
in2isatth
satthepos
en the pin
totheforw
the pin 2 tr
ckwardpos
crank pin 2
btainedbyt
ofstrokeof
m the pivo
ntheram.
ouspartsan
partsofas
LOGY
Questionb
itworthqui
nted the sl
4.Attheoth
a pin 9 and
ecrankpin
ding block 3
rvelocity.P
rymotiono
r to the cra
esthrough
heposition
sitionB,the
2 travels f
wardpositio
ravels from
ition.Asth
2 to travel
themechan
ftheramm
ot 5. The po
ndtheirfun
lottingmac
bankwiths
ckreturnm
liding block
herendof
d the ram 8
2withthe
3 will cause
Pin9fitted
ofthepin9
ank and con
thepin5an
Ctheramw
eextremef
from C to B
oninthecu
m B to C or
eanglevel
through an
nism.
maybechan
osition of s
nctionsofs
chineare:
olution
mechanism
k 3. Sliding
thecrankp
8 by a pin
eslidingblo
e the crank
ontheoth
9willbeco
nnecting ro
ndisnorma
willbeate
forwardpo
B the crank
uttingstrok
r the pin 9
ocityofthe
nd an arc c
ngedbysh
troke may
lottermach
Manufacturin
g block 3 f
plate4,aco
7. When b
ock3willro
plate to ro
erendofth
onvertedint
od mechani
altothelin
extremebac
ositionofth
k pin 9 pass
ke,andthe
passes fro
ecrankpin
overing BD
iftingthep
be altered
hine?
ngprocessI
ix into the
onnectingr
bull gear wi
otateonac
otate about
hecrankpla
toreciproca
ism. The ax
eA5.
ckwardpos
heramwill
ses through
returnstro
om the forw
isuniform
DC. Thus a q
positionofp
by shifting
3rd
semeste
e slot
rod6
ill be
crank
t the
ate4
ating
xis of
sition
have
h the
okeis
ward
,the
quick
pin9
g the
er
5
NAGPUR
57
3) S
4) C
5) R
6) R
7) R
8) F
Baseor
the mac
thesadd
Column
housesd
thecolu
Saddle:
awayfro
thewor
crossslid
Crosss
movedp
eitherby
Rotating
cross sli
gearcon
R INSTITUTE
addle
Crossslide
Rotatingtab
Ramandtoo
Ramdrivem
eedmecha
Bed:the
chine. The t
dleismoun
: The colu
drivingmec
mnisaccur
The sadd
omthecolu
k.Thetopf
de.Theseg
lide:Thec
paralleltot
yhandorp
gtable:Th
de. The tab
nnectedto
OF TECHNOL
ble
olheadasse
mechanism
nism
FIG
baseisrigid
top of the
ted.Thegu
umn is the
chanismof
ratelyfinish
dle is moun
umneither
faceofthe
guideways
crossslidei
thefaceof
powertosu
herotaryta
ble may be
theunders
LOGY
Questionb
embly
G.3.9main
dlybuiltto
bed is accu
uidewaysa
vertical me
theraman
hedforprov
nted upon t
bypowero
saddleisa
areperpen
smounted
thecolumn
pplycrossf
ableisacir
e rotated b
sideofthet
bankwiths
partsofslo
takeupall
urately finis
reperpend
ember whi
ndfeedingm
vidingway
the guide w
ormanualc
ccuratelyfi
diculartot
upontheg
n.Themov
feed.
rculartable
by rotating
table.Ther
olution
otter.
lthecutting
shed to pro
diculartoth
ch is cast i
mechanism
onwhichth
ways and m
controltos
inishedtop
theguidew
guideways
ementofth
ewhichism
a worm wh
rotationof
Manufacturin
gforcesan
ovide guide
hecolumnf
ntegral wit
m.Thefront
heramreci
may be mo
supplylong
providegui
waysonthe
ofthesad
heslidema
mountedon
hich meshe
thetablem
ngprocessI
dentireloa
ways on w
face.
th the base
tverticalfac
iprocates.
ved toward
gitudinalfee
dewaysfo
base.
dleandma
aybecontro
nthetopo
es with a w
maybeeffe
3rd
semeste
adof
which
e and
ceof
ds or
edto
rthe
aybe
olled
fthe
worm
ected
er

3rd
semester
58
either by hand or power. In some machines the table is graduated in degrees that
enablethetabletoberotateforindexingordividingtheperipheryofajobinequalno
of parts. Tslots are cut on the top face of the table for holding the work by different
clamping devices. The rotary table enables a circular or countered surface to be
generatedontheworkpieces.
Ram and tool head assembly: The ram is the reciprocating cutting members of the
machine mounted on the guide ways of the column. It supports the tool at its bottom
end on a tool head. A slot is cut on the body of the ram for changing the position of
stroke. In some machines, special type of tool holders is provided to relieve the tool
duringitsreturnstroke.
Ram drive mechanism: A slotter removes metal during downward cutting stroke only
whereas during upward return stroke no metal is removed. To reduce the idle return
time, Quick return mechanism is incorporated in the machine. The usual types of ram
drivemechanismare
i) Whitworthquickreturnmechanism
ii) Variablespeedreversiblemotordrivemechanism.
iii) Hydraulicdrivemechanism.
Q5ExplaininshortwithneatsketchtheHydraulicmechanisminshapermachine.
Ans:Inhydraulicshapertheramismovedforwardandbackwardbyapistonmoving
inacylinderplacedundertheram.Themachinemainlyconsistsofaconstantdischarge
oilpump2,avalvechamber,acylinderandapiston7.Thepistonrod6isboltedtothe
ram body; the oil under high pressure is pumped from the reservoir 1 and is made to
passthroughthevaluechambertotherightsideoftheoilcylinder5exertingpressure
on the piston 7. This cause the ram 4 connected to the piston 7 to perform forward
stroke, and any oil present on the left side of the cylinder is discharge to the reservoir
throughthethrottlevalve3.Attheendofextremeforwardstroke,theshaperdog8hits
againstthereversinglever9causingthevalve12toaltertheirpositionswithinthevalve
chamber.oil under high pressure is now pumped to the left side of the piston causing
the ram to perform return stroke. Oil present on the right side of the piston is now
discharge to the reservoir. At the end of the return stroke another shaper dog hits

3rd
semester
59
againstreservoirleveralteringthedirectionofstrokeofthepistonandthecycleisthus
repeated.

Fig.3.10hydraulicshapermechanism.
Thequickreturnmotionisaffectedduetothedifferenceinstrokevolumeofthe
cylinderatbothends,thelefthandendbeingsmallerduetothepresenceofthepiston
rod.Asthepumpisconstantdischargeone,withinafixperiod,thesameamountoilwill
bepumpedintotherightortothelefthandsideofthecylinder.Thiswillmeanthatthe
same amount of oil will be packed within a smaller stroke volume causing the oil
pressuretoriseautomaticallyandincreasingthespeedduringthereturnstroke.
Thelengthandpositionofstrokeisadjustedbyshiftingthepositionofreversingdogs.
The cutting speed may be changed by controlling the throttle valve 3 which regulates
the flow of oil. When the throttle valve is partially closed the excess oil flows out
through the relief valve 11 to the reservoir maintain uniform pressure during cutting
stroke.Ahydraulicshaperisnowwidelyusedforhavingmanyadvantages.
Q6Explainwithneatsketches:
Tablefeedmechanisminshaper
Ans The automatic cross feed mechanism of the table is very simple. This is done by
rotating a ratchet wheel, mounted on cross feed screw C by the same amount each
time. This enables a corresponding equal rotation of the cross feed screw after each
stroke.Thecompletemechanismisasfollows:
6
NAGPUR
60
Itconsis
andtot
to the l
about th
setecce
whichis
being ec
turn,ma
more te
movest
N
powerfe
theretu
In some
compara
V
centrea
andvice
required
coarsefe
R INSTITUTE
Fig.3.11
stsofslotte
hisisattach
ower end
he screw C,
entricwitht
drivenbyt
ccentric wit
akesthero
eeth and th
hetable.
Note, that t
eedtoope
urnstrokeo
e latest typ
ativelymor
Variationin
andthecen
eversa.The
d on the jo
eedisneed
OF TECHNOL
1automatic
eddisc,whi
hedaconne
of the rock
, and at its
theslotted
thebullgea
th the disc
ockerarmt
hus transm
he lower e
rateineith
only.Ifothe
es of shap
reefficienta
thefeedca
ntreofadju
eamounto
b. For roug
ded.Against
LOGY
Questionb
ctablefeed
ichcarriesa
ectingrod.
ker arm of
upper end
disccentre
ar.Asthed
centre, cau
toswingab
it an interm
end of the p
herdirection
erwisethe
ers, cam d
andprovide
anbeprovi
stablepin.
offeedtob
gh machini
tthis,afine
bankwiths
dmechanism
aTslot,in
Theothere
f the pawl
d carries a
e.Theslott
discrotates
uses the co
boutthesc
mittent mo
pawl is be
n,butthes
mechanism
riven feed
edawider
idedbyvar
Largerthe
begivenlar
ng heavier
erfeedisem
olution
mofashap
thisslotis
endofthec
mechanism
spring load
eddiscati
sthrought
onnecting r
rewCtom
otion to th
eveled on o
sameshoul
mwillbesu
mechanism
rangeoffe
ryingthedi
setdistanc
gelydepen
cuts are e
mployedin
Manufacturin
per.
fittedand
connecting
m. The rock
ded pawl, a
tsbackcar
hisgearthe
rod to recip
movethepa
e cross fee
one side. Th
dbesetto
bjectedto
m are prov
eds.
stanceRbe
cegreaterw
ndsuponth
mployed a
finishingo
ngprocessI
adjustable
grodisatta
ker arm sw
adjustable p
rriesaspur
eadjustable
procate. Th
awloveron
ed screw w
his facilities
operatedu
aseverest
vided which
etweenthe
willbethe
hetypeoff
nd therefo
operations.
3rd
semeste
pin
ched
wings
pin is
gear
epin
is, in
neor
which
s the
uring
tress.
h are
edisc
feed
finish
re, a
er

3rd
semester
61
Q7Describesinbriefthepuncherslottersandtoolroomslotters.
AnsPuncherslotters:Puncherslottersareheavydutymachines.Usuallysuchjibsare
machinedonthesemachineswhicharecomparativelyheavierandhavebeenpreviously
brought roughly to the required shape through other operation like sawing, forging or
stampingetc.theslottingmachineisthenusedtocutofthesurplusmetalandfinished
the work to the required shape and size. According to the nature of the work, either a
squareorcirculartablecanbefittedonthemachine.
Tool room slotters: these slotting machines are precession type is used for accurate
machining. Usually titling type of frame is provided in these machines to enable
machining at different angles. Slotted link type drive is commonly used in these
machines.Restoftheconstructionissimilartothatofaproductionslotter.
Q8Statethefunctionofthefollowingpartsofshaper.
Crossrail:Thecrossrailismountedonthefrontverticalguidewaysofthecolumn.It
has to parallel guide ways on its top in the vertical plane that are perpendicular to the
ramaxis.Thetablemayberaisedorloweredtoaccommodatedifferentsizesofjobsby
rotating an elevating screw which causes the cross rail to slide up and down on the
verticalfaceofthecolumn.A
Horizontal cross feed screw which is fitted within the cross rail and parallel to the top
guidewaysofthecrossrailactuatesthetabletomoveincrosswisedirection.
Clapperbox:
Thetwoverticalwallsontheaproncalledclapperboxhousestheclapperblockwhichis
connectedtoitbymeansofahingepin.Thetoolpostofismountedupontheclapper
blockontheforwardcuttingstroketheclapperblockfeedssecurelytotheclapperbox
tomakearigidtoolsupport.Onthereturnstrokeaslightfunctionaldragofthetoolon
the work lifts the block out of the clapper box a sufficient amount preventing the tool
cuttingedgefromthedraggingandconsequentwear.
Toolhead:Thetoolheadofashaperholdsthetoolrigidlyprovidesverticalandangle
feed movement of the tool and allows the tool to have and automatic relief during its
return stroke. The vertical slide of the tool head has a swivel base which is held on a

