Machine Tools, Foundry and Forging

MACHINE TOOLS
Dept. of Mech & Mfg. Engg.

1
Define a machine tool
A machine tool may be defined as a power driven
machine which accomplishes the cutting or
machining operations in it.
Examples: Lathe
Milling machine,
Grinding machine,
Drilling machine,
Planning machine etc.
2
Define a lathe
A lathe is a machine tool generally employed produce

circular objects.
Almost all the operations that can be performed on other

machine tools like
drilling machine,
milling machine,
shaping machine can be performed on a lathe.

3
Lathe classification
Based on characteristics:
• Engine Lathe
• Speed Lathe
• Turret Lathe
• Capstan Lathe
• Automatic Lathe
• CNC Lathe
4
Working principle of lathe
Chuck
Direction of rotation of
work piece
Work piece
Cutting tool
Direction of cutting tool

14
Working principle of lathe
• cutting tool can remove material

in the form of chips from Chuc
Direction of
rotating work pieces to produce k
circular objects rotation of
work piece
• work piece held rigidly by one of Work
the work holding devices known piece
as chuck
• V – shaped cutting tool V –
Cutting
shaped cutting tool Direction of cutting tool
• produces circular surfaces as tool
shown in the figure.

15
Explain with neat diagram the principal parts of an
engine lathe.

16
17
LATHE

18
Dept. of Mech & Mfg. Engg. 19
Bed:
• Is a foundation part of a
lathe
• supports all its other parts.
• two precision machined

guide ways formed on the
top of the bed
• outer guide ways
• inner guide ways.

20
Headstock:
• Housing comprising of
• feed gear box
• stepped cone pulley
• Rigidly mounted on the

inner guide ways of lathe
bed at its left end.

22
Tailstock:
• Movable part of the lathe
that carries the dead
centre in it.
• Used to clamp tools like:
Twist drills
Reamers
• For making holes, taps
and dies for cutting
threads.
• Mounted loosely on the
inner guide ways of lathe
bed and can be moved
and locked in any
position.
26
Carriage assembly:
• Serves to support the tool
• Rides over the outer guide
ways longitudinally between headstock
and tailstock.
It is composed of 5 main
parts.
1. Saddle 2. Cross slide
3. Compound Rest 4. Apron
5. Tool post

27
Saddle
• H shaped casting that slides
over set of guide ways
• serves as the base for the
cross slide.
Cross slide
• mounted on the saddle
• enables the movement
of the cutting tool laterally
across the lathe bed by
means of cross feed hand
wheel.

28
Compound Rest
•Mounted on the top of the cross slide
•Supports the tool post.
•Can be swiveled to any
angle in the horizontal
plane
•to facilitate following
operations: taper turning and threading operations
•Moved manually by the compound rest feed handle independent of
the lathe cross feed.

29
Apron
• Mounted on the front of the saddle
• Beneath it and houses
- Carriage
- Cross slide mechanisms
The apron hand wheel moves carriage manually by
means of the rack and pinion gears.
31
Tool post
•Mounted on the T – slot of the compound rest.
•Clamps the tool holder in the proper position for
machining operations.
34
Lead Screw:
• A screw rod which runs longitudinally in front of the lathe
bed.
• The rotation of the lead screw moves the carriage to and fro
longitudinally during thread cutting operation.
35
Feed rod:
• A stationary rod mounted in front of the lathe
bed
• Facilitates longitudinal movement of carriage
during turning, boring and facing operations.
36
Main drive:
An electric motor mounted in the left leg of the lathe in
conjunction with the transmission system like belt or
gear drive from the motor to the spindle i.e. from main
drive of the lathe.

37
Cone pulley and back gear:
• Cone pulley which drives the main spindle is
driven by the motor.
• Various spindle speeds can be obtained by shifting the belt on
different steps of the cone pulley.
• Spindle speeds can be further varied using a back gear
arrangement.
38
With a neat sketch highlight the specification of a
lathe.

