MCT-113 Manufacturing Processes

Report on Lathe and Milling Machine

Submitted by:
Muhammad Abu Bakar Khan Niazi
2022-MC-10
Submitted to:
Misbah Rehman
Submission Date
6th-July-2023

Department of Mechatronics and Control Engineering

University of Engineering and Technology, Lahore.
CONTENTS:
(SECTION I)
 Introduction to lathe machine________________________ 3
 Different parts of lathe machine_______________________3-4
 Operations performed on lathe machine________________4-5
 Lathe machine picture_______________________________5
 Work perfomed____________________________________6
 Tools available on lathe______________________________6-7
 CNC lathe_________________________________________7-8
(SECTION II)
 Introduction to milling machine_______________________8
 Different parts of Milling Machine_____________________8-9
 Milling Machine____________________________________10
 Work performed in lab______________________________10
 Details of milling operations__________________________10-11
 Milling tools and cutters_____________________________11-12
 CNC milling machine________________________________12-13
 (Section I)
 Introduction to Lathe Machine
A lathe machine is a versatile and widely used tool in machining processes. It is
designed to rotate a work piece on its axis while various cutting tools are
applied to shape the material into the desired form. The lathe machine can
perform operations such as cutting, drilling, turning, and facing.

 Parts of Lathe Machine

 Bed: The bed is the main base of the lathe machine. It provides
support and rigidity to the other components and ensures the
accuracy of the machining process.
 Headstock: The headstock is located at one end of the lathe's bed. It
houses the main spindle, which rotates the work piece. The headstock
also contains gears and pulleys that enable the spindle to rotate at
different speeds.
 Tailstock: The tailstock is positioned at the opposite end of the lathe
bed. It can move along the bed and is used for supporting the work
piece during machining. The tailstock may include a centre, which
helps in aligning the work piece with the spindle.
 Carriage: The carriage is mounted on the lathe bed and can move
longitudinally along the bed ways. It consists of several components,
including the saddle, cross-slide, and tool post. The carriage carries
the cutting tools and controls their movements.
 Saddle: The saddle is an essential part of the carriage. It provides
support to the cross-slide and can move transversely along the
carriage. The saddle allows for precise tool positioning and feed
adjustments.
 Cross-slide: The cross-slide is mounted on the saddle and can move
perpendicular to the spindle axis. It carries the tool post and can be
adjusted to control the depth and direction of the cut.
 Tool post: The tool post holds the cutting tools and allows for their
quick and easy change. It can be adjusted to set the tool height and
angle, ensuring proper tool alignment with the work piece.
 Chuck: The chuck is a device attached to the spindle for securely
gripping the work piece. It may be a three-jaw chuck, four-jaw chuck,
or other specialized types depending on the application.
 Feed rod: The feed rod enables the carriage to move automatically
along the bed ways. It is connected to the lead screw, which
translates rotary motion into linear motion for precise tool feed.
 Lead screw: The lead screw is responsible for the longitudinal
movement of the carriage. It engages with the feed rod and allows
for accurate positioning of the tool along the work piece.
 Apron: The apron is a protective cover located below the carriage. It
safeguards the mechanisms such as gears, clutches, and feed
mechanisms from debris and ensures smooth operation.
 Speed control: A lathe machine often includes a speed control
mechanism to adjust the rotational speed of the spindle. This allows
for optimal cutting conditions depending on the material and
machining operation.
 These are the basic components of a lathe machine. Depending on
the type and complexity of the lathe, there may be additional parts
and accessories for specialized operations, such as taper turning
attachments, steady rests, and follow rests.
 Lathe Machine
  Performed work on lathe machine

Hexagonal shape

 Operations Performed on lathe machine

A lathe machine provides a wide range of machining capabilities and plays
a crucial role in various industries, including metalworking, woodworking,
and fabrication. The lathe Machine can perform operations such drilling,
cutting, turning and facing.

