ES .

I N
N O T
KTU

MODULE VI
ARUN JOSE TOM, MLMCE, BME 1
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 ES . I N
N O T
KTU

MACHINE TOOLS
ARUN JOSE TOM, MLMCE, BME 2
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 MACHINE TOOL

A machine, which performs the material removal operations

with tools, to produce desired shape and size of the work-
piece is known as machine tool

Types of Machine Tools

ES . I N
1. Lathe
N O T
KTU
2. Shaping machine
3. Drilling machine
4. Milling machine
5. Grinding machine
6. Slotting machine
7. Planer machine

ARUN JOSE TOM, MLMCE, BME 3

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 Milling
Drilling Machine Grinding
Machine Machine

Shaping Slotting
Machine ES . I N Machine
N O T
KTU
Lathe
Types of Planer
Machine Tools Machine

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 Tools Used

• Single Point Cutting Tool: One cutting edge(used in lathe)

ES . I N
N O T
KTU
• Multipoint Cutting Tool: Number of teeth or cutting edges on
the periphery

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 SINGLE POINT
CUTTING TOOL

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 6

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 ES . I N
N O T
KTU
MULTIPOINT
CUTTING TOOL

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 LATHE

It is a general purpose machine tool , which removes

excess material from the work piece, in the form of chips, by
ES . I N
rotating the work piece against a single point cutting tool
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 8

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 9

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 10

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 ES . I N
N O T
KTU

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Principle of working
• Hold the work piece and to rotate it about an axis

• Cutting toll is fed either parallel or perpendicular to the axis

of the work piece removes material from the rotating work
E
to give the required size and shapeS . I N
N O T
KTU
• Tool is moved parallel to the axis of rotation of the work
piece gives a cylindrical surface

• Tool is moved perpendicular to the axis of rotation of the

work piece gives a flat surface
ARUN JOSE TOM, MLMCE, BME 12
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 Principal Parts of a Lathe

1) Bed
• Base foundation of the lathe

S . I N
• Headstock, tailstock, carriage…etc are mounted on the bed
E
U N O T
• K T
Provides strength & rigidity to the machine

• Top of the bed is provided with guides or ways for carriage

& tailstock

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 ES . I N
N O T
KTU

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 2) Headstock

• Permanently mounted on the bed at the left end

• Spindle is supported in headstock, spindle is a hollow
cylindrical shaft supported by bearings
S . I N
• Work holding devices such as face plate, driving plate or
E
N O T
KTU
chucks may be mounted on the spindle nose
• Headstock has a gear box for changing the speed of rotation
of spindle and thereby the speed of rotation of work piece
• Spindle is driven by a motor

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 ES . I N
N O T
KTU

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 THREE JAW CHUCK

ES . I N
N O T
KTU
FOUR JAW CHUCK

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 3) Tailstock

• It is mounted on the bed at the right end and can be

clamped at any convenient position
ES . I N
N O T
KTU
• It supports one end of the work piece

• It is also used for holding a tool for performing operations

such as drilling, reaming…etc

ARUN JOSE TOM, MLMCE, BME 18

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 4) Carriage
• Carriage consists of several parts that serves to support the
cutting tool and to control the action of the cutting tool
• It can be moved along the bed ways provided at the top of
the bed

S .
E partsI N
CarriageN O
has 5T major
K T U
a) Saddle: base of the carriage. It slides along the guide ways
b) Cross slide: mounted on saddle. It is used to move the tool
towards and away perpendicular to centre line of lathe

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c) Compound rest: mounted on the top of cross slide. Tool post
is fixed on the compound rest. Compound rest can be rotated
about the saddle, which makes positioning of cutting tool at
the desired angle
d) Tool post: mounted on compound rest. Cutting tool can be
firmly held on it.
ES . I N
O T
e) Apron: it is fixed below the saddle. It contains gears and levers
N
KTU
for manual and automatic motion of carriage. For manual
motion of carriage along the bed, there is a hand wheel in
front of the apron. Automatic motion of carriage is made
possible by engaging hand wheel shaft of apron with the lead
screw(for thread cutting operation).

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 24

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 25

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 ES . I N
N O T
KTU
TOOL POST

ARUN JOSE TOM, MLMCE, BME 26

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 ES . I N
N O T
KTU

COMPOUND REST
ARUN JOSE TOM, MLMCE, BME 27
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 ES . I N
N O T
KTU

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 5) Lathe Centres
• Lathe centres are tapered components fit into spindles
provided in the headstock and tailstock

• Centre connected to the headstock is called live

I N
T E S .
T
centre(rotates with U
theN O
spindle)
K
• Centre connected to the tailstock is called dead
centre(does not rotate, only support the work piece)

ARUN JOSE TOM, MLMCE, BME 29

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 31

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 32

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 6) Feed Mechanism
Movement of tool relative to the work piece is termed as feed