39
Specification of a lathe
1. Distance between centers:
• Maximum distance that can be obtained between the
lathe centers
• Represents the maximum length of the work piece that
can be held between centers.
2. Overall length of the bed:
• Maximum length of the bed starting from the head stock
end to tailstock end.
3. Swing diameter over the bed:
• Largest diameter of the work piece that can be rotated
without touching the bed.
4. Swing diameter over a gap in the bed:
• Maximum diameter and the width of a work piece that
can be mounted between the centers.
41
Name the various operations that can be
conducted on a lathe.
The various operations that can be conducted on a lathe
are:
1. Turning
2. Taper turning.
3. Thread cutting.
4. Boring.
5. Facing.
6. Drilling.
7. Reaming
8. Knurling.
9. Milling.
10. Grinding.

42
Plain turning operation a with neat sketch.
Plain Turning:
• The process of metal removal from the cylindrical jobs is
called straight or plain turning.
• Cross slide and the carriage are used to perform turning
operations.
• Plain turning operation is performed in two steps.
• Rough turning (Roughing)
• Finish turning (Finishing)
43
Step turning operation a with neat sketch.
• A step turning operation is illustrated in the as shown figure.
• Performed using a wide tool after the plain turning
operation.
• The work is held in between the lathe centers or
with the chuck
• The tool is held at the height of the axis of the work.
• The depth of cut to obtain the step on the cylinder
is provided by cross slide movement and feed by
the carriage movement.
• This operation is performed manually.

44
What is taper turning operation in lathe?
Taper turning involves producing a conical surface on a
cylindrical surface in lathe.
A taper surface can be produced either by,
1. Rotating the job normally and feeding the tool at some angle
(like in compound rest swivel method)
2. Rotating the job at an off–set angle and feeding the tool
normally (like in tail stock set – over method).

45
Methods of taper turning:
1. Swiveling the compound rest.
2. Tailstock set over method.
3. Taper turning attachment method.
4. By using form tool.

46
Explain the principle of taper turning by swiveling compound tool rest
method.

47
The principle of taper turning operation by swiveling
the compound rest method is as shown in the figure.
• In this method the job is rotated on the lathe axis,
• Tool feeding is done at an angle, by the swiveled
compound rest.
• To assist in swiveling at particular angle, the base of the
compound rest is graduated in degrees.

48
The taper angle i.e. the angle at which the compound
rest to be rotated is calculated as below.
tan α =
D−d
2L
where, α = half taper angle ( simply taper angle ), degrees
D = larger diameter of the taper in mm.
d = smaller diameter of the taper in mm.
L = length of the taper in mm.
By calculating the taper angle, the compound rest can be swiveled
to the angle.
The tool feeding is done only by the compound rest handle so that
the tool moves at the set angle only.
49
Taper turning using Taper Attachment

50
Taper turning using Taper Attachment
• It is used to cut both internal and external tapers
• Consists of a bracket, connected to the rear side of the lathe
bed
• A guide bar is mounted over the bracket
• Guide bar is swiveled in the horizontal plane and locked in
position
• A guide block pivoted to a draw-link will slide in the
longitudinal slot in the guide bar
• The draw-link is connected firmly to the cross-slide
• Tool is mounted on the tool post slide
• The cross slide is allowed to move freely on its ways
• This is done by loosening the cross feed screw and the
engaging nut
51
Taper turning by Tailstock set over method

52
Taper turning by Tailstock set over method
• This method is also known as Offsetting the Tailstock
• Most common method for taper turning
• Best suited for long work pieces having less taper
• Only external tapers can be produced
• Amount of offset is limited by the size of the tailstock
Working:
• The tailstock centre is set out of alignment, as a result
• Axis of the work piece gets inclined at an angle to the
longitudinal movement of the tool
• Movement of the tool post is parallel to the lathe bed
• Entire carriage has to be moved parallel to the lathe bed
• Now carriage is moved to cut the taper
• This produces taper on the long work pieces
53
DRILLING

