Production Engineering and Production Technology

Department

COURSE NAME: Production Technology

YEAR: Engineering Prep
RESEARCH TITLE: 5 traditional cutting machines

Asst. Prof. Abou bakr elshalakan

Submitted By:

Students code Students e-mail Participation

rate%

1901048 ME‐1901048.Shrouk@akhbaracademy.edu.eg 25%

1901003 ME‐1901003.Dina@akhbaracademy.edu.eg 25%
1901005 ME‐1901005.Menna@akhbaracademy.edu.eg 25%
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Akhbar El-yuom Academy 2019\2020

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 Introduction

Machining is one of many processes where a piece of raw material is cut

down to a desired final shape and scale via a controlled material-
removal process. Processes with this general theme, controlled material
removal, are more generally referred to as subtractive manufacturing, as
opposed to controlled material addition processes, known as additive
manufacturing. It can vary exactly what the "restricted" aspect of the
term implies, but it almost always implies the use of machine tools
(apart from power tools and hand tools). Machining is part of the
production of many metal products, but it can also be used in materials
like wood, plastics , ceramics and composites.

A person specializing in machine making is called a machinist. A room,

house, or firm is called a machine shop where the machining is
performed. Most modern machining is done by CNC, where computers
are used to monitor the movement and function of turbines, lathes and
other cutting machines.

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Turning

Turning is a process of machining in which a cutting tool, typically a non-

rotary tool bit, describes a helix tool path by moving more or less linearly
while the workpiece rotations.

Turning operations
Turning

The general turning method involves rotating a part by shifting a single-

point cutting tool parallel to the rotation axis Turning can be performed
both on the outer surface of the part and on the internal surface (the
process known as boring). In general, the starting material is a workpiece
created by other processes such as casting, forging, extruding or
drawing.

Tapered turning
Tapered turning produces a cylindrical shape which decreases gradually
in diameter from one end to the other. This can be done by using a)
from the compound slide b) from the taper turning attachment c) using

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a hydraulic copy attachment d) using a C.N.C. lathe e) using a shape
device f) by offsetting the tailstock-this approach is more suitable for
shallow tapers

Spherical generation
Spherical generation produces a finished spherical surface by
transforming a form around a fixed axis of revolution. Methods include
(a) the use of hydraulic copy attachment (b) C.N.C. (computerized
numerically controlled) lathe (c) the use of a form tool (raw and ready
method) (d) the use of bed jig (need to explain the drawing)

Hard turning
Hard turning is a type of turning carried out on materials with a hardness
of Rockwell C greater than 45. It is typically executed after heat
treatment of the workpiece. The method is for replacing or reducing
conventional grinding operations. Fast turning, when applied for
removal purposes solely from stock, competes favorably with rough
grinding. Nevertheless, grinding is superior when applied for finishing
where shape and dimension are important. Grinding produces
roundness and cylindricity with higher dimensional precision.
Additionally, Rz=0.3-0.8z polished surface finishes can't be achieved with
hard turning alone. Difficult turn is Suitable for parts requiring 0.5-12
micrometer roundness, and/or Rz 0.8–7.0 micrometer surface
roughness. Among other applications it is used for gears, injection pump
parts, and hydraulic components

Facing

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Facing in turning work requires placing the cutting tool at the right
angles to the axis of rotation of the rotating workpiece. This can be
achieved by cross-slide action, if mounted, as distinct from the
longitudinal feed (turn). This is often the first procedure carried out in
the creation of the workpiece, and often the last-hence the term "end
up."

Parting
This process, also known as partitioning off or cutoff, is used to create
deep grooves that remove a completed or partially complete component
from the parent stock.

Grooving

External grooving, Face grooving

Grooving is like slicing, except that grooves are cut to a particular depth
rather than removing a completed / part-complete portion from the
stock. Grooving can be performed on both internal and external
surfaces, as well as on the part's lip (lip grooving or trepidation).
Operations which are not specific include:

Boring

Extension or smoothing of an existing hole created through drilling,

moulding etc.i.e. Machining (generating) internal cylindrical shapes (a)
by mounting the workpiece to the spindle via a chuck or faceplate (b) by
mounting the workpiece onto the cross slide and placing the cutting tool
in the chuck. This job suits castings that are too difficult to place on the
face plate. Large workpiece can be bolted on long bed lathes to a fixture
on the bed and a shaft passed onto the workpiece between two lugs and

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these lugs can be bored out to size. A restricted application but one that
the professional turner / machinist is able to use.