3rd
semester
62
circular seat on the ram. The swivel base is graduated in degrees, so that the vertical
slidemaybesaidperpendicularsotheworksurfaceoratanydesiredangle.Byrotating
thedownfeedscrewhandle,theverticalslidecarryingthetoolexecutesdownfeedor
anglefeedmovementwhilemachiningverticaloranglesurface.Theamountoffeedor
depthofcutmaybeadjustedbyofmicrometerdialonthetopofthedownfeedscrew.
Apronconsistingofclapperbox,clapperblockandtoolpostisclampeduponthevertical
slidebyascrew.Byreleasingtheclampingscrew,theapronmaybeswiveleduponthe
apron swivel pin either towards left or towards right with respect to the vertical slide.
This arrangement is necessary to provided relief to the tool while making vertical or
angle cuts. The two vertical walls on the apron called clapper box houses the clapper
blockwhichisconnectedtoitbymeansofahingepin.Thetoolpostofismountedupon
theclapperblockontheforwardcuttingstroketheclapperblockfeedssecurelytothe
clapperboxtomakearigidtoolsupport.Onthereturnstrokeaslightfunctionaldragof
thetoolontheworkliftstheblockoutoftheclapperboxasufficientamountpreventing
thetoolcuttingedgefromthedraggingandconsequentwear.Theworksurfaceisalso
preventedfromanydamageduetodraggingillustratesthetoolheadofshaper.
Q9whatarethevariouspartsandtheirfunctionsofshapermachine?
The working principle of shaper is illustrated in fig. in case of shaper, the job is rigidly
heldinasuitabledevicelikeviceorclampdirectlyonthemachinetable.Thetoolisheld
inatoolpostmountedontheramofthemachine.Thisramreciprocatetoandfroand,
in doing so, makes the tool to cut the material in the forward stroke. No cutting of
material takes place during the return stroke of the ram. Hence, it is termed as idle
stroke. In case of draw cut shaper, the cutting takes place in the return stroke and the
forwardstrokeinanidlestroke.Thejobisgivenandtheindexfeed(equalamountafter
eachcut)inadirectionnormaltothelineofactionofthecuttingtool.
Principlepartofashaper:
6
NAGPUR
63
1) Ta
a) B
o
b) C
fo
su
In
O
g
c) C
T
p
ra
jo
d
H
to
d) T
R INSTITUTE
ablesupport
Base:itis
therpartso
Column:It
or the oper
upportforo
ncaseofth
On its top it
uidewaysa
Crossrail:
hecrossra
arallel guid
am axis. Th
obs by rota
ownonthe
Horizontalc
opguidewa
Table:
OF TECHNOL
Fig.3.
2)Table3)Cl
aheavyan
ofthemach
isaboxtyp
rating mech
otherparts
hehydraulic
t carries ma
atitsfront.
ilismounte
de ways on
he table ma
ating an ele
everticalfa
rossfeeds
aysofthec
LOGY
Questionb
12partsof
lapperbox4)
drobustca
hinewhich
pecastiron
hanism of t
softhemac
cshaper,it
achined wa
edonthef
its top in t
ay beraised
evating scre
aceoftheco
crewwhich
crossrailac
bankwiths
fashaper
)ApronClamp
astironbod
aremounte
nbodymou
the machin
chinesucha
carriesthe
ays, in whic
frontvertica
the vertica
d or lowere
ew which c
olumn.
hisfittedw
tuatesthe
olution
pingbolts5)d
dywhichac
edoverit.
untedonth
ne and the
ascrossrai
ehydraulic
ch the ram
alguidewa
l plane that
ed to accom
causes the
withinthecr
tabletomo
Manufacturin
downfeedha
ctsasasup
ebaseand
electrical. I
landram.e
drivemech
reciprocat
aysoftheco
t are perpe
mmodated
cross rail t
rossrailand
oveincross
ngprocessI
andwheel
pportforal
actsashou
It also acts
etc.
hanisminsid
tes, and ver
olumn.Ith
endicular to
ifferent size
to slide up
dparallelto
swisedirec
3rd
semeste
llthe
using
as a
deit.
rtical
asto
o the
es of
p and
othe
ction.
er

3rd
semester
64
Itismadeofcastironandhasaboxtypeconstruction.Itholdsandsupportsthe
work during the operation and slides along the cross rail to provide feed to the
work.Tslotareprovidedonitstopandsidesforsecuringtheworktoit
.
e) Ram:
Itisalsoanironcasting,semicircularinshapeandprovidedwithribconstruction
in side for rigidity and strength. It carries the tool head and travels in dovetail
guidewaystoprovideastraightlinemotiontothetool.Itcarriesthemechanism
foradjustmentoframpositioninsideit.
f) Toolhead:
The tool head of a shaper holds the tool rigidly provides vertical and angle feed
movementofthetoolandallowsthetooltohaveandautomaticreliefduringits
return stroke. The vertical slide of the tool head has a swivel base which is held
onacircularseatontheram.Theswivelbaseisgraduatedindegrees,sothatthe
vertical slide may be said perpendicular so the work surface or at any desired
angle.Byrotatingthedownfeedscrewhandle,theverticalslidecarryingthetool
executes down feed or angle feed movement while machining vertical or angle
surface. The amount of feed or depth of cut may be adjusted by of micrometer
dialonthetopofthedownfeedscrew.Apronconsistingofclapperbox,clapper
blockandtoolpostisclampedupontheverticalslidebyascrew.Byreleasingthe
clamping screw, the apron may be swiveled upon the apron swivel pin either
towardsleftortowardsrightwithrespecttotheverticalslide.Thisarrangement
isnecessarytoprovidedrelieftothetoolwhilemakingverticaloranglecuts.The
twoverticalwallsontheaproncalledclapperboxhousestheclapperblockwhich
isconnectedtoitbymeansofahingepin.Thetoolpostofismounteduponthe
clapper block on the forward cutting stroke the clapper block feeds securely to
the clapper box to make a rigid tool support. On the return stroke a slight
functional drag of the tool on the work lifts the block out of the clapper box a
sufficient amount preventing the tool cutting edge from the dragging and
consequent wear. The work surface is also prevented from any damage due to
draggingillustratesthetoolheadofshaper.

3rd
semester
65
g) Vice:
It is a job holding device and ismounted on the table. It holdsand supports the
work during the operation. Alternately, the job can be directly clamped to the
machinetable.
MILLINGMACHINEANDITSOPERATIONS:

3rd
semester
66
UNITIV
Q1ExplainwithaneatsketchUniversalMillingMachine.
6
NAGPUR
67
Universa
adopted
distingu
ismount
swivelle
can be s
spindle.
incorpor
is fed at
helicalm
milling a
increase
milling
produce
allconve
every ty
universa
veryacc
Table 2
moveme
connect
wheel f
R INSTITUTE
al Milling M
dto a very
ishedfrom
tedonacir
dtoanyan
swivelled a
Thus in a
ratedinap
t an angle
millingoper
attachment
edbytheus
attachmen
espur,spira
entionalmi
ype of ope
almachine
curatework
. Hand w
ent 4. Tabl
ions 7. Mo
for longitu
OF TECHNOL
Machine: A
wide range
aplainmil
rcularswive
ngleupto4
bout is ver
a universa
plainmilling
to the mil
rationwhich
t is used. T
seofspecia
t, rotary a
al,bevelge
illingopera
erations tha
is,therefor
k.
Fig4.1Un
heel for s
e stop 5. H
otor for aut
dinal feed
LOGY
Questionb
universal m
e ofmilling
llingmachin
ellingbasew
45degreeo
rtical axis a
l milling m
gmachine,
lling cutter
hcannotbe
he capacity
alattachme
attachment
ars,twistd
ation.Itmay
at can be
re,essentia
niversalmill
election of
Hand whee
tomatic fee
10. Overr
bankwiths
milling mac
operations
neinthatt
whichhasd
oneithers
and set an
machine, in
thetablem
. This addi
edoneona
y of a unive
entssuchas
t, slotting
drills,reame
yalsobee
performed
allyatoolr
ingmachin
f spindle
el for feed
ed 8. Lever
ran 11. Co
olution
chine is so
s.Aunivers
thetableof
degreegrad
ideofthen
angle othe
n addition
mayhavea
tional featu
aplainmilli
ersal millin
sdividinghe
attachmen
ers,milling
mployedw
on a shap
oommach
ne
3. Adjusta
selection 6
r for vertica
over for m
Manufacturin
named bec
salmilling m
funiversalm
dationsand
normalpos
er than righ
to three
fourthmov
ure enable
ngmachine
g machine
eadorinde
nt, etc. The
cutters,etc
withadvanta
per or on
inedesigne
ble stop f
6. Terminal
al and cros
main drive
ngprocessI
cause it ma
machine ca
millingmac
dthetaleca
sition.Thet
ht angles to
movement
vementwh
s it to perf
eunlessas
is consider
exhead,ver
e machine
c.besidesd
ageforany
a drill pres
edtoprodu
for longitu
l box for m
ss feed 9. H
12. Arbor
3rd
semeste
ay be
an be
chine
anbe
table
o the
ts as
henit
form
spiral
rably
rtical
can
doing
yand
ss. A
ucea
dinal
mains
Hand
r 13.
er

3rd
semester
68
Longitudinal feed changing lever 14. Hand wheel for cross travene 15. Handle for
verticaltraverseofknee16.Base.
Q2Namethevarioustypesofcuttersusedinmillingoperation.SketchaPlainmilling
cuttershowingitselements.
Commontypeofmillingcuttersisthefollowing:
1. Plainmillingcutters
2. Sidemillingcutters
3. Endmillingcutters
4. Facemillingcutters
5. MetalSlittingcutters(Slittingsaws)
6. Anglemillingcutters
7. Formedmillingcutters
8. Woodruffkeymillingcutters
9. Tslotmillingcutters
10. Flycutters
Plainmillingcutters
These milling cutters may have the cutting teeth on their periphery. The teeth may be
either straight, i.e., parallel to the axis, or helical. Their end faces are either ground
square with the axis or slightly concave to reduce friction. Thus no cutting action is
providedbythesidefaces.Thesecuttersareemployedformillingflatsurfacesparallel
totheaxisofrotation.
6
NAGPUR
69
1.)andt
upto20
sot cutt
teeth.T
cutters
calledhe
carryles
veryhea
withless
atallve
up with
lefthand
SideMil
cuttingt
R INSTITUTE
Fig4
Thesecu
thehelical
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LOGY
Questionb
illingcutter
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7
NAGPUR
70
purpose
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Questionb
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7
NAGPUR
71
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LOGY
Questionb
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7
NAGPUR
72
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LOGY
Questionb
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7
NAGPUR
73
Face mi
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LOGY
Questionb
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7
NAGPUR
74
2
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LOGY
Questionb
13Metals
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7
NAGPUR
75
Form m
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LOGY
Questionb
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7
NAGPUR
76
3
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LOGY
Questionb
4.19Aconca
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These
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7
NAGPUR
77
Woodru
Itisasm
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LOGY
Questionb
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7
NAGPUR
78
Fly cutte
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Screws a
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LOGY
Questionb
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pointcutti
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,fillet,land
cutterteet
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thecutting
measuredin
e given to
igher the v
rgerreliefa
efinish,bu
make the
between t
rmal to the
hiptoflows
less wear
wo grinds. H
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Manufacturin
nted on a c
asaboring
lders. Cutti
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er, if prope
mberofsing
ngtool,as
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ngle betwee
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the variou
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tatthesam
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he axial pla
e cutting ed
smoothy.T
on the to
However, it
ipanglewi
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cylindrical b
inaboring
ing edge of
ormed tool.
erly designe
glepointcu
shownby
ouspartso
oththicknes
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en the plain
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is lesser wi
ncreasethe
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ane PP and
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ooth face
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3rd
semeste
body
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f the
. It is
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arto
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etool
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sless
and
ot be
aken
er
7
NAGPUR
79
calledlip
lipangle
feasible,
particula
employe
and50d
Q3Diff
Milling m
meanso
isthesa
that eac
This allo
Obvious
cylindric
operatio
1. U
d
2. D
co
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pangle().
econserves
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arly import
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degree.The
erentiateb
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ofamultite
ameasthat
ch tooth, af
ows the to
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cal cutters,
on:
Up or conv
irectionop
Down or cli
oincideswi
Theabov
noted at
OF TECHNOL
The angle
.Itsvalued
sastronger
oconsidera
tant while
having he
erecommen
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Milling, as h
eethrotatin
tofasingle
ftertaking
oth to coo
zes the effe
the follow
entional m
positetoth
imb milling
thdirection
Fig.4.27C
verelatived
t the point
LOGY
Questionb
between
dependsup
rtooth.As
ationthefa
milling ha
lical teeth
ndedvalue
pMillingan
has already
ngtool,cal
epointtool
cut,comes
ol down be
ect of heat
wing two me
milling. In t
hatinwhich
g. In this m
nofworkfe
Conventiona
directionso
of contact
bankwiths
the face a
ponthevalu
such,ende
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rder metal
are made t
ofprinciple
ndDownM
y been stat
ledcutter.
l.However,
in operatio
efore the n
developed
ethods are
his method
hthework
method the
eed,assho
almilling
ofmoveme
t between t
olution
nd the lan
uesofrake
eavorshoul
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esanglesar
Milling.
ted, is a pr
Theformo
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next cutting
in cutting
commonly
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isfed[see
e direction
wninFig2.
Fig.4.28
entsofthec
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Fig1].
of rotation
.
Climbmilli
cutterand
On comparin
ngprocessI
c utter too
angles.Ala
epitaslarg
ragraphs.Th
cuts are t
gle betwee
Table1.
metal cuttin
thofthecu
etobenot
nterval of t
n is done b
ting edge.
performing
er rotates
n of the cu
ng
workshoul
ng Figs 1 a
3rd
semeste
oth is
arger
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hisis
o be
en 10
ng by
utter
edis
time.
by it.
With
g this
in a
utter
ldbe
nd 2
er

