8/1/2022

Machine Tools

Definition of Machine Tool

• A machine tool is a non-portable power operated
and reasonably valued device or system of
devices in which energy is expended to produce
jobs of desired size, shape and surface finish by
removing excess material from the preformed
blanks in the form of chips with the help of
cutting tools moved past the work surface(s).
• The term machine tool is usually reserved for
tools that used a power source other than human
movement, but they can be powered by people if
appropriately set up.

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Machining
A material removal process in which a sharp cutting
tool is used to mechanically cut away material so
that the desired part geometry remains
• Most common application: to shape metal parts
• Most versatile of all manufacturing processes in
its capability to produce a diversity of part
geometries and geometric features with high
precision and accuracy
– Casting can also produce a variety of shapes, but it lacks the
precision and accuracy of machining

©2007 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
Modern Manufacturing 3/e

Machining Operations and Part Geometry

Each machining operation produces a

characteristic part geometry due to two
factors:
1. Relative motions between tool and work part
• Generating – part geometry determined by feed
trajectory of cutting tool
2. Shape of the cutting tool
• Forming – part geometry is created by the shape of the
cutting tool

©2007 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
Modern Manufacturing 3/e

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Generating Shape

Figure 22.2 Generating shape: (a) straight turning, (b) taper turning, (c)
contour turning, (d) plain milling, (e) profile milling.
©2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e

Forming to Create Shape

Figure 22.3 Forming to create shape: (a) form turning, (b) drilling, and (c)
broaching.

©2007 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
Modern Manufacturing 3/e

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Forming and Generating

Figure 22.4 Combination of forming and generating to create shape: (a)

thread cutting on a lathe, and (b) slot milling.
©2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e

Classification of Machine Tools

• Machine tools may be classified under three main
categories: Conventional chip-making Machine
Tools, Presses, and Unconventional Machine Tools.
– Conventional chip-making tools shape the workpiece by
cutting away the unwanted portion in the form of chips.
– Presses employ a number of different shaping processes,
including shearing, pressing, or drawing (elongating).
– Unconventional machine tools employ light, electrical,
chemical, and sonic energy; superheated gases; and high-
energy particle beams to shape the exotic (unusual)
materials and alloys that have been developed for
modern technology

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Classification of Machine Tools Cont’d

Alternative classification of Machine Tools 1

• Rotational - cylindrical or disk-like shape

• Non rotational - block-like or plate-like

Machined parts are classified as: (a) rotational, or (b) non rotational,
shown here by block and flat parts.

©2007 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
Modern Manufacturing 3/e

Classification of Machine Tools Cont’d

• Alternative classification of Machine Tools 2
– According to the geometrical shapes of the
workpieces
• Machine tools for machining flat surfaces (shapers,
planers)
• Machine tools for machining cylindrical surfaces (lathes)
• Machine tools for making holes(drilling machines)
• Machine tools for machining profiles(milling, hobbing
machine tools)

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Classification of Machine Tools Cont’d

• Alternative classification of Machine Tools Cont’d
– According to the type of work and number of the
workpieces
• Simple Machine Tools
• Universal Machine Tools (general purpose)
• Production Machine Tools (special purpose)
• Special Machine Tools (limited purpose)
• Transfer Machine Tools
• Numerical Controlled Machine Tools

Classification of Machine Tools Cont’d

• Alternative classification of Machine Tools Cont’d
– According to the functions of the machines
• Turning Machines
• Drilling Machines
• Milling Machines
• Shaping Machines
• Grinding Machines
• Sawing Machines
• Broaching Machines
• Gear Cutter Machines
• Super Finish Machines

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Classification of Machine Tools Cont’d

• Alternative classification of Machine Tools Cont’d
– According to direction of major axis
• Horizontal centre lathe, horizontal boring machine
etc.
• Vertical – vertical lathe, vertical axis milling
machine etc.
• Inclined – special ( e.g. for transfer machines).
– According to purpose of use
• General purpose – e.g. centre lathes, milling machines,
drilling machines etc.
• Single purpose – e.g. facing lathe, roll turning lathe etc.
• Special purpose – for mass production.