Drilling

Is used for extracting material from a workpiece's inside. This process

uses standard drill bits which are held stationary in the lathe tail stock or
tool turret. The method can be performed by drilling machines which
are available separately.

Knurling

Cutting a serrated pattern onto a part 's surface to be used as a hand

grip or as a visual enhancement using a special purpose knurling
instrument.

Reaming

The sizing operation which removes a small amount of metal from an

already drilled hole.It is done to make very precise diameters of internal
holes. For example, by drilling with a drill bit of 5.98 mm a 6 mm hole is
made and then reamed to precision dimensions.

Threading

Using the appropriate cutting tool, both standard and non-standard

screw threads can be turned onto a lathe. (Usually having a nose angle
of 60, or 55 °) Either externally or within a bore. This is generally referred
to as a single point thread. Tapping of threaded nuts and holes (a) using
hand taps and tailstock core (b) using a slipping clutch tapping tool to
reduce the possibility of tap breakag . Threading operations include a)all
types of external and internal thread shapes, including single-point
threads, double-start threads, multi-start threads, worms used in worm
wheel reduction boxes, single- or multi-start thread leadscrews. B) by
using threading boxes fitted with 4 shape tools, with threads up to 2 "in
diameter but larger boxes can be found than this

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Polygonal turning

In which non-circular forms are machined without the rotation of the

raw material being interrupted.

Tooling
Main article: Tool bit

The different angles, shapes , and sizes of a single-point cutting tool

have a direct relation to a workpiece 's resulting surface in machining
operations. Different angle types, such as rake angle, side rake angle,
cutting-edge angle, relief angle, nose radius, may exist, and may differ
from the workpiece. There are also many forms of single-point cutting
tools, like V-shaped and Square. A special toolholder is usually used to
keep the cutting tool securely during operation.

Workholding methods
.Chuck: Chucks is a very traditional form of workholding. Several forms
exist, some for round and square stock and others for irregular shapes.

.Collet: It is used mainly for small round workpieces.

.Faceplate: To transform workpieces such as gear blanks, a faceplate,

drive dog, and mandrel can be used.

.Centers: Pointed cones, often driven by a 'dog' between which the part
spins. May be used to turn the shafts and cylinders longer.

.Drive center: Use hydraulic or spring-loaded teeth that "bite" into the
end of workpieces and can be used when machining the whole length of
the workpiece.

Drilling

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Working Principle of Drilling Machine:
The spindle rotates when the power is given to the motor, and thus the
stepped pulley attached to it rotates as well. On the other end, another
stepped pulley is attached, which is inverted in order to increase or
decrease the rotational motion speed. Now, a V-belt is placed in
between the stepped pulleys to drive the transmission of power. Instead
of a flat belt, here a V-belt is used to increase the power efficiency. Now
the drill bit is also rotating which was placed in the chuck and which was
related to the spindle. The spindle often rotates as the Pulleys rotates
which will rotate the drill bit. Now, by hand-wheel rotation, the spindle
is moving up and down in Component that was placed in the vice
machine.

Spot drilling

Spot drilling is intended to dig a hole which will serve as a guide to

drilling the final hole. The hole is only drilled part way into the workpiece
as it is used only to guide the start of the next drilling process.

Center drilling

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Center drill is a two-floated tool consisting of a 60 ° countersink twist
drill; used for drilling countersink center holes in a workpiece to be
mounted between turning or grinding centres.

Deep hole drilling

Deep hole drilling is characterized as drilling a depth hole greater than 10

times the hole diameter.These types of holes require special equipment to
maintain straightness and tolerances. Roundness and surface finish are
another considerations. Deep hole drilling is typically possible with a few
tooling methods , usually with gun drilling or with BTA drilling. These
are distinguished by method of coolant entry (internal or external) and
method of chip removal (internal or external).Use of Methods such as
rotating tools and counter-rotating workpieces are common techniques for
achieving the required straightness tolerances.[4] Secondary tooling
methods include treading, skiving and burning, pulling boring, or
bottling. Finally, there is a new kind of drilling technology available to
deal with this problem: vibration drilling. This technology breaks up the
chips with a small axial vibration controlled by the drill. The little chips
are easily removed through the drill's flutes. For the control of force ,
torque, vibrations and acoustic emissions, a high tech monitoring system
is used. Vibration in deep hole drilling is considered a major defect that
can often cause the drill to break. A Coolant Special is usually used to aid
in this type of drilling.