3 Types of Feed
. I N
a) Longitudinal feed: tool is moved parallel to the axis of
ES
rotation of work piece N O T
KTU
b) Cross feed: tool is moved perpendicular to the axis of
rotation of work piece
c) Angular feed: tool is moved at an angle to the axis of rotation
of work piece

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 Specification of Lathe
 Length of bed

 Height of live and dead centers

 Maximum distance between centers

ES . I N
 Range of spindle speed
U N O T
K T
 Power rating of electric motor

 Diameter of lead screw and the number and range of threads

that can be cut

ARUN JOSE TOM, MLMCE, BME 36

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 Knurling Drilling
Thread
Boring
Cutting

Taper ES . I N
N O T Reaming
Turning
KTU
Operations
Turning Performed on a Facing
Lathe

ARUN JOSE TOM, MLMCE, BME 37

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 Operations Performed on a Lathe

• Lathe centres are used for holding the work piece during
turning operation
ES . I N
N O T
KTU
• Chuck is also used for holding and rotating a workpiece.
Chucks are of two types three jaw chuck and four jaw chuck

ARUN JOSE TOM, MLMCE, BME 38

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 39

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 ES . I N
N O T
KTU

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 a) Facing

• Operation of machining the ends of a work piece to obtain

flat surface

E S . I N
• Moving the cutting tool at
U N O T
right angles to the axis of rotation
KTpiece
of the rotating work

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 42

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 ES . I N
N O T
KTU

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 b) Turning

• Removal of material from the periphery of a work piece to

obtain a cylindrical surface

E S . I N
•
U toO
Cutting tool fed parallelN T
the axis of rotation of the work
KT from the rotating work piece
piece, removes material

ARUN JOSE TOM, MLMCE, BME 44

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 45

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 46

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 47

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 ES . I N
N O T
KTU

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 c) Taper Turning

Producing a conical surface by gradual reduction in

diameter from a cylindrical work piece
ES . I N
N O T
KTU

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 Taper Turning - Three methods are used

i) Forming tool method: forming tool is used

ii) Tailstock set over method: shift the axis of rotation of the

ES . I N
work piece at an angle to the lathe axis and feeding the
N O T
tool parallel to the lathe axis
KTU
iii) Compound rest method: rotate the work piece on the
lathe axis and feeding the tool at an angle to the axis of
rotation of the work piece. Tool is mounted on the
compound rest, has a circular base graduated in degrees

ARUN JOSE TOM, MLMCE, BME 50

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 51

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 52

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 Compound rest method

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 53

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 55

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 56

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 ES . I N
N O T
KTU

Tailstock set over method

ARUN JOSE TOM, MLMCE, BME 57
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 d) Thread Cutting

• lead screw is used for the movement of tool

• Lead screw is driven by a set of gears from spindle

E S . I N
• N
Saddle receives its motionO T
from lead screw
KTU
• For each turn of the screw, saddle moves along the bed a
distance equal to the pitch of the lead screw. Tool is held in
the tool post also moves the same distance

ARUN JOSE TOM, MLMCE, BME 58

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 59

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 60

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 ES . I N
N O T
KTU

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 e) Knurling

• Process of roughening a smooth surface of a cylindrical

work piece

E S . I N
• Purpose of knurling is to
N O
get T
grip over the surface
KTU
• Knurling tool is pressed against the revolving workpiece and
is traversed along the length to be knurled

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 64

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 65

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 ES . I N
U N O T
KNURLING K
TOOL T

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 f) Drilling

• Operation of producing a cylindrical hole in a work piece

• Workpiece is held in the chuck and the drill is held in the

ES . I N
tailstock
N O T
KTU
• Drilling is accomplished on a lathe by feeding the stationary
drill into the rotating workpiece

ARUN JOSE TOM, MLMCE, BME 67

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 68

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 69

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 ES . I N
N O T
KTU

DRILL BIT

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 g) Boring

• Enlarging an already existing hole

• A single point cutting tool is traversed through the hole

. I N
O T ES
and parallel to the axis of rotation removes metal and thus
KTU N
increases the diameter of the hole

ARUN JOSE TOM, MLMCE, BME 71

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

BORING TOOL

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 h) Reaming

• Operation of finishing and sizing an already existing hole

• The tool used is called the reamer, which has multiple

cutting edges
ES . I N
U N O T
•
K T
Workpiece is rotated at a very slow speed and a fine feeding
is given to the reamer

• Reamer cannot produce a hole in a solid job. It can

accurately size and finish the already drilled holes

ARUN JOSE TOM, MLMCE, BME 76

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 77

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 ES . I N
N O T
KTU
REAMER

ARUN JOSE TOM, MLMCE, BME 78

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 79

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 ES . I N
N O T
KTU

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 SHAPING MACHINE

• It is used for the production of flat surfaces(horizontal,

vertical or inclined)