Classification of Machine Tools Cont’d

• Alternative classification of Machine Tools Cont’d
– According to degree of automation
• Non-automatic – e.g. centre lathes, drilling machines etc.
• Semi-automatic – capstan lathe, turret lathe, Hobbin machine etc.
• Automatic – e.g., single spindle automatic lathe, swiss type automatic lathe,
CNC milling machine etc.
– According to size
• Heavy duty – e.g., heavy duty lathes (e.g.≥ 55 kW), boring mills, planning
machine, horizontal boring machine etc.
• Medium duty – e.g., lathes – 3.7 ~ 11 kW, column drilling machines, milling
machines etc.
• Small duty – e.g., table top lathes, drilling machines, milling machines.
• Micro duty – e.g., micro-drilling machine etc.
• According to precision
• Ordinary – e.g. , automatic lathes
• High precision – e.g., Swiss type automatic lathes

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Classification of Machine Tools Cont’d

• Alternative classification of Machine Tools Cont’d
– According to number of spindles
• Single spindle – centre lathes, capstan lathes, milling
machines etc.
• Multi-spindle – multispindle (2 to 8) lathes, gang drilling
machines etc.
– According to blank type
• Bar type (lathes)
• Chucking type (lathes)
• Housing type

Classification of Machine Tools Cont’d

• Alternative classification of Machine Tools Cont’d
– According to type of automation
• Fixed automation – e.g., single spindle and multi spindle
lathes
• Flexible automation – e.g., CNC milling machine
– According to configuration :
• Standalone type – most of the conventional machine tools.
• Machining system (more versatile) – e.g., transfer machine,
machining centre, FMS etc.

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Conventional Chip-Making Machine Tools

Lathe

Conventional Chip-Making Machine

Tools Cont’d
Shaper

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Conventional Chip-Making Machine

Tools Cont’d
Shaper

Conventional Chip-Making Machine

Tools Cont’d
Planer

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Conventional Chip-Making Machine

Tools Cont’d
Planer

Conventional Chip-Making Machine

Tools Cont’d

Vertical
Milling
Machine

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Conventional Chip-Making Machine

Tools Cont’d

Horizontal
Milling
Machine

Conventional Chip-Making Machine

Tools Cont’d

Drilling
&
Boring Machines

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Conventional Chip-Making Machine

Tools Cont’d

Drilling
&
Boring Machines

Conventional Chip-Making Machine

Tools Cont’d

Drilling
&
Boring Machines

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Conventional Chip-Making Machine

Tools Cont’d

Surface Grinding Machine

Conventional Chip-Making Machine

Tools Cont’d
Saws

Power-Driven Saws

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Turning
Single point cutting tool removes material
from a rotating workpiece to generate a
cylinder
• Performed on a machine tool called a
lathe
• Variations of turning performed on a
lathe:
– Facing
– Contour turning
– Chamfering
– Cutoff
– Threading

Turning

Turning operation.

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Turning Operation

Close-up view of a
turning operation on
steel using a titanium
nitride coated carbide
cutting insert (photo
courtesy of Kennametal
Inc.)

Facing

Tool is fed
radially inward

(a) Facing

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Contour Turning

• Instead of feeding
tool parallel to axis
of rotation, tool
follows a contour
that is other than
straight, thus
creating a
contoured shape
(c) contour turning

Chamfering
• Cutting edge cuts an angle on the corner
of the cylinder, forming a "chamfer"

(e) chamfering

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Cutoff

• Tool is fed radially into rotating work

at some location to cut off end of part

(f) cutoff

Threading
• Pointed form tool is fed linearly across surface of
rotating workpart parallel to axis of rotation at a
large feed rate, thus creating threads

(g) threading

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Engine Lathe

Figure 22.7
Diagram of an
engine lathe,
showing its
principal
components

Methods of Holding the Work in a

Lathe
• Holding the work between centers
• Chuck
• Collet
• Face plate

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Holding the Work Between Centers

(a) mounting the work between centers using a "dog”