HOLDING WORK AND DRILLING DEVICES

Work-holding devices are used to keep the work steady for a precise hole
to be drilled, so a safe drilling operation can be performed. Drilling
support tools are used to keep the workpiece above the worktable or to
keep the surface aligned to drill. Some tools are relatively easy and do not
need a perfect hole for drilling operations. Many instruments are very
complex and are designed to drill more accurately. Many work-holding
devices are used together to create the most stable drilling work-setup.

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Milling machine

In the phase cycle a number of operations can be performed on the

workpiece to produce the part's desired shape. The following operations
are each specified by the type of cutter used, and the direction of the
cutter to extract material from the piece of work.

Operations
End milling-To machine a defined element, such as a profile, slot, pocket
or even a complex surface contour, either peripheral or slot cut across the
workpiece, determined by the step-over width. The characteristic depth
can be machined in a single pass or can be achieved by machining at a
smaller axial cutting depth and several passes are made.

Chamfer milling-A chamfer end mill creates a peripheral cut along the
edge of the workpiece or a characteristic to produce an angled surface,
known as a chamfer. This chamfer, typically with an angle of 45 degrees,
can be machined either on the outside or inside of a part, and can either
follow a straight or curved path.

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Face milling-A face milling machines a flat workpiece surface to provide
a smooth finish. The face depth, usually very high, can be machined in a
single pass, or can be reached by machining at a smaller cutting axial
depth and making several passes.

Drilling-A drill enters axially into the workpiece and cuts a hole with a
diameter equal to that of the instrument. A drilling operation may create a
blind hole that extends into the workpiece to some depth, or a through
hole that extends through the workpiece entirely.

Boring-A boring tool axially enters the workpiece and cuts to form
different features along an inner surface. The boring tool is a single-point
cutting tool which can be set by means of an adjustable boring head to cut
the desired diameter. After drilling a hole, boring is commonly performed
to enlarge the diameter or get more precise dimensions.

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Against-A counterbore tool axially approaches the workpiece and
stretches the top portion of an existing hole to the tool 's diameter. After
drilling, counterboring is often done to provide space for a fastener 's
head, such as a bolt, to sit beneath the surface of a part. The counter-tool
has a pilot at the end to guide it into the existing hole straight away.

Countersink-A counter-sink tool axially enters the workpiece and extends

the top portion of an existing hole to a cone-shaped opening. After
drilling, countersinking is often done to provide space for a fastener 's
head, such as a screw, to sit flush with the surface of the workpiece.
Common inclusive angles include 60, 82, 90, 100, 118 and 120 degrees

for a countersink.

Reaming-A reamer enters axially into the workpiece and enlarges an

existing hole to the tool diameter. Reaming removes a small amount of
material and is mostly performed after drilling to achieve both a more
precise diameter and a cleaner interior finish.

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 Tapping-A tap axially penetrates the workpiece and cuts internal threads
into an existing hole. Usually, the existing hole is drilled by the correct
tap drill size which will fit the tap you want. Threads can be cut inside the
hole to a specified depth (bottom tap) or to the complete depth of a
through hole (through tap).

Tooling
The tool needed for milling is a sharp cutter which the spindle must
rotate. The cutter is a cylindrical device spaced around the top, with sharp
teeth. The gaps between the teeth are called flutes and allow the chips of
material to travel away from the piece of work. The teeth may be direct
along the cutter 's side, but are more commonly arranged in a helix. The
angle of the helix reduces the stress on the teeth by distributing the forces.
The number of teeth varies on a cutter, too. A larger number of teeth can
provide a better finish to the bone. The cutters which can be used for
milling operations are highly versatile, allowing a variety of features to be
created. While these cutters differ greatly in diameter , length, and they
will form by the shape of the cut, they also differ according to their
orientation, whether they will be used horizontally or vertically. A cutter
to be used in a horizontal milling machine will have the teeth stretching
along the whole length of the tool. The tool's interior should be
unfinished, so it can be placed onto the arbor. There are still several
different types of cutters with this basic shape that can be used in
horizontal milling, including the ones mentioned below.