3rd
semester
80
you will find that the shape of chip (shaded area between points A and B)
removed by the cutter in both the cases is same, but an difference is that in
conventional milling, as the cut proceeds, the chip thickness increases
gradually;asfromAtoB.Againstthis,thechipthicknessdecreasesincaseof
climb milling. In other words we can say that the chip thickness in
conventionalmillingisminimum(zero)atthestartofcutandmaximumatthe
end of the cut, whereas in climb or down milling. It is a reverse case, i.e.,
maximuminbeginningandzeroattheend.
The selection of a particular method, of the above two,
depends upon the nature of work. The former method, i.e., conventional
milling is commonly used for machining castings and forgings since this
method enables the cutter to digin and start the cut below the hard upper
surface. The second method i.e., climb milling is particularly useful for
finishing operations and small work, such as slot cutting, milling grooves,
slitting, etc. It gives a better surface finish but it should be ensured, before
employingthismethod,thatthereisnobacklashinthefeedingmechanismof
thetableandtheworkisrigidlyheld.
Q4writesshortnoteson:
i) Millingmachinespecification:
Size and specifications: Size of milling machine is usually denoted by the
dimensions (length and breadth) of the table of the machine. Different
manufactures,however,thesesizesbydifferentnumbers0,1,2,3,4,5,6,
etc. Each of these indicates a particular standard size adopted by the
manufacturerandtherelativeliteraturefromthemanufacturershouldbe
thoroughly consulted before for a particular number. The corresponding
dimensionstoaparticularshouldbeknownbeforeorderingforitsothatit
canmeettherequirement.Othermainspecificationsofthemachinetobe
considered at the time of orders are the horse power of driving motor,
number of spindle. Speeds, drive, taper of spindle nose, required floor
area,grossweight,etc.
8
NAGPUR
81
ii
of the w
amounte
which r
columns
direction
Cutters
cutters a
theperi
andthe
comein
R INSTITUTE
) Drum
Iti
work piece
ed on stud
otates abo
s. These h
n along th
mountedo
and the low
pheryofdr
workpiece
contactwi
OF TECHNOL
mtypemillin
sanotherh
es are mac
dy base. A
out a horiz
eads carry
e column.
nthesespi
wer two fin
rumtocarr
esaremou
ththelowe
Fig.4.29AD
LOGY
Questionb
ngmachine
heavyduty
hined simu
heavy drum
zontal axis.
y horizonta
A typical
ndlesarefa
nishing cutt
rythejobst
ntedonthe
ercutters.
Drumtype
bankwiths
e
production
ultaneously
m is mount
The millin
al spindles
design car
acemills.T
ters. Well d
tobemach
efixtureso
millingmac
olution
nmachinei
y. It consist
ted vertical
ng heads a
and can b
rying 4 spi
heuppertw
designed fix
hined.Thed
ontherear
chine
Manufacturin
nwhichthe
t of two ve
lly, betwee
are mounte
be adjuste
indles is sh
wospindles
xtures are
drumrotat
sideofthe
ngprocessI
etwoendf
ertical colu
en the colu
ed on the
d in a ver
hown in Fi
scarryroug
mounted a
escontinuo
emachine.T
3rd
semeste
faces
umns
mns,
two
rtical
g. 1.
ghing
along
ously
They
er
8
NAGPUR
82
ii
R INSTITUTE
i) Differ
Millin
auxili
comp
range
millin
cutte
used
Vertic
used
on th
attac
With
mach
point
canno
to be
advan
vertic
toma
OF TECHNOL
rentattach
ng machine
ary devices
ponents of
e versatility
ng machine
r by alterin
forposition
cal milling
both on ho
he machin
hment bolt
the use o
hine can be
, which ne
otbeadjust
e adjusted
ntageous fe
calplane,to
achineanin
LOGY
Questionb
hmentofm
e attachme
s intended
the milling
y, productiv
e attachme
ng the cutt
ning,holdin
attachmen
orizontal as
e the ove
ted on to th
of this atta
e made to
eeds attent
tedinaver
by raisin
eature that
omakethe
nclinedsurf
Fig4.30
bankwiths
illingmach
ents The a
to be faste
g machine
vity or acc
ents are us
ter axis an
ngandfeed
t: It is also
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he front fac
achment t
act as vert
ion here, i
rticaldirect
g the tab
t it can be
spindleand
faceonthe
0Verticalm
olution
hine:
attachment
ened to or
for the pu
uracy of op
sed for po
d speed, w
ding.
o sometime
niversal mi
the latter
ce of the co
he horizon
tical milling
s that the
tion.Assuc
le of the
e swivelled
dhencethe
workpiece
millingattac
Manufacturin
s are stand
r joined wit
urpose of a
peration. S
ositioning a
whereas ot
es called sw
lling machi
is pushed
olumn, as s
ntal and u
g machines
universal m
h,thedept
machine.
to a desi
ecutter,ro
e.
hment
ngprocessI
dard or sp
th one or m
augmenting
Some classe
and driving
her classes
wivel head.
ne. For fixi
back and
shown in F
niversal m
s. An impo
milling mac
thofcutha
But it ha
red angle,
tateatana
3rd
semeste
pecial
more
g the
es of
g the
s are
It is
ing it
the
ig. 2.
illing
rtant
chine
sgot
s an
in a
angle
er
8
NAGPUR
83
For prov
horizont
through
the vert
universa
attachm
Operatio
thisatta
Spiral m
can be
adjusted
spindlee
article.I
asurface
Slotting
keyway
perform
machine
usedfor
column
mechan
motion
thefron
R INSTITUTE
viding the d
talspindleo
atrainofs
tical spindle
almillingm
ment, still i
ons like fac
achment.
milling attac
swivelled
datanyde
exactlyint
tthusprov
eonthewo
attachmen
cutting, gr
med, but th
e. In such c
rthispurpo
in the sam
ismwhichc
of the ram
toftheatt
OF TECHNOL
drive to ver
ofthemach
spurgears
e. It may,
machinesca
it will not
ce milling, g
chment: Th
in two pla
siredinclin
thesamew
videsagrea
orkwithout
nt: In mach
rooving, slo
he bulk of
cases the m
ose.Thisat
me way as
convertsth
of this att
achment.It
LOGY
Questionb
rtical spind
hine.Itdriv
andfinally
however, b
nbeconve
be as eff
grooving, T
is is a univ
anes. This
ationintw
wayasinav
atflexibility
tdisturbing
hine shops
otting, and
work may
milling mac
ttachment(
a vertical m
herotarym
tachment. A
tcarriesthe
bankwiths
le of the at
vesahorizo
apairofb
be noted t
ertedintov
ficient as
Tslot cuttin
versal type
enables th
wodifferent
verticalmil
ytoadjustt
gthesetting
s, simple sl
internal ge
not justify
chine, fitted
(Fig3)isfit
milling atta
otionofth
A slide or r
eslottingto
olution
ttachment
ontalspindle
evelgearst
hat even t
verticalmill
a regular
ng, etc. can
of vertical
e spindle
tplanes.Th
lingattach
thecutteri
gofthewo
lotting mac
ear cutting,
y the exist
d with a sl
ttedtothe
chment. It
emachine
ram works
ool.
Manufacturin
an adapter
eintheatt
thedriveis
hough the
ingmachin
vertical m
easily be p
milling att
of the atta
hedriveiso
mentdescr
inanyposit
rk.
chine oper
, etc., may
tence of se
otting atta
frontface
s body car
spindleint
in the guid
ngprocessI
r is fitted to
achment.T
stransmitte
horizontal
esbyusing
milling mac
performed
achment w
achment to
obtainedby
ribedinthe
tiontomac
ations, suc
be require
eparate slo
chment ca
ofthemac
ries an inte
toreciproca
des provide
3rd
semeste
o the
Then,
edto
and
gthis
hine.
with
which
o be
ythe
elast
chine
ch as
ed to
otting
n be
chine
ernal
ating
ed on
er

3rd
semester
84
Fig4.31ASlottingattachment
Rackmillingattachment:Thisattachmentisusedforcuttingteethinracks.Itcanalsobe
employed,conjunctionwiththeuniversaldividinghead,forcuttingworm,Itismounted
onthemachinecolumnandcutterismountedonthearborprovidedinthisattachment.
Thearbormeansparalleltothelongitudinaltraverseofthemachinetableonwhichthe
workpieceisheldforcuttingtheteeth.
Q5Givetheclassificationofmillingmachine.
Types of milling machine: A large variety of different types of milling machines is
availableanditisreallydifficulttoaccountforallthesetypesinthissmallchapter.The
broadclassificationofthesemachinescanbedoneasfollows:
1. Columnandkneetypemillingmachines,
2. Fixedbedtypeormanufacturingtypemillingmachines.
3. Planertypemillingmachines.
4. Productionmillingmachines.
5. Specialpurposemachines.
Further detailed classification and descriptions of these machines will follow in the
forthcomingarticles.
Column and knee type milling machines: These machines are all general purpose
machinesandhaveasinglespindleonly.TheyderivetheirnameColumnandknee
typefromthefactthattheworktableissupportedonakneelikecasting,whichcan
slide in vertical direction along a vertical column. These machines, depending upon
thespindlepositionandtablemovements,arefurtherclassifiedasfollows:
a) Handmillingmachine,
b) Plainorhorizontalmillingmachine,
c) Verticalmillingmachine,
d) Universalmillingmachine,and
e) Omniversalmillingmachine.

3rd
semester
85
Fixedbedtypeormanufacturingtypemillingmachines:Thesemachineincomparisonto
thecolumnandkneetype,aresturdy,heavierinweightandlargerinsize.Theyarenot
suitable for tool rooms of these machines are either automatic or semiautomatic in
operation, carry a single or multiple spindles. The common operations performed
machinesareslotcutting,grooving,gangmilling,andfacing.Alsofurtherclassificationis
asfollows:
a) Plaintype(havingsinglehorizontalspindle)
b) Duplexhead(havingdoublehorizontalspindle)
c) Triplexhead(havingtwohorizontalandoneverticalspindle)
d) Riseandfalltype(forprofilemilling)
Planer type milling machines: They are used for heavy work. Up to a maximum of four
tool headscan be over it, whichcan be adjusted vertically and transverse directions.It
hasmassiveconstructionlikeaplaner.Itsdetaileddescriptionwillfollowarticles.
Productionmillingmachines:Theyarealsomanufacturingmachinesbutdifferfromthe
abovedescribedinthattheydonothaveafixedbed.Theyincludethefollowing:
a) Rotarytableorcontinuoustype.
b) Drumtype,and
c) Tracercontrolled.
Special purpose machines: These machines are designed to perform a specific type of
operationonly.Includethefollowingmachines:
a) Threadmillingmachine,
b) Profilemillingmachine,
c) Gearmillingorgearhobbingmachine,
d) Cammillingmachine,
e) Planetarymillingmachine,
f) Doubleendmillingmachine,
g) Skinmillingmachine,
h) Spurmillingmachine,
8
NAGPUR
86
Q7 Dra
partsof
Vertical
Thismac
type.Pr
1 and 2.
made in
head, ca
always r
canbes
The kne
along th
saddleis
R INSTITUTE
w a neat s
it.
milling ma
chineisava
inciplespar
. It carries
ntegral with
an be of fix
remains ve
swivelledto
Fig4
ee carries a
he parallel
smounted
OF TECHNOL
sketch of co
achine: It d
ailableinb
rtsofthela
a vertical
h the colum
xed type (F
rtical and c
oanydesire
4.32Vertica
n enclosed
vertical gu
onthekne
Fig4.33Ve
LOGY
Questionb
olumn and
erives its n
othtypes;t
attertypea
column on
mn and ca
Fig 1) or sw
can be adju
edangleto
almillingma
screw jack
uideways p
eandcanb
erticalmillin
bankwiths
knee type
name from
thefixedb
areillustrat
a heavy b
arries housi
wiveling typ
usted up an
machineth
achinewith
k, by mean
provided on
bemoved,a
ngmachine
olution
milling ma
the vertic
edtypesas
edbymean
ase. The ov
ing at its f
pe (Fig. 2)
nd down. In
heinclineds
hfixedhead
s of which
n the front
alongthe
ewithswive
Manufacturin
achine? An
al position
swellasco
nsofblock
verarm in
front. This
In fixed ty
n swiveling
surfaces.
d
it is move
t side of th
ellinghead.
ngprocessI
nd explain m
of the spi
olumnand
diagramsi
this machi
housing, c
ype, the sp
type, the
d up and d
he column,
.
3rd
semeste
main
ndle.
knee
nFig
ne is
alled
indle
head
down
The
er