About drilling
• Drilling is the operation of making holes in a work piece using
drill bit.
• Tool used – Twist Drill
• Consist of helical groove (FLUTE) along the length of the body
• Machine used – Drilling Machine
• The stationary work is held in a fixture and the rotating tool is
fed vertically down.
• Removes the material, layer by layer
• Chips get curled and escape through the groove

WHAT IS DRILLING?
Drilling is a metal cutting process carried out by a rotating

cutting tool to make circular holes in solid materials.

What is a Drilling Machine?
A power operated machine tool, which holds the drill in its

rotating spindle and when manually actuated to move linearly
against the work piece produces a hole.

Why coolant is used during machining?
• To remove the heat of friction
• To provide better finish to the hole

Types of Drilling Machines
Drilling machines may be classified as
1. Portable drilling machine.
2. Bench or sensitive drilling machine.
3. Radial drilling machine.
4. Upright drilling machine.
5. Gang drilling machine.
6. Multiple spindle drilling machine.

Bench Drilling Machine

• Located generally on the work bench hence the name bench
drilling
• Since it is used for small jobs, it is also referred to as sensitive
drilling machine.
• Used for drilling small and medium sized holes (up to 15mm ).
• It consists of a round column with a rigid base fastened to the
bench
• Has a work holding table and an arm mounted on the round
column
• Arm carries the drill spindle on one side and the drive motor
on the other side
• A stepped cone pulley with V – belt is used to transmit the
power from motor to spindle

• The work table can be moved up and down to suit the

required job height and can be locked at suitable height
• The arm can swing around to set the work below the drill bit.
The table can rotate about its axis by 360°
• The drilling operation is performed by fixing the job properly
on the work table
• The drill bit is gradually fed by rotating hand feed lever
towards the operator
• Once the required depth of cut is completed, the feed lever is
rotated in the opposite direction to withdraw the tool from
the work
• Complete operation is done manually

Radial Drilling Machine

Radial Drilling Machine
• Radial drilling machine is used for medium and heavy duty
applications
• Consists of a heavy, circular column mounted on a very strong
base
• Radial arm that can swing around is mounted on the column
and the radial arm can be raised and lowered
• Drill head with drive and feed mechanism is fitted on to the
radial arm
• Drill head can move horizontally along the slides of the arm and
can be locked at any desired position
• These movements of the arm and the drill head make it easier
and faster to locate the drill centre on the work
• All the motions can be clamped at necessary positions
Other operations that can be performed on a
drilling machine are:
• Reaming
• Counter boring
• Counter sinking
• Spot facing
• Thread tapping

List the operation performed on a drilling machine.
The different machining operations that can be performed
operation performed on a drilling machine are as follows.
1. Drilling
2. Reaming
3. Boring.
4. Counter Boring
5. Counter sinking
6. Spot facing
7. Tapping.
8. Trepanning

Boring:
• Done on a drilling machine to
increase the size of an
already drilled hole
When a suitable size drill is not
available,
■ Initially a hole is drilled to
the nearest size
■ Using a single point cutting
tool, the size of the hole is
increased to required size
By lowering the tool while it is
continuously rotating,
■The size of the hole is
increased to its entire depth.
Counter bore
Counter boring
Tool
It is to increase the size of a hole
at one end only through a small Pilot
depth
It forms a larger sized recess or a
shoulder to the exiting hole
• The cutting tool will have a
small cylindrical projection
known as pilot
• It guides the tool
Counter bore
Counter boring Tool
Condition:
• Diameter of the pilot will Pilot
always be equal to the
diameter of the
previously drilled hole
Cutting Speed:
• Two-third of the drilling
speed
Purpose:
It is done on the hole to accommodate the socket head screw, or
grooved nuts, or round head bolts.
Countersinking
It is the operation of making
the end of the hole into a
conical shape
• Using countersinking tool
• May also be employed for

