Machining

Introduction
 1776: James Watt built the steam engine
Boring of the cylinder casting: Major bottleneck
How cylinder was manufactured: Used sheet metal, but could
not make it steamtight.
Attempted to fill the gap b/w piston and cylinder with cloth,
leather etc

History 1774: Patented a technique for boring iron guns from a solid
piece

This technology was used to manufacture cylinders using

boring machine. Involved a boring bar with cutting tools
mounted and the unit supported in bearing outside the
cylinder. Boring bar could be rotated and fed through the
cylinder
 Generating Surfaces
• Two kinds of relative motion
• Primary Motion (Absorbs most of
the total power required to cut)
• Feed Motion (produces chips)
 Resultant Cutting Speed
𝑣𝑓 Feed speed

𝑣 𝑒 Resultant cutting speed

Resultant cutting speed angle (for most
practical purposes, this angle is very small
and can be neglected
 • Closer dimensional control
• Tighter tolerance
• Special surface quality
• Part has external and
internal geometric features

Machining: When to use

 Types of
machining process
Machining
by cutting
 Concept of Generatrix and Directrix in Machining
• Generation of Flat surfaces
The principle is shown where on a flat
plain a straight line called Generatrix (G)
is traversed in a perpendicular direction
called Directrix (D) resulting a flat
surface

• Generation of cylindrical surfaces

⎯ A long straight cylindrical surface is obtained by a circle
(G) being traversed in the direction (D) parallel to the axis
as shown in Fig. (A)
⎯ A cylindrical surface of short length is obtained by
traversing a straight line (G) along a circular path (D) as
indicated in Fig. (B)
⎯ Form cylindrical surfaces by rotating a curved line (G) in
a circular path (D) as indicated in Fig. (C and D).
Tool-Work Motions: Principle of turning
(cylindrical surface)
Tool-Work Motions: Principle of producing
flat surface in shaping machine
Tool-Work Motions: Drilling
Tool-Work Motions: Form Milling

Form milling cutters will produce formed surfaces where the ‘G’ is the
tool-form.
 Ways of Obtaining Generatix & Directix
• Tracing (Tr) – where the
continuous line is attained as a
trace of path of a moving point
• Forming (F) – where the
Generatrix is simply the profile of
the cutting edge
• Tangent Tracing (TTr) – where the
Directrix is taken as the tangent
to the series of paths traced by
the cutting edges
• Shows the generatrix (G)
and directrix (D) while
producing flat surface by a
plain or slab milling cutter
• The G and D are connected
here with the tool work
motions as given
• Generatrix is tangent to FM
which is given to the tool
• Here G and D are
independent of the cutting
motion and the G is the line
of contact between the
milling cutter and the flat
work surface. The present
cutter being of roller shape,
G has been a straight line
and the surface produced
has also been flat.
Cutting:
Classify
• Cutting tool has the
finishing contour of
the workpiece
(FORM)
• Main motion and
feed motion
generates the cut
Cutting
Types
Generation
Machining by Abrasion
Machining by
bonded abrasives

Grinding/Honing/Superfinishing
Surface Grinding
• Workpiece: Linear
• Tool: Rotary
Lapping

• Workpiece: Stationary
• Tool: Linear
Superfinishing

• Workpiece: Rotary
• Tool: Linear
Centreless
Grinding
• Work: Rotary
• Tool: Rotary