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MACHINE TOOLS
(2015-16)
Dr. G. R. C. PRADEEP
E-mail: grcpradeep@gmail.com
1
MACHINE TOOLS
INTRODUCTION:
The process of metal cutting in which chip is formed is
effected by a relative movement b/w the work piece and
the hard edge of the cutting tool.
The relative motion is produced by a combination of rotary
and translatory motion of either work piece (or) tool (or)
both.
Relative Motion
Machine Tool
The relative motion Work Tool
present between Work Lathe R T
and Tool in various Shaper, Planer T T
Drilling Fixed R & T
Machine Tools. Milling T R
Surface Grinding T R
Cylindrical Grinding R & T R
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The motion responsible for the cutting action is known as
the primary motion or cutting motion.
The motion responsible for gradually feeding the uncut
portion is termed as the secondary motion or feed motion.
Depending on the nature of these relative motions, various
types of surfaces can be produced.
The line generated by the CUTTING MOTION is called
the GENERATRIX and the line generated from the
FEED MOTION is called the DIRECTRIX.
Various geometries can be obtained depending on the
shapes of the Generatrix and the Directrix and their relative
directions.
They are represented in the following figures:
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Generation of various surfaces
S.No Generatrix (G) Directrix (D) Surface obtained Process
(a) Straight Line Straight Line Plain Surface Tracing of G
(b) Circular Straight Line Cylindrical Surface Tracing of G
(c) Circular Straight Line Plain Surface (Lines) Envelope of G
(d) Plain Curve Circular Surface of revolution Tracing of G
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LATHE MAIN PARTS
Video
1
TOOLPOST (1)
COMPOUND SLIDE (2)
SWIVEL PLATE (2B)
HANDWHEELS (2A, 3B, 5A)
CROSS-SLIDE (3)
SADDLE (4)
APRON (5)
CARRIAGE FEED MECHANISM (5C)
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SPECIFICATIONS OF LATHE
1) Height of centers over
bed U.K. spec.
2) Maximum swing over
bed USA spec.
3) Maximum swing over
carriage
4) Maximum swing over
Gap
5) Maximum distance b/w
centers
6) Length of bed
7) No. of speeds and
feeds etc.
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EARLY LATHES
Video
2,3
Non-
Live centre Revolving Dead centre
Revolving
Dead centre (Used for high speeds
and high clamping
pressures)
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5) Mandrel Used to support the work pieces and also for
holding hollow parts to meet concentricity requirements
Live Work piece
Centre
Dead
Centre
Face Plate
Mandrel
Carrier Dog
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6) Steady rest mounted on bed, used for long heavy jobs
that deflect centrally by self weight.
7) Follower rest mounted on carriage and moves with
tool, used for long thin jobs that deflect laterally by cutting
force.
1) 2)
D1 = Larger Dia
D2 = Smaller Dia
L = Taper length
= Half Cone Angle
2= Included Angle /
Full cone Angle
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2. Tailstock set over Small Angle, Long Job
Distance
d
f
d, f
Video
17,18,19
Video
17,18,19
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Feed Rod is provided in medium to big size lathes and is
engaged for other lathe operations except threading and
operates by rack and pinion mechanism operated by change
gears and other gears in apron.
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Video
20
Rt
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SLOTTER
INTRODUCTION:
This operates almost on the same principle as that of a
shaper. Slotter was invented before shaper. Here the ram
reciprocates in a vertical axis. There is no quick return
and the mechanism used for ram is Crank and connecting
rod mechanism. The slotter is provided with a rotary
table that can be moved longitudinally and cross wise.
The slotter is used for making regular and irregular
surfaces both internal and external and also for handling
complex work pieces. Slotter is more robust compared to
vertical shaper.
Video
1,2
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TYPES
1) Puncher slotter:
A heavy, rigid
machine, for
removing large
amount of metal
from large
forgings and
castings. The
length of stroke
is very large
(1.8 - 2m).
OPERATIONS:
1) Machining slots, keyways, grooves of various shapes,
both internal and external, Internal machining of blind
holes, machining of dies, punches etc.
2) Machining flat surfaces, Cylindrical surfaces, Cams,
internal and external gears.
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Dr. G. R. C. PRADEEP 87 Email: grcpradeep@gmail.com
PLANER
INTRODUCTION: The planer like shaper is a m/c tool
primarily intended to produce plane and flat surfaces by a
single point cutting tool. A planer is very large compared
to shaper. In a planer the work which is supported on
the table reciprocates past the stationary cutting tool and
feed is given by the lateral movement of the tool.
Video
5,6
CROSS RAIL
TABLES
OPERATIONS:
(1) Planning flat horizontal, vertical, angular surfaces
(2) Slots and grooves.