3rd
semester
87
Q8Explainmillingmachinepowerfeedmechanism?
Milling machine mechanism: The milling machine mechanism is composed of spindle
drivemechanismandthetablefeedmechanism.
The spindle drive mechanism is incorporated in the column. All modern machines are
driven by individuals motors housed within the column, and the spindle receivers
powerfromacombinationofgearsandclutchassembly,Multiplespeedofspindlemay
beobtainedbyalteringthegearratio.
Fig. 1. illustrated the power feed mechanism contained within the knee A of the
machinetoenablethetableCtohavethreedifferentfeedmovements,i.e.longitudinal,
cross, and vertical. The power is transmitted from the feed gear box H consisting of
change gears to shaft 23 in the knee A of the machine by a telescopic shaft 11. Both
ends of the shaft 11 are provided with universal joint 10 and 12. Telescopic shaft and
universal joints are necessary to allow vertical movement of knee A, gear 14, attached
to the jaw clutch 20, is keyed to the shaft 23 and drives gear 13 which free rotate on
shaft23andisinmeshwithgear19fastenedtotheevaluatingscrew15,16servesasa
nut for 15, and as screw in nut 17. 15 and 16 therefore serves as telescopic screw
combinationandaverticalmovementofthekneeisthuspossible.Assoonastheclutch
20 is engaged with the clutch attached to the bevel gear 22 y means of a lever 4, 22
rotatesandthisbeinginmeshwithgear19causestheelevatingscrew15torotatein16
givingaverticalmovementoftheknee.Likewise,whentheclutch21,whichiskeyedto
thecrossfeedscrew7throughgears14and13.Thiscausesthescrew7torotateinnut
6oftheclampbedgivingacrossfeedmovementoftheclampbedDandsaddleB.
Gear18isfastenedtoshaft23,andmesheswithgear25whichisfastenedtothe
bevelgear24.Again24mesheswithgear5attachedtoaverticalshaftwhichcarriesat
its upper end another bevel gear 3. Gear meshes with gear 2 which is fastened to the
table feed screw1. Therefore, longitudinal feed movement of the table is possible
throughgears18,25,24,5,3,and2.
8
NAGPUR
88
1
6
U
sc
R INSTITUTE
AKn
.Longitudi
. Nut, 7. Cr
Universal jo
crew,23.Fe
OF TECHNOL
Fig.4.34M
nee,B.Sadd
F.Bed,G
nalfedscre
rossfeed s
oint, 11. Te
eedshaft.
LOGY
Questionb
Millingmach
dle,C.Table
G.Column,H
ew,2,3,5,
crew, 8, 20
elescopic fe
bankwiths
hinepower
e,D.Clamp
H.Feedgea
19,22,24.B
0, 21. Powe
eed shaft,
olution
feedmecha
bed,E.Fee
arbox.
Bevelgears,
erfeed clut
13, 14, 18
Manufacturin
anism
edhandwh
,4.Clutcho
tch, 9. Sadd
8, 25. Gear
ngprocessI
heel,
operatingle
dle nut, 10
rs, 15 Eleva
3rd
semeste
ever,
0, 12.
ating
er

3rd
semester
89
GRINDINGPROCESSANDSUFERFINISHING

3rd
semester
90
UnitV
QUE:1) HOW GRINDING WHEELS ARE CLASSIFIED? STATE HOW THE GRINDING
WHEELSARESPECIFIED?
COMMONWHEELSHAPES
ThemostcommonshapesofgrindingwheelsareshowninFig.5.1andthose
of wheel faces in Fig. 5.2. The straight sheels shown at (a), (b) and (c) are used for
internalgrinding,toolgrinding,centrelessgrinding,cylindricalandoffhandgrindingand
snagging. The recesses are provided to accommodate the manufacturing flanges. The
plainwheeliscommonlyusedforpartingoffandisnotmorethan3mmthick.

Fig.5.1Commonshapesofgrindingwheel
So as to prevent the wheel pieces from flying off, if the same gets broken during the
operation. Straight cup wheel (e) is mainly employed for surface grinding on both the
horizontalandverticalspindlegrinders.Cylindricalwheel(f)hasthesameapplicationas
straight cup wheel. The Saucer wheel (g) is principally used for sharpening the saws.
Dishwheel(h)findsitsprincipalapplicationontoolandcuttergrindersforgrindingthe
teeth of various cutting tools, like milling cutters broaches, etc., for the reason that its
thin edge can easily enter the narrow spaces between adjacent teeth on tool. Flaring
cupwheel(i)isalsomainlyusedontoolandcuttergrinders.Itmayhaveaplainedgeor

3rd
semester
91
beveled edge. The common shape of wheel faces is shown in Fig 5.2. The proper
selectionofaparticulartypeoffacewilldependonthenatureofwork.

Fig.5.2.Commonshapesofgrindingwheelfaces.
BUILTUPWHEELS:
Thesewheelsaremadeinmanyways.Essentially,theyconsistofanumberof
bondedabrasiveblocks,heldtogetherbysuitablemeans.Atypicalexampleofthesewill
consist of a these blocks fastened to a metal wheel, which consist of formed abrasive
blocksheldinacirclebyachuck.Spacersarealwaysprovidedbetweentheblocks.Itis
mainly employed on vertical spindle grinders with reciprocating or rotary type tables.
Theyaremainlyusedinsurfacegrindingandcarrythefollowingmainadvantages:
Itiseasiertomanufacturethesewheelsinlarge
sizesincomparisontothesolidwheelsofsamesize.Fig.(5.3segmentalgrinding
wheel)
Theycutintermittently,andhencecoolgrinding
istheresult.
AsegmentalgrindingwheelisshowninFig.5.3.
Other than those shown in Fig.5.1, there is a special variety of grinding wheels
which possesses Cone and Plug shapes. They are employed to grind intricate
shapes to which their outer surfaces suit. They carry threaded bushings on the
mountingside,asshownat(d)inFig.5.4.ThisfigureshowsthestandardShapes
of cone and plug grinders as per IS: 2324 (Part I)1985. Their detailed

3rd
semester
92
dimensions are also given in this standard. An imported point to note is that in
this type of wheels grinding is performed by all the surfaces except the flat
surfaceonthemountingside.

Fig.5.4coneandpluggrindingwheelasperIS:2324(PARTI)1985
Cone(type 16), (b) Cone (type 17), (c) Cone (type 17R), (d) plug(type 18), (e) Plug
(type18R),(f)Conicalplugsquaretip(type19),(g)Conicalplugroundtip(type19R)
MOUNTEDWHEELSANDPOINTS:
Thesearesmallgrindingwheelswithshanksattachedtothem.Theyare
madeinvariousdifferentshapesandsizessoastoenablegrindingeveninthoseplaces
whicharenoteasilyaccessibleotherwise.(seeFig5.5).


3rd
semester
93
Fig5.5.Commonshapesofmountedwheelsandpoints
They are commonly used on portable grinders and run at extremely high speeds up to
100,000r.p.m.Afewoftheapplicationsofthesewheelsandpointsareinfinishingdies,
metal moulds, recesses, small circular and tapered holes, fillets and other small
curvatures.Suchrequirementsfrequentlyoccurinfoundry,forgingandtoolroomwork,
such as for cleaning the surfaces of casting and forgings and production and
maintenance of tools and dies for diecasting, plastic moldings, pressing (hot), drop
stampingandmetalextrusion,etc.
DIAMONDWHEELS
These wheels are also made in almost similar shapes as of aluminium oxide or
silicon carbide wheels. Theyare also provided with thecentral hole for being mounted
on a spindle. Alternatively, they can be attached or fastened to metallic backing.
Artificialdiamondbondedwheelsarenowpreferredoverthenaturaldiamondbonded
wheels,particularlyingrindingcarbidetippedtools.Thewheelsmayhaveavitreousor
resinoid bond. It is reckoned that the artificial diamond bonded wheels are more free
cutting and enable more stock removal with less power consumption as compared to
thenaturaldiamondbondedwheels.
METHODOFSPECIFYINGAGRINDINGWHEEL
The methods of specifying a grinding wheel differ slightly in different
countries. In order to maintain uniformity throughout the country in the system of
markinggrindingwheelstheBureauofIndianStandardshasdevisedastandardsystem
to be followed by all manufactures. Its details are given in (IS: 5511954). According to
thissystemthevariouselementsandcharacteristicsofgrindingwheelsarerepresented
onallthewheelsindefinitesequencesasfollows:
1. Abrasive2.Grainsizeorgril,
2. Grade4.Structureand5.Bond.
In addition, a manufacturer can use a suitable prefix, presiding the abrasive notation,
to indicatehis own trade brand of the abrasive used and a suffixat the endof all the
notations to indicate the manufacturers own symbolic representation for that
particular type of wheel. The use of prefix and /or suffix is, however, optional. The

3rd
semester
94
marking system recommended by the Bureau of Indian Standards in there IS code No.
5511989isgiveninFig.(5.6).
Apartfromtheaboveinformation,inordertospecifyagrindingwheelcompletely,the
size,i.e.,diameterandwidthorthicknessandthediameterofborearealsorequiredto
bementioned.
Thus, a grinding wheel carrying the markings, 250 x 25 x 32 W A 46 L 4 V 17 will
confirmtothefollowingspecifications:
Wheeldia.=250mm
Thicknessofwheel=25mm
Boredia.=32m
WManufacturersprefixtoabrasive.Itisoptional.HereitdenotesWhite
AAbrasive(ALO)
46Itisagrainsize(medium)
LItisagrainmediumgrade.
4Representsadensestructure
VStandsforvitrifiedbond.
17Itisasuffixdenotingthebondtypeofthemanufacturer.
QUE2) DRAW A NET SKETCH TO GRINDING MACHINE, HORIZONTAL SPINDLE
RECIPROCATING TABLE TYPE SURFACE AND EXPLAIN FUNCTIONS OF ITS VARIOUS
PARTS?
RECIPROCATINGTABLETYPESURFACEGRINDERS
The principal of grinding, as applied to reciprocating table type surface grinders, is
illustrated by means of the diagram of relative movements in Fig. 5.6 and 5.7 A
reciprocating table type surface grinder Wheel (see Fig. 5.6 or a vertical Spindle of the
same,asshowninFig5.6Theformerwillcarryastraightwheelandthelatteracuptype
wheel. Hydraulic drives are commonly used in all such grinders. Cutting is done on the

3rd
semester
95
peripheryofthestraightwheelincasehorizontalspindletype,andonrevolvingedgeof
thecupwheelonverticalspindlemachines.

Fig.5.6workingprincipleofahorizontalspindlereciprocatingtablesurfacegrinder.
Thehorizontalspindlemachinesarewidelyusedintoolrooms.Theworkpieceisusually
held on a magnetic chuck on these machines. They are vastly used for grinding flat
Surfaces. The machine size is designed by the dimensions of the working area of the
table. A typical design of a Grinder is shown in Fig.5.7 illustrating its main Parts and
controls.Thelongitudinalfeedtotheworkisgivenbyreciprocatingthetable.Forgiving
crossfeed,therearetwomethods.Oneistomountthetableonasaddleandgivethe
cross feed by moving the saddle. Alternatively, the cross feed can be given by moving
thewheelheadinandout.Itisthismethodwhichisemployedinthemachineshownin
Fig. 5.7 In feed is provided by lowering the wheelhead along the column.
In case of vertical spindle reciprocating table grinders the table, along with the work
piece,reciprocatesunderthewheel.Thewheelcoversalloramajorportion

Fig.5.7Workingprincipleofaverticalspindlereciprocatingtablesurfacegrinder

3rd
semester
96

Fig.5.8Reciprocatingtablehydraulicsurfacegrinder.
1.Stop pushbutton for hydraulic pump motor, 2.Start pushbutton for hydraulic
pumpmotor,3.Adjustabletravelcumdog,4.MasterStoppushbutton.5.Pushbutton
for engaging rapid upward traverse of the wheel head. 6. Control lever of
Electromagnetic ebuck(switched on, switched off and demagnetized).7. Signal
lamp indicating that electromagnetic chuck is switched on. 8. Electromagnetic chuck
operation switches (with chuck or without chuck). 9. Feed switch on and off. 10.
Startpushbuttonforcoolantpumpmotor.11.Worklightswitch.12.Pushbuttonfor
engaging rapid downward traverse of the wheel head. 13. Changeover switch for
startingcoolantfloweithertogetherwithgrindingwheelrotatingortogetherwithtable
travel. 14. Stop pushbutton for grinding wheel rotation. 15. Start pushbutton for
grindingwheelrotation.16.Leverfortabletravel.(Start,stop).17Leverformanually
reversingtabletravel.18.Knobforsettingtablespeed.19.Pushbuttonfordisengaging
band wheel and dial.20. Hand wheel for vertical wheel head feed. 21. Leverfor setting
the positive stop.22.Lever for engaging rapid vertical traverse of wheel head. 23. Knob
setting rate of automatic vertical feed of wheel head. 24. Knob for setting rate of
intermittentcrossfeed.25.Knobforsettingrateofcontinuouscrossfeed.26.Leverfor
engagingeitherintermittentorcontinuouscrossfeed.27.Adjustabletablecamdog.28.
Coolantfeedcock.29.Handwheelforcrosstraverseofwheelhead.30.Handwheelfor
cross traverse of wheel head. 31. Reversing camdog for hydraulic cross feed of wheel
head. 32. Lever for reversing hydraulic cross feed of wheel head. 33. Table reversing
leverofthewidthofthejob,asshowninFig.5.8.Crossfeedtotheworkcanbegivenas

3rd
semester
97
usual by moving the saddle. A manual or power feed can be employed to feed the
wheelheadvertically.Anindividualmotordriveisusuallyprovidedtorotatethewheel.
QUE3) WHAT DO YOU UNDERSTAND FROM GRAIN,GRIT STRUCTURE AND GRADE
OFGRINDINGWHEELEXPLAIN?
GRAINORGRIT
ThetermGrainorGritdenotestheapproximatesizeoftheabrasiveparticlesandgive
anideaofthecoarsenessorfinenessofthegrindingwheel.Agrindingwheelmayhave
the abrasive particles of same size or different sizes. The former is known as a straight
wheel and the latter compound wheel. The choice of grainsize or grit depends upon
many factors, viz,, quality of finish required, amount of stock material to be removed
and physical properties of the material to be ground. The coarser grit will remove the
stock at a faster rateand finer finish will always require a finer grit.Coarsegrit wheels
are more suitable for grinding soft and ductile materials hard and brittle materials are
bestgroundwithfinergritwheels.
Thegritorgrainsizeofanabrasiveisdenotedbyanumberrepresentingthe
numberofmeshesperinchofthescreenthroughwhichthegrainsofcrushedabrasive
are passed for grating. The standard numbers representing different grain sizes are
giveninTable.

