Professional Documents
Culture Documents
Production Technology
Production Technology
Angular Velocity : Of a rotating body is the distance covered per second by a point lying
at a distance of one meter from the axis of rotation, along the periphery of circle of 1
meter radius and having its centre along the axis of rotation.
Machine tools produce the required shape by performing some metal removing
operation on the raw material. For this the machine tools
1. Machine Bed frame and Structure : This houses and supports other parts. Some
are in motion and others are fixed. this provides stability.
2. Slide ways and Slide : They are attached to the top of bed and guide the slides.
The movement of slides should be accurate. The different types are flat, vee,
dovetail, cylindrical and combined.
3. Spindles and Bearings : Spindles are provided to ensure that the position of axis
or rotation is within line. Members that rotate the work piece and cutters are
called spindles. These spindles are shaft mounted on bearings. The spindles must
be rigid and must have rotational accuracy.
4. Machine tool drives : electric motor is the power unit and the power from motor
reaches the work piece or cutter through belts, gears, chains and pulley.
Cutting speed : It is the distance traveled by work surface related to the cutting edge of
Tool
Depth of cut (t) : It is measured perpendicular to axis of work piece and in straight
turning in one pass. This can be estimated from the relation
t = ( D - d ) / 2 mm
Undeformed chip (Fc) : The cross sectional area of chip before it is removed from work
piece. it is equal to the product of feed and depth of cut.
Fc = s x t mm2
All tools have a major and minor cutting edge. The major cutting edge removes
bulk of material. Where as the minor cutting edge gives good surface finish.
1. Axial force
2. Tangential force and
3. Radial force.
Wattmeter is a indirect method for measuring cutting force. More exact method is
the use of dynamometer. Of the total heat generated during machining process, given
below is the rough heat distribution.
Tool life :
• Tool life
• mm3 of stock removed
Metal Sawing : This machine is used to produce work piece of desired length.
Following are the different sawing machines.
3. Circular saw ( Cold saw, Steel friction disk and Abrasive disk )
1. Head stock,
2. Tail stock,
3. live centre,
4. dead centre,
5. apron,
6. cross slide
8. Tool post.
A lathe is specified by
• Length of bed,
• width of bed,
• Speed lathe,
• Engine lathe,
• Special lathe
• Automatic lathe,
• Bench lathe,
• Turret lathe.
Machining time :
• L - Length of cut.
• f - feed in mm / rev
Shaping operations :
3. Hydraulic mechanism.
Cutting speed : On a shaper may be defined as the average speed of tool during the
cutting stroke and primarily depends on number of strokes / min and length of stroke.
L - length of stroke
N - Number of strokes / min.
Distance moved per minute = LN.
Machining is done during cutting stroke and return stroke is a idle stroke.
Cutting stroke / Return stroke = 3 / 2
Cutting time / Total time = 3 / 5.
Thus actual time to cut LN metres is 3 / 5 min and not 1 minute. Hence in one
minute the tool cuts 5 / 3 LN metres.
Planners : These are similar to shaping machines, but the tool is stationer and the work
piece slides back and forth. The following are the different types of planers.
SHAPER PLANNER
Drilling Machines :
The characteristics of drilling that set it apart from other powered metal cutting
operations are:
• The chips must exit out of the hole created by the cutting.
• Chip exit can cause problems when chips are large and/or continuous.
• The drill can wander upon entrance and for deep holes.
• For deep holes in large work pieces, coolant may need to be delivered through the
drill shaft to the cutting front.
• Of the powered metal cutting processes, drilling on a drill press is the most likely
to be performed by someone who is not a machinist.
Reaming : This uses a multipoint cutting tool. Cannot produce holes but produces
accurate size and good finish. Reaming is a process which slightly enlarges a pre-
existing hole to a tightly toleranced diameter. A reamer is similar to a mill bit in that it
has several cutting edges arranged around a central shaft, as shown below. Because of the
delicate nature of the operation and since little material is removed, reaming can be done
by hand. Reaming is most accurate for axially symmetric parts produced and reamed on a
lathe.
Reamed holes should not intersect with drilled holes, so the configuration below should
NOT be implemented
Boring : This operation, enlarges a existing hole and finishes it. Used when a drill of a
particular size is not available. Adjustable boring head eliminate the need for a complete
inventory of expensive large size drills.
Counter boring : Where as boring enlarges for a entire length of hole, counter boring
does not.
Counter sinking : Bevels the mouth of hole with a tool called counter sink.
• Machine vice,
• V- Block,
• T bolts,
• Strap clamps,
• Step blocks and
• Angle plate.
Broaching :
It is very similar to shaper but uses a multipoint cutting tool, as it has many teeth.
Each successive tooth has a greater cutting edge. Each tooth removes a predetermined
quantity of material.
Welding :
It is the process of joining different metals. Various welding and allied process
are classified below.
1. Gas Welding
• Air acetylene
• Oxy acetylene
• Oxy hydrogen
• Pressure gas welding.
2. Arc welding
• Carbon arc welding and
• Shielded metal arc welding.
Oxy-Acetylene Welding :
It is a arc welding process done by heating the work piece by striking a arc
between the electrode and work piece. The arc melts the electrode and job and molten
metal is transferred from electrode to work piece. The flux coating melts and forms a
gaseous shield and slag to prevent atmospheric contamination of molten metal.
In this instead of a flux coated electrode, granular flux and base electrode is used.
The job remain submerged under the flux. The flux serves a shield and protects the
molten metals from contamination.
It is a arc welding process done by heating the job within a electric act struck
between tungsten electrode and job. A gas shield namely helium or Argon is used to
avoid atmospheric contamination of welding pool.
It is done by striking a arc between a continuously fed metal electrode and the
job. No flux is used by t he act and molten metal is protected by helium or Argon.
In this arc is circulated between tungsten electrode and water cooled nozzle. Two
inert gases are used. One of them produces the plasma arc and the second acts as a
shield. In this there are two types.
1. Non-transfer arc process: In this arc is produced between nozzle and tungsten
electrode. Work piece does not form part of electrical circuit.
2. Transfer arc process : This is a arc between tungsten electrode and work piece.
Resistance Welding :
In this the join is produced b using the resistance of the work piece for the flow of
current and by application of pressure. No filler metal is required.
Spot welding :
Cold Welding :
Ultrasonic Welding :
In this a high frequency vibratory energy is applied on work piece. The work
piece is held in a interface. The combine effect of pressure and vibration causes
movement of metal molecules and this creates a sound bonding. This completed in 0.5 -
1.5 seconds.
The work piece are rotated and suddenly pressure is applied and both pieces get
welded, Because of the high heat generated.
Atomic-Hydrogen Welding :
Brazing :
The melting point of the filler material is below 427o C. The melting point of
filler material used in brazing is above 427o C.
Last updated on ,