Chuck

(b) three-jaw chuck

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Collet

(c) collet

Face Plate

(d) face plate for non-cylindrical workparts

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Turret Lathe
Tailstock replaced by “turret” that holds up to
six tools
• Tools rapidly brought into action by indexing
the turret
• Tool post replaced by four-sided turret to
index four tools
• Applications: high production work that
requires a sequence of cuts on the part

Chucking Machine
• Uses chuck in its spindle to hold workpart
• No tailstock, so parts cannot be mounted
between centers
• Cutting tool actions controlled automatically
• Operator’s job: to load and unload parts
• Applications: short, light-weight parts

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Bar Machine
• Similar to chucking machine except collet
replaces chuck, permitting long bar stock to
be fed through headstock
• At the end of the machining cycle, a cutoff
operation separates the new part
• Highly automated (a.k.a. automatic bar
machine)
• Applications: high production of rotational
parts

Automatic Screw Machine

• Same as automatic bar machine but smaller
• Applications: high production of screws and
similar small hardware items

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Multiple Spindle Bar Machines

• More than one spindle, so multiple parts
machined simultaneously by multiple tools
– Example: six spindle automatic bar machine works on six
parts at a time
• After each machining cycle, spindles (including
collets and workbars) are indexed (rotated) to
next position

Multiple Spindle Bar Machine

Figure 22.9 (a) Part produced on a six-spindle automatic bar machine; and (b)
sequence of operations to produce the part: (1) feed stock to stop, (2) turn
main diameter, (3) form second diameter and spotface, (4) drill, (5)
chamfer, and (6) cutoff.

©2007 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
Modern Manufacturing 3/e

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Boring
• Difference between boring and
turning:
– Boring is performed on the inside diameter of an
existing hole
– Turning is performed on the outside diameter of
an existing cylinder
• In effect, boring is internal turning
operation
• Boring machines
– Horizontal or vertical - refers to the orientation of
the axis of rotation of machine spindle

Vertical Boring Mill

A vertical boring mill – for large, heavy workparts.

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Drilling

• Creates a round
hole in a workpart
• Compare to boring
which can only
enlarge an existing
hole
• Cutting tool called
a drill or drill bit
• Machine tool: drill
press
Figure 21.3 (b) drilling

Through Holes vs. Blind Holes

Through-holes - drill exits opposite side of work
Blind-holes – does not exit work opposite side

Two hole types: (a) through-hole, and (b) blind hole.

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Reaming

• Used to slightly
enlarge a hole,
provide better
tolerance on
diameter, and
improve
surface finish

Machining operations related to

drilling: (a) reaming

Tapping

• Used to provide
internal screw
threads on an
existing hole
• Tool called a tap

Figure 22.14 (b) tapping

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Counterboring
• Provides a
stepped hole, in
which a larger
diameter follows
smaller diameter
partially into the
hole

(c) counter boring

Drill Press
• Upright drill press
stands on the
floor

• Bench drill similar

but smaller and
mounted on a
table or bench

Upright Drill Press

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Radial Drill

Large drill
press
designed for
large parts

Radial drill press (photo

courtesy of Willis Machinery
and Tools).

Work Holding for Drill Presses

• Workpart in drilling can be clamped in any of
the following:
– Vise - general purpose workholder with two jaws
– Fixture - workholding device that is usually
custom-designed for the particular workpart
– Drill jig – similar to fixture but also provides a means of
guiding the tool during drilling

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Milling
Machining operation in which work is fed past
a rotating tool with multiple cutting edges
• Axis of tool rotation is perpendicular to
feed
• Creates a planar surface
– Other geometries possible either by cutter path or
shape
• Other factors and terms:
– Interrupted cutting operation
– Cutting tool called a milling cutter, cutting edges called
"teeth"
– Machine tool called a milling machine

Two Forms of Milling

Two forms of milling: (a) peripheral milling, and (b) face milling.

