MACHINING

Mr. Dhananjay
Assistant lecturer
Mechanical department, NITK
 What is Manufacturing?
The process of converting raw materials, components, or parts into finished goods that
meet a customer's expectations or specifications. (or)
Transformation of materials and information into goods for the satisfaction of human
needs.

•Manufacturing
•Technologically

•Economically

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 CLASSIFICATION
• Subtractive (Material Removal)
– Ex : Milling, turning, grinding

• Additive (Material Build-up)

– Ex : Stereolithography

• Formative (Sculpture)
– Ex : Forging, Casting

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 Manufacturing Processes

1. Welding
2. Casting
3. Forging Fundamentals of Manufacturing
Processes
4. Rolling
(ZERO wastage of
5. Metal Forming parent material)

6. Extrusion

7. Machining Machining Processes

(Wastage of parent material)
 What is Machining?
• Machining = Chip formation by a tool

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 Big lathe with big chips

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 Basic requirements for metal cutting

• There should be a relative motion

between the cutting tool and the
workpiece.
• The cutting tool should be harder
than the workpiece
• There should be sufficient power
Hot blue chips
available to overcome the cutting
forces
Metal cutting is chip forming machining process where the excess material
is removed
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8
 Types of Chips in metal cutting

1. Continuous Chips

2. Discontinuous Chips (Segmental chips)

3. Continuous Chips with Built Up Edges (BUE)

 Types of Chips in metal cutting

Finished surface / work piece

Chips

o l
To

Work piece
Cutting tip of the tool
(Single point cutting tool)
 Types of Chips in metal cutting

1. Continuous Chips

2. Discontinuous Chips

3. Continuous Chips with Built Up Edges

Continuous Chip

Tool

Work piece
 Types of Chips in metal cutting

1. Continuous Chips

2. Discontinuous Chips

3. Continuous Chips with Built Up Edges

 Types of Chips in metal cutting

1. Continuous Chips

2. Discontinuous Chips

3. Continuous Chips with Built Up Edges

Discontinuous Chip (Segmental chips)

Tool

Work piece
 Types of Chips in metal cutting

1. Continuous Chips

2. Discontinuous Chips

3. Continuous Chips with Built Up Edges

 Types of Chips in metal cutting

1. Continuous Chips

2. Discontinuous Chips

3. Continuous Chips with Built Up Edges

Continuous Chips with BUE

Tool

Work piece
Types of Chips in metal cutting
 Turning-Chip Formation
Chips

Discontinuous chip Continuous chip

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 Chip-formation Process

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 Why Machining?
Very accurate
• highest of all manufacturing processes
• small amounts of materials removed
• precise tools, dies, molds can be made
Highly Flexible
• shape is programmed
• many different parts can be made on one machine
• any arbitrary shape can be machined
Low cost tooling
• contour is generated by path of tool, rather than its shape, in most
cases
• cutting tools are mass-produced in
• standardized shapes
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 Lathe and its types
• Lathe is the oldest machine tool invented, starting with the Egyptian
tree lathes. It is the father of all machine tools. Its main function is to
remove material from a work piece to produce
the required shape and size.
• It is used to machine cylindrical parts.
• Generally single point cutting tool is used.
• In the year 1797 Henry Maudslay, an Englishman, designed the first
screw cutting lathe which is the forerunner of the present day high
speed, heavy duty production lathe
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 Pole Lathe
• Medieval Machine
• Turned Round Parts
• “Bodgers”
– Itinerant Woodworkers
• Carpenters
• Blacksmiths
• Metalworkers/Jewlers
• Made Furniture, Home,
& Farm Implements
 Pole Lathes
• Non-continuous
Cutting Action
• “One man’s foot
power” motor
• Slow, Tedious Process
 Wheel Lathe
• Replace Pole
with a Wheel
• Hand-cranked by
assistant
• Continuous Cutting &
Contouring
 Treadle Wheel Lathe
• Heavy Flywheel &
Foot Treadle
• Solo Operation
• Continuous Cutting
& Contouring
Treadle Lathe
 Powered Lathes
• Continuous Turning
• Water wheels
– Central, Overhead Shafts
– Leather belts transfer power to
individual machines
• Factory System
 Engine Lathes
• Invented by the English
Inventor Henry Maudsley
in 1800
• First powered lathe
with a “Lead Screw”
– Couples rotation of the spindle to the movement of the
carriage (tool holder)
– Cut accurate screw (i.e., another lead screw)
– A machine that builds itself, jump starts the…
 Industrial Revolution

• Lathes
• Steam Engine
–Accurate cylinders & pistons
• Steel
–Tough for cutting tools
–Ductile for boilers & rails
 Modern Engine Lathe

• Electric Motor
• Geared Head
– Variable Spindle Speeds
(Rotation)
– Variable & Accurate
Feeds (Tool Movement)

• Tolerances of
0.001 inch
• Multiple Screws
 Lathe Parts

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 Major parts of a centre lathe

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 working principle of a centre lathe

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 Work holding device-Chuck

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 Mounting of tools in lathe
• Carbide, ceramic and
cermet inserts of
various size and shape
are mechanically
clamped in the seat of
rectangular sectioned
steel bars which are
mounted in the tool
post

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 Operations in lathe

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 Operations in lathe

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 Operations in lathe
• Rough and finish turning - The operation of producing cylindrical surface.
• Facing - Machining the end of the work piece to produce flat surface.
• Centering - The operation of producing conical holes on both ends of the work piece.
• Chamfering - The operation of beveling or turning a slope at the end of the work
piece.
• Shouldering - The operation of turning the shoulders of the stepped diameter work
piece.
• Grooving - The operation of reducing the diameter of the work piece over a narrow
surface.
• Taper turning
• Boring (internal turning); straight and taper – The operation of enlarging the diameter
of a hole.
• Forming-external and internal.
• Cutting helical threads; external and internal.
• Parting off - The operation of cutting the work piece into two halves.
• Knurling - The operation of producing a diamond shaped pattern or impression on the
surface.
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 TAPER TURING METHODS
• Offsetting the tailstock.
• Swivelling the compound slide.
• Using taper turning attachment
• Using form tool with taper over short length.

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 TAPER TURING METHODS

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