3rd
semester
98
Grit
designation
GrainsizeorGritNo.
Coarse
Medium
Fine
Veryfine
101214162024
3036465460
80100120150180
220240280320400500600
Standardgrainsizeforgrindingwheels
Note.Thefirstthreetypesi.e.coarse,mediumandfine,areusedingrindingworkand
theveryfinegrit,i.e.,havinggrainsizeno.from220onwards,inhoningwork.
GRADE:
The term Grade indicates the strength of bond in a wheel, i.e., the power of the
abrasiveparticlestoholdtogetherandresistdisintegrationunderthecuttingpressure.
Higher the proportion of bond for a specified quantity of abrasive particles the harder
will be the wheel and a lower proportion will render it soft. The abrasive grains of a
softwheelwilleasilybebrokenawayfromthebondwhereasthehardwheelwillretain
these particles for a much longer period. The selection of a particle grade of wheel is
largely governed by the nature of work, its composition, size and hardness, etc. Softer
wheelsarepreferredforgrindinghardermaterialsandviceversa.Similarly,smallerthe
sizeofthework,thehardershouldbethewheelandviceversa.Themachinecondition
alsoplaysanimportantroleinthisselection.Wherevibrationsarelikelytooccurharder
wheelsareemployed,suchasintoolpostgrindersonlathes.Allwheelsmanufacturers
always provide tables of recommended grits and grills for specific operation and
materialstobemachinedanditisadvisabletofollowthesameinselectingawheelfora
specificjob.
Different wheel grades are represented by English alphabets from A to Z, A
beingthesoftestandZbeingthehardest.Thestandardgroupingisasfollows:
Soft
Medium
Hard
ABCDEFGH
IJKLMNOP
QRSTUVWXYZ
Differentgradesofgrindingwheels

3rd
semester
99
STRUCTURE
This term denotes the spacing between the abrasive grains, or in other
words thedensity of the wheel.The proportion of the bond in a certain volume of the
wheel affects the structure. A higher proportion will render an open structure and a
lowerproportionwillleadtoacloserstructure.Iftwowheelsofsamegritandgradeare
usedonthesamematerial,onehavinganopenstructureandtheotherclosestructure,
the former will be found to cut faster and more freely in comparison to the latter and
willhavemorelifeascomparedtoit.
Theabovetwotypesofstructuresarerepresentedbynumbersasfollows:
Structuresofgrindingwheels
Note. Selection of a particular structure will depend upon the hardness of work
material, Type of grinding operation and quality of surface finish needed on the work
surface.Brittleandhardmaterialsandfinishgrindingworkwillneedadensestructure,
while a soft and tough work material and rough grinding operation will need an open
structure.
QUE4)EXPLAINSDIFFERENTTYPESOFSURFSCEGRINDERS?
SURFACEGRINDERS:
Surface grinders do almost the same operation as the planers, shapers or milling
machines,butwithmoreprecision.Primarilytheyareintendedtomachineflatsurface,
although irregular, curved or tapered surfaces can also be ground on them. The
commonclassificationofsurfacegrinderscanbemadeasfollows:
1. Accordingtothetablemovement:
(a) Reciprocatingtabletype.(b)Rotarytabletype.
2. Accordingtothedirectionofwheelspindles:
Structuretype RepresentedbyNos.
Dense
Open
12345678
9101112131415or
up

3rd
semester
100
(a) Verticalspindletype.(b)Horizontalspindletype.
3. Specialtypeandsinglepurposemachines.
(a) Facegrinders(b)waygrinders(c)Wetbeltgrinders.
RECIPROCATINGTABLETYPESURFACEGRINDERS
The principal of grinding, as applied to reciprocating table type surface grinders, is
illustrated by means of the diagram of relative movements in Fig. 5.9 and 5.10 A
reciprocating table type surface grinder Wheel (see Fig. 5.9 or a vertical Spindle of the
same, as shown in Fig The former will carry a straight wheel and the latter a cup type
wheel. Hydraulic drives are commonly used in all such grinders. Cutting is done on the
peripheryofthestraightwheelincasehorizontalspindletype,andonrevolvingedgeof
thecupwheelonverticalspindlemachines.

Fig.5.9Workingprincipleofahorizontalspindlereciprocatingtablesurfacegrinder.
Thehorizontalspindlemachinesarewidelyusedintoolrooms.Theworkpieceisusually
held on a magnetic chuck on these machines. They are vastly used for grinding flat
Surfaces. The machine size is designed by the dimensions of the working area of the
table. A typical design of a Grinder is shown in Fig.5.10 illustrating its main Parts and
controls.

Fig.5.10Workingprincipleofaverticalspindlereciprocatingtablesurfacegrinder

3rd
semester
101
The longitudinal feed to the work is given by reciprocating the table. For giving cross
feed,therearetwomethods.Oneistomountthetableonasaddleandgivethecross
feed by moving the saddle. Alternatively, the cross feed can be given by moving the
wheelheadinandout.ItisthismethodwhichisemployedinthemachineshowninFig.
5.10.Infeedisprovidedbyloweringthewheelheadalongthecolumn.
In case of vertical spindle reciprocating table grinders the table, along with the
workpiece,reciprocatesunderthewheel.Thewheelcoversalloramajorportion

Fig.5.11Reciprocatingtablehydraulicsurfacegrinder.
1. Stop pushbutton for hydraulic pump motor, 2.Start pushbutton for
hydraulic pump motor, 3. Adjustable travel cumdog, 4. Master Stop push
button.5.Pushbuttonforengagingrapidupwardtraverseofthewheelhead.6.
Control lever of Electromagnetic ebuck (switched on, switched off and
demagnetized).7.Signallampindicatingthatelectromagneticchuckisswitched
on.8.Electromagneticchuckoperationswitch(withchuckorwithoutchuck).
9. Feed switch on and off. 10. Start pushbutton for coolant pump motor. 11.
Worklightswitch.12.Pushbuttonforengagingrapiddownwardtraverseofthe
wheelhead.13.Changeoverswitchforstartingcoolantfloweithertogetherwith
grindingwheelrotatingortogetherwithtabletravel.14.Stoppushbuttonfor
grinding wheel rotation. 15. Start pushbutton for grinding wheel rotation. 16.
Lever for table travel. (start, stop).17. Lever for manually reversing table
travel. 18. Knob for setting table speed. 19. Push button for disengaging band
wheelanddial.20.Handwheelforverticalwheelheadfeed.21.Leverforsetting
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3rd
semester
103
cross feed by the horizontal movements, of the wheel spindle. a straight wheel is
used on these machines, which cuts on its periphery. Same machines carry the
provisiontoraiseorlowerthetablealsoandalsotoinclinethesame.

Fig.5.13.Relativemovementofdifferentpartsofverticalspindlerotarytablesurface
grinders
Fig.5.13illustratestherelativemovementsofthewheelandtableofaRotary
tableverticalspindlesurfacegrinder.Acupwheelhastobeusedonthesemachines,
asshownindiagram.Verticalfeedtothewheelisgivenbymovingthewheelhead.
Theworkpieceismountedontheroundchuckinthesamewayasinthehorizontal
spindletype.Thetablerotatesinadirectionoppositetothatofthewheelandbrings
the work piece one after the other under the rotating wheel. The table is usually
mounted on a slide so as to give cross feed. Some rotary table surface grinders are
provided with two tables instead of one so that, while the work pieces are being
groundononetable,theothertablecanbeusedforloadingthefreshbatchofwork
pieces.
OTHERTYPESOFSURFACEGRINDERS
1. Face grinder: It is more or less similar in operation to a horizontal spindle
reciprocating table surface grinder, but differ in that a vertical flat surface is
ground instead of a horizontal one. The cutting is done on the face of the
wheel and not the periphery. Usually cup, ring or segmental type wheels are
used, which are mounted on a horizontal spindle and fed on to the vertical
surface of the work piece, mounted on the reciprocating table. This type of
1
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3rd
semester
105
Fig5.14Simplifieddia.ofacentrelessgrinder.
The relative movements of the work piece and the two wheels are shown in fig.5.14.
The principle of centre less grinding is used for both the external grinding as well as
internalgrinding.Manyhollowcylindricalandtaperedworkpieces,likebushes,pistons,
valvestubesandballs,etc,whicheitherdonotorcannothavecentre,arebestground
oncentrelessgrinders.
AsimplifieddiagramofcentrelessgrinderisshowninFig.5.14illustratingitsmain
parts and controls. It carries a heavy base and two wheel heads, one carrying the
grinding wheel (large one) and the other regulating wheel(smaller one3). The work
piecerestsonthebladeoftheworkrestbetweenthesetwowheels.Eachheadcarriesa
separatewheeltruingmechanismforthewheelitcarries.Ahousingcanprovideonone
sideofthemachinebodytohousethemaindrivingmotor.Therearetwocontrolpanels
onthefront.Thelefthandpanelcarriescontrolofspeedadjustmentofthetwotruing
mechanism and the infeed grinding mechanism. The right hand panel carries for
hydraulic mechanism, speed adjustment of regulating wheel, automatic working cycle
switch,startandstopswitches,etc.
In operation, grinding operation is performed by the grinding wheel only while
the function of the regulating wheel is to provide the required support to the work
pieceswhileitispushedawaybythecuttingpressureofthegrindingwheel.Thishelps
the work pieces to remain in contact with the grinding wheel. At the same time,
required support from bottom is provided by the work rest as the work piece, while
rotating,andrestsonthebladeoftheworkrest.Theregulatingwheelessentiallycarries
rubber bond and helps in the rotation of work piece due to friction. The direction of
rotation of the two wheels is the same. The common methods used for feeding the
workare:
1. Throughfeed2.Infeed3.Endfeed
1. Through feed grinding: In this method of centre less grinding, the work piece is
supportedand revolved asdescribed above but,is simultaneously givenan axial
movement also by the regulating wheel and guides so as to pass between the
wheels.
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3rd
semester
108
6. Since there is no end thrust, there are no chances of any springy action or
distortioninlongworkpieces.
7. Theoperationconditionautomaticallyprovidesatruefloatingtypecentrefor
the work pieces and, as such, the common errors normally associated with
thecentreandcentreholesareautomaticallyeliminated.
8. Theworkpieceissupportedrigidlyduringtheoperationandcanbesubjected
toheavycuts,resultinginarapidandmoreeconomicalgrinding.
9. Sincetheneedformarkingandmakingcentreholesistotallyeliminatedanda
smaller grinding allowance is needed, the grinding time is considerably
reduced.
10. Largegrindingwheelsareusedanderrorsduetowheelweararereduced.So,
therequirementofwheeladjustmentisminimum.
11. Aheavylittlemaintenanceisneededforthemachine.
12. Very highly skilled operations are not needed for operating centre less
grinders.
13. Directadjustmentforsizescanbemade,resultinginahigheraccuracy.
14. Afairlywiderangeofcomponentscanbeground.
Somedisadvantagesare:
1) Inhollowworkthereisnocertainlythattheoutsidediameterwillbeconcentric
withtheinsidediameter.
2) Workhavingmultiplediametersisnoteasilyhandled.
QUE6)EXPLAINSTHEPROCESSOFHONINGANDLAPPING?
LAPPING
It is an abrading process employed for improving the surface finish by
reducingroughness,wavinessandotherirregularitiesonthesurface.Itisusedonboth
heattreatedandnonheattreatedmetalparts.Itshouldhowever,benotedthatwhere
goodappearanceofthejobsurfaceistheonlyrequirement,itshouldnotbeemployed,
sincethereareotherfinishingmethodswhichwillgivethesamedesiredresultwithlow