Use:
deburring the holes
When the countersunk screws are to
Cutting speed be screwed into the holes, so that
their top faces have to be in flush
One - half of that used for
with the top surface of the work
similar size drill piece.
MILLING MACHINES
Milling Machine
• Milling is a metal cutting operation in which the operating
tool is a slow revolving cutter having cutting teeth formed
on its periphery.
• The milling cutter is a multipoint cutting tool. The work
piece is mounted on a movable work table which will be fed
against the revolving milling cutter to perform the cutting
operation.
• The difference between drilling and milling is that, in drilling
a rotating drill is fed against a stationary work-piece, while
in milling the work-piece is fed against a milling cutter which
only revolves.
• Similarly, it also differs from the lathe operation because the
lathe tool is fed against rotating work-piece.
• A milling machine is a power operated machine tool in which
the work-piece mounted on moving table is machined to
various shapes when moved under a slow revolving serrated
cutter.
Principle of Milling
• The principle of cutting action is from the milling cutter.
• The milling cutter is mounted on a rotating shaft known as arbor.
• The work-piece which is mounted on the table can be fed either in the
direction opposite to that of the rotating cutter and in the same
direction of that of the cutter.
• When the work-piece is
fed in the opposite
direction to the cutter
tooth at the point of
contact, the process is
called conventional or up
milling.
• In this process, as the
work-piece advances
against the rotating
cutter, the chip that is Fig 1 A
removed gets
progressively thicker as
shown in Fig.1A
• The action of the cutter forces the work-piece and the
table against the direction of the table feed, thus each
cutter tooth enters a clean metal gradually thus the
shock load on each tooth is minimized.
• The disadvantage of this method is that when making
deep cuts, such as in heavy slotting operations, the
cutter tends to pull the work-piece out of the vice or
the fixture since the cutting force is directed upward
at an angle.
• When the work-piece is fed in
the same direction as that of the
cutter tooth at the point of
contact, as shown in Fig. 1B, the
process is called climb or down
milling.
• In this process, the cutter enters
the top of the work-piece and
removes the chip that gets
progressively thinner as the
cutter tooth rotates.
• Generally, more metal can be removed for each cut
than the conventional up milling. Climb milling is used
only on materials that are free of scale and other
surface imperfections that would damage the cutters.
• Classification of Milling Machine
• Plain or Horizontal Type of Milling Machine
• Vertical Milling Machine
• Universal Milling Machine
• Planer Type Milling Machine
• Profile Cutting Milling Machine
SHAPER (SHAPING MACHINE)
• Shaping Machine (Shaper) is a reciprocating type of
machine tool used for producing small flat surfaces
• with the help of a single point tool reciprocating over the
stationary work piece
• surface may be horizontal, inclined or vertical

Parts produced on a shaper
Principal Parts of a Shaper
Isometric View of Shaper
• Base: It is a heavy structure of cast iron which supports other parts
of a shaper.
• Column: It is a box-like structure made up of cast iron and mounted
upon the base. It contains the driving mechanism and is provided
with two machined guide ways on the top of it on which the ram
reciprocates.
• Ram: It is a reciprocating member which reciprocates on the guide
ways provided above the column. It carries a tool-slide on its head
and a mechanism for adjusting the stroke length.
• Tool head: It is attached to the front portion of the ram with the help
of a nut and a bolt. It is used to hold the tool rigidly, it also provides
the vertical and angular movements to the tool for cutting.

• Cross-rail: It is attached to the front vertical portion of the column.
It is used for the two purposes:
(a) It helps in elevating the table over the column in the upward
direction, and
(b) The table can be moved in a direction perpendicular to the axis of
the ram over this cross rail.

