ME 8451 – MANUFACTURING TECHNOLOGY II

Part-A (06 X 02= 12)

1. How are shaping machines specified?

The shaping machine is specified by the size and shape of the machine and the size of the job to be machined. The shaper is
specified as follows.
i). Maximum length of stroke ii) Type of Driving mechanism iii). Size of Table. iv) Power of motor v). Speed and Feed
available.

2. Give the functions of flute on taps

The flute is the helical groove. It is used to remove the chip through the helical groove and the cutting fluid will enter through
the flute surface. Also, Flutes are used i) To reduce the cutting forces. ii) To avoid friction between work piece and tap
interface.

3. What is a deep hole drilling? State its applications

It is a drilling process of producing very deep holes of L/D ratio 6 to even 30. The depth of the holes so long so it is called deep
hole drilling process. It is used to produce deep holes in rifle barrels, cranks shafts, long spindles, oil holes in shafts, bearings,
connecting rods etc.

4. What is climb milling? Mention its advantages

In climb milling, the work moves parallel to the cutter rotation. Its advantages are
1.Cutter with higher rake angle can be used. This reduces power requirements.
2.Cutter wear is less because chip thickness is maximum at the start of cut.

5. What is the difference between a plain and a universal milling machine?

The basic difference between a universal horizontal milling machine and a plain horizontal milling machine is the addition of a
table swivel housing between the table and the saddle of the universal machine. This permits the table to swing up to 45° in
either direction for angular and helical milling operations.

6. How do you classify milling cutters?

Milling cutters are classified by their performance of operations and volume of work piece. i).Plain milling cutters, ii) Side
milling cutters iii) End milling cutters iv) Face milling cutters v) T-slot milling cutters, vi) Angle milling cutters vii). Form
milling cutters viii) Slitting milling cutters.
Part-B (02 X 06 = 12)
1. (a) Explain the principle of gear hobbing with neat sketch
Gear hobbing is a machining process in which gear teeth are progressively generated by a series of cuts with a helical cutting
tool [hob]. All motions in hobbing are rotary, and the hob and gear blank rotate continuously as in two gears meshing until all
teeth are cut. Hobbing is the process of generating gear teeth by means of a rotating cutter called a hob. It is a continues
indexing process in which both the cutting fool & work piece rotate in a constant relationship while the hob is being fed into
work. For in route gears, the hob has essentially straight sides at a given pressure angle. The hob and the gear blank are
connected by means of proper change gears. The ratio of hob & blank speed is such that during one revolution of the hob, the
blank turns through as many teeth. The teeth of hob cut into the work piece in Successive order & each in a slightly different
position. Each hob tooth cuts its own profile depending on the shape of cutter, but the accumulation on the shape of cutter, but
the accumulation of these straight cuts produces a curved form of the gear teeth, thus the name generating process. One rotation
of the work completes the cutting up to certain depth.
 (b) Sketch the drive mechanism of a shaping machine having crank and slotted type of quick return
In this type of shaper machine mechanism, the power is transmitted to the bull gear through a pinion which receives its motion
from an individual motor. Or overhead line shaft through speed control mechanism. The bull gear is a large gear mounted
within the column. The radial slide is bolted to the centre of the bull gear it carries a sliding block into which the crank pin is
fitted.
Rotation of the bull gear will make the crank pin to revolve at a uniform speed. The sliding block which is mounted upon the
crank pin is fitted within the slotted link. The slotted link which is also known as the rocker arm is pivoted at its bottom end
attached to the frame of the column. The upper end of the rocker arm is forked and attached to the ram block by a pin. As the
bull gear rotates causing the crank pin to rotate, the sliding block fastened to the crank pin will rotate on the crank pin circle.
And at the same time will run up and down the slot in the slotted link providing it with a rocking movement which is
communicated to the ram. Thus the rotary motion of the bull gear is converted to reciprocating movement of the ram. The
speed of the bull gear may be changed by a different combination of gearing or by shifting the belt on the step cone pulley.

2. (a) What are the operations performed on a milling machine

Plain Milling

 The plain milling is the most common types of milling machine operations.
 Plain milling is performed to produce a plain, flat, horizontal surface parallel to the axis of rotation of a plain milling cutter.
 The operation is also known as slab milling.
 To perform the operation, the work and the cutter are secured properly on the machine.
 The depth of cut is set by rotating the vertical feed screw of the table. And the machine is started after selecting the right speed
and feed.
Face Milling
 The face milling is the simplest milling machine operations.
 This operation is performed by a face milling cutter rotated about an axis perpendicular to the work surface.
 The operation is carried in plain milling, and the cutter is mounted on a stub arbor to design a flat surface.
 The depth of cut is adjusted by rotating the crossfeed screw of the table.
Side Milling
 The side milling is the operation of producing a flat vertical surface on the side of a workpiece by using a side milling cutter.
 The depth of cut is set by rotating the vertical feed screw of the table.
Straddle Milling

The straddle milling is the operation of producing a flat vertical surface on both sides of a workpiece by using two side milling
cutters mounted on the same arbor.
 Distance between the two cutters is adjusted by using suitable spacing collars.
 The straddle milling is commonly used to design a square or hexagonal surfaces.
Angular Milling

 The angular milling is the operation of producing an angular surface on a workpiece other than at right angles of the axis of the
milling machine spindle.
 The angular groove may be single or double angle and may be of varying included angle according to the type and contour of
the angular cutter used.
 One simple example of angular milling is the production of V-blocks.
 Gang Milling

 The gang milling is the operation of machining several surfaces of a workpiece simultaneously by feeding the table against a
number of cutters having the same or different diameters mounted on the arbor of the machine.
 The method saves much of machining time and is widely used in repetitive work.
 Cutting speed of a gang of cutters is calculated from the cutter of the largest diameter.
[OR]

(b) Sketch the following operations performed in the drilling machine

a) Drilling, b) Reaming c) Boring d) Counter boring

Part-C (01 X 06 = 06) Compulsory

1. Why is gear finishing required? .Discuss the various types of gear finishing operations
 Surface of gear teeth produced by any of the generating process is not accurate and of good quality (smooth). Dimensional
inaccuracies and rough surface generated so become the source of lot of noise, excessive wear, play and backlash between the
pair of gears in mesh. These all result in loss of power to be transmitted and incorrect velocity ratios.

Gear shaving
Gear shaving is a process of finishing of gear tooth by running it at very high rpm in mesh with a gear shaving tool. A gear
shaving tool is of a type of rack or pinion having hardened teeth provided with serrations. These serrations serve as cutting
edges which do a scrapping operation on the mating faces of gear to be finished. Both are gears in mesh are pressed to make
proper mating contact. A shaving tool with serrated teeth is explained by illustration in Figure

Roll finishing of gear tooth

This process involves use of two hardened rolling dies containing very accurate tooth profile of the gear to be finished. The gear to be
finished is set in between the two dies as shown in Figure and all three are revalued about their axis. Pressure is exerted by both the
rolling dies over the gear to be finished. The material of the die is very hard as compare to the material of gear so there is a plastic
deformation.