3rd
semester
109
cost. It should be used only where accuracy is a vital consideration in addition to the
surface finish. The basic purpose of lapping is to minimize the extremely minute
irregularitiesleftonthejobsurfaceaftersomemachiningoperation.
In brief, we can say that Lapping is basically employed for removing minor
surface imperfection, obtaining geometrically true surfaces, obtaining better
dimensional accuracy and, thus, facilitate a very close fit between two contacting
surfaces.
Thematerialtobeselectedformakingalappingtoolorlaplargelydepends
upon the individual choice and the availability, and no specific rule can be laid for the
same.Theonlyconsiderationthathastobemadeisthatthematerialusedformakinga
lap should be soft so that the abrasive grain can be easily embedded in its surface. In
caseahardmaterialisusedformakingthelap,theabrasiveparticleswillquicklygoout
of their places. The commonly used material is soft cast iron, copper, brass, lead and
sometimeshardwood.
Abrasive: All the abrasive, i.e., natural as well as artificial are used for lapping.
Aluminium oxide is preferred for lapping soft ferrous and nonferrous metals. Silicon
carbide and natural corundum are used for hardened steel parts. Powdered garnet is
used for lapping soft ferrous and nonferrous metals, emery for hardened steel
componentsanddiamondforextremelyhardmateriallikecementedcarbides.
Vehicle:
The term vehicle in lapping denotes the lubricant used to hold or retain the abrasive
grains during the operation. To some extent it also controls the cutting action of the
latter.Somecommonvehicleusedinlappingincludesthevegetableoroliveoil,hardoil,
water so9luble oil, mineral oil, kerosene mixed with a little machine oil, alcohol, and
heavy grease. For cleaning the laps, naphtha is commonly used. No specific
recommendationcan,although,belaidfortheselectionofaparticularvehicle,stillthe
vehicleusedshouldpossesthefollowingqualities:
1. Itshouldbeabletoholdtheabrasiveparticlesuniformlyduringtheoperation.
2. Itsviscosityshouldnotbeconsiderablyaffectedbytemperaturechanges.
3. Itshouldnotevaporatequickly.
1
NAGPUR
10
4.
5.
Pressure
Th
Fo
Fo
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LAPPING
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3rd
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3rd
semester
111
Fig.5.18AnexampleofHandLapping
Machinelapping:
Machine lapping is performed for obtaining a highly finished surface on many articles
like races ball and roller bearings, gears, crankshafts, machine bearings, pistons, pins
and gauges, gauge blocks, various automobile engine parts and micrometer spindles,
etc.

Fig5.19workingprincipleofaverticalspindlelappingmachine.
HONING
Itisalsoanabradingprocess,usedforfinishingpreviouslymachinedsurfaces.It
is mostly used for finishing internal cylindrical surfaces such as drilled or bored holes.
The tool used, called a hone, is a bonded abrasive hone made in the form of a stick.
Although honing cradles the maximum stock removal out of the surface finishing
operation,stillitisnotprimarilyametalremovingoperation.However,thishigherstock
removing capacity enables the application of honing for correcting slight out of
roundnessorlapper.Holelocationcannotbecorrectedthroughit.Theusualamountof
stock left for removal by honing is form 0.1 mm to 0.25 mm; although it is capable of
removingthestockupto0.75mm.Honingisperformedatrelativelyslowspeedsinthe
rangeof1030m/min.
The honing stock are so held ina holder or mandrelthat they can be forced outwards
by mechanical or hydraulic pressure against the surface of the bore. Aluminium oxide,
1
NAGPUR
12
silicon c
shelter
longerto
Both in
largely a
5.20.
The han
coolant
doneby
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will fail
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LOGY
Questionb
grains of su
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tingaction.
Ahandhon
flat surfac
indrical sur
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uality durin
neisrotate
length of st
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ess of hon
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eneral pur
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3rd
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1
NAGPUR
13
QUE7
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LOGY
Questionb
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3rd
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1
NAGPUR
14
itfor
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LOGY
Questionb
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de a
er

3rd
semester
115
Surfaceroughnessisspecifiedbyreferringtothecentrelineaverageorthe
rootmeanaverageofthemicroirregularities.InstrumentgivesthedirectreadingofCLS
&RMSvalues.
QUE9)EXPLAINSTHEPROCESSOFGALVANIZINGGIVINGITSAPPLICATION?
GALVANIZATION:
Itisaprocessofprovidingthinlayerofzinccoating(highlycorrosionresistance)oriron
orlowcarbonsteelbydippingtheminabathofmoltenzinc.Itimprovetheresistance
against corrosion due to atmosphere and water. Since zinc is anodic to iron or steel
(which serve as cathodic), therefore the zinc coating (also called anodic coating) is
obtainedbyelectrochemicalreactionbetweenzincandtheironorsteel.Theprocessis
carriedoutasfollows:
Firstofalltheworkiscleanedbypickingwithdilutesulphuricacid,
to remove any scale, rust and impurities. After washing and drying it is dipped in the
bathofmoltenzincmaintainedattemperatureatabout450c.Thesurfaceofthebath
kept covered with a molten flux layer usually of zinc ammonium chloride to prevent
oxideformation.Thedeviationofimmersioninazincbathdependuponthesizeofthe
worktobecoated,itisthentakenoutofthebathapassedthroughthepairofrollersto
removeandexcessofzinc.Finely,theworkiscooledanddried.
Thegalvanizingprocessiswidelyusedforsheetingforroofsandwallsof
buildings,structuralparts,pipes,container,fencingmaterial,nails,wires,etc.Sincethe
zincgetdissolveindiluteacidstoformhighlytoxiccompound,thereforethegalvanized
utensilsshouldnotbeusedforpreparingandstoringfoodstuffsespeciallyacidicone.
Applications:
1)itismainlyuseforlargesheetingforroofsandwallsofthebuildings.
2)itisusedforstructuralparts,pipes,containers,fencingmaterial,nails,wires,etc.
QUE10)WRITESHORTNOTESON
a) SUPERFINISHINGPROCESS
b) ELECTROPLATING
1
NAGPUR
16
c) CYL
a) S
It
used is a
conditio
particula
necessa
compon
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0.0025 m
the corr
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employe
It is the
and som
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R INSTITUTE
LINDRICAL
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OF TECHNOL
GRINDING
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Fig.5.2
oplating:
ular means
nonmetal
n, for appea
ulder and t
LOGY
Questionb
lappingpro
he abrasive
h quality su
not essen
in order t
hedshould
n average t
ckto berem
to 0.025 m
such a cl
ing.
23Principle
s of applyin
. This is do
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Manufacturin
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3rd
semeste
asive
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metal
ainst
make
uring
er

3rd
semester
117
heat treatment common plating metals are chromium, nickel, copper, zinc, cadmium,
andtin.Themorepreciousmetalssilver,gold,platinum,andrhodiumandalsoapplied
byplatingsurfacetobe
Platted must be buffered smooth work is then cleaned in suitable cleaning solution to
remove all grease, dirt, buffering, compound etc. After rinsing the part is ready for
platinum
=> Four essential elements of the platting process are the cathode, anode,
electrolyteanddirectcurrent(showninfig)
=> The current leave the bar of anode which is a bar of platting metal, and
migratethroughelectrode(watersolutionofsaltsofthemetaltoapply)tothecathode,
orparttobeplated.Astheionsdepositedoncathode,theygiveuptheirchargeandare
deposited as metal on cathode. Part to be platted should be designed with generous
filtrate and radii instead of sharp corners, since current concentration occurs at sharp
points,resultinginexcessivedeposits.

Fig5.24Electroplating
1) Platingtank2)D.Csource3)workpiece4)Anode

3rd
semester
118
c)CylindricalgrinderMachine:
TheprincipleofcylindricalgrindingasillustratedinFig.13.14involvesholdingthework
piecesrigidlyoncenters,inachuckorinasuitableholdingfixtures,rotatingitaboutits
axisandfeedingafastrevolvinggrindingwheelagainstthesame.Iftheworksurfaceto
be ground is longer than the face width of the grinding wheel. The work is traversed
past the wheel or the wheel past the work. Traversing of wheel or work is done either
byhydraulicormechanicalpowerorbyhand.Feedisgiventotheworkorthewheelat
theendofeachtraversingmovements.Incasewidthofwheelfaceismoreorequalto
thelengthoftheworksurfacetobeground,thewheelmaybefedinwithnotraversing
movementofitorthatofthework.Thisisknownasplungegrinding.Thesimplestand
quite commonly used type of cylindrical grinder is a tool pass grinder used on lathes.
When wheels of large diameters are used, they can be mounted directly on the motor
shaft.Formountingsmallwheelsanauxiliaryshaftisprovided,whichrunsatarelatively
much higher speed than the motor. Both external and internal cylindrical grinding can
bedoneonlathebythisequipment.Atypicaltypeoftoolpostgrinderisshown.
Cylindricalgrindingmachinesaremainlyofthefollowingthreetypes:
1) Plaincylindricalgrinders
2) Universalcylindricalgrinders
3) Centrelessgrinders
Other forms of cylindrical grinders include roll grinders, camshaft grinders,
crankshaft grinders, etc. these machines differ a lot in their designs to suit the
particularrequirementsbuttheyallworkonthecommonprincipleofcylindrical
grinding,involvethefollowingnecessarybasicmovements:
1) The work must revolve 2) the grinding wheel must revolve. 3) either the
wheelortheworkmusthaveatraversingmovementpasttheother.
4) Eitherthewheelshouldbefedintotheworkortheworkontothewheel.These
cylindrical grinders are special purpose machines and will, therefore, be dealt
withseparately.
Plaincylindricalgrinders.:onthesegrinders,theworkpieceisusuallyheldbetween
two centers. One of these centers is in the headstock and other in the tailstock. In
operation,therotatingworkistraversedacrossthefaceoftherotatingwheel.Atthe
endofeachtraverse,thewheelisfedintotheworkbyanamountequaltothedepth
of cut. While mounting the work between centres , the head stock centre is not

3rd
semester
119
disturbed. It is the tailstock centre which is moved in or out, manually or
hydraulically, to insert and hold the work. Tailstock and headstock both can be
movedalongthetabletosuitthework.Thetableisusuallymadeintwoparts.The
uppertablecarriesthetailstock,headstockandtheworkpieceandcanbeswiveled
inahorizontalplanetoamaximumguidewaystoprovidelongitudinaltraversetothe
uppertable,andhencethework.Tableisusuallypreferred.
Universalcylindricalgrinders.:
A universal cylindrical grinder carries all the parts and movement of a plain
cylindrical grinder and, in addition, carries the following advantageous
features.
a) Itsheadstock,canbemadetocarryaliveordeadspindle,asdesiredtheformer
beingneededwhentheworkisheldinachuck.
b) Theheadstockcanitselfbeswiveledinahorizontalplane.
c) Itswheelheadcanberaisedorlowerandcanalsobeswiveledto+_90
0
togrind
taperedsurfacehavinglargetaperangle.
Allthese factorscontribute towards the greater versatility of these grinders.Allthe
modern universal type cylindrical grinders carry hydraulic drive for wheel head
approachandfeed,tabletraverseandeliminationofbacklashinthefeedscrewnut.
A typical hydraulically operated universal cylindrically grinders, with its main parts
control.
Mostofthemodernuniversalgrindersareprovidedwithnecessaryextraequipment
like work rest to support slender work, wheel trueing device, arbour for balancing
thewheel,internalgrindingspindleandthreejawselfcenteringchuck,etc.

3rd
semester
120
DRILLINGMACHINE,BORING,BROACHINGANDREAMINGMACHINES

3rd
semester
121
UNITVI
DRILLINGMACHINE,BORING,BROACHINGANDREAMINGMACHINES
Q1 Describe the different operations which are performed on drilling machine with
neatsketches.
Thereisno.ofoperationsdoneonadrillingmachine,asshowninFig6.1.theseareas
follows:
1. Drilling 5.Countersinking
2. Reaming 6.Spotfacing,and
3. Boring 7.Tapping
4. Counterboring
1.Drilling:
It is the main operation done on this machine. It is the operation of producing the
circularholeinasolidmetalbymeansofarevolvingtoolcalleddrill.
2.Reaming:
Itistheoperationoffinishingaholetobringittoaccuratesizeandhaveafinesurface
finish. The operation is performed by means of a multitooth tool called reamer. The
operation serves to produce a straight, smooth and accurate hole. The accuracy to be
expectediswithin0.005mm.