• It uses a single point cuttingT E

tool S . I N
T U N O
K
• Tool reciprocates over the work

• It is also used for cutting external and internal slots,

grooves and keyways

ARUN JOSE TOM, MLMCE, BME 81

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 Working Principle

• Work is held in a vice fastened to the work table and the tool
moves forward and backward over the work

. I N
• Material is cut when the single point cutting tool is moving
ES
N O T
in the forward direction(cutting stroke)
KTU
• No material cut takes place during the return stroke(idle
stroke)

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• Horizontal feed is given by moving the table horizontally

• Depth of cut is given by moving the tool vertically

• Forward and return strokes of the tool is obtained by a

N
T ES . I
O
quick return mechanism, time for return stroke is half of
N
KTU
that for forward stroke

ARUN JOSE TOM, MLMCE, BME 83

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 Principal Parts of a Shaper

1) Base
ES . I N
N O T
KTU
It supports the whole machine and is rigidly bolted to the floor

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 2) Column

• It is mounted on the base

• Top of the column is machined to form guide ways for ram

ES . I N
reciprocation
N O T
KTU
• Front vertical face of the column is also machined to enable
the table to be raised or lowered

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 ES . I N
N O T
KTU

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 3) Ram

• It is the reciprocating part of the shaper

• It reciprocates on the guide ways provided on the top of the

column
ES . I N
U N O T
• K T
It carries the tool head at the front end

• Ram is connected to a quick return mechanism which allow

the ram to move at a slower speed during the cutting stroke
and at a faster speed during the return stroke

ARUN JOSE TOM, MLMCE, BME 90

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 4) Tool Head

• Mounted at the front of the ram

• It can be swivelled to any angle to enable the tool to take

ES . I N
angular cuts
N O T
KTU
• Vertical feed to the tool is given by the vertical tool feed
screw

ARUN JOSE TOM, MLMCE, BME 93

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 ES . I N
N O T
KTU

TOOL HEAD

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 ES . I N
N O T
KTU

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 5) Table

• Vice is clamped on the table

• Vice is a device to hold work on the table of the shaper

ES . I N
N O T
KTU
• Elevating screw for vertical movement

• Cross feed screw for horizontal movement

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 Vertical Angular
Shaping Shaping

ES . I N Machining
Horizontal
N O T Irregular
Shaping KTU
Operations Surfaces
Performed On
A Shaper

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 Operations Performed on a Shaper

a) Horizontal Shaping

• Workpiece is fed in horizontal direction under the

ES . I N
reciprocating tool
N O T
KTU
• Depth of cut required is given by lowering the tool post
using a handle
• The tool, as it moves forward removes material from the
work in the form of chips

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 ES . I N
N O T
KTU

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 ES . I N
N O T
KTU

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 b) Vertical Shaping

• Shaping vertical surface on the workpiece

• It is used to cut grooves, keyways…etc on vertical face
• Vertical slide is set at zero position and the apron is swivelled
ES . I N
N O T
by an angle in a direction away from the surface to be
machined KTU
• Tool is fed downwards by operating the downfeed screw of
the tool head

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 ES . I N
N O T
KTU

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 c) Angular Shaping

• Vertical slide of the tool head is swivelled to the required

angle from the vertical position

E S . I N
• N O T
Apron is then further swivelled
U away from the work
KT
• Down feed is given by rotating the downfeed screw

ARUN JOSE TOM, MLMCE, BME 103

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 104

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 105

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 ES . I N
N O T
KTU

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 d) Machining Irregular Surface

Forming tool is used for small irregular surface

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 107

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 SLOTTING MACHINE
• Vertical shaping machine

• Single point cutting tool reciprocates vertically

ES . I N
• Ram holding the tool moves in a vertical axis
U N O T
• K T
Work piece is mounted on the table, is given longitudinal,
cross and rotary feed

ARUN JOSE TOM, MLMCE, BME 108

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 109

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 110

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 ES . I N
N O T
KTU

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 Principal Parts of a Slotter

1) Base(bed)

• Acts as a support for column, driving mechanism, table and

ES . I N
all other fittings
N O T
KTU
• Top of the bed is provided by guide ways on which saddle is
mounted. These guide ways are perpendicular to the
column face

ARUN JOSE TOM, MLMCE, BME 112

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 2) Column

• Vertical member which houses the driving mechanism

E S . I N
•
U N O T
Front vertical face of the column is accurately finished for
providing waysK
T
on which the ram reciprocates

ARUN JOSE TOM, MLMCE, BME 113

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 3) Saddle

• It is mounted on the guide ways of base and may be moved

toward or away from the column

ES . I N
U N O T
• K T
Top face of the saddle is accurately finished to provide guide
ways for the cross-slide. These guide ways are perpendicular
to the guide ways on the base

ARUN JOSE TOM, MLMCE, BME 114

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 4) Cross Slide

Mounted upon the guide ways of the saddle and maybe moved

. I N
parallel to the face of the column to supply cross-feed
ES
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 115

