EXPERIMENT NO: 01&02

PRODUCTION
TECHNOLOGY-II

LATHE AND MILLING OPERATION

NAME : K.PIRUTHUVIRAJAN
REG. NO : 2015/0087
COURSE : HNDE-MEC (4TH YEAR)
DATE OF INT : 2018/08/09 & 2018/08/16
DATE OF SUB : 2018/08/29
LATHE MACHINE OPERATIONS
Introduction:
Lathe is one of the most versatile and widely used machine tools all over the
world. It is commonly known as the mother of all other machine tool. The main
function of a lathe is to remove metal from a job to give it the required shape
and size. The job is securely and rigidly held in the chuck or in between centers
on the lathe machine and then turn it against a single point cutting tool which
will remove metal from the job in the form of chips. An engine lathe is the most
basic and simplest form of the lathe. It derives its name from the early lathes,
which obtained their power from engines. Besides the simple turning operation
as described above, lathe can be used to carry out other operations also, such as
drilling, reaming, boring, taper turning, knurling, screw thread cutting, grinding
etc.

Operations on Lathe machine:

To understand the different operations the machinist must know how to give
different feeds on the machine. And also must have a clear idea about the
cutting tools. Different types of lathes are available in the industry. So let’s
discuss the processes and follow the diagrams for a better understanding.

Operations, which can be performed in a lathe either by holding the work piece
between centers or by a chuck are:
1. Straight turning 2. Shoulder turning
3. Taper turning 4. Chamfering
5. Eccentric turning 6. Thread cutting
7. Facing 8. Forming
9. Filing 10. Polishing
11. Grooving 12. Knurling
13. Spinning 14. Spring winding
Operations which are performed by holding the work by a chuck or a faceplate
or an angle plate are:
1. Undercutting 2. Parting-off
3. Internal thread cutting 4. Drilling

5. Reaming 6. Boring

7. Counter boring 8. Taper boring

9. Tapping

Operations which are performed by using special lathe attachments are:

1 Milling 2. Grinding

Facing Work piece on centers Straight (Cylindrical) Shouldering

turning

Filleting (Form tool) Radius turning (Form tool) Necking (Form tool)

Taper turning External thread cutting Forming

 MILLING OPERATION

Introduction:
• Milling is the machining process of using rotary cutters to remove material
from a work piece advancing (feeding) in a direction at an angle with the axis of
the tool.

• It covers a wide variety of different operations and machine on scales from small
individual parts to large, heavy-duty gang milling operations.

• It is one of the most commonly used processes in industry and machine shops
today for machining parts to precise sizes and shapes.

Type of milling machine operation

1. Plain milling: Up milling and down milling Machining is done by the teeth
on the cylindrical surface of the cutter, finished surface is parallel to the
axis of the cutter.
2. Face milling: Machining is done by the teeth on the flat surface of the
cutter, finished surface is perpendicular to the axis of the cutter.
3. Side milling: Machining is done by the teeth on the cylindrical surface of
the cutter, finished surface is parallel to the axis of the cutter.
4. End milling: Machining is done by the cutter teeth on the end as well as
periphery of the cutter. It’s used for machining of complicated profile.
5. Profile milling: The cutter has outline same as that of the shape of the
profile. It’s used for gear teeth manufacturing.
6. Gang milling: Two or more milling cutter are mounted on the arbor.
Horizontal and vertical surfaces are machined simultaneously.
7. Saw milling: The thickness of cutter is Small (0.75to 5mm) it’s used for
cutting deep slots or for Cutting operations.
Method of indexing

Direct indexing: Simplest form of indexing Performed by disengaging

worm shaft from worm wheel by means of disengaging the drive gear
Spring-loaded tongue lock engages numbered slots in index plate Used
for quick indexing of work piece when cutting flutes, hexagons.

Simple indexing: Work positioned by means of crank, index plate, and sector
arms Worm attached to crank must be engaged with worm wheel on dividing
head spindle: 40 teeth on worm wheel which means: One complete turn on
index crank causes the spindle and work to rotate one-fortieth of a turn.
Calculating the indexing or number of turns of crank for most, simply divide 40
by number of divisions or flats to be cut.

Turns of the crank = 40

No of flats needed

Angular indexing: One complete turn of index crank turns work 1/40
of a turn –1/40 of 360° equals 9 degrees

Turns of the crank = Angle required

9
Index head:
The index head of the indexing fixture contains an indexing mechanism which is
used to control the rotation of the index head spindle to space or divide a work
piece accurately. A simple indexing mechanism consists of a 40-tooth worm
wheel fastened to the index head spindle, a single-cut worm, a crank for turning
the worm shaft, and an index plate and sector. Since there are 40 teeth in the
worm wheel, one turn of the index crank causes the worm, and consequently,
the index head spindle to make 1/40 of a turn; so 40 turns of the index crank
revolve the spindle one full turn.

Index plate
The indexing plate is a round plate with a series of six or more circles of equally
spaced holes; the index pin on the crank can be inserted in any hole in any circle.
With the interchangeable plates regularly furnished with most index heads, the
spacing necessary for most gears, bolt heads, milling cutters, splines, and so
forth can be obtained.
To cut the hexagonal:

40 turns of the index crank revolve the spindle one full turn. 9 degree is travel
for a 1 turn.

So hexagon, 40/ 6 = 6 4/6 turn of index crank. Plate has 24 holes so, we have to
turn 16 holes. Finally, 6 full turn and 16 hole on 24 holes circle.