3rd
semester
122

Fig.6.1.Operationsdoneondrillingmachine
3.Boring:
It is an operation used for enlarging a hole to bring it to the required size and have a
better finish. It involves the used of an adjustable cutting tool having a single cutting
edge. In addition to the above objective, this operation can be used for correcting the
holelocationandoutofroundness,ifany,asthetoolcanbeadjustedtoremovemore
metalfromonesideoftheholethantheother.Itisaslowerprocessthanreaming.The
accuracytobeexpectediswithin0.0125mm.
4.Counterboring:
The operation is used for enlarging only a limited the portion of the hole is called
counterboring.Itcanbeperformedeitherbyameansofadoubletoolboringbar,ora
counter boring tool. In order to maintain alignment and true concentricity of the
counterboredholewiththepreviouslydrilledholethecounterboringtoolisprovided
withapilotatitsbottom.
5.Countersinking:
Itistheoperationusedforenlargingtheendofaholetogiveitsaconicalshapefora
short distance. This is done for providing a seat for the counter sunk heads of the

3rd
semester
123
screw, show that the letter may be flush with the main surface of the work. The
standardcountersinkscarryincludedanglesof60
0
,82
0
or90
0
.
6.Spotfacing:
This operation is used for squaring and finishing the surface around and at the end of
hole, so that the same can be provide smooth and true seat to the underside of bolt
headsorcollars,etc.Thisisusuallydoneoncastingorforgings.Thewholemaybespot
facedbelowtheroughsurfaceoraboveit.i.e.,ontheuppersurfaceoftheboss,ifthe
sameisprovided.
7.Tapping:
Itistheoperationdoneforformingtheinternalthreadsbymeansofthetoolcalledtap.
To perform this operation the machine should be equipped with a reversible motor or
someotherreversingmechanism.Alternatively,acollapsibletighttypingattachmentis
used.
Q2Explainwithneatsketchplanertypehorizontalboringmachine.
Thismachineresemblesinconstructionwiththetabletypeonlythedifferenceisinthe
construction and operation of the work supporting mechanism. In this, a heavy cross
bed is incorporated between the spindle column and the end support column. This is
mounted across the axis of the spindle and carries a table over it. On its two sides it
carries the two columns. The main column carrying the headstock, rigidly fixed
whereas the endsupport column can move towards or away from this bed along the
horizontalwaysprovidedonthetopofthecrossbed,atrightanglestotheformerbed.
Thejobismountedonthetable.Inoperationitresemblesaplaner

3rd
semester
124

Fig.6.2.Blockdiagramofaplanertypeboringmachine.
1. End support column. 2. Spindle head column. 3. Table. 4. Spindle. 5. Spindle
head.6.Crossbed.7.Electricmotorforspindlehead.8.Longitudinalbed.
Inthattoolisheldbetweenthetwocolumnsormountedontheheadstockonlyandthe
work,mountedonthetable,movespastthetool.(SeeFig6.2).Thistypeofmachineis
verysuitableforlongjobs.
Q3Drawneatsketchofatwistdrillandshowitsvariouselementsclearly?
The most common type of drill in use today is the twist drill. It was originally
manufacturedbytwistingaflatpieceoftoolsteellongitudinallyforseveralrevolutions,
then grinding the diameter and the point. The present day twist drills made by
machiningtwospiralflutesorgroovesthatturnlengthwisearoundthebodyofthedrill.

Fig.6.3.Principlepartsoftwistdrills

3rd
semester
125
Twist drill is an end cutting tool. Different types of twist drills are classified by Indian
Standard Institution according to the type of shank, length of the flute and overall
lengthofthedrill.
Twistdrillelements:
Thefollowingarethetwistdrillelements.
Axis:Thelongitudinalcentrelineofthedrill.
Body:Thatportionofthedrillextendingfromitsextremepointtothecommencement
oftheneck,ifpresent,otherwiseextendingtothecommencementoftheshank.
Body clearance: The portion of the body surface which is reduced in diameter to
providediametricclearance.
Chisel edge: The edge formed by the intersection of the flanks. The chisel edge is also
sometimescalleddeadcentre.Thedeadcentreorthechiselangleactsasaflatdrilland
cuts its own hole in the workpiece. A great amount of axial thrust is required to cut a
hole by the chisel edge. In some drills chisel edge is made spiral instead of a straight
one. This reduces the axial thrust and improves the whole location. Chances of
productionofoversizeholesarealsoreduced.
Chiseledgecorner:
Thecornerformedbytheintersectionofalipandthechiseledge.
Face:
Theportionoftheflutesurfaceadjacenttotheliponwhichthechipimpingesasitiscut
fromthework.
Flank;
Thatsurfaceonadrillpointwhichextendsbehindtheliptothefollowingflute.
Flutes:
Itisthegrooveinthebodyofthedrillwhichprovidesthelip.
Thefunctionsofflutesare:

3rd
semester
126
1. Toformthecuttingedgesonthepoint.
2. Toallowthechipstoescape.
3. Tocausethechipstocurl.
4. Topermitthecuttingfluidtoreachthecuttingedges.
Heel:theedgeformedbytheintersectionoftheflutesurfaceandthebodyclearance.
Lands:
Thecylindricallygroundsurfaceontheleadingedgesofthedrillflutes.Thewidthofthe
landismeasuredattherightanglestotheflutehelix.Thedrillisfullsizeonlyacrossthe
landsatthepointend.Landkeepsthedrillaligned.
Lip(cuttingedge):
Theedgeformedbytheintersectionsoftheflankandtheface.Therequirementsofthe
drilllipsare:
1. Both lips should be at the same angle of inclination with the drill axis, 59
0
for
generalwork.
2. Bothlipsshouldbeoftheequallength.
3. Bothlipsshouldbeprovidedwiththecorrectclearance.
Neck:
It is the diametrically undercut portion between the body and shank of drill. Diameter
andotherparticularsofthedrillareengravedattheneck.
Outercorner:
Thecornerformedbytheintersectionoftheflankandface.
Point:
The sharpened end of the drill, consisting of all that part of the drill which is shape to
producelips,face,flanksandchiseledge.
Righthandcuttingdrill:

3rd
semester
127
Adrillwhichcutswhenrotatingincounterclockwisedirectionviewedonthepointend
ofthedrill.
Shank:
Thatpartofthedrillbywhichitisheldanddriven.Themostcommontypesoftheshank
are the taper shank and the straight shank. The taper shank provides the means of
centeringandholdingthedrillbyfrictioninthetaperedendofthespindle.
Tang:
The flattened end of the tapered shank intended to fit into a drift slot in the spindle,
socketordrillholder.Thetangensurespositivedriveofthedrillfromthedrillspindle.
Web:
The central portion of the drill situated between the roots of the flutes and extending
from the point towards the shank; the point end of the web or core forms the chisel
edge.
Lineardimensions:
Thefollowingarethelineardimensionsofthedrill:
Backtaper(longitudinalclearance):
Itisthereductionindiameterofthedrillfromthepointtowardtheshank.Thispermits
all parts of the drill behind the point to clear and not rub against the sides of the hole
being the drilled the paper varies from 1:4000 for small diameter drills to 1: 700 for
largerdiameters.
Bodyclearancediameter:
Itisthediameteroverthesurfaceofthedrillbodywhichissituatedbehindthelands.
Depthofthebodyclearance:
Theamountofradialreductiononeachsidetoprovidebodyclearance.

3rd
semester
128
Diameter:
Themeasurementsacrossthecylindricallandsattheoutercornersofthedrill.
Flutelength:
Theaxiallengthfromtheextremeendofthepointtotheterminationofthefluteatthe
shankendofthebody.
Leadofhelix:
Thedistancemeasuredparalleltothedrillaxisbetweenthecorrespondingpointonthe
leadingedgeofthefluteinonecompleteturnoftheflute.
Liplength:
Theminimumdistancebetweentheoutercornerandthechiselendcornerofthelip.
Overalllength:
Thelengthovertheextremeendsofthepointsandtheshankofthedrill.
Web(Core)taper:
Theincreaseintheweborcorethicknessfromthepointofthedrillintotheshankend
oftheflutethisincreaseinthicknessgivesadditionalrigiditytothedrillandreducesthe
cuttingpressureatthepointend.
Webthickness:
The minimum dimensions of the web or core measured at the point end of drill.
Considerablepowerisrequiredtoforceportionthework,andwebthinningisemployed
toreducethewebthickness.
Drillangles:Followingarethedrillangleswhicharegroundonatwistdrillforefficient
removalofmetal.
Chisel edge angle: The obtuse angle included between the chisel edge and the lip as
viewedfromtheendofthedrill.Theusualvalueofthisanglevariesfrom120
0
to135
0
.

3rd
semester
129
Helixangleorrakeangle:Thehelixorrakeangleistheangleformedbytheleadingedge
ofthelandwithaplanehavingtheaxisofthedrill.Ifthefluteisstraight,paralleltothe
drillaxisthentherewouldbenorake;ifthefluteisrighthandedthenitispositiverake;
and if it is left handed then the rake is negative. The usual value of rake angle is 30
0
,
angle,greaterwillbetorquerequiredtodrivethedrillatagivenfeed.
Point angle: This is the angle included between the two lips projected upon a plane,
paralleltothedrillaxisandparalleltothetwocuttinglips.Theusualpointangleis118
0
,
butforhardersteelalloys,theangleincreases.
Lipclearanceangle:Theangleformedbytheflankandaplaneatrightanglestothedrill
axis. The angle is normally measured at the periphery of the drill. Lip clearance is the
relief that is ground to the edges in order to allow the drill to enter the metal without
interference.Thelipclearanceangleshouldincreasetowardthecentreofthedrillthan
atthecircumference.Thisisduetothefactthatdifferentcuttingedgesfollowdifferent
helicalpaths.Anypointonthecuttingedgenearcentre.Thishappenstobesuchdueto
theleadofthehelixbeingsameineachcaseandhencetheclearanceanglegiventothe
drillcuttingedgeshouldincreasetowardsthecentre/.Theclearanceangleis12
0
inmost
cases. The clearance angle should be minimum to add rigidity and strength to the
cuttingedge.

Q4 Draw a neat sketch of radial drilling machine, Name the various parts and their
functions.
The radial drilling machine is intended for drilling medium to large and heavy work
pieces. The machine consists of a heavy, round, vertical column mounted on a large
base. The column supports a radial arm which can be raised and lowered to
accommodate workpieces of different heights. The arm may be swung around to any
position over the work bed. The drill head containing mechanism for rotating and
feedingthedrillismountedonaradialarmandcanbemovedhorizontallyontheguide
ways and clamped at any desired position. These three movements in a radial drilling
machinewhencombinedtogetherpermitthedrilltobelocatedatanydesiredpointon
alargeworkpiecefordrillingthehole.Whenseveralholesaredrilledonalargework
piece,thepositionofthearmandthedrillheadisalteredsothatthedrillspindlemay
be moved from one position to the other after drilling the hole without altering the

3rd
semester
130
settingofthework.Thisversatilityofthemachineallowsittoworkisverylargeitmay
beplacedonthefloororinapit.Fig6.4illustratesaradialdrillingmachine.

Figure6.4Radialdrillingmachine.
1. Base,2.Column,3.Radialarm,4.Motorforelevatingthearm,5.Elevatingscrew,
6.Guideways,7.Motorfordrivingthedrillspindle,8.Drillhead,9.Drillspindle,
10.Table.
Plain radial drilling machine: In a plain radial drilling machine provisions are made for
vertical adjustment of the arm, horizontal movement of the drill head along the arm,
andcircularmovementofthearminhorizontalplaneabouttheverticalcolumn.
Semiuniversal machine: In a semiuniversal machine, in addition to the above three
movements, the drill head can be swung about a horizontal axis perpendicular to the
arm. This fourth movement of the drill head permits drilling hole at an angle to the
horizontalplaneotherthanthenormalposition.

3rd
semester
131
Universal machine: In a universal machine, in addition to the above four movements,
the arm holding the drill head may be rotated on a horizontal axis. All these five
movementsinauniversalmachineenableittodrillonaworkpieceatanyangle.
Q5Explainsjigboringoperation.
Jigboringmachineisthemostaccurateofallmachinetools.Thiswasfirstdevelopedin
theyear1910inSwitzerlandandusedasalocatingmachine.Therealjigborerwasfirst
built in the year 1917 by Pratt and Whitney. They are characterized by provisions of
highest accuracy through rigidity, low thermal expansion and precise means of
measuringdistanceforaccuratelylocatingandspacingholes.Themachiningaccuracyis
veryhigh,withinarangeof0.0025mm.Ajigboringmachineresemblesinappearance
to vertical milling machine, but so far its operation and accuracy are concerned there
cannotbeanycomparisonbetweenthetwo.Thespindleandotherpartsofthemachine
areextremelyrigidtoresistdeflectionandthevibrationisminimum.Thespindlerunsin
preloaded antifriction bearings. The spindle housings are made of invar having a very
low coefficient of linear expansion. The jig boring machine requires to be operated in
temperature controlled rooms where temperature can be maintained constant. This is
essentialtopreventinaccuracyinthemachine.
TypesofJigboringmachines:Therearemainlytwotypesofjigboringmachines:
1. Verticalmillingmachinetype.
2. Planertype
1. Vertical milling machine type: It resembles in construction to a vertical milling

machine. The spindle rotates on a verticalcolumn and the horizontal table rests
on the bed in front of the column. The positioning of the work mounted on the
tablemaybeobtainedbycompoundmovementsofthetable,perpendicularand
paralleltothecolumnface.
2. Planertype:Itconsistsoftwoverticalcolumnsatthetwosidesofthetableanda
mounted on the base. The table has reciprocating movement for adjustment of
the work. The spindle is mounted on the crossrail bridging the two vertical
columns.Inaplanertypejigborer,twocoordinatemovementsforholelocation
areprovidedbythelongitudinalmovementofthespindlealongthecrossrail.
1
NAGPUR
32
Q6Wha
Reaming
In order
size, the
byhand
reamer.
Element
Theelem
Axis:Th
Backer
entering
Bevelle
reamer
Body:Th
commen
Circular
leadinge
Clearanc
R INSTITUTE
atisreamin
g:Itisnotp
r to achieve
e same is d
andmach
tsofreame
mentsofre
elongitudin
taper: The
gendtowar
ead:Thean
intohole.I
hatportion
ncementof
land: The
edgeofthe
ce:
OF TECHNOL
ng?Drawa
practicallyp
e this, i.e.,
rilled a littl
ine.Theop
er:
amerared
nalcentrel
reduction
rdstheshan
gularcuttin
Itisnotpro
F
noftherea
fitsshank.
cylindrical
eland.
LOGY
Questionb
asketchof
possibletop
to produce
e undersize
perationof
escribedas
ineofther
in a diam
nk.
ngportiona
ovidewitha
ig6.5mach
merextend
lly ground
bankwiths
reamer.
produceah
e an exactl
e and then
reamingin
sbelow:
reamer.
meter per 1
attheente
acircularla
hinereamer
dingfromt
surface ad
olution
holeofthe
y round an
reamed. R
nvolvesthe
100 mm le
eringendto
nd.
r
heentering
djacent to
Manufacturin
exactsizet
nd smooth
Reaming ca
multitoot
ngth of re
ofacilitatet
gendofthe
the cutting
ngprocessI
throughdri
hole of co
n bedone
thtoolcalle
amer from
theentryo
ereamerto
g edge, on
3rd
semeste
lling.
rrect
both
edas
m the
fthe
othe
n the
er