Table: It is used for holding the work piece. It can be adjusted horizontally
and vertically with the help of spindles.
Cutting action and functioning of clapper box

SHAPER MECHANISM
• In a shaper, rotary motion of the drive is converted into reciprocating
motion of the ram by the mechanism housed within the column or
the machine.
• In a shaper metal is removed in the forward cutting stroke.
• The return stroke goes idle and no metal is removed during this
period.
• The reciprocating movement of the ram and the quick return
mechanism of the machine are generally obtained by anyone of the
following methods:
• (a) Crank and slotted link mechanism
• (b) Whitworth quick return mechanism
• (c) Hydraulic shaper mechanism

Crank and Slotted Link Mechanism
SHAPER OPERATIONS
Machining horizontal surface

Machining vertical surface
Machining angular surface
Slot cutting
Keyway cutting
Machining irregular surface
Grinding Machines
• Grinding, also called abrasive machining, is a process
in which the material is removed in the form of fine
chips, almost as dust particles by the abrasive action
using some kind of abrasive materials.
• The thickness of the material chips removed by
grinding ranges from 0.25 to 0.50 mm in finishing and
general grinding operations.
• Abrasive is the mineral material employed for
sharpening, grinding and polishing operations
• The two types of abrasives used are; natural and
artificial.
• The examples of natural abrasives are emery,
corundum, quartz. sandstone, diamond, etc.
• The important properties of abrasives are, hardness,
toughness, uniformity in grain sizes, and sharpness.
Grinding wheel Terminology
• Grit
• The grit is the grain size of the abrasive grain. The grain size can be
classified as per the mesh number of the screen through which the grain
falls. The grain size is expressed as a number. Thus, coarse grain size can be
between 10 and 24, Medium grain size can be between 30 & 60, Fine grain
size can be between so and, very fine grain size can be between 220 and
600.
• Grade
• Grade is the hardness of the bond, which is
designated by alphabets. The letter "A" Stands for
very soft material and the letter " Z" stands for very
hard grade.
• Wheel structure
• The abrasive grains are distributed over the abrasive
wheel in a structural form. The wheel structure is also
represented as a number. For example, Dense can be
from 1 to 8 and Open can be from 9 to I5.
• Bond type
• It is denoted by alphabets like V is for vitrified Bond, B
is for Resinoid, R is for Rubber, E is for shellac and S is
for silicate, and so on.
• Abrasive
• Abrasives are denoted by alphabets-Example: A
stands for Aluminum oxide & C Stands for Silicon
Carbide.
Foundry
(Metal Casting)
119
CASTING
It is the process of producing metallic parts by pouring a
molten metal in to the mould and allowing the metal to
solidify.
120
Casting Process
• Mould prepared.
• Metal is Heated Above Melting Temp.
• Liquid Metal Poured into Mold
• Metal Solidifies into Shape of Mold
• Part Removed from Mold
• Post Casting Operations
• Clean Up
• Machining
121
122
123
Molding sand classification
They can be classified as:
1. Natural molding sand (Green sand)
- Taken from river beds & contain major amount of clay
- easily available at low cost
2. Synthetic sand
- contain little or no binder (clay)
- strength & bonding property can be easily controlled
- more expensive than natural sand
3. Special sand
- ideal in getting special characteristics..
124
Sand preparation
• Very few natural sands have all the qualities required by a

