WORKSHOP PRACTICE-

ME F112
R. S. Vidyarthy
PhD (IIT R)
Assistant Professor
BITS Pilani Mechanical Engineering Department
Hyderabad Campus BITS Pilani, Hyderabad Campus, India
 BITS Pilani
Hyderabad Campus

Metal cutting basics

MATERIAL REMOVAL PROCESSES
MRPs

Traditional Advanced

Cutting Finishing

Other/Prismatic
Circular Shape Bonded Abrasive Loose Abrasive
Shape

•Turning • Milling • Grinding • Lapping

•Drilling • Planning • Honing • Polishing
•Boring • Shaping • Coated
• Gear Cutting Abrasive
• Broaching
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Machine Tools

Machine tools are kind of machines on which the metal

cutting or metal forming processes are carried out.

• Degree of specialization

• Types of surface produced

• Type of motion

• Degree of automation

• Duty cycle

• Type of energy used

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NATURE OF RELATIVE MOTION
BETWEEN THE TOOL AND WORKPIECE
OPERATION MOTION OF JOB MOTION OF FIGUREOF OPEARTION
CUTTINGTOOL
TURNING ROTARY TRANSLATORY
https://www.youtube.co (FORWARD)
m/watch?v=MwgobIVj4f
U&ab_channel=Glacern
MachineToolsGlacernMa
chineTools

BORING ROTATION TRANSLATION

(FORWARD)

DRILLING FIXED (NO ROTATION AS WELL

https://www.youtube.co MOTION) AS TRANSLATORY
m/watch?v=HqNRlDsqW
ho&ab_channel=e4educa FEED
tione4education

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NATURE OF RELATIVE MOTION
BETWEEN THE TOOL AND WORKPIECE
OPERATION MOTION OF JOB MOTION OF FIGUREOF OPEARTION
CUTTINGTOOL
PLANING TRANSLATORY INTERMITTENT
https://www.youtube TRANSLATION
.com/watch?v=4S4nG
SoYeYM&ab_channel
=e4educatione4educ
ation

MILLING TRANSLATORY ROTATION

https://www.youtube
.com/watch?v=LDxq9
AkxYfk&t=295s&ab_c
hannel=e4educatione
4education

GRINDING ROTARY / ROTARY

https://www.youtube TRANSLATORY
.com/watch?v=7f_LIJ
MpLGo&ab_channel=
e4education

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Examples of cutting processes.

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Operating conditions in metal
cutting
Workpiece
Cutting
speed
Depth of cut (d)
N
Machined
surface
Chuck
Feed
Chip

Tool
Depth of cut
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Metal cutting features: Positive

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Metal cutting features: negative

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Essentials of Metal Cutting
Operation

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Cutting Tools

• Cutting tool is a device, used to remove the unwanted

material from a given workpiece.

Two-dimensional cutting
process, also called orthogonal
cutting. Note that the tool
shape and its angles, depth of
cut, to, and the cutting speed, V,
are all independent variables.
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Common Tool Material

❖ Tool steel
❖ High-speed steel (HSS)
❖ Carbides
❖ Abrasives
❖ Diamond
❖ Cubic boron nitride (CBN)
❖ Ucon
❖ Ceramics
❖ Tipped tools
❖ Coated tools

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Tool materials…

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Effect of carbon..

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Effect of Alloying Elements on Steel

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Tool materials…

18 % W, 4 % Cr, 1 % V
8 % Mo, 4 % Cr, 1 % V

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Tool materials…

Carbides
Tungsten carbide + titanium carbide+
cobalt
❖High Hot Hardness
❖High Cutting Speeds (>HSS)
Diamond
* Speeds 50 times HSS
* Can Machine 1,00,000 pieces/set Up
* High Speeds & Low Feed, Depth of Cut
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Tool Materials ..

Ceramics
* Can cut almost any metal
* Speeds: twice of Carbides.
* Hot Hardness ~1200 0C
* Very Brittle and cannot take Shock
Abrasives
–for harder materials
–for better dimensional accuracy
–for better surface finish
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Cubic Boron Ucon
Nitride • Alloy Of
• Second Hardest Columbium(50%),
Material Titanium(30%) &
• Red Hardness up to Tungsten (20%)
1000 0C • Harder than WC
• Used For Machining • Tool Life 3-5 times
Ferrous Metals of Carbides.

