Manufacturing Technology

8
DEPARTMENT OF MECHATRONICS & MECHANICAL ENGINEERING
U. V. PATEL COLLEGE OF ENGINEERING,
GANPAT UNIVERSITY
CLASS: - SEM. IV
th
ME SUBJECT:-MANUFACTURINGTECHNOLOGY
EXPT NO.: - DATE: -
AIM: To t!"# "$%%&'&(t O)&'*t$o( )&'%o'+&" o( L*th& +*,h$(&.
INTRODUCTION:
In order to perform different machining operation in a lathe, the work piece may be
supported and driven by any one of the following methods:
1. Held between centers and driven by carries and catch plates.
2. Held on mandrel, which is supported between centers and driven by, carries catch
plates.
. Held and driven by chuck with the other end supported on the tailstock centers.
!. Held and driven by a chuck or a faceplate or an angle plate.
"he above methods of holding the work may be broadly classified under two headings:
1. #orkpiece held between centres.
2. #orkpiece held by a chuck or any other fi$ture.
O)&'*t$o(, -h$,h *'& )&'%o'+&" $( * .*th& &$th&' /# ho."$(0 th& -o'1 )$&,&
/&t-&&( ,&(t&' o' /# * ,h!,1, *'&:
1% &traight turning 8% "aper turning
2% &houlder turning '% (ccentric turning
% )hamfering 1*% +olishing
!% "hread *cutting 11% ,rooving
-% .acing 12% &pinning
/% 0nurling 1% &pring winding
1% .iling 1!% .orming
O)&'*t$o(, -h$,h *'& )&'%o'+&" /# ho."$(0 th& -o'1 /# ,h!,1 o' * %*,&).*t& o' *(
*(0.& ).*t&, *'&:
1% 2rilling /% Internal thread cutting
2% 3eaming 1% "apping
% 4oring 8% 5ndercutting
!% )ounter boring '% +arting6off
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Vidyanagar
Manufacturing Technology
'
-% "aper boring
O)&'*t$o(, -h$,h *'& )&'%o'+&" /# !$(0 )&,$*. *tt*,h+&(t, *'&:
1% ,rinding 2% 7illing
CENTERING:
#here the work is re8uired to be turned between centers or a chuck and a centre, conical
shape holes must be provided at the ends of the workpiece to provide bearings surface for
lathe centers. )entering is the operation of producing conical holes in workpiece. "o
prepare a cylindrical workpiece for centering, it is first necessary to locate the centre hole
by making off. 3ubbing the end with chuck does this and the centre may be located by
any one of the following instruments:
1% 5sing a centre head and steel rule obey combination set,
2% 5sing a hermaphrodite caliper,
% 5sing a divider and surface plate,
!% 5sing a surface gauge, and
-% 5sing a bell centre punch.
TURNING:
"urning in lathe is to remove e$cess material from the workpiece to produce a cone6
shaped or a cylindrical surface. "he various types of turning for various purposes, which
are described under:
STRAIGHT TURNING:
"he work is turned straight when it is made to rotate about the lathe a$is, and the tool is
fed parallel to the lathe a$is the straight turning produces a cylindrical surface by
removing e$cess metal from the workpiece.
"here are two kinds of cuts in a machine shop work:
1. 3oughing cut or rough turning.
2. .inishing cut or finish turning.
ROUGH TURNING:
"he rough turning is the process of removal of e$cess material from the workpiece in
a minimum time by applying high rate of feed and heavy depth of cut. "he roughing cut
should be so made that the machine, the tool, and workpiece can bear the load and it does
not make too rough a surface and spoil the center. "he depth of cut for roughing operation
in average machine shop work is from 2 to - mm and the rate of feed is from *. to 1.-
mm per revolution of the work. In fig. 3ough turning operation is shown.
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FINISH TURNING:

"he finish turning operation re8uires high cutting speed, small feed, and a very small
depth of cut to generate a smooth surface. 9 finish turning tool having sharp cutting edge
is held securely on the tool post for this purpose. In finish turning operation shown in fig.
"he depth of cut ranges from *.- to 1 mm and feed from *.1 to *. mm per revolution of
the workpiece. :nce the correct setting is made, the rest is finished by the automatic feed.
)opious supply of coolant and lubricant should be used to produces smooth surface.
SHOULDER TURNING:
#hen a work piece having different diameters is turned, the surface forming the step
from one diameter to other is called the shoulder, and machining this part of the
workpiece is called shoulder turning.
"here are four kinds of shoulder:
1. &8uare shoulder
2. 9ngular or beveled shoulder
. 3adius shoulder
!. 5nder cut shoulder
"he location of the shoulder is first marked on the workpiece by a hermaphrodite caliper,
measuring from one end by a steel rule. "he first diameter is then turned to the finished
si;e within *.- to 1 mm of the shoulder mark. .or s8uare or beveled shoulder a right cut
facing tool is used to finish up to the shoulder mark. 9 round nose tool will produce a
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radius shoulder. 9n undercut shoulder may be machined by using a parting tool, being fed
into the work below the first diameter surface to the desired depth.
TAPER ELEMENTS:
9 tapered piece shown in fig. may be designated by the following symbols:
"he amount of taper in a work piece is usually specified by the ratio of difference in
diameters of the taper to its length. "his is termed as the conicity and its designated by
the letter 0.
0 < 2 6 d
=
TAPER TURNING METHODS:
9 taper may be turned in a lathe by feeding the tool at an angle to the a$is of rotation of
the workpiece. "he angle formed by the path of the tool with the a$is of the workpiece
should correspond to the taper angle.
#hile the workpiece is correctly in centers then we get the correct taper shape. 9 taper
may be turned by any one of the methods:
1. 4y a broads nose from tool.
2. 4y setting over the tailstock centre.
. 4y swiveling the compound rest.
!. 4y a taper turning attachment.
-. 4y combining longitudinal and cross feed in a special lathe.
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TAPER TURNING BY A FORM TOOL:
9 broad nose tool having straight cutting edge is set on to the work at half taper angle and
is fed straight into the work to generate a taper surface. In this method the tool angle
should be properly checked before use. "his method is limited to turn short length of
taper only. "his is due to the reason that the metal is removing by the entire cutting edge,
and any increase in the length of the taper will necessitate the use of a wider cutting edge.
In fig. "here are shown as method of turning taper by a form tool.
TAPER TURNING BY SETING OVER THE TAIL STOC2:
"he principle of turning taper by this
method is to shift the a$is of rotation of the
workpiece and feeding the tool parallel to
the lathe a$is. "he angle at which the a$is of
rotation of workpiece is shifted is e8ual to
half angle of taper. "his is done when the
boly of the tailstock is made to slide on its
base towards or away from the operator by a
set over screw as illustrated in fig. "he
amount of set over being limited, this
method is suitable small taper on long >obs.
7oreover the lathe carrier being set an
angle, the angular velocity of the work is not
constant.
TAPER TURNING BY S3IVELLING THE COMPOUND REST:
"his method employs the principle of turning taper by rotating the workpiece on the lathe
a$is and feeding the tool at an angle to the a$is of rotation of the workpiece. "he tool
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mounted on the compound rest is attached to a circular base, graduated in degree, which
may be swiveling and clamped at any desired angle. "his is shown in fig. "his method is
limited to turn a short taper owing to the limited movement of the compound rest. "he
compound rest may be swiveled at !-? on either side of the lathe a$is enabling it to turn a
steep taper. "he movement of the tool in this method being purely controlled by hand,
this gives a low production capacity and poorer surface finish.
TAPER TURNING BY A TAPER ATTACHMENT:
"he principle of taper turning taper by a taper attachment is to guide the tool in a straight
path set at an angle to the a$is of rotation of the workpiece, while the work is being
revolved between centres or by a chuck aligned to the lathe a$is. 9 taper turning
attachment is shown in fig.
#hen the taper turning attachment is used, the crosslide is first made free from the lead
screw by removing the binder screw. "he rear end of the crosslide is then tightened which
the guide block by means of a bolt. "he re8uired depth of cut is given by the compound
slide, which is placed at right angle to the lathe a$is. "he guide bar must be set at half
taper angle and the taper on the must be converted in degrees. "he ma$imum angle
through which the guide bar may be swivelled is 1*? to 12? on either side of the centre
line.
tan < 2 6 d
2l
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TAPER TURNING BY COMBINING FEEDS:
"his is a more speciali;ed method in which certain lathes both longitudinal and cross
feeds may be simultaneously causing the tool to follow a diagonal path which is the
resultant of the magnitude of the two feeds. @arying the rate of feeds by change gears
provided inside the apron may change the direction of the resultant. "aper turning by
combining feeds is shown in fig.
ECCENTRIC TURNING:
If a cylindrical workpiece has two separate a$is of rotation one being out of center to the
other the workpiece is termed eccentric and turning of different surfaces of the workpiece
is known as eccentric turning which is shown in fig.
"he shaft is first mounted on its true center and the part forming the >ournal is turned. "he
>ob is then remounted on the offset center and the eccentric surfaces are machined. In
eccentric turning, counterbalance weights are mounted on the face plate to get uniform
turning movement.
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CHAMFERING:
)hamfering, is shown in fig., is the operation on beveling the e$treme end of a
workpiece. "his is done to remove the burrs, the protect the end of the workpiece from
being damaged and to have a better look. "he operation may be performed after knurling,
rough turning, boring, drilling or thread cutting. )hamfering is an essential operation
after threads cutting so that the nut may be pass freely on the threaded workpiece.
THREAD CUTTING:
"hread cutting is one of the most important operations performed in a lathe. "he principle
of thread cutting is to produce a helical groove on a cylindrical or conical surface by
feeding the tool longitudinally when the >ob is revolved between the centers or by a
chuck. "he longitudinally feed should be e8ual to the pitch of thread to be cut per
revolution of the workpiece. "he leadscrew of the lathe, through which the saddle
receives its traversing motion, has a definite pitch. 9 definite ratio between the
longitudinal feed and rotation of the headstock spindle should therefore be found out so
that the relative speed of rotation of the work and the leadscrew will result in the cutting
of a screw of the desired pitch. )hange gears arranged between the spindle and the
leadscrew or by the change gear mechanism or feed bo$ used in a modern lathe where it
provides a wider range of feed and the speed ratio can be easily and 8uickly changed
affect this. .ig illustrates the principle of thread cutting.
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FACING:
.acing is the operation of machining the ends of a piece of work to produce a flate
surface s8uare with the a$is. "he operation involves feeding the tool perpendicular the
a$is of rotation of the workpiece. 9 properly ground facing tool is mounted in a tool
holder in a tool post. "he cutting edge should be set at the same height as the center of the
workpiece.
2NURLING:
0nurling is the process of embossing a diamond shaped pattern on the surface of a
workpiece. "he purpose of knurling is to provide an effective gripping surface on a
workpiece to prevent it from slipping when operated by hand. In some press fit work
knurling is done to increase the diameter of a shaft. "he operation is performed by a
special knurling tool which consists of 1 set of hardened steel rollers in a holder with the
teeth cut on their surface in a definite pattern. .ig., illustrates a revolving holder with
three sets of knurls. 9ny one set or pair may be brought into operation by revolving the
unit.
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FILING:
.iling is the finishing operation performed after turning. "his is done in a lathe to remove
burrs, sharp corners and feed marks on a workpiece and also to bring its si;e by removing
very small metal. "he operations consist of passing a flate single cut file over the
workpiece at high speed.
POLISHING:
+olishing is performed after filling to improve the surface 8uality of the workpiece.
+olishing with successively finer grades of emery clothe after filing result in very
smooth, bright surface. "he lathe is run at high speed from 1-** to 18** m per min, and
oil is used on the emery cloth.
GROOVING:
,rooving is the process of reducing the diameter of a workpiece over a very narrow
surface. It is done at end of the thread to a shoulder to leave a small margin. "he work is
revolved at half the speed of turning and a grooving tool of re8uired shape into the work
by rotating the cross6slide screw. 9 grooving tool is similar to a parting of tool. "his is
shown in fig.
SPINNING:
&pinning is the process of forming a thin
sheet by revolving the >ob at high speed
and pressing it attach to the headstock
spindle. 9 support is also given from the
tailstock end. "he pressure applied to the
revolving sheet metal by a long ground
on the special too, when the piece is
slowly ac8uires the shape of the former
shown in fig.
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FORMING:
.orming is the process of turning a conve$, concave or of any irregular shape. .rom
turning may be accomplished by the following method:
1. 5sing a forming tool.
2. )ombining cross6land longitudinal feed.
. "racing or coping a template.
.or turning a small surface, forming tool having cutting edge conforming to the shape
re8uired is fed straight into the work. .orming tools are used mainly for finishing formed
surfaces. 5sually two types of forming tools are used A &traight and )ircular. &traight
type is used for wider surface and the circular type for narrower surfaces fig. shown
forming operation performed by straight or )ircular tools. "he cross feed ranges from
*.*1 to *.*8 mm per rev. #hen the length of the formed surface is sufficiently grate, the
re8uired shape may be obtain by using straight turning tool. "he process is tedious and
re8uires much skill.
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DRILLING:
2rilling is the operation of producing a cylindrical hole by the rotating cutting a edge of a
cutter known as the drill. "here are two methods to drilling in a lathe.
1. "he workpiece is revolved in a chuck and the drill is held in the drill holder. "he
movement of the tailstock spindle effects feeding.
2. "he drill is held and driven by a drill chuck attached to the headstock spindle. "he
movement of the tailstock spindle effects feeding. #hen workpiece is in irregular
shape, which cannot be accommodated on a chuck.
&peeds and feeds for drilling in a lathe are 2-B lower than the corresponding figures for
drilling in a drilling machine.
REAMING:
3eaming is the operation of finishing and si;ing a hole, which has been previously drilled
or bored. "he tool used is called the reamer, which has multiple cutting edges. "he
reamer is held on the tailstock spindle, either direct or through a drill chucks and is held
stationary while the work is revolved at a very slow speed. "he feed varies from *.- to 2
mm per revolution.
BORING:
4oring is the operation of enlarging and truing a hole producing by drilling, punching,
casting or forging. 4oring cannot originate a hole. 4oring is similar to the e$ternal
turning operation and can be performed in a lathe by the following two methods:
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1. "he work is revolved in a chuck or a faceplate and the tool, which is fitted to the
tool post, is fed into the work. :ne piece6forged tool is used for boring small hole,
whereas a boring bar with a tool bit attached to it is suitable for machining a large
hole. "he depth of cut is given by the )rosslide screw and the feed is effected by
the longitudinal travel of the carriage.
2. "he work is clamped on the carriage and a boring bar holding the tool is supported
between the centers and made to revolve. In fig. &hown a operation of boring bar.
INTRNAL THREAD CUTTING:
"he principle of cutting internal thread shown in fig. &imilar to an e$ternal thread,
difference being in the tool used. "he tool is similar to boring tool with cutting edges
ground to the shape conforming to the thread to be cut. .or cutting metric thread, the
compound slide is swiveled *? towards the headstock. "he tool is fi$ed on the tool post
after setting it at right angle, using a thread gauge. "he depth of cut is given by the
compound slide and the thread is finished in the usual manner.
UNDERCUTTING:
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5ndercutting is shown in fig., similar to grooving operation. It is the process of boring a
groove or a large hole at fi$ed distance from the end of a hole, e$cept that a s8uare nose6
parting tool is used. 5ndercutting is done at the end of an internal thread or a counterbore
to provide )learance for the tool or any mating parts.
PARTING-OFF:
In fig parting6off, the operation of cutting workpiece after it has been machined to the
desired si;e and shape. "he process involves rotating the workpiece on a chuck at half the
speed by narrow parting of tool perpendicular to the lathe a$is. 4efore the operation is
started, the carriage is locked in a position on the lathe bed and the cutting tool is held
rigidly on the tool post with the compound slide set parallel to the lathe a$is. "he feed
varies from *.*1 to *.1- mm per rev. and the depth of cut tool ranges from 6to1* mm. In
stages the parting tool is first fed through a certain depth, two more cuts are made at the
two slides of the central groove.

U. V. Patel College of Engineering, Ganpat
Vidyanagar