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Peripheral Milling vs. Face Milling

• Peripheral milling
– Cutter axis parallel to surface being machined
– Cutting edges on outside periphery of cutter
• Face milling
– Cutter axis perpendicular to surface being milled
– Cutting edges on both the end and outside periphery of
the cutter

Slab Milling
• Basic form of peripheral milling in
which the cutter width extends
beyond the workpiece on both sides

(a) slab milling

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Slotting
• Width of cutter is less than workpiece
width, creating a slot in the work

(b) slotting

Conventional Face Milling

Cutter overhangs work
on both sides

(a) conventional face milling

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High speed face

milling using
indexable inserts
(photo courtesy
of Kennametal
Inc.).

End Milling
• Cutter diameter is
less than work
width, so a slot is
cut into part

(c) end milling

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Profile Milling
Form of end milling
in which the
outside periphery
of a flat part is
cut

Figure 22.20 (d) profile milling

©2007 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
Modern Manufacturing 3/e

Pocket Milling

• Another form
of end milling
used to mill
shallow
pockets into
flat parts

(e) pocket milling

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Surface Contouring
• Ball-nose cutter
fed back and forth
across work along
a curvilinear path
at close intervals
to create a three
dimensional
surface form

(f) surface contouring

Horizontal Milling Machine

(a) horizontal knee-and-column milling machine.

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Vertical Milling Machine

(b) vertical knee-and-column milling machine

Machining Centers
Highly automated machine tool can
perform multiple machining
operations under CNC control in one
setup with minimal human attention
– Typical operations are milling and drilling
– Three, four, or five axes
• Other features:
– Automatic tool-changing
– Pallet shuttles
– Automatic workpart positioning

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Universal machining center; highly automated, capable of multiple

machining operations under computer control in one setup with
minimal human attention (photo courtesy of Cincinnati Milacron).

CNC 4-axis turning center (photo courtesy of Cincinnati

Milacron); capable of turning and related operations, contour
turning, and automatic tool indexing, all under computer control.

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Mill-Turn Centers
Highly automated machine tool that can perform
turning, milling, and drilling operations
• General configuration of a turning center
• Can position a cylindrical workpart at a specified
angle so a rotating cutting tool (e.g., milling
cutter) can machine features into outside surface
of part
– Conventional turning center cannot stop workpart at a defined
angular position and does not include rotating tool spindles

Operation of Mill-Turn Center

Figure 22.28 Operation of a mill-turn center: (a) example part with turned, milled, and
drilled surfaces; and (b) sequence of operations on a mill-turn center: (1) turn
second diameter, (2) mill flat with part in programmed angular position, (3) drill hole
with part in same programmed position, and (4) cutoff.

©2007 John Wiley & Sons, Inc.

M P Groover, Fundamentals of
Modern Manufacturing 3/e

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Shaping and Planing

• Similar operations
• Both use a single point cutting tool moved
linearly relative to the workpart

(a) Shaping, and (b) planing.

Shaping and Planing

• A straight, flat surface is created in both
operations
• Interrupted cutting
– Subjects tool to impact loading when entering work
• Low cutting speeds due to start-and-stop
motion
• Typical tooling: single point high speed steel
tools

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Shaper

Components of a shaper.

Planer

Open side planer.

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Broaching

• Moves a multiple tooth cutting tool linearly

relative to work in direction of tool axis

Broaching operation.

Broaching
Advantages:
• Good surface finish
• Close tolerances
• Variety of work shapes possible
Cutting tool called a broach
• Owing to complicated and often
custom-shaped geometry, tooling is expensive

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Internal Broaching

• Performed on internal surface of a hole

• A starting hole must be present in the part
to insert broach at beginning of stroke

Work shapes that can be cut by internal broaching; cross-hatching

indicates the surfaces broached.

Sawing
• Cuts narrow slit in work by a tool consisting of
a series of narrowly spaced teeth
• Tool called a saw blade
• Typical functions:
– Separate a work part into two pieces
– Cut off unwanted portions of part

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Power Hacksaw

(a) power hacksaw –linear reciprocating motion of hacksaw

blade against work.

Band Saw

(b) bandsaw (vertical) – linear

continuous motion of
bandsaw blade, which is in
the form of an endless flexible
loop with teeth on one edge.

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Circular Saw

(c) circular saw – rotating saw blade provides continuous

motion of tool past workpart.

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