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 5) Rotary Table

• Mounted on the top of the cross slide

. I N
• Table may be rotated manually or by automatic means
ES
N O T
KTU
• Rotary table enables a circular or contoured surface to be
generated on the work piece

ARUN JOSE TOM, MLMCE, BME 116

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 6) Ram

• Moves in vertical direction between the vertical guide-

ways provided in front of the column

ES . I N
N O T
KTU
• Ram supports the tool head to which the tool is attached

• Cutting action takes place during the downward

movement of the ram

ARUN JOSE TOM, MLMCE, BME 117

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Slotting machine is used for

• Cutting grooves
• Key ways
• ES . I N
Rectangular grooves
N O T
• KTU
Slots of various shapes

ARUN JOSE TOM, MLMCE, BME 118

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 PLANER MACHINE
• Used for producing flat surfaces in different planes

• Work piece moves to and fro against the stationary single

point cutting tool ES . I N
N O T
KTU
• Planer machine is used for machining very large work pieces
which cannot be machine in a shaping machine

ARUN JOSE TOM, MLMCE, BME 119

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 120

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 121

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 122

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 Principal Parts of a Planer Machine

1) Bed
• Supports the column and all other moving parts
E S . I N
• Table slides overT U
the N
bedO T
through precision ways
K
• Driving mechanism for the table is provided in hollow
space of bed

ARUN JOSE TOM, MLMCE, BME 123

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 2) Table

• It reciprocates along the ways of the bed and supports

the work
E S . I N
• N
Top surface of the table
U O
is T
provided with slots to clamp
the work piece
KT

ARUN JOSE TOM, MLMCE, BME 124

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 3) Housing/Column

• Vertical structures placed on each side of the bed

• Front vertical surface of the column has guide-ways to

E S . I N
U N O T
enable movement of the cross rail vertically up and down
K T
• Cross rail slides up and down on the housing

• Tool head is placed on the cross rail

ARUN JOSE TOM, MLMCE, BME 125

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 4) Cross Rail

• Mounted on the machined ways of the two housings

ES . N
• It may be raised or lowered on the housings to
I
N O T
KTU
accommodate work of different heights on the table and
to allow for the adjustment of the tools

ARUN JOSE TOM, MLMCE, BME 126

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 5) Tool Head

• Mounted on the cross rail by a saddle

S
• Saddle is used to give cross feed
E . I N
N O T
KTU
• Tool head fed in crosswise or vertical direction

ARUN JOSE TOM, MLMCE, BME 127

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 Shaping Machine Planer Machine

Tool moves and work is Work moves and tool is

stationary stationary

Suitable for small size

machining ES . I N Suitable for large size
N O T
KTU
Tools used are lighter and Tools used are larger, heavier
smaller and stronger

One cutting tool can be used More tools can be used

ARUN JOSE TOM, MLMCE, BME 128

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 DRILLING MACHINE
• Operation of making holes in a work piece by forcing a
rotating tool called drill against it

• Drill – a multi point cutting tool

ES . I N
U N O T
•
K T
Drill is a cylindrical bar with helical grooves cut or formed in
the body of the drill to provide cutting edges and permit
removal of chips and allow the cutting fluid to reach the
cutting edges

ARUN JOSE TOM, MLMCE, BME 129

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 130

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 131

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 Principal Parts of a Drilling Machine

1) Base

ES . I N
Rectangular casting on which the column is mounted
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 132

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 2) Column

• Vertical member of the machine which supports a table

. I N
• Head supporting the motor and spindle is mounted on
ES
N O T
KTU
the top of the column

ARUN JOSE TOM, MLMCE, BME 133

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 3) Table

• Supports the work piece or other work holding device.

• It can be moved up and down on the column

N
T ES . I
N O
KTU
• It can be set in various positions in the horizontal plane

ARUN JOSE TOM, MLMCE, BME 134

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 4) Drill Head

• Mounted on the top of the column and supports the spindle

head and motor
• Spindle head houses drill holding and rotating devices
S . I N
• Hand wheel is provided for upward and downward
E
N O T
KTU
movement of the spindle
• Drill chuck is mounted in the spindle for holding the drill
• Spindle receives power from the motor through belt and
pulley system

ARUN JOSE TOM, MLMCE, BME 135

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 ES . I N
N O T
KTU

DRILL CHUCK & KEY

ARUN JOSE TOM, MLMCE, BME 136

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 137

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DRILL BIT ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 138

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 Counter
Boring Counter
Boring
Sinking

Spot
Reaming
ES . I N Facing
N O T
KTU
Operations
Drilling Performed On A Taping
Drilling Machine

ARUN JOSE TOM, MLMCE, BME 139

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 Operations Performed on a Drilling Machine

a) Drilling

ES . I N
• Operation of producing a circular hole using a drill by
N O T
KTU
removing metal from the work piece
• Drill bit is a multi point cutting tool
• It cuts by applying pressure and rotation of the drill , forms
chips at the cutting edge