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Types of Tools
Multipoint
Single Point
Types of Cutting

• Orthogonal Cutting (2-D Cutting): Cutting edge is (1) straight, (2)

parallel to the original plane surface on the workpiece and (3)
perpendicular to the direction of cutting. For example: Operations:
Lathe cut-off operation, Straight milling, etc.
• Oblique Cutting (3-D Cutting) : Cutting edge of the tool is inclined
to the line normal to the cutting direction. In actual machining,
Turning, Milling etc./ cutting operations are oblique cutting (3-D)

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Orthogonal and Oblique
Cutting
Machined Tool
Tool
Chip Chip
Cutting edge
at 90°
Motion of
Cutting edge Workpiece
inclined
Motion of
Workpiece
Orthogonal cutting Oblique cutting
Tool geometry

https://www.youtube.com/watch?v=bUrp8JMRwx4&ab_channel=LesicsLesics

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Types of Chips

• Continues Chips
• Discontinues Chips
• Continuous Chips with Built up Edge (BUE)

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 Types of Chips

Built-up
Chip edge
Chip Tool

Workpiece
Continuous Discontinuous
chip chip

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Conditions for Continuous Chips:
• Sharp cutting edges
• Low feed rate
• Large rake angle
• Ductile work material
• High cutting speed
• Low friction at Chip-Tool interface

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Continuous chip Results in:

• Good surface finish

• High tool life
• Low power consumptions

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Conditions for discontinuous
chips:
• Brittle Material
• Low cutting speed
• Small rake angle

Discontinuous Chip
results in:
• Easy disposal
• Good surface finish

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Built up Edge:

• High friction between Tool & chip

• Ductile material
• Particles of chip adhere to the rake face of the
tool near cutting edge

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Thermal Aspects in Machining..
Distribution of Heat..
Work 10%
Tool 10%
% Heat

Chips 80%

Cutting Speed v
Tool Life

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Tool Life (Influencing Factors )

Operating/cutting conditions
Workpiece material
Tool material
Geometry of tool
Cutting conditions (dry or wet)
 Tool Life ..
Cutting Speed (v) vs Tool life (T)

Intercept (log C)
1
Slope (n)
log v  2

0 log T
Tool Life..
Taylor’s Expression
n
vT =C
v = Cutting Speed (m/min)
T = Tool Life (min)
n, C are constants.
 Tool Life..
Influence of operating conditions on tool life

v 1  2  3

log v
f
log f 
log d
d


log T
Modified Taylor’s equation
EXAMPLE 1
Ex 1.Using Taylor equation and using n=0.5, C=400, Calculate the
percentage increase in tool life when cutting speed is reduced by
50%.
Sol.
EXAMPLE 1
Ex 1.Using Taylor equation and using n=0.5, C=400, Calculate the
percentage increase in tool life when cutting speed is reduced by
50%.
Sol.
VT = C
n

V1T1n = V2T2n
= 0.5 V T
1 2
n

n
 T1 
  = 2
 T2 
T 2= 4 T1
T2 − T1
Percentage Increase = 100 = 300 %
T1
 EXAMPLE-2
The useful tool life of a HSS tool machining mild steel
at 18 m/min is 3 hours. Calculate the tool life when
the tool operates at 24 m/min.
Sol.
 EXAMPLE-2
The useful tool life of a HSS tool machining mild steel
at 18 m/min is 3 hours. Calculate the tool life when
the tool operates at 24 m/min.
Sol. VT n = C
V = 18m / min
T = 3  60 = 180 min
C = 18  (180) n
Let n = 0.125
C = 18  (180) 0.125 = 34.45
Now V = 24m/min
VT n = C
1
 34.45  0.125
T =  = 18 min
 24 
EXAMPLE-3
Ex 3. The following equation for tool life is given
for a turning operation VT 0.13 f 0.77d 0.37 = C
A 60 mm minute tool life was obtained while cutting
at V=30m/min, f=0.3 mm/rev and d=2.5mm.
Determine the change in tool life if the cutting
speed , feed and depth of cut are increased by
20% individually and also taken together.
 Solution
VT 0.13 f 0.77d 0.37 = C
C = 30  60 0.13  0.30.77  2.50.37
= 28.38
(i) V = 30 1.2 = 36 m/min
28.38
T 0.13 = = 1.419
36  0.3  2.5
0.77 0.37