o Turning
It involves rotating the work piece against a cutting tool to remove
material and create a cylindrical shape.
o Facing
It is the process of creating a flat surface perpendicular to the axis of
rotation.
o Boring
 It is the process of enlarging the existing hole or creating a cylindrical
cavity in a work piece.
o Drilling
Some lathe machines have the capability to perform the drilling
operations. The lathe spindle can be fitted with a drill chuck to hold
drill bits.
o Thread cutting
Lathe machines can be used to cut external and internal threads on a
work piece.
o Knurling
It is process of creating a textured pattern on the surface of a work
piece.
o Parting
Parting is the operation of cutting off work piece from a larger stock.
 Tools available for lathe
Here are some common tools used with a lathe:

 Cutting tools: These tools are used for shaping and cutting the
material being turned on the lathe. They included:
o Parting tools: Use for cutting of the work piece from the stock.
o Boring tools: Use for enlarging the existing holes or creating internal
features.
o Threading tools: Used for cutting threads on the work piece.
 Tool holders: These are holders or tools posts that secure the
cutting tools and allow for quick and easy tool changes.
 Chuck: A chuck is a device used to hold the work piece securely in
place on the lathe.
 Faceplates: A faceplate is a flat, circular metal plate attached to the
spindle of the lathe.
 Centres: Centres are used to support the work piece during turning
operations. They include:
1. Dead centre: A fixed centre that is inserted into the tailstock.
2. Live centre: A rotating centre that supports the work piece
and rotates with it.
  Steady Rest: A steady rest is a device used to support long, thin
work pieces during vibration during turning.
 Lathe chuck key: A chuck key is use to tightened or loosen the jaws
of a lathe chuck.
 Measuring tools: Various tools are used for the accurate
measurement and alignment including callipers, micrometre, dial
indicators, and depth gauges.
 Cutting fluids: lubricant and cutting fluids are often used during
machining operations to improve cutting performance.
 Lathe accessories: There are numerous additional accessories
available such as tool resets, lathe dogs, tailstock drill chucks,
collets, steady resets.
 CNC Lathe:
A CNC lathe, also known as a computer numerical control lathe, is a type
of machine tool used in manufacturing processes. It is designed to
perform various operations such as turning, facing, drilling, and
threading on a rotating work piece.

Here are some key features and components of a CNC lathe:

1. Bed: It is the base of the machine and provides a stable platform

for other components.
2. Headstock: The headstock contains the main spindle that holds
and rotates the workpiece. It may have multiple speed settings to
accommodate different machining requirements.
3. Chuck: The chuck is used to secure the workpiece in place. It can
be either a three-jaw chuck or a four-jaw chuck, depending on the
shape and requirements of the workpiece.
4. Tool Turret: The tool turret holds various cutting tools that can be
automatically positioned and engaged during the machining
process. It allows for quick tool changes and reduces downtime.
5. Tooling: Different types of cutting tools are used for various
machining operations, such as turning tools, boring tools,
threading tools, and grooving tools.
 6. Control System: The CNC lathe is operated by a computerized
control system that manages the movement and operation of the
machine. The operator programs the desired specifications and
machining instructions into the system.
7. Axis Movement: A CNC lathe typically has two main axes: The X-
axis and the Z-axis. The X-axis controls the horizontal movement of
the tool, while the Z-axis controls the longitudinal movement
along the work piece.
8. Automatic Feed: CNC lathes are capable of automatic feed,
meaning the cutting tool moves along the work piece without
manual intervention. This allows for precise and consistent
machining.
9. Coolant System: To prevent overheating and remove chips from
the work piece, CNC lathes often include a coolant system that
sprays cutting fluid onto the tool and work piece during
machining.

CNC lathes offer several advantages over conventional lathes, such as

increased accuracy, repeatability, and efficiency. They are widely used in
industries like automotive, aerospace, electronics, and general
manufacturing for producing a variety of components with high
precision.

(Section II)
 Introduction to milling machine
A milling machine is a versatile machine tool that is used to remove material
from a work piece by rotating a cutting tool called a milling cutter. It is one of
the fundamental machines in the manufacturing industry and is widely used
for various machining operations such as milling, drilling, boring, and
threading.
The primary function of a milling machine is to accurately shape and size solid
materials, typically metal, but it can also be used on other materials like wood
or plastic. The machine consists of a stationary worktable or bed, on which the
work piece is securely clamped, and a movable cutting tool that is controlled
by a spindle.

 Parts of Milling Machine

The parts are:
 Base: The base is a heavy, solid foundation that supports all the
other components of the milling machine.
 Column: The column is a vertical structure mounted on the base. It
provides support and houses the mechanism for raising and
lowering the knee or the entire vertical milling head.
 Knee: The knee is a vertically adjustable part of the milling machine
that moves up and down on the column. It is used to support and
adjust the position of the saddle and table.
 Saddle: The saddle is a horizontal part that moves along the knee.
It supports the table and can be moved manually or automatically.
 Table: The table is a flat surface located on the saddle. It provides
support for the workpiece and can be moved in different directions
to achieve precise machining.
 Spindle: The spindle is a rotating shaft that holds the cutting tool.
It can be driven by an electric motor and can rotate at different
speeds.
 Arbor: The arbor is a cylindrical device that holds the milling cutter.
It is mounted on the spindle and rotates with it to perform cutting
operations.
 Overarm: The overarm is a horizontal beam that extends from the
top of the column. It provides support for the arbor and can be
adjusted in different positions.
 Milling Head: The milling head is the upper part of the milling
machine that contains the spindle, arbour, and other components.
It can be moved vertically or horizontally to perform different types
of milling operations.
  Controls: The milling machine is equipped with various controls
and handles that allow the operator to adjust the speed, feed rate,
direction of movement, and other parameter.
 Milling Machine

 Work Performed

 Milling Operation
Milling operations refer to the process of using rotary cutters to
remove material from a work piece, resulting in the desired shape
and surface finish. Milling is a common machining process used in
various industries, including manufacturing, aerospace, automotive,
and more.
 Machine Tool: Milling operations are typically performed on a
milling machine, also known as a mill. There are different types of
milling machines, such as vertical mills, horizontal mills, and
 universal mills, each offering specific advantages depending on the
application.
 Work piece and Featuring: The work piece is the material being
machined. It can be metal, plastic, wood, or other materials. The
work piece is usually secured to the milling machine's table or a
fixture to ensure stability during the cutting process.
 Cutting Tools: Milling employs a rotating cutting tool known as a
milling cutter. These cutters have multiple cutting edges and come
in various shapes and sizes to accommodate different machining
tasks. Common types of milling cutters include end mills, face mills,
ball mills, and slot drills.
 Types of Milling Operations: There are several types of milling
operations, including face milling, peripheral milling, end milling,
slot milling, and more. Each operation involves a specific cutter and
cutting path to achieve the desired result. For example, face milling
is used to create flat surfaces, while slot milling is used to cut slots
or grooves.
 Cutting Parameters: Milling operations req uire careful selection of
cutting parameters to achieve optimal results. These parameters
include the cutting speed, feed rate, depth of cut, and the direction of
cutter rotation. Adjusting these parameters can impact the material
removal rate, surface finish, and tool life.
 CNC Milling: Computer Numerical Control (CNC) milling machines are
widely used in modern machining operations. They are automated
machines controlled by computer programs that dictate the tool's
movement and cutting parameters. CNC milling offers greater
precision, repeatability, and the ability to produce complex shapes.
 Milling Applications: Milling is used for a wide range of applications,
such as creating flat surfaces, contours, pockets, and holes in the
work piece. It can also be used for precision machining, prototyping,
production runs, and customization of parts.
 Milling operations provide great versatility and are capable of
producing intricate and precise parts. However, they require skilled
operators and appropriate tooling to ensure optimal results.
 Milling tools and cutters
Milling tools and cutters are essential equipment used in the machining
process of milling, which involves removing material from a workpiece to
create complex shapes and features. These tools are typically used in
milling machines, which are power-driven machines that utilize rotary
cutters to perform the milling operation.

Here are some common types of milling tools and cutters:

 End Mills: End mills are one of the most common types of milling
cutters. They have cutting edges on the periphery and the end of
the tool. End mills are available in various shapes, such as square
end, ball end, corner radius, and tapered end, each suitable for
specific milling applications.
 Face Mills: Face mills have a large cutting diameter and multiple
cutting edges. They are primarily used for facing operations and
creating flat surfaces on the workpiece. Face mills may have
insertable carbide or HSS (high-speed steel) cutting inserts.
 Slotting Cutters: Slotting cutters are used to create slots or grooves
in the workpiece. They have a cylindrical body with teeth on the
periphery and are available in different widths to produce slots of
various sizes.
 Ball Nose Cutters: Ball nose cutters are similar to end mills but have
a rounded end. They are commonly used for 3D contouring and
machining curved surfaces. The rounded end helps in reducing
stress concentration and producing smooth finishes.
 Shell Mills: Shell mills are large-diameter cutters with multiple
cutting edges. They are typically used for heavy-duty milling
operations, such as facing large surfaces or machining wide slots.
 Slitting Saws: Slitting saws are thin, circular saw blades with teeth
on the periphery. They are used for cutting narrow slots, grooves,
and parting off operations. Slitting saws can be either solid or with
inserted carbide or HSS teeth.
 T-Slot Cutters: T-slot cutters are specialized cutters used for
machining T-shaped slots. They have a unique T-shaped body with
cutting edges on the bottom and sides.
  Fly Cutters: Fly cutters consist of a single-point cutting tool
mounted on a rotating spindle. They are used for light milling
operations and producing flat surfaces. Fly cutters are often used
with manual milling machines.
 These are just a few examples of milling tools and cutters available
in the industry. The selection of the appropriate tool depends on
factors like the desired shape, material being machined, cutting
speed, feed rate, and other machining parameters.
 CNC Milling
Here are the key steps involved in the CNC milling process:
 Design: A 3D model or a 2D drawing of the desired part is created using
computer-aided design (CAD) software. This model defines the shape,
dimensions, and specifications of the part.
 CAM Programming: Computer-aided manufacturing (CAM) software is
used to generate the toolpaths and instructions for the CNC milling
machine. The CAM program takes into account the geometry of the part,
cutting tool selection, cutting parameters, and other factors.
 Machine Setup: The workpiece, typically a solid block of material such as
metal or plastic, is secured to the milling machine's worktable using
clamps or vises. The cutting tool is installed in the machine's spindle.
 Tool Setup: The CNC machine operator installs the appropriate cutting
tool based on the requirements of the part and the CAM program. The
tool may need to be properly aligned and calibrated.
 Program Loading: The CAM program is loaded into the CNC milling
machine's control unit. This program contains the instructions for the
machine's movements, tool changes, cutting speeds, and other
parameters.
 Execution: The CNC milling machine begins executing the program,
moving the cutting tool along the specified toolpaths to remove material
from the work piece. The machine may perform multiple passes, varying
cutting speeds and depths as necessary to achieve the desired result.
 Finishing Operations: After the initial milling, additional operations like
drilling, tapping, or surface finishing may be performed using different
tools or setups.
 Inspection: The finished part is inspected for dimensional accuracy and
quality. Any necessary adjustments or corrections can be made at this
stage.
 CNC milling offers several advantages, including high precision,
repeatability, complex part geometries, and the ability to work with a
wide range of materials. It allows for efficient and accurate production of
parts and components for various applications.
The End.