By Dr.

Vikash Kumar
 Machining
 Machining is an essential process of finishing by which jobs of desired
dimensions and surface finish are produced by gradually removing the
excess material from the preformed blank in the form of chips with the
help of cutting tools.

 Machining Process
 Conversion of raw material (preformed blank by casting, forming etc.)
into product by removing the excess material in the form of chips.

 Purpose of machining is to enable the product

 Fulfill the functional requirement
 Good performance
 To survive longer
Machining requirements
Machine Tools
 Major components of a machining system:
 Workpiece and its fixture
 the machine tool,
 the cutting tool, and
 the tool holder.

 Cutting tool: the body which removes the excess material

through a direct contact

 Machine tool: the machine which provides the necessary

relative motions between the work and the tool
Or,
any stationary power-driven machine that is used to shape or form
parts made of metal or other materials.
 Basic functions of Machine Tools
 Machine Tools basically produce geometrical surfaces like flat,
cylindrical or any contour on the preformed blanks by
machining work with the help of cutting tools.

 The physical functions of a Machine Tool in machining are:

 firmly holding the blank and the tool
 transmit motions to the tool and the blank
 provide power to the tool-work pair for the machining action
 control of the machining parameters, i.e., speed, feed and depth of
cut.
 Concept of Generatrix and Directrix

 For material removal by machining, the work and the tool need relative movements.

 The relative motion responsible for the cutting action is known as the primary or
cutting motion.

 The relative motion responsible for the gradually feeding the uncut portion is
termed as the secondary or feed motion.

 Generation of flat surface

 The principle is shown in Figure where on a flat plain a straight line called Generatrix (G)
is traversed in a perpendicular direction called Directrix (D) resulting a flat surface.

The line generated by

the cutting motion is
called the generatrix.

Line from the feed

motion is termed as
the directrix. Generation of flat surfaces by Generatrix and Directrix.
 Generation of cylindrical surfaces
 A long straight cylindrical surface is obtained by a circle (G)
being traversed in the direction (D) parallel to the axis as
shown in Fig. 2(a)
 A cylindrical surface of short length is obtained by traversing
a straight line (G) along a circular path (D) as indicated in Fig.
2(b)
 Form cylindrical surfaces by rotating a curved line (G) in a
circular path (D) as indicated in Fig. 2 (c and d).

Fig. 2 Generation of cylindrical surfaces (of revolution)

Tool – work motions
 The lines representing the Generatrix and Directrix are usually produced by
the locus of a point moving in two different directions and are actually
obtained by the motions of the tool-tip (point) relative to the work surface.
 The Generatrix and Directrix, tool and the work and their motions generally
remain interconnected.
 Tool work interconnection for straight turning

Fig. 3 Principle of turning (cylindrical surface)

 The connections in straight longitudinal turning shown in Fig. 3 (a) are:
Generatrix (G) – Cutting motion (CM) – Work (W)
Directrix (D) – Feed motion (FM) – Tool (T)
 In case of transverse turning shown in Fig. 3 b
Generatrix (G) – No motion (X) – Tool (T)
Directrix (D) – Cutting motion (CM) – Work (W)

Fig. 3 Principle of turning (cylindrical surface)

 In case of making flat surface in a shaping machine the tool-work
connections are
G – CM – T (Generatrix is provided by the cutting motion imparted to
the cutting tool )
D – FM – W (Directrix is provided by the feed motion of the work)

Fig 4. Principle of producing flat surface in shaping machine

 There are three principal types of machine tools.
 Conventional machine tools are
 designed to perform one or several operations on a variety of parts.

 Production machine tools also called special purpose machines are

 used in high-volume manufacturing systems to perform one or a sequence of
operations repetitively.
 They can be adapted for more than one part of the same family, but the
changes required to switch from one part to another
are usually time-consuming and uneconomical.
 conventional machine tools, integrated with an automated materials
handling system.

 CNC machine tools

 numerically controlled machine tools, which move cutting tools along
complicated paths, often involving simultaneous motions of multiple axes,
according to a stored program.
 CNC machine tools are flexible and can produce very
complex parts in quantity with consistent quality and repeatability.
Conventional machine tools
 Lathe
 Milling
 Shaper
 Planer
 Drilling machine
 Shear
 Grinding machine
 Broaching Machine
Lathe Machine Tool
Cutting Tool for Lathe machine
 Components Manufactured by Turning Operation
Ref.:https://www.google.com/search?q=products+manufactured+using+lathe+machine&sxsrf=ALiCzsbuSDamS0kG8m7sWxYvAr0L44hS0A:1672720978752&source=lnms&tbm=isch&sa=X&ved=2ahU
KEwjSsPydy6r8AhXx7TgGHcgBDQEQ_AUoAXoECAEQAw&biw=1366&bih=568&dpr=1#imgrc=rkVMNRYzZIWRxM
 Major components of lathe and their function
 Head stock: it holds the blank and through that power and
rotation are transmitted to the job at different speeds
 tailstock: supports longer blanks and often accommodates
tools like drills, reamers etc for hole making.
 carriage: accommodates the tool holder which in turn holds
the moving tools
 bed: headstock is fixed and tailstock is clamped on it.
Tailstock has a provision to slide and facilitate operations at
different locations.carriage travels on the bed
 columns: on which the bed is fixed
 Specification of Centre lathe
 Max. diameter and length of job that can be
accommodated.
 Power of the main drive
 Range of spindle speeds
 Range of feeds
 Space occupied by the machine.
Shaper
Machine
Cutting tool is given a
reciprocating motion and
after every stroke, work is fed
perpendicularly.

Shaping machines are generally

used for producing flat
surfaces, grooving, splitting
etc.

Because of poor productivity and process

capability these machine tools are not
widely used now-a-days for production.
 The major parts are
 Ram: it holds and imparts cutting motion to the tool through
reciprocation
 Bed: it holds and imparts feed motions to the job (blank)
 Housing with base: the basic structure and also accommodate the
drive mechanism
 Power drive with speed and feed change mechanisms.

Schematic view of a shaping machine

 Planer Machine
The workpiece is
provided with the
Cutting motion

Feed Motion is given

to the cutting tool.

Planing machines are

usually very large in
size and used for
large jobs and heavy
duty work.
Components Manufactured by Shaping Operation
 Specification of Shaping or Planing Machine
 Length, breadth and depth of the bed
 Maximum axial travel of