T = 14.75 min
(ii ) f = 0.3 1.2 = 0.36mm / rev
28.38
T 0.13 = = 1.48
30  0.36  2.5
0.77 0.37

T = 20.39 min
(iii )d = 2.5 1.2 = 3mm
28.38
T 0.13 = = 1.591
30  0.3  3
0.77 0.37

T = 35.55 min
Therefore, the maximum effect on tool life is cutting speed
and the least effect is depth of cut.
 Solution

(iv) Now V = 36 m/min, f = 0.36mm/rev , d = 3mm

28.38
T =
0.13
= 1.154
36  (0.36)  (3)
0.77 0.37

T = (1.154) 7.69 = 3.011 min

 BITS Pilani
Hyderabad Campus

Lathe
 Schematics of lathe
• The Lathe is the most versatile machine tool among all standard of the machine tool
• Lathe machine is generally divided into three types:
o Engine Lathe, Turret Lathe, and Special Purpose Lathe

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Parts of Lathe

Constructional Details of Lathe (Animation) - YouTube

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• Headstock:
The headstock is usually located on the left side of the lathe and is equipped with
gears, spindles, chucks, gear speed control levers, and feed controllers.
• Tailstock:
Usually located on the right side of the lathe, the workpiece is supported at the
end.
• Bed:
The main parts of the lathe, all parts are bolted to the bed. It includes the
headstock, tailstock, carriage rails and other parts.
• Carriage:
The carriage is located between the headstock and the tailstock and contains
apron, saddle, compound rest, cross slide and tool post.
Designed to slide along the ways of the lathe in order to feed the tool parallel to
the axis of rotation
• Lead Screw
The lead screw is used to move the carriage automatically during threading.
• Feed Rod
It is used to move the carriage from left to right and vice versa.
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Headstock

• Head Stock is situated at the left side of the lathe bed

and it is the house of the driving mechanism and
electrical mechanism of a Lathe machine tool.
• It holds the job on its spindle nose having external screw
threads and internally Morse taper for holding lathe
center.
• There is a hole throughout spindle for handling long bar
work.
• Head Stock transmit power from the spindle to the feed
rod, lead screw and thread cutting mechanism.

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Bed

• It is the base of the lathe machine.

• It is made of single piece casting of Semi-steel ( Chilled
Cast Iron).
• It is sufficiently rigid and good damping capacity to
absorb vibration.
• It prevents the deflection produced by the cutting forces.
• It supports the headstock, tailstock, carriage and other
components of the lathe machine.

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 Tailstock
• Tail Stock is situated on the right side above the lathe bed.
• It is used for:
• Support the long end of the job for holding and minimizes its sagging.
• It holds the tool for performing different operations like drilling,
reaming, tapping, etc.

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 Carriage
• The carriage is used for support, guide and
feed the tool against the job when the
machining is done.
• It holds moves and controls the cutting tool.
• It gives rigid supports to the tool during
operations.
• It transfers power from feed rod to cutting
tool through apron mechanism for
longitudinal cross-feeding.
• It simplifies the thread cutting operation with
the help of lead screw and half nut
mechanism.
Carriage provides the following
Carriage is consists of: movements to the tool:
• Saddle: part of carriage • Longitudinal feed-through carriage
• Cross-slide: On top of saddle movement
• Compound rest: supports tool post • Cross feed-through cross slide
• Tool post: to hold tools movement
• Apron: house of feed mechanism
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Lead screw:
• A lead screw is also known as a power screw or a translation
screw. It converts rotational motion to linear motion.
• Lead Screw is used for Thread Cutting operation in a lathe
machine tool.
Feed Rod:
• Feed rod is used to move the carriage from the left side to the
right side and also from the right side to the left side.
• A split nut in apron is used to engage the lead screw with
carriage
Chuck:
• Chuck is used to hold the work piece securely.

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