ARUN JOSE TOM, MLMCE, BME 140

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 141

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 142

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 b) Reaming

• Operation of finishing and sizing an already existing hole

• The tool use is called the reamer, which has multiple

N
T ES . I
N O
cutting edges
KTU
• This operation removes a very small amount of metal
from the drilled hole

ARUN JOSE TOM, MLMCE, BME 143

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 144

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 ES . I N
N O T
KTU
REAMER

ARUN JOSE TOM, MLMCE, BME 145

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 146

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 c) Boring

• Enlarging an already existing hole by means of an

adjustable single point tool

E S . I N
• U N O T
K T
Single point tool traversed through the hole and parallel
to the axis of the rotation removes metal and thus
increases the diameter of the hole

ARUN JOSE TOM, MLMCE, BME 147

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 148

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BORING TOOL

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 149

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 150

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 d) Counter Boring

Operation of increasing the diameter of a hole for a certain

distance down
ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 151

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 152

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 153

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 154

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 COUNTER BORING TOOL

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 155

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 e) Counter Sinking

Operation by which a cone shaped enlargement is made at

the end of a hole
ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 156

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 157

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 158

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 ES . I N
N O T
KTU

COUNTER SINKING TOOL

ARUN JOSE TOM, MLMCE, BME 159

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 f) Spot Facing

• Operation of smoothening and squaring the surface

. I
around a hole drilled in a rough surface
ES N
N O T
KTU
• It provides a flat seating for nut and washer

ARUN JOSE TOM, MLMCE, BME 160

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 161

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 162

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 ES . I N
N O T
KTU

SPOT FACING TOOL

ARUN JOSE TOM, MLMCE, BME 163

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 g) Taping

• Operation of cutting internal threads in a drilled hole by

means of a tool called tap
ES . I N
N O T
KTU
• Tap cuts a thread on the inside surface of a hole

ARUN JOSE TOM, MLMCE, BME 164

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 165

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 166

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 ES . I N
N O T
TAP KTU

ARUN JOSE TOM, MLMCE, BME 167

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 MILLING MACHINE

• Process of removal of metal by feeding the work piece

against rotating multi-point cutter

E S . I N
• U
As the cutter rotates, N
eachO T
cutting edge removes small
K T
amount of material from the work piece

ARUN JOSE TOM, MLMCE, BME 168

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 ES . I N MILLING CUTTER
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 169

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 Principle Of Operation

• Based on the direction of the cutter motion and work piece

feed, milling can be classified into two
• Conventional milling or Up milling
• Climb milling or Down milling
ES . I N
N O T
KTU
• Based on spindle position milling can be classified into two
• Horizontal milling machine
• Vertical milling machine

ARUN JOSE TOM, MLMCE, BME 170

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 Conventional Milling or Up Milling

• Work piece is fed in the opposite direction of that of the

rotating cutter

S . I N
• Chip thickness varies from minimum at the start of cut to a
E
N O T
KTU
maximum at the end of cut

• Load on each cutting edge is gradually increased

• Cutter tends to lift the work piece from the table

• Poor surface finish

ARUN JOSE TOM, MLMCE, BME 171

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 172

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 Climb Milling or Down Milling

• Work piece is fed in the same direction of that of the

rotating cutter
• Chip thickness varies from a maximum at the start of cut to a
minimum at the end of cut OTES . I N
K T U N
• Cutter forcing the work piece towards the table
• Down milling produce higher surface finish, because the
cutting pressure keeps the work piece firmly pressed against
the table

ARUN JOSE TOM, MLMCE, BME 173

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 174

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 175

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 176

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 177

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Horizontal Milling Machine

Spindle axis is kept S . I N

horizontal
U N O TE
KT

ARUN JOSE TOM, MLMCE, BME 178

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 179

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 180

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 Principal Parts

1) Base
• Foundation for all other parts of the milling machine
ES . I N
N O T
KTU
• Gives the machine the required strength and rigidity

ARUN JOSE TOM, MLMCE, BME 181

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 2) Column

• Main supporting frame mounted vertically on the base

• Front face of the column has vertical guide ways

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 182

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 3) Knee

• Slides up and down on the vertical guide ways of the column

• It has horizontal guide ways on its top surface

ES . I N
• O
It supports saddle and table
U N T
K T
• Elevating screw for adjusting the height of the knee

ARUN JOSE TOM, MLMCE, BME 183

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 4) Saddle

• It supports and carries the table

ES . N
• It is adjustable on guide ways on the top of the knee
I
N O T
KTU
• Horizontal movement

ARUN JOSE TOM, MLMCE, BME 184

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 5) Table

• It rests on guide ways on the saddle

• It can be moved longitudinally, perpendicular to the

ES . I N
motion of saddle
N O T
K TU
• It supports the work piece

ARUN JOSE TOM, MLMCE, BME 185

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 6) Elevating Screw

• Height of the knee is adjusted by elevating screw

ES . I N
• N
It also supports the knee
U O T
K T

ARUN JOSE TOM, MLMCE, BME 186

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 7) Spindle

• It obtains power from the motor and transmits it to an arbor

S . I N
• Spindle has a tapered socket for inserting the arbor
E
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 187