molding sand
• It is mixed with other sands which possess the required

characteristics
• Sufficient moisture must be added to the sand
• Sand must be properly conditioned before use
125
Properties of a molding sand
• Porosity (permeability)
• Sand must be porous to allow the gases/ moisture present within the
molds to be removed freely when molten metal is poured
• Adhesiveness
• sand particles must be capable of adhering to sides of molding
boxes
• Cohesiveness / Strength
• Ability of sand particles to stick together
• Should be sufficient to permit the mold to be formed to the desired
shape even after the hot metal is poured in the mold
• Refractoriness
• Molding sands with a poor refractoriness may burn on to the casting
• Measured by sinter point of sand
126
Properties of a molding sand
• Collapsibility
• Mold made out of sand to collapse as the molten metal gets
solidified in it
• Flowability
• Ability of the sand to behave like a fluid so that, when rammed sand will
flow to all portions of a mold and around the pattern and take up the
required shape
• It increases as clay & water content increase
• High flowability is required of a molding sand of uniform density
• To obtain good impression of the pattern in the mold.
127
Terminology
128
Components of a gating system
129
PATTERN
• A pattern is an replica of a casting to be made.
• Using pattern, impressions (mould cavity) can be formed in the damp

sand to make a mould.
130
Pattern materials
-Any material which will retain exact outline of the design for
required number of molds
131
Pattern materials
• Wood – easy to work & readily available
– can be cut in to required shapes
– used when small number of castings
• Metal - do not change their shape when subjected to
moist condition
– used when small number of castings
• Plastics – do not absorb moisture, smooth
– can be withdrawn from the mold easily,
without damaging the mold
• Plaster – High compressive strength
132
Green sand mold
133
Basic steps in making sand casting
1. Pattern making
2. Core making
3. Moulding
4. Melting and pouring
5. Cleaning
134
Green sand mold Drag
Pattern
with pattern
Molding board
FIRST OPERATION
Vents
Weight Lifter
Riser pin Sprue pin Pouring basin
Cope
Riser
Parting Parting
line line Runner
Gate
Core
SECOND OPERATION COMPLETE MOLD 135

Scooping
• It is the process of making a cavity in the sand mould
without using a pattern.
• Instead it makes use of casting hand tools like shovel,
rammer etc.
136
Types of patterns
-Single piece pattern
-Match plate pattern
-Gated pattern
-Split pattern
-Cope & Drag pattern
-Loose-piece pattern
-Skeleton pattern
137
Types of patterns
Dowel
Split pattern
One piece pattern Loose piece pattern
138
Match Plate pattern Gated pattern
Cope plate
Sand
Drag plate
Cope & Drag pattern
Gated pattern
139
Single piece pattern
• Made from one piece & does not contain loose pieces
• Inexpensive & are of simplest type
Split pattern
• Most widely used pattern for intricate castings
• Here the pattern is split in to 2 parts so that one part is in
the cope & other is in the drag
• Two halves of the pattern is aligned properly by using
dowel pins
140
Cope and Drag pattern
• Similar to split patterns
• The cope & drag halves of the pattern along with the gating
and risering systems prepared separately
• But they are attached separately to the metal or wooden
plate along with alignment pins
Match plate pattern

• An extension of cope and drag pattern
• Here the cope & drag patterns along with the gating &
risering are mounted on a single matching or metal plate
on either side
141
Loose piece pattern
• Used when contour of the part is such that withdrawing the
pattern from the mold is not possible
• Obstructing part is held as a loose piece
Skeleton pattern
• Made of strips of wood for preparing final pattern
by pouring the sand around the pattern and packing it
142
Gated pattern
• Usually made of metal which increases their strength and
reduces tendency to warp
• Section connecting different patterns serve as runner
and gates
• A gated pattern can manufacture many castings at one
time
• Used in mass production systems
143
Pattern Allowances
1. Shrinkage allowance
2. Machining or Finishing allowance
3. Draft or Taper allowance
4. Camber or distortion allowance
5. Shake or Rapping allowance
6. Mould wall movement allowance
144
Pattern Allowances
1. Shrinkage allowance
• Most of the metals used in casting contract during cooling
from pouring temperature to room temperature
• Provided to compensate for solid contraction by providing