3rd
semester
133
1. Primary: That portion of the land removed to provide clearance immediately
behindthecuttingedge.
2. Secondary: That portion of the land removed to provide clearance behind the
primaryclearanceorcuttingedge.
Cuttingedge:Theedgeformedbytheintersectionofthefaceandthecircularlandor
thesurfaceleftbytheprovisionofprimaryclearance.
Face:Theportion ofthe flutesurface adjacent tothe cutting edge on awhichthechip

impingesasitiscutfromthework.
Flutes: The grooves in the body of the reamer to provide cutting edges, to permit the
removalofchipsandtoallowcuttingfluidtoreachthecuttingedges.
Heel: The edge formed by the intersection of the surface left by the provision of
secondaryclearanceandtheflute.
Land: That portion of the fluted body left standing between the flutes, the surfaces
includedbetweenthecuttingedgeandtheheel.
Pilot: A cylindrically ground portion of the body at the entering end of the reamer to
keepthereamerinalignment.
Recess:Thatportionofthebodywhichisreducedindiameterbelowthecuttingedge,
pilotorguideddiameter.
Shank:Thatportionofthereamerbywhichitisheldanddriven.
Diameter:Themaximumcuttingdiameterofthereamerattheenteringend.
Rotationofcutting:Areamerisnamed,accordingtothedirectionofrotationas:
Left hand cutting reamer: A reamer which cuts while rotating in a clockwise direction,
whenviewedontheenteringendofthereamer.
Right hand cutting reamer: A reamer which cuts while rotating in a anticlockwise
direction,whenviewedontheenteringendofthereamer.

3rd
semester
134
Reamerangles:Thereameranglesaregivenbelow.
Bevel lead angle: The angle formed by the cutting edges of the bevel lead and the
reameraxis.
Clearance angles: The angles formed by the primary or secondary clearances and the
tangenttotheperipheryofthereameratthecuttingedge.
Helixangle:Theanglebetweenthecuttingedgeandthereameraxis.
Rakeangle:Theangles,inadiametricplane,formedbythefaceandaradiallinefrom
thecuttingedge.
1. If the face and the radial line coincide, the angle is zero degree and the face is
calledradial.
2. Iftheangleformedbythefaceandtheradiallinefallsinbehindtheradiallinein
relationtothedirectionofcut,therakeangleisnegative,andthefaceisknown
asovercut.
Taper lead angle: The angle formed by the cutting edges of the taper lead and the
reameraxis.
Q7 Differentiate with neat sketches between counter boring and countersinking

operations.Alsosatetheirnecessity.
Counterboring Countersinking
This operation is used for enlarging

onlylimitedportionofthehole.
This operation is used for enlarging
the end of the hole to give it a
emicalshapeforashortdistance.
The tool is used for counterboring
iscalledascounterbore.
The tool is used for countersinking
iscalledascountersink.
The enlarged hole forms a square The enlarged hole form emical

3rd
semester
135
shoulderwithaoriginalhole. shapewithoriginalhole.
This is necessary in some cases to
accommodate the heads of bolts,
studsandpins.
This is necessary in some cases to
provide a seat for the countersunk
headsofthescrews.

Fig6.6CounterboringFig6.7Countersinking
Q8Differentiateoperationsofdrilling,boringandreamingclearly?
Drilling Boring
Reaming
The hole is
generated by a
rotating edge of
cutting tool known
as the drill and
operation known as
thedrilling.
It is the operation of
enlarging and
turning a hole
produced by
punching, casting or
forging.
It is the operation of
finishing and giving
dimensions accuracy
toholeorborehole.
The speed of spindle
is double than that
of boring and much
morethanreaming.
is half than that of
drilling but more
thanreaming.
is less than that of
drillingandboring.
A 12 mm drill may
produce a hole as
much as 0.125 mm
oversize and 22 mm
drill may produce as
much as 0.5 mm
The material
removed by this
process is around
0.375 mm and for
accurate work
should not be
The accuracy is as
high as 0.00125
mm.

3rd
semester
136
oversize. exceed0.12mm.
In this process,
removes large
amountofmetal.
In this process,
removes very small
amountofmetal.
In this process,
removes very rare
amountofmetal.
Tool used for drilling
isknownasdrill.
Tool used for boring
is known as bore
tool.
Tool used for
reaming is known as
reamertool.
Q9Writeshortnoteson:
a) Verticalboringmachine:
A vertical boring machine illustrated in Fig 6.8 is so named because the work
rotatesonahorizontaltableaboutaverticalaxisandthetoolisstationaryexcept
for the feed. The machine may be looked upon as a vertical lathe with its head
stock resting on the floor and its large faceplate or chuck lying in a horizontal
plane. This specific design of the machine provides certain distinct advantages
overalatheforaparticularclassofwork.
Theadvantagesare:
1. Large diameter and heavy workpieces, similar to chucking jobs on
lathe,maybesetupmoreconvenientlyandquicklythanonalathe.It
is easier to lay a workpiece down on the table rather than to hang it
up.
2. Thetableandtheworkitcarriesrotateinahorizontalplane,andthere
is no, overhang as in the case lathe spindle, and consequently any
chanceofbendingthespindlewhichsupportstheheavyworkpieceis
eliminated.
3. Thetablebeinghorizontal,thediameterofthetablemaybedesigned
aslargeaspossibletosupportlargeworkpieces.
4. Multiple tooling may be adapted in the case of a vertical boring
machinewithitsturrettypetoolpostincreasingtherateofproduction.
1
NAGPUR
37
Avertica
andcum
rolling s
circular
machine
Thevert
(1
(2
1. V
R INSTITUTE
alboringm
mbersomew
tock tires,
shaped par
ecantakeo
ticalboring
1) Verticalt
2) Standard
Verticalturr
OF TECHNOL
Fig
achineisp
workpieces
steam and
rts. The siz
onlycircular
machineis
turretlathe
dverticalbo
retlathe:
LOGY
Questionb
.6.8Vertica
articularlya
s.Thetypic
water turb
e of the wo
rcut.
softwotyp
e,and
oringmachi
bankwiths
alboringma
adaptedfor
alworksar
bine casting
ork is limite
pes:
ine
olution
achine
rholdingan
re:largerge
gs, fly whee
ed by the d
Manufacturin
ndmachini
earblanks,
els flanges
diameter of
ngprocessI
nglarge,he
locomotive
and numb
f the table.
3rd
semeste
eavy,
eand
er of
. The
er

3rd
semester
138

fig6.9Verticalturretlathe
Thistypeofboringmachinecombinestheadvantagesoftheverticalboringmillandthe
turretthelathe.Averticalboringmachineofsmallersizeiscalledaverticalturretlathe.
It has an indexible turret mounted upon the crossrail above the table for multiple
tooling. A four station square turret sidehead which enables facingturning under
cutting and many other operations is mounted at the side of the lathe. The crossrail
may have vertical adjustments and for case of operation it is counter balanced. The
turret mounted on the saddle may be moved crosswise by hand or power. The turret
mayalsobemovedinaverticalplane.Thesideheadalsohasupanddownandtoand
fro adjustments from the centre of the table. The machine is suitable for boring and
turningrailroadwheels,pistonrings,gearblanks,etc.Averticalturretlatheisshownin
Fig6.9
2. Standard vertical boring machine: Vertical boring machines are larger in size
than vertical turret lathe and there is no turret head. The machine is provided
withtwoverticalheadsandoneortwosideheads.Thetoolheadsaremounted
on the crossrail which may be adjusted up and down. The saddle of the tool
headmaybefedcrosswiseandthetoolheadramfedinverticaldirection.

3rd
semester
139

Fig.6.10Standardverticalboringmachine
Theramheadscanbeswiveledtoinclinetheramupto60
0
oneithersideofthevertical
axis for machining tapers. The machine is particularly intended for boring large,
cylindrical and symmetrical workpieces. Turbine castings, locomotive tires, etc. are
someofthecommonexampleswhichneedverticalboringmachineisshowninFig6.10
b) Timeestimationfordrillingoperations:
Machiningtimeindrillingisdeterminedbytheformula:
L
T=min.
nxs
r
Where,n=r.p.m.ofthedrill
s
r
=Feedperrevolutionofthedrillinmm
L=Lengthoftravelofthedrillinmm
AndT=Machiningtimeinmin
14
NAGPUR
40
Where,
iii)
R INSTITUTE
l
1
=leng
l
2
=ap
l
3
=len
l
4
=ov
Abroach
Broachin
surfaces,
to enlar
punching
OF TECHNOL
F
gthofthew
pproachof
ngthofthe
vertravel
hingtool:
ng of inside
,externalo
ge and cu
g,casting,f
LOGY
Questionb
ig.6.11Dril
workpiece
drill,
drillpoint
Fig
surfaces c
orsurfaceb
ut various
orging,etc.
Fig6.13B
bankwiths
lling
g6.12broac
called intern
broaching.I
contours
.
roachteeth
olution
chterms
nal or hole
nternalbro
in holes a
hdetails
Manufacturin
broaching
oachingtoo
already ma
ngprocessI
and of out
olsaredesig
ade by dri
3rd
semeste
tside
gned
lling,
er

3rd
semester
141
Broach elements: Ordinary cut broaches for machining previously drilled or

boredholesconsistofthefollowingelements(Fig.6.9)
Pull end: This is designed to permit engagement of the broach with the
broachingmachinethroughtheuseofapullerhead.
Frontpilot:Thiscentersthebroachintheholebeforetheteethbegintocut.
Roughingandsemifinishteeth:Theyremovemostofthestockinthehole.
Finishingteeth:Theyareforsizingtheholeandmusthavetheshaperequired
ofthefinishedhole.
Rear pilot and follower rest: They support the broach after the last tooth
leavesthehole.
Theformofbroachteethrevealsfeatureslikethoseofothercuttingtools.
Land:Thetopportionofatoothiscalledthelandandinmostcasesgroundto
giveaslightclearance.
Back off or clearance angle: This corresponds to the rake angle on a lathe
tool.Thisis1.5
0
to2
0
forbothcastironandsteel.Finishteethhaveasmaller
anglerangingfrom0to1.5
0
.
Rake or hook angle or face angle: This corresponds to the rake angle on a
lathetool.Therakeanglevariesfromaccordingtothematerialbeingcut,and
in general, increases as the ductility increases. Values of this angle for most
steelsrangefrom12to15
0
.
Pitch: The linear distance from the cutting edge of one tooth to the corresponding
edgeonthenexttoothiscalledthepitchtanddiffersforcuttingandfinishingteeth.
Forthecuttingteeth,thepitchisselectedinaccordancewiththelengthlofthehole
being broached (t=1.25to1.5). On an average, the pitch of finishing teeth is
usually equal to one half of the cutting teeth pitch. The pitch should vary by 0.2 to
0.3mmafterseveralteeth.
The height of the roughing and semi finish teeth gradually increases from shank
to the finishing teeth. This increment, called the cut per tooth, depends on the
material being machined and the hole size. The cut per tooth is usually taken from
0.01to0.2mm.

3rd
semester
142

3rd
semester
143

3rd
semester
144

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NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

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NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

It is a method of identification of tool angles standardized by the American Standards

As mentioned in the previous article, the machinabiity of a material is

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

ith the hea

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

1. Vertical milling machine type: It resembles in construction to a vertical milling

Face:Theportion ofthe flutesurface adjacent tothe cutting edge on awhichthechip

Q7 Differentiate with neat sketches between counter boring and countersinking

This operation is used for enlarging

Broach elements: Ordinary cut broaches for machining previously drilled or

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

NAGPUR INSTITUTE OF TECHNOLOGYManufacturingprocessI

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