• Plane (helical) mill

• Form relieved mill

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• Staggered tooth mill
• Double angle mill

With a horizontal milling machine, a further operation known as straddle

milling is also possible This method of milling refers to the use of several
cutters that are attached to the arbor and used at the same time Straddle
milling can be used to form a complex, single-cut feature The cutters take
a very different shape to vertical milling machines The cutter teeth only
cover a portion of the blade, while the remaining length is a smooth
surface, the shank is called For attachment to the spindle, the shank is the
cutter section which is secured inside the collet In addition, many vertical
cutters are designed for cutting using both the cutter sides and the cutter
bottom Several are listed below common vertical cutters.

• Flat end mill

• Ball end mill
• Chamfer mill
• Face mill
• Twist drill
• Reamer
• Tap

All cutters that are used in milling can be found in a variety of materials,
which will determine the cutter's properties and the workpiece
materials for which it is best suited. These properties include the cutter's
hardness, toughness, and resistance to wear. The most common cutter
materials that are used include the following:

• High-speed steel (HSS)

• Carbide
• Carbon steel
• Cobalt high speed steel

The cutter material is selected based on a number of factors including

workpiece material, cost and lifespan of the tool Tool life is an
important feature that is considered when selecting a cutter, since it
greatly affects the cost of manufacturing Not only will a short tool life
require additional tools to be purchased but it will also take time to
change the tool whenever it becomes too worn Often the cutters listed
above have the teeth coated with a different material to provide
additional wear resistance, thereby extending the tool life Sprinkling
of a lubricant and/or coolant on the cutter and workpiece during
milling can also reduce tool wear higher feed rates can be used, the
surface finish can be improved, and the material chips can be pushed

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away. Typical cutting fluids include mineral, synthetic, and water
soluble oils.

Workpiece
• elect a material that minimizes overall cost. An inexpensive
workpiece may result in longer cut times and more tool wear,
increasing the total cost
• Minimize the amount of milling that is required by pre-cutting the
workpiece close to the desired size and shape
• Select the size of the workpiece such that a large enough surface
exists for the workpiece to be securely clamped. Also, the clamped
surface should allow clearance between the tool and the fixture for
any cuts

Shaper machine
The Shaper Machine is a reciprocating type of machine tool that is used
to generate horizontal, vertical

or inclined flat surfaces through straight line reciprocating single-point

cutting tools similar to those used in lathe operation.

Types of Shaper Machine:

Based on the type of driving mechanism types of shaper machines.

• Crank type (Example: Quick return Motion Mechanism)

• Geared type shaper
• Hydraulic type (I mentioned the working principle of hydraulic
shaper machine below in this article)

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Based on ram travel types of shaper machines.

• Horizontal Shaper
• Vertical Shaper

Based on the table design types of shaper machines.

• Standard or Plain Shaper

• Universal shaper

Based on cutting stroke types of shaper machines.

• Push type shaper machine

• Draw type shaper machine

Operations Performed on Shaper Machine:

There are 4-types of operations performed in a shaper machine, and
those are:

• Horizontal cutting
• Vertical cutting
• Inclined cutting
• Irregular cutting

Horizontal cutting:

Horizontal surfaces are machined by shifting the work placed in a cross

direction on the machine table with respect to the rotation of the ram. You
can set the clapper box upright or slightly inclined toward the uncut
surface. This arrangement allows for automatic lifting of the tool during
the return stroke. The tool is not being dragged onto the machined
surface.

Vertical cutting:

A vertical cut is made while the end of a workpiece is being machined, a

block squared or a shoulder machined. The feed is given to the tool by
rotating vertical slide down feed screw. To this end the table is not shifted
vertically. The apron is swivelled away from the machining vertical
surface.

Inclined cutting:

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An angular cut to the horizontal or vertical plane is done at any angle
other than a right angle. The work is set on the table, and from the
vertical position the vertical slide of the tooth head is swivelled to the
required angle either to the left or to the right.

Irregular cutting:

For this operation a round nose tool is employed. The apron can be placed
vertically for a shallow cut, but if the curve is very straight, the apron in
the apron swivels away from the surface to be cut to the right or left.