adequate allowances in the pattern
• Amount of contraction varies with different metals
145
Pattern Allowances
2. Machining allowance
• Given on the surface of the pattern by increasing the metal
thickness there to compensate for loss of metal due to
machining on these surfaces
• Depends mainly upon method of machining to be employed
• Given in addition to the shrinkage allowance
146
Pattern Allowances
3. Draft or Taper allowance
• Given slight taper on the vertical surfaces of the pattern
parallel to the direction of withdrawal from the mould
• Provided on both internal & external surfaces
• For easy withdrawal of pattern from the mould
147
Pattern Allowances
4. Rapping allowance
• Negative allowance to be provided in the pattern
• When pattern is withdrawn from the mould by striking over
it from side to side, size of the cavity increases
• To compensate this rapping allowance is provided
148
Pattern Allowances
5. Distortion allowance
• Castings having irregular shape, will not have uniform
contraction during their cooling
• Results in distortion of the castings
Remedy:
An opposite distortion is provided in the pattern
149
Pattern Allowances
6. Mould wall movement allowance
• Mould wall movement takes place because of excessive
heat and pressure applied by the molten metal on the surface
layer of the sand
• Affects the size of the casting
Remedy:
•Provide proper allowance in the pattern
•Controlling the density & temperature of molten metal
•Controlling the composition of the molding sand
150
Defects in casting
• Blowholes
• Smooth round holes appearing in the form group of small holes
below the surface of casting
• Due to entrapped bubble of gases
• Scabs
• Projection on the casting that occur when a portion of the mould
lifts and metal flows
• Drop
• Occurs when upper surface of the mold cracks and pieces of sand
falls in to the molten metal
• Shrinkage cavity
• Void created in the casting mainly due to uncontrolled
solidification of the metal
151
• Internal air pocket
• It appears as small holes inside the casting, due to rapid pouring of
molten metal in to the mold
• Shifts
• An external defect caused due to core misplacement or mismatching
of top and bottom parts of the casting
• Fin
• A thin projection of the metal
• Caused due to incorrect assembling of molds or cores
• Swell
• Enlargement of metal cavity by metal pressure
• This is caused by improper ramming
• Warpage
• Unintentional and undesirable deformation in a casting that occurs
during solidification
152
Smithing & Forging
Smithing
It is a process of performing various operations on relatively small
work pieces, heated in an open fire (hearth) by means of hand
hammers or small power hammers in a smithy shop.
Forging
Is a process of producing those parts, which must be heated in a
closed furnace, by means of heavy hammers or forging machines or
presses.
Forging Tools
Beak
3) Punch 4) Flatter
2) Fuller
5) Swage 6) Flat tongs
7) Ring Tongs 8) Gad Tongs 9) Swage block

Hammers
a) Ball peen b) Cross peen
Sledge Hammer
Set hammer
c) Straight peen
Chisels
Hot Chisel
Anvil: Provides a support for blacksmith’s workpiece
when hammering.
-Beak is used for bending the workpieces
Fuller: Necking down a piece of work
Swage: To obtain reduced and finished to round, square or

hexagonal form
- Made with half grooves of dimensions to suit the
work being reduced
Punch: Used for making holes in metal part when it is in
forging heat.
Flatter: To give smoothness and accuracy to components which have
been already shaped by fullers and swages.
Tongs: To hold the workpiece
1) Flat Tong : For holding work of rectangular section
2) Ring Tong : For holding work of circular section
3) Gad Tong : For general pick-up, either straight or tapered
Swage block:
Used for squaring, sizing, bending operations
Chisels: For cutting metals & for nicking prior to breaking
- They may be hot or cold depending on the metal to be cut
is hot or cold.
Hand hammers: They may be classified as a) Ball peen hammer
b) Straight peen hammer c) Cross peen hammer
d) Sledge hammer
Set hammer: Used for finishing corners in shouldered work,
where flatter is inconvenient.
Forging processes
They are classified as:
1) Smith Die forging
a) Hand Forging
b) Power Forging
2) Impression Die forging

a) Drop Forging
b) Press Forging
c) Machine Forging
Power forging
-Also called as an air and
steam hammer
-Operated by either steam or