Tip
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Drill Chuck with Chuck key
Morse taper is provided on all
Drilling M/c Spindle drilling accessories, inside drilling
machine spindle, lathe tail stock,
lathe turret, and lathe centres
Drift Sleeve
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DRILL GEOMETRY
Lip angle/ Tip Angle/ Point Angle
Video
9,10,11
Video
1,2
Side View
Bottom View
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METHODS OF MILLING
1. Peripheral Milling: It is the operation performed by a
milling cutter to produce a machined surface parallel to the
axis of rotation of the cutter. Here the cutting force is not
uniform throughout the length of cut by each tooth. Due to
this reason, a shock is developed in the mechanism of the
machine that leads to a vibration. The quality of surface
generated and the shape of the chip formed is dependent
upon the rotation of the cutter relative to the direction of feed
movement of the work. According to the relative movement
between the tool and work, the peripheral milling is
classified into two types:
Spindle
Cutter Holder
Collet Holder
Collet Wrench
Collet
End Mill
Video
9
Convex Cutter
Concave Milling
Convex Milling
Concave Cutter
OPTICAL
INDEXING
HEAD
FRONT
VIEW
FRONT
VIEW
ATT calculation neglecting clearance
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(v) Maximum uncut chip thickness =
Special Cases
ii) Tool fully engaged, Finishing Pass
requires Full Wiping (Single pass feed)
iii) Tool not fully engaged with W<D/2;
Offset Cases
iv) Tool not fully engaged but W D/2;
(i) W O A B
TOP
W/2
VIEW
C
A
TOP
(ii) AL = 0.5 cm L1 OT = 0.5 cm VIEW
W
W/2
L = L1 + AL + OT + D
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(iii) AL L1 OT
W
A
B
TOP
O VIEW
AL L1 OT
(iv)
TOP
AL = OT = D/2
VIEW
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BROACHING
Broach is bar type cutter with series of cutting edges
gradually increasing in size to remove all materials in one
stroke. In broaching there is only one motion, i.e. the
primary cutting motion is provided by the machine, where
as the feed is obtained by placing the teeth progressively
deeper. Since there is no feed motion, the shape of the
broach determines the shape of the machined part.
Broach is used to produce internal forms like spline holes,
non-circular holes, slots, grooves, gears etc. Internal
broaching is done by either pulling (or) pushing the broach
through a hole drilled in the work piece. Pulling is highly
preferred to facilitate alignment and avoid buckling.
Video
1
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Similar external forms can also be produced by using pot
broach. Here the broach is made in segments and fixed
inside a fixture called pot fixture. The broach is stationary
but the W.P. is pulled / pushed through it.
Pot broach
Internal broaches
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GRINDING
Introduction: Grinding is the process of removing excess
material by the abrasive action of a rotating wheel on the
surface of the work piece. It is basically a finishing process
employed to produce high accuracy and surface finish. The
grinding wheel consists of sharp crystals called abrasives
held together by suitable bonding. Natural abrasives available
in nature include sand stone (natural silica), diamond,
corundum and emery (natural alumina). Artificial abrasives
are free from impurities and possess better performance
properties. They include Al2O3, SiC, CBN etc.
Video
6,7
Video
4
Hydraulic cylinders
roller burnished on lathe
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Polishing
Polishing is a finishing operation to improve the surface
finish by means of a polishing wheel made of fabrics or
leather and rotating at high speed. The abrasive grains are
glued to the outside periphery of the polishing wheel.
Polishing is used to remove scratches and burrs and to
smoothen the rough surfaces. Polishing may be used to
enhance and restore the looks of certain metal parts or object
on cars and other vehicles, handrails, cookware, kitchenware,
and architectural metal.
Gear Hobbing
1. Grinding using
form wheels
a) b)
a) Fixed Type When work piece is having uniform
dimensions. (Fixed Distance)
b) Adjustable Type When piece is having non-uniform
dimensions. (Adjustable Distance)
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3) Jack Pins: Used to accommodate different work pieces
with different sizes and also in press tools for sheet metal
location
V-Locators: Used for locating
circular or semi-circular work
pieces.
b) Swinging
Latch Clamp
a) Bridge Clamp
d) Hinged Clamp
c) Heel / Dog Clamp
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3) Quick Clamping:
WP
Wire EDM:
7. MRR = (CSA of cut x Wire feed) mm3 /sec
CSA of cut = Width of cut x thickness of WP
Width of cut = Wire Diameter + Spark gap around wire
Video
11
Video
12
P2 P3
P1 P2 P1 P2
(1) (2) (3)
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3. Continuous path (or) contouring control:
This system enables machining of profiles, contours and
curved surfaces. The method by which continuous path
system moves from one point to another point is called
interpolation. Three types of interpolation are used linear,
circular and parabolic. Only few systems use parabolic
interpolation. Linear interpolation enables machining along
st. line including taper and circular interpolation enables
machining circles and arcs. In linear interpolation, the
coordinates of the end point of line act as the beginning of
next line. In circular interpolation also, the current point acts
as the starting point and hence the end point of arc, arc
radius etc. have to be mentioned.
P1 = POINT / 6,5,4
L1
P1
(b) By intersection of two lines
L1
P1 = POINT / INTOF, L1, L2
C1
P1
(c) By centre of circle
P1 = POINT / CENTER, C1
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(2) Defining a Line:
L1
P1 P2
(a) By joining two points
L1 = LINE / P1, P2
L2
L1 = LINE / P1, PARLEL, L2
P1
(c) By a point and a perpendicular line
L1
L1 = LINE / P1, PERPTO, L2
L2
P1
3) DEFINING A CIRCLE: C1
20
(a) By centre point and radius P1
P1
P1
P2
PL = PLANE / P1, P2, P3
PL2
CS
PS
DS
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Auxiliary and post processor statements: