ME 2252 MANUFACTURING TECHNOLOGY II

II year Mechanical Engg. B-Sec

Notes on Lesson

UNIT I : THEORY OF METAL CUTTING

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Material removal process

Types of machine tools

Turning machines

Drilling machines

Boring machines

Milling machines

Grinding machines

Shaping and planing machines

Gear cutting machines

Unconventional machining machines

Special machines like automats, copy turning machines, reaming ,

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copy milling machines, centreless grinding machine, broaching

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machine etc.

Chip formation

Discontinuous chip

Continuous chip

Continuous chip with built-up edge

Orthogonal cutting

Mechanics of orthogonal cutting

Merchants cutting force circle

Orthogonal cutting with shear plane

Strain and strain rate in orthogonal cutting

Requirement of a cutting tool material

High speed steel

Cast cobalt alloys

Cemented carbides

Coated carbides

Ceramics

Diamond

Cubic boron nitride(CBN)

Crater wear

Diffusion wear

Tool life

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Flank wear

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Tool wear

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Carbon tool steels

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Cutting tool materials

Taylors tool life equation

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Surface finish

Ideal surface finish in turning

Cutting fluids

Function of a cutting fluid

o Cooling action

o Lubricating action

Types of cutting fluid

Water based emulsions

Straight mineral oils

Mineral oils with additives

UNIT II : CENTRE LATHE AND SPECIAL PURPOSE LATHES

Centre lathe constructional features

Head stock

Tail stock

Bed

Carriage

Feed rod

Lead screw

Feed change gear box

Distance between centers

Swing over the bed

Swing over the cross slide

Horse power of the motor

Number of speeds

Number of feeds

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Cutting tools

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Lathe specifications

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Cutting tool geometry

o Back rake angle

o Side rake angle

o End relief angle

o Side relief angle
o End cutting edge angle
o Side cutting edge angle
o Nose radius

Turning tool

Right hand turning tool

Left hand turning tool

Radius turning tool

Thread cutting tool

Chamfering tool

Internal turning tool

Inter facing tool

Recess or groove making tool

Internal threading tool

Lathe operations
Turning

Facing

Knurling

Parting

Drilling

Boring

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Parting tool

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Types of tools

Taper turning methods

Form tool method

Compound rest method

Tailstock set over method

Using taper turning attachment

Thread cutting method

Copy turning attachment

Radius turning attachment

Special attachments

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Machining time and power estimation

Capstan And Turret Lathe

The principle parts are
Bed

Head stock

Cross slide and saddle

The turret saddle and auxiliary slide

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Comparison of capstan and turret lathe

S.No.
1.

Capstan lathe

Short slide since the saddle is Saddle moves along the bed, thus

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clamped on the bed in position.

2.

Turret lathe

allowing the turret to be of large

size.

Light duty machine, generally for Heavy duty machine, generally for
components whose diameter is less components with large diameters
as 200mm.

than 50mm.

3.

Too much overhang of the turret Since the turret slides on the bed,
when it is nearing cut.

there is no such difference.

Automatic lathes
Classification

Size

Type of blank machined

Processing capacity

Machining accuracy obtained

Principle of operation design features

Number of spindles and work positions

Type

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Single spindle automates

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Automatic lathes may be classified based on their

Cutting off

Swiss type

Automatic screw machine

Special type

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Multiple spindles automates

Cutting off bar

Drilling, forming, cutting off bar

Bar

Special type

UNIT-III : RECIPROCATING AND MILLING MACHINES

Shaper
The main parts of shaper are
Base

Column

Table

Ram

Tool head assembly- tool feed handle, tool slide, apron, clapper box, tool

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holder

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Specifications
Stroke length

Length and width of table

Number of ram double strokes per minute

Motor horse power

Range of ram speeds

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Planer

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The main parts of planer are

Bed

Table

Columns or housing

Cross rail

Tool head

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Specifications

Dimensions of the table

Horizontal distance between the two vertical housings

Length that the table can travel

Height from top of the table to the top of cross rail

Type of drive

Types Of Milling Machine

Column and knee type

o Horizontal
o Vertical

o Universal
o Turret type

Production type

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o Simplex
o Duplex

Planomillers

Special type
o Rotary table

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o Drum type

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o Triplex

o Copy milling

o Keyway milling

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o Spline shaft milling machine

Horizontal Milling Machine

The basic parts of the horizontal milling machine are

Base

Column

Knee

Saddle

Table

Arbor

Over-arm

Spindle

Specifications

The maximum length of longitudinal, cross and vertical travels of the table

Main drive motor power

Number of spindle speeds

Distance from spindle nose to table surface

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Milling cutters

Solid

Inserted tooth type

Based on mounting
Arbor mounted

Shank mounted

Nose mounted

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Based on construction

and its dimensions

Based on rotation

Left hand rotation

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Right hand rotation

Based on helix

Right hand helix

Left hand helix

Plain milling cutters

Side and face milling cutters
Slitting saw
Special form cutters
End mills

Methods of milling

Upmilling (conventional milling)

Down milling (climb milling)

Hole making operations

Drilling

Boring

Reaming

Counter sinking

Counter boring

Tapping

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The types of hole making operations performed on these holes are

The main parts are

Base

Column

Radial arm

Drill head

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Salient features

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Universal Drilling Machine(Radial Drilling Machine)

Provides movement of the spindle in three directions

Several holes can be drilled on a work piece without moving the same.

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UNIT-IV : ABRASIVE PROCESS, SAWING, BROACHING AND GEAR

CUTTING
Grinding wheel specification and selection

Aluminium oxide

Silicon carbide

Cubic boron carbide

Diamond

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Abrasive types

Fine

Medium

Coarse

Vitrified

Silicate

Synthetic resin
Rubber

Shellac

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Grain size

Metal

Soft

Medium

Hard

Grade

Structure

Open

Medium

Dense

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Grinding wheel types

Wheel balancing

Dressing and truing

Cylindrical grinding

Surface grinding

Centreless grinding

The main parts are

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Cylindrical Grinding Machine

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Types of grinding machines

Base

Tables lower and upper table

Head stock

Tail stock

Wheel head

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Surface grinding machine

Horizontal spindle and reciprocating table

Vertical spindle and reciprocating table

Horizontal spindle and rotating table

Vertical spindle and rotating table

Centreless grinding machine

The main parts are

Grinding wheel

Regulating wheel

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Types of feed in centreless grinding

Infeed

Through feed

End feed

Honing

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Honing is a low abrading process which uses bonded abrasive sticks for
removing stock from metallic and non-metallic surfaces.
The advantages of honing are

Out of roundness

Taper

Axial distortion

Dimensional accuracy

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Correction of geometrical accuracy

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Lapping

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Lapping is generally the final finishing operation done with loose abrasive grains.
The process is employed to get

Extreme accuracy of dimension

Correction of minor imperfection of shape

Refinement of the surface finish

Close fit between mating surfaces

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Super finishing

Super finishing is another abrasive process which utilizes either a bonded

abrasive like honing for cylindrical surfaces or a cup wheel for flat surfaces. It is
generally used for

Removing surface fragmentation

Reducing surface stresses and burns and thus restoring surface

integrity

Correcting inequalities in geometry

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Polishing and Buffing

Polishing is done with a very fine abrasive in loose form smeared on the

polishing wheel with the work rubbing against the flexible wheel. A very small
amount of material is removed in polishing. In buffing the abrasive grains in a
suitable carrying medium such as grease are applied at suitable intervals to the

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buffing wheel. Negligible amount of material is removed in buffing while a very

high luster is generated on the buffed surface. The dimensional accuracy of the
parts is not affected by polishing and buffing operations.

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Abrasive belt grinding

In this process a continuous moving belt with an abrasive is used for grinding the

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surfaces. The abrasive belt is normally passed between two wheels with one
being driven while the other remains idle. The workpiece is oscillated across the

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face of the abrasive belt to obtain a uniform belt wear and surface finish.
Sawing machines

The various types of sawing machines used are

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Hack saw

Manual

Power

Band saw

Vertical

Horizontal

Contour

Circular saw

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Broaching
Broaching is a multiple tooth cutting operation with the tool reciprocating similar
to the sawing operations. The similarities end there, since in broaching the

machining operation is completed in a single stroke as the teeth on the cutting

tool called broach, are at a gradually increasing height corresponding to the feed

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per tooth of a milling cutter.

Broaching machines
Push broaching machines

Pull broaching machines

Surface broaching machines

Continuous surface broaching machines

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Gear cutting

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Gear shaping

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Gear hobbing

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Gear forming Vs Gear generation

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UNIT-V : CNC MACHINE TOOLS AND PART PROGRAMMING

Numerical Control (N.C)
It can be defined as a programmable automation in which the process is

controlled by numbers, letters and symbols.

Components of N.C

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o Program of instructions
o Machine control unit

N.C. Procedure
o Process planning

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o Part programming

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o Machine tool

o Tape preparation
o Tape verification

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o Production
Components Of CNC
A tape reader

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Micro or mini computer

Computer hardware interface and servo mechanism

Machine tool

Advantages

Greater flexibility

High productivity

Good reliability

Metric conversions

Memory functions

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Feed function

Speed function

Tool function

Preparatory functions

Miscellaneous functions

Program number

Tool length compensation

Cutter radius compensation

Canned cycles

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Coordinate function

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Manual part programming

Computer assisted part programming

Preparing the part programs for CNC machine tools manually is a viable system
for any kind of job. But the assistance of a computer is desirable for part

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programming because of a variety of reasons. The first and foremost in this

respect is the complexity of the work piece which makes manufal part
programming a very difficult exercise. Close tolerance contouring to some

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mathematically defined, or through a set of points other than a circular arc, is an

example requiring too many coordinate calculations making manual part
programming too tedious to be practicable.

APT language

The complete APT part program consists of the following four types of

statements

Geometry

Motion

Post processor

auxiliary

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