Ram
compressed air
-Principle of operation is
Upper Die
illustrated in the sketch
Work -Require additional facilities

Lower Die
for supplying high pressure steam
Anvil or compressed air.
Fig. Steam Hammer
Drop Forging (Stamping/ Die forging)
-Also called as Gravity Hammer
Roll
Working:
-Ram is fixed to the lower end of
the board
Board
-Board is placed between 2 rolls
-Ram will be lifted, when both rolls
are pressed against the board
Upper Die
work
-Working stroke is produced when
Lower Die the rolls are released.
-Process continues till operator
holds down the treadle
Board Hammer
Smith forging operations
Most commonly used forging operations are:
1. Upsetting
2. Bending
3. Punching
4. Drawing down
5. Setting down
6. Cutting
7. Fullering
Smith forging operations
Upset forging operations
Upsetting:
Process of increasing the thickness of a bar by
reducing its length by end pressure.
Bending:
Curvilinear
Process of producing curvilinear or
angular bends on a bar.
Done on the edge of the anvil face or
beak or swage block Angular
Bending operations
Punching operation
Process of producing of holes by a hot

Step 1
punch by placing the job over the pritchel
hole of the anvil.
Step 2
Step 3
Drawing down or Swaging
Process of increasing the length of a bar at the expense of its width
or thickness or both.
Setting Down
It is a localized drawing down or swaging operation.
Cutting
Process of removing a forging from the stock.
Fullering
Process of spreading the metal along the length of the
job.
Drop forging
Gravity hammer
-Uses drop hammers of 2 types
Steam hammer
-Hammers can make 50 – 75 strokes/ min
-Lower maintenance cost & easy to operate
-Tools, Gear blanks, Machine parts

Press forging
•Done in presses than with hammers
•More accurate than drop forgings
•Relatively slow squeezing but better penetration
•Screws, nuts & rivets can be made
• High operating speed
Machine / Upset forging
• Lengthwise pressure will be applied on the component held
between grooved dies to enlarge some sections
• Operates at very high rate
• Bolts, nuts, washers can be made
• Produce 400 – 600 forgings per hour

Pritchel hole

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MACHINE TOOLS

Dept. of Mech & Mfg. Engg.

A lathe is a machine tool generally employed produce

Almost all the operations that can be performed on other

shaping machine can be performed on a lathe.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

• cutting tool can remove material

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

• supports all its other parts.

• two precision machined

• outer guide ways

• inner guide ways.

Dept. of Mech & Mfg. Engg.

• Rigidly mounted on the

Dept. of Mech & Mfg. Engg.

• Rides over the outer guide

ways longitudinally between headstock

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

•Clamps the tool holder in the proper position for

conjunction with the transmission system like belt or

drive of the lathe.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

cylindrical surface in lathe.

A taper surface can be produced either by,

(like in compound rest swivel method)

2. Rotating the job at an off–set angle and feeding the tool

normally (like in tail stock set – over method).

Dept. of Mech & Mfg. Engg.

1. Swiveling the compound rest.

2. Tailstock set over method.

3. Taper turning attachment method.

4. By using form tool.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

the compound rest method is as shown in the figure.

• In this method the job is rotated on the lathe axis,

• Tool feeding is done at an angle, by the swiveled

• To assist in swiveling at particular angle, the base of the

compound rest is graduated in degrees.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

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Dept. of Mech & Mfg. Engg. 55

Drilling is a metal cutting process carried out by a rotating

Dept. of Mech & Mfg. Engg. 56

A power operated machine tool, which holds the drill in its

Dept. of Mech & Mfg. Engg. 57

• To remove the heat of friction

• To provide better finish to the hole

Dept. of Mech & Mfg. Engg. 58

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• The work table can be moved up and down to suit the

Dept. of Mech & Mfg. Engg. 62

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