Working Principle of Shaper Machine:

A shaper machine is working on the following principle:

• A shaper machine holds the Single point cutting tool in ram and
workpiece is fixed over the table.
• The ram holding the tool reciprocates over the workpiece and
metal is cut during the forward stroke called a cutting stroke and
• No metal is cut during its return stroke is called an Idle stroke.
• The feed is given at the end of the cutting stroke.
• Generally, the cutting stroke is carried out at slow speed and the
idle stroke is carried at high speed with the help of quick return
mechanism.

In the shaper machine, there is another mechanism called Quick return

Motion Mechanism.

So what happens in quick return motion mechanism is,

The Slider moves swiftly in the forward stroke and removes the material
from the workpiece. Whereas in the return stroke, the Slider moves faster
than the forward stroke that means Quick return, it takes less time to
return, called a return stroke. Fast Return Mechanism

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Parts of a Shaper Machine with Function:
Base:

The Base is designed to take the entire machine tool load and it is bolted
to the shop floor. This is made of grey cast iron to withstand vibration
and bear the compressive effect.

Column:
The column is a casting box consisting of cast iron and placed on a base.
It is given on top with precisely machined guideways on which the ram
reciprocates. The guideways for cross rail movement are also provided on
the vertical front face. The column encloses the mechanism to move the
hammer.
Cross rail:
The transverse rail is mounted on the column's vertical ground
guideways. It consists of two parallel guideways on its top perpendicular
to the axis of the ram being called as a saddle to move the table in a
cross-sectional direction using a feed screw. The table can be raised or
lowered by rotating elevating screw which causes the cross rail to move
up and down on the vertical face of the column to accommodate different
sizes of the job.
Saddle:
To keep the table securely on top it is placed on the cross rail. The
saddle's cross-section rotation allows the table to shift in a cross-sectional
direction by spinning the crossfeed screw.

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Table:
The saddle is fitted. By rotating the crossfeed rod, and rotating the
elevating screw vertically, it can be moved crosswise. The table is a box-
like construction, with top and side surfaces precisely machined. Such
surfaces have t-slots to hold the job clamped. The table can be swiveled
onto a horizontal axis in Universal shaper and its upper portion can be
angled upwards or downwards. In heavy shaper the table front is
supported by adjustable table support to offer more stiffness.

Ram:

It is a reciprocating shaper member that holds the tool and the

reciprocates at the top of the column on the guideways by means of a
mechanism for quick return motion. It houses the shaft that has been
screwed to alter the RAM 's position regarding the work. The RAM is
semi-cylindrical in shape and tightly ribbed in to make it stiffer.
Tool Head:
The tool head keeps the cutting tool tightly and provides the tool with
the help of a down feed screw handle, both vertical and angular
movement. The head allows for an automatic relief to the machine during
the return stroke. A machine head's vertical slide consists of a swivel base
that is graded in degrees. So, with the work surface, the vertical slide will
set at any angle. A micrometer dial on top of the down feed screw can
adjust the amount of feed or cut-depth.
A tool head again consists of:
• Apron
• Clapper box and clapper block
Apron consisting of clapper box and tool post is clamped on the vertical
slide by the screw.
The apron Can be swiveled upon the apron swivel pin towards left or
right.
The clapper box houses the clapper block by means of a hinge pin.
The tool post is mounted on the clapper block.

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 Conclusion

So today we've completed the Shaping machine issue, we 're discussing

description, components, function, forms,
operation, advantages , disadvantages, and a Shaper Machine
specifications, hope you understand the entire concept.
If you want to read this sort of article on the lathe machine tool and
drilling machine you can search
this article for that "Lathe Machine Tool: Description, Parts, Types and
Operations" & "Drilling Machine: Description, Parts, Types, and
Operations"

References

-https://learnmechanical.com/shaper-machine/
https://www.productionmachining.com/articles/hard-turning-as-an-
alternative-to-grinding

Hackett, Donald F.; Spielman, Patrick E. (1968). "Modern wood

technology".

-https://books.google.com.eg/books?id=6x1smAf_PAcC&redir_esc=y

-https://books.google.com.eg/books?id=tjt481jg4WAC&pg=SA4-
PA56&redir_esc=y

-https://www.unisig.com/information-and-resources/what-is-deep-hole-
drilling/

-https://archive.org/details/treatiseonmillin00cinc/page/8/mode/2up

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