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 8) Overarm

• Mounted on the top of the column

• Overarm support provided at the free end of overarm can be

E S . I N
N O T
moved horizontally on the guide ways provided at the bottom
KTU
surface of the overarm

ARUN JOSE TOM, MLMCE, BME 188

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 9) Arbor

• Rod on which cutter is mounted

• It is tapered at one end to fit into the spindle

E S . I N
• O T
Other end of the arbor is mounted
U N in a bearing provided in
K T
the overarm support

ARUN JOSE TOM, MLMCE, BME 189

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 190

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 Vertical Milling Machine

Spindle axis is kept vertical

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 191

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 192

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 193

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 Principal parts

1) Base
• Foundation for all other parts of the milling machine
I N
T ES .
T U N O
• K
Gives the machine the required strength and rigidity

ARUN JOSE TOM, MLMCE, BME 194

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 2) Column

• Main supporting frame mounted vertically on the base

• Front face of the column has vertical guide ways

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 195

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 3) Knee

• Slides up and down on the vertical guide ways of the column

• It has horizontal guide ways on its top surface

ES . I N
• O
It supports saddle and table
U N T
K T
• Elevating screw for adjusting the height of the knee

ARUN JOSE TOM, MLMCE, BME 196

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 4) Saddle

• It supports and carries the table

ES . N
• It is adjustable on guide ways on the top of the knee
I
N O T
KTU
• Horizontal movement

ARUN JOSE TOM, MLMCE, BME 197

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 5) Table

• It rests on guide ways on the saddle

• It can be moved longitudinally, perpendicular to the

ES . I N
motion of saddle
N O T
K TU
• It supports the work piece

ARUN JOSE TOM, MLMCE, BME 198

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 7) Spindle Head

• It is mounted on the top of the column

• It has a swivel base and hence the spindle head can be

E S . I N
N
swiveled at an angle for
U O T
machining angular surfaces
KT

ARUN JOSE TOM, MLMCE, BME 199

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 9) Arbor

• Rod on which cutter is mounted

• It is tapered at one end to fit into the spindle

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 200

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 201

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 End T-slot
milling milling
Side Angular
milling milling

Face Form
milling ES . I N milling
N O T
KTU
Slab or
Milling Gear
plain
operations cutting
milling

ARUN JOSE TOM, MLMCE, BME 202

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 Milling Operations

a) Slab or Plain Milling

S . I N
• Production of flat surfaces with the milling cutter axis
E
N O T
KTU
parallel to the surface being milled

• Flat surfaces may be milled with a plain milling cutter

mounted on the arbor

ARUN JOSE TOM, MLMCE, BME 203

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 204

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 205

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 ES . I N
N O T
KTU
PLAIN MILLING
CUTTER

ARUN JOSE TOM, MLMCE, BME 206

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 b) Face Milling

• Flat surface perpendicular to the axis of cutter is

produced

ES . I N
• Cutter is mounted on a spindle having an axis of rotation
N O T
KTU
perpendicular to the work piece surface

• Face milling cutter is used

ARUN JOSE TOM, MLMCE, BME 207

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 208

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 FACE MILLING CUTTER

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 209

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 c) Side Milling

• Flat vertical face is produced at the side of a work piece

• Side milling cutter is used ES . I N

N O T
KTU

ARUN JOSE TOM, MLMCE, BME 210

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 ES . I N
N O T
KTU

SIDE MILLING CUTTER

ARUN JOSE TOM, MLMCE, BME 211

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 212

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 d) End Milling

• Cutter generally rotates on an axis vertical to the work piece

• End milling cutter has cutting edges on the periphery of a

ES . I N
N O T
shank, these cutters are the most common tool used in a
vertical milling KTU
• It is used for producing slots, grooves, keyways etc

ARUN JOSE TOM, MLMCE, BME 213

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 214

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 215

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 END MILLING CUTTER
ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 216

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 ES . I N
U N O T
K T
END MILLING CUTTER

ARUN JOSE TOM, MLMCE, BME 217

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 e) T-slot Milling

• T-slot cutter is used

• First of all a plain slot is cut on the work piece using an end
ES . I N
N O T
milling cutter. Then the T-slot cutter is fed from one end of
the work piece KTU
• Neck portion of the cutter passes through the already milled
plain slot

ARUN JOSE TOM, MLMCE, BME 218

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 219

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 220

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 221

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 T –SLOT CUTTER

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 222

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 f) Angular Milling

• Process in which angular surface are produced on a work

piece

• Angle milling cutter is used ES . I N

N O T
KTU
• Usual angle of the cutter is 45⁰, 50⁰, 55⁰ or 60⁰

• Eg. Milling dovetails

ARUN JOSE TOM, MLMCE, BME 223

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 224

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 ES . I N
N O T
KTU
ANGLE MILLING CUTTER

ARUN JOSE TOM, MLMCE, BME 225

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 226

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 227

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 g) Form Milling

• Process by which profiles on the work piece are produced

• Form milling cutter is used

ES . I N
N O T
KTU
• Shape of form milling cutter corresponds to the profile of the
surface to be produced

ARUN JOSE TOM, MLMCE, BME 228

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 229

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 ES . I N
N O T
KTU

FORM MILLING CUTTER

ARUN JOSE TOM, MLMCE, BME 230

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 h) Gear Cutting

• Process by which gears are produced using gear cutters

• Profile of the cutter corresponds to the tooth space of the

ES . I N
gear
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 231

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 232

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 233

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 234

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 235

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 ES . I N
N O T
KTU

GEAR CUTTER

ARUN JOSE TOM, MLMCE, BME 236

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 Specification of Milling Machine

• The dimension of table

• Maximum length of vertical and horizontal movement of
knee and saddle
. I
• Number of different speeds of spindle
ES N
N O T
KTU
• Power of electric motor
• Floor space required
• Net weight

ARUN JOSE TOM, MLMCE, BME 237

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 Grinding Machine

Process of metal removal in which the cutting tool used is an

abrasive wheel
ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 238

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 Purpose for grinding

 Remove small amount of metal from the work piece to bring

its dimension within very close tolerance of the size desired

 Obtain better finish on the surface

ES . I N
N O T
K TU
 Sharpen the cutting tool

 Machine hard surfaces which are otherwise difficult to be

machined by other means

ARUN JOSE TOM, MLMCE, BME 239

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 Grinding Wheels

• These are made of abrasive particles bonded together by

some suitable bond

• Natural abrasive particles: sand stone, emery, diamond…etc

N
T ES . I
T U N O
• K
Artificial abrasive particles: silicone carbide, aluminium oxide
and boron

ARUN JOSE TOM, MLMCE, BME 240

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 GRINDING WHEEL

ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 241

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 ES . I N
N O T
KTU
DIAMOND GRINDING
WHEEL

ARUN JOSE TOM, MLMCE, BME 242

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 Surface
Grinding

Cylindrical Form
Grinding . I N Grinding
O T ES
KTU N
Types Of
Grinding

ARUN JOSE TOM, MLMCE, BME 243

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 Types of Grinding

1) Cylindrical Grinding

• Produces cylindrical surface on a work piece

E S . I N
• U N
Work piece is rotated about O T
its axis and is traversed across the
face of a rotatingK
T
abrasive wheel

• Both tool and work piece are rotated by separate motors and
at different speeds

ARUN JOSE TOM, MLMCE, BME 244

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 245

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 246

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 2) Surface Grinding

• It produces flat surfaces

• Grinding wheel can be fed downward in very small increments

into a work piece, which is moved to the left and the right and
in and out ES . I N
N O T
KTU
• Work is traversed under the revolving grinding wheel

• This allows the wheel to contact all areas of the surface of the
work piece

ARUN JOSE TOM, MLMCE, BME 247

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 248

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 249

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 250

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 251

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 3) Form Grinding

• Produces formed surfaces on a revolving cylindrical work

piece

E S . I N
• U
Grinding wheel hasTthe N O T
exact shape of the final product
K

ARUN JOSE TOM, MLMCE, BME 252

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 253

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 254

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 255

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 ES . I N
N O T
KTU

FORM GRINDING TOOL

ARUN JOSE TOM, MLMCE, BME 256
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 Tool and cutter
Surface grinding grinding
machine machine

Cylindrical ES . I N Internal
N O T
grinding KTU grinding
machine Types of machine
grinding
machines

ARUN JOSE TOM, MLMCE, BME 257

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 1. Surface Grinding Machine

• Produce finish and flat surface

• It consists of a base, table, column and wheel head

ES . I N
• Spindle is horizontal
N O T
K TU
• Wheel head can be raised or lowered with the grinding
wheel

• Table can be moved along the ways

ARUN JOSE TOM, MLMCE, BME 258

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 259

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 260

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2. Cylindrical Grinding Machine

Two types

S . I N
• Centre Type Grinding Machine
E
N O T
KTU
• Centreless Type Grinding Machine

ARUN JOSE TOM, MLMCE, BME 261

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 a) Centre Type Grinding Machine

• It consists of a bed, wheel head, headstock and a tailstock

• Work piece is supported in between the centres

S . I N
• Wheel head is located backO theEheadstock and tailstock
of T
K T U N
• Grinding wheel is driven by a motor

• Table on which the headstock and tailstock are mounted can

be moved to and fro in the bed guide ways

ARUN JOSE TOM, MLMCE, BME 262

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 263

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 264

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 b) Centreless Type Grinding Machine

• Work is supported and fed to the grinding wheel on a knife

edge support
• It consists of a bed, wheel head, regulating wheel and a work
rest blade
ES . I N
N O T
KTU
• Work is supported on the work rest and is backed up by
regulating wheel
• Regulating wheel controls the speed of rotation of the work
piece and also the rate of feeding of the work piece past the
grinding wheel

ARUN JOSE TOM, MLMCE, BME 265

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 266

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 267

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 268

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 269

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 270

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 3. Tool and Cutter Grinding Machines

• Used for sharpening of tools and cutter

ES . I N
• These machines hold the cutter while a rotating abrasive
N O T
KTU
wheel is applied to the edges for the purpose of sharpening it

ARUN JOSE TOM, MLMCE, BME 271

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 272

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 273

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 274

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 Automation

• Automatically controlled operation of an apparatus, process,

or system by mechanical or electronic devices that take the
place of human organs of observation, effort and decision

Types of automation ES . I N
N O T
KTU
• Numerically controlled(NC) equipment
• Computer numerical control(CNC)
• Direct numerical control(DNC)
• Computer-Aided manufacturing(CAM)
• Computer integrated manufacturing(CIM)

ARUN JOSE TOM, MLMCE, BME 275

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 276

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 NUMERICAL CONTROL

• Control of a machine tool by means of recorded information

on punched tape or cards
• It is a method of automation in which various functions of
machine tools are controlled by letters, numbers and symbols
ES . I N
• System automatically interprets these data and converts
N O T
KTU
them to output signals, which, in turn control various
machine components
• Functions carried out by an operator in a conventional
machine are translated into instructions that can be
understood by a MACHINE CONTROL UNIT(MCU).

ARUN JOSE TOM, MLMCE, BME 277

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• The MCU translates it into electrical signals. These signals
operate a servo system which controls the motion of tool,
work piece and the related auxiliaries

It consists of 3 basic components

• Program of instructions
ES . I N
N O T
KTU
• Machine Control Unit(MCU)
• Processing equipment

ARUN JOSE TOM, MLMCE, BME 278

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 279

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 280

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 281

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 282

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• Program of instructions: detailed step by step commands that
directs the actions of the processing equipment. Co-ordinate
information(x, y and z movements required for work and tool)
regarding the component is recorded on a tape and is fed to
the control unit

S . I N
• MCU: it consists of tape reader, data buffer, signal output
E
N O T
KTU
channels, sequence control and related control hardware that
stores the program of instruction. Control unit convert the
commands into electric signals and these signals are sent to
processing equipment(machine tool)

• Processing equipment: performs useful work with the help of

a servo system
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• Feed back transducer is provided to check the positions
achieved and to send signals to the control unit for position
correction

In NC machine tools one or more of the following functions

may be automatic
• ES . I N
N O T
Starting and stopping of machine tool spindle
• KTU
Controlling the spindle speed
• Controlling the rate of movement of the tool tip(feed rate)
• Changing of tools in the spindle
• Positioning the tool tip at desired locations and guiding it
along desired paths

ARUN JOSE TOM, MLMCE, BME 284

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Advantages
• Greater accuracy
• Lower scrap rates
• More – complex part geometries are possible
• Less floor space is required
• Operator skill level requirements are less
ES . I N
• Higher production rate
N O T
KTU
Disadvantages
• Higher investment cost
• Higher maintenance effort

ARUN JOSE TOM, MLMCE, BME 285

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 CNC MACHINES

• A computer is used to prepare and control the operations of

the machine tool
• CNC refers to a computer that is joined to the NC machine
• The program is entered into the computer through a keyboard
ES .
or disc or tape and stored in its memoryI N
N O T
KTU
• Whenever the part is to be machined, the program is called
from its memory
• Also, if it is required to have a change in any dimension, the
program can be called and edited to incorporate the
changes(not possible in a NC machine). This eliminates the
repeated use of tape

ARUN JOSE TOM, MLMCE, BME 286

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 287

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 288

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Advantages
• High accuracy in machining
• Storage of more than one program
• Program can be edited
• Short production time
• Greater manufacturing flexibility
ES . I N
N O T
KTU
• Better quality control
• Repeatability of accuracy is possible
Disadvantages
• High cost
• Requirement of skilled programmer

ARUN JOSE TOM, MLMCE, BME 289

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 ES . I N
N O T
KTU

CNC LATHE MACHINE

ARUN JOSE TOM, MLMCE, BME 290
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 ES . I N
N O T
KTU

CNC MILLING MACHINE

ARUN JOSE TOM, MLMCE, BME 291

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 DNC

• In Direct Numerical Control(DNC) system, a number of

machine tools are controlled by a single computer

E S . I N
• N O
The program was transmitted
U T
to the MCU directly from the
KTof instructions at a time
computer, one block

• Central computer also received data back from the machines

ARUN JOSE TOM, MLMCE, BME 292

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 ES . I N
N O T
KTU

ARUN JOSE TOM, MLMCE, BME 293

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