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Machining: A Subtractive Type Manufacturing Process which Imparts Desired Shape, Size, and Finish to the Product by Removing Material in the Form of Chips by a Suitable Cutting Tool and by Providing Suitable Relative Motion Between the Work piece and Cutting Tool
Cutting Tool: Removes Excess Material through Direct Mechanical Contact Tool
Machine Tool: Provides Necessary Relative Motion Between the Work piece and Tool
Turning Step Turning Taper Turning Form Turning Contour Turing Facing Necking Parting-Off Boring Counter-Boring Counter-Sinking Shaping Planing
Directrix
Straight Line Straight Line Straight Line Circular
Process
Tracing Tracing Generation Tracing
Surface Obtained
Planar Surface Cylindrical
Machining Process
Shaping, Planing
Turning
Tailstock
Bed
Lathe Bed
Rib
Headstock assembly
Tailstock assembly
Carriage assembly
Specification of Lathe
Size of a Lathe is Designated by Two Dimensions: 1. Swing: This is the maximum diameter of work piece that can be rotated on a lathe. 2. Maximum distance between headstock and tailstock centres: Indicates the Maximum Length of work piece that can be mounted between centers. 3. Length of Bed
Machining parameters
DN 1000
2.
3.
TOOLROOM Lathe: Most-accurate version, versatile requirements of tool and die work, suitable for smaller parts
to
meet
the
4. GAP-BED Lathe: section of the bed adjacent to headstock is removed to permit larger swing
6. TURRET Lathe A longitudinally feedable hexagon turret replaces the tailstock Ordinary turret lathes use the 11 station tooling setups for complete machining of a piece and minimize machine controlling time. SIX tools can be mounted on the hexagon turret Turret can be rotated about the vertical axis to bring each tool into the operating position and the entire unit can be translated parallel to the ways either manually or by power
7. VERTICAL Lathe
Cutting tools
Geometry, cutting temperature, chip breaker, coolant, Shear plane, Shear angle, throw away type tool,
The point angle, or the angle formed at the tip of the drill, is determined by the material the drill will be operating in. Harder materials require a larger point angle, and softer materials require a sharper angle.
Rotational Speed in Turning ( N in RPM ) is Related to Desired Cutting Speed (V in m/min) at the Surface of the Cylindrica l Workpiece (at the Larger Diameter D1 in mm) by N 1000 V D1 (1)
Feed Rate ( s ) in Turning is Generally Expressed in as mm/rev. Linear Travel Rate D1 2 sL D2 s.N (2)
Depth of Cut t
(3)
Machining Time, Tm
(4)
2 D2 )L 1 4 Tm
Using Expression s of Machining Time (Eq. 4) and Rotational Speed (Eq.1) MRR ( D12
2 D2 )L 4
s.N L
MRR
1000V D1 1 (5)
Usi Expression for Depth of Cut (Eq. 3) and Approximat ing ng MRR 1000 V . s . t (mm 3 / min)
(D1 D2 ) 2 D1
Workholding in Lathe
1. Holding in chuck 2. Holding between centers 3. Holding in a collet 4. Mounting on the faceplate 5. Mounting on the carriage
Live center
Dead center
Face plate
Lathe dog
Half center
Holding in a collet
Forms a collar around the object to be held and exerts a strong clamping force
Advantages:
1. Strong clamping force 2. Speed of chucking is less 3. Self-centering 4. Resistance against being untightened
Holding in a Mandrel
Solid mandrel
Mounting on the carriage Internal turning / Boring Steady and follow rest
Slideways
Shape of the slideway depends on 1. 2. 3. 4. 5. Load carrying capacity ease of manufacturing ease of chip disposal effective lubrication position of slideways
Milling
Milling is the process of machining flat, curved, or irregular surfaces by feeding the workpiece against a rotating cutter containing a number of cutting edges. The milling machine consists basically of a motor driven spindle, which mounts and revolves the milling cutter, and a reciprocating adjustable worktable, which mounts and feeds the workpiece.
Milling Machine
1. Column and knee type 2. Bed type 3. Planer type
Slab milling
Face milling
End milling
Tooth, Cutting edge, Tooth face, Rake surface, Clearance surface, Rake angle, Clearance angle (Primary and secondary), Flute, Land, Heel, Keyways, Hole diameter, Outside diameter, Width, Pitch of teeth
1. Milling cutter, 2. Work piece, 3. Direction of rotation of cutter (primary motion), 4. Feed direction of work piece (secondary motion)
Drilling machine