Machining

Machining
A subtractive process used to get desired shape,
size, and finish by removing surplus material in
the form of chips by a cutting tool and by
providing suitable relative motion between the
workpiece and cutting tool
 Cutting tool and Machine tool
• Cutting tool: removes excess material
through direct mechanical contact
• Machine tool: provides necessary relative
motion between the work-piece and tool
 ACCORDING to TYPE of CUTTING TOOL
Machining Processes

Using SINGLE-Point Using MULTI-Point Using ABRASIVES

Cutting Tools Cutting Tools as Cutting Tools

 Turning  Milling
 Grinding
 Step Turning  Drilling
 Honing
 Taper Turning  Reaming
 Lapping
 Form Turning  Knurling
 Contour Turing  Super-Finishing
 Tapping
 Facing  Polishing
 Hobbing
 Necking  Buffing
 Broaching
 Parting-Off
 Sawing
 Boring
 Counter-Boring
 Counter-Sinking
 Shaping
 Planing
 Basics of shape generation by
machining
Two relative motions (between work and tool) generally
needed to produce surfaces
– Cutting Motion: line generated by it is called generatrix:
Primary cutting motion
– Feed Motion : line generated by it is called directrix:
Secondary cutting motion
Relative motions needed for various types
surface generation
Surface Machining Generatrix Directrix
Obtained Process (cutting) (feed)

Planar Shaping, Straight Line Straight

Surface Planing Line

Cylindrical Turning Circular Straight

Line
Planar Milling Circular Straight
Surface Line
Surface of Contour Plain Curve Circular
Revolution Turning,
Boring
 TYPES OF MACHINING PROCESSES
BASED ON ANGLE BETWEEN CUTTING
EDGE and CUTTING VELOCITY
Oblique Machining Orthogonal Machining
 Cutting edge of the tool is  Cutting edge of the tool is
inclined with normal to perpendicular to the direction
the cutting velocity. of cutting velocity
 Cutting Forces Act along All  Cutting Forces Act Along x and z
Three Directions i.e. x, y, Directions Only i.e. No Cutting
and z Axes. Force along y Direction

 Examples:  Examples:
Turning, Sawing,
Milling, Broaching,
Drilling, Parting-Off of Tube Wall
Shaping
 Lathe Machines
Lathes are Machine Tools Designed Primarily
to Do Turning, Facing, and Boring.
Because Lathes also can do Drilling, and
Reaming, their Versatility permits Several
Operations
 DESIGN and TERMINOLOGY of the
ENGINE LATHE
The Essential Components of an Engine Lathe are
1. Bed
2. Headstock Assembly
3. Tailstock Assembly
4. Carriage Assembly
Tailstock
5. Feed Rod
6. Leadscrew
7. Quick Change Gearbox

Bed

Schematic Diagram of an Engine Lathe

Bed
Headstock assembly
Headstock assembly - Work holding
device

3 jaw chuck 4 jaw chuck

Face Plate

Lathe centres
Magnetic chuck
Tailstock assembly

T1 – Feed screw
T2 – Reduction gear box
T3 – Body
T4 – Adjustable base
T5 – Spindle
T6 – Locking lever
Carriage Assembly
 Feed rod
• Feed rod provides the
powered movement of
the carriage and cross
slide for automatic
movement of tool used
in turning operation
• Leadscrew for cutting
threads, a leadscrew is
used to provide
automatic movement to
carriage.
 Lathe Operations
• Straight turning
• Taper turning
• Facing
• Chamfering
• Threading
• Drilling
• Boring
• Parting off or necking
• Knurling
• Reaming
 Turning
Straight Turning Taper Turning
For producing cylindrical shapes For producing conical shapes
 Different types of Taper turning
• Compound rest method
• Tail stock set-over method
• Taper turning attachment
• Forming tool
Compound rest method
• Used for turning steep
and short tapers
• A circular base
graduated in degrees
which can be swivelled
at any angle from the
centre line of lathe
centres
• The angle swivelled is
half of the taper angle
Tail stock set-over method
• Method used for turning
small tapers on long jobs and
is confined to external tapers
only
• Tail stock is set over by
loosening the nut from the
centre line equal to the
formula given below
Taper turning attachment
• Used only for external
tapers
• Bolted on the back of lathe
and has a guide bar which
may be set at desired angle
of taper
• As carriage moves along
bed length, a slide over the
bar causes the tool to move
in and out according to the
setting of bar
Forming Tool
• The edge of the tool
must be exactly straight
if the work is to be
accurate
 Turning
Contour Turning
The tool follows a contour
creating a contoured form on
the turned part instead of
parallel to the axis. Cross slide
is made free to follow the path
of contour.
Form Turning
Cutting edge of Tool has a
Specific Form or Shape and is
fed radially inward towards
the axis of rotating work piece
 Facing
• Cutting tool is fed radially
inwards (at 90° w.r.t. the axis of
rotation) into the rotating work
piece.

• End facing: facing by tool moving

radially outward from the center

• Shoulder facing: facing the

stepped cylindrical work piece
 Lathe operations
Chamfering Parting off and necking
The tool is fed radially inward
• Tool is fed perpendicular to the
used to cut an angle on the
rotational axis
corner of the cylinder,
• Necking is a making partial cutoff
forming a chamfer to avoid
sharp edges.
 Lathe operations
Drilling Boring
The tool (Drill) mounted on Tool mounted to tailstock is fed
the tailstock of the engine parallel to the lathe axis after
lathes is fed by hand against a giving suitable depth of cut
rotating work piece along the
axis of lathe
 Lathe operations
Reaming
It is semi-finishing operation
that enlarges an existing hole.
Tool is rotated and fed along
rotational axis.
Knurling
 Roughening the surface of
work piece for better
gripping.
 No machining operation
only cold-forming takes
place
 Types of Lathes
• Centre lathe or Engine lathe
• Speed lathe
• Tool room lathe
• Turret lathe
• Capstan lathe
• Automatic lathe
• Numerical control lathe
 Centre lathe or engine lathe
• Most frequently used in
manufacturing
• They are heavy duty
machine tools with all the
components have power
drive for all tool
movements except on
compound rest.
• Most engine lathes are
equipped with chip pans
and a built-in coolant
circulating system.
 Speed Lathe
 Speed lathes usually have
only a headstock, a
tailstock, and a simple
tool post
 Usually three or four
speeds
 Mainly used for wood
turning, polishing, or
metal spinning
 Spindle speeds up to
4000 rpm.
 Tool room lathe
• These lathes are of
precision category with
wide range of speeds and
feeds
• Equipped with gear box to
cut threads of varying
pitches like metric, inches
• Used for production of
small tools, dies, gauges,
fixtures and precision
parts etc
 Turret Lathe
• Designed for short and
continuous production runs
• Have a tool turret in place
of tailstock
• Different tools for drilling,
countersinking, reaming
and tapping are mounted
on different turret stations,
which can be indexed
• Can be operated by less
skilled labour
 Capstan Lathe
• A production lathe
• Used for small
components
• Small in size as
compared to turret lathe
• Slide mechanism
difference as compared
to turret
 Automatic Lathe
• Can be of bar or
chucking types with a
single or multiple
spindles
• All operations like
speed and feed change,
tool change, tool
movement are carried
automatically by cam or
limit switch
 Numerical Control Lathe
• All the operations are
done using pre-
programmed numerical
data codes
• Computer numerical
Control (CNC) lathe
machines are latest
advancements
 Cutting tools used in lathe
Single Point Cutting Tools
Bit-Type Cutting Tools
Form Tools (tapering and Threading Tool)
 Tool Materials
1. Tool steels
2. High speed steel (HSS)
3. Cemented carbides
4. Coated carbides
5. Ceramics
6. Cermets (ceramic material in a metallic binder)
7. Sintered polycrystalline cubic boron nitride
(CBN)
8. Sintered polycrystalline diamond (PCD)
Tool Comparison
Single Point Cutting tool geometry
Single Point Cutting tool geometry
Tool designation
Continuous chips without Continuous chips with BUE Discontinuous chips
BUE
Ductile material Stronger adhesion b/w chips and Brittle material
tool face
Large rake angle Low rake angle Small rake angle
Smaller uncut thickness Large uncut thickness Large uncut thickness
High cutting speed Low cutting speed
 Drilling
• It is a machining process by which a hole is
produced or enlarged by the use of a specific
type of end cutting tool called the drill
• Most effective and economical method of
producing holes
 Operations related to drilling
Reaming Tapping
A Semi-Finishing Operation to • To make INTERNAL Threads
on an Existing Hole Using Taps
– Slightly Enlarge an Existing
Hole
– To Provide Better Tolerance on
Hole Diameter
– To Improve Surface Finish
 Operations related to drilling
Counterboring Countersinking
• Making of INTERNAL • Similar to Counter-Boring,
STEPPED HOLE in which a Except that the Step in the
Lager Diameter Follows a Hole is Cone Shaped for
Smaller Diameter Partially Flat-Head Screws and Bolts.
into the Hole
 Operations related to drilling
Centering or Centre Drilling

• Drilling of a Starting Hole to Accurately

Establish its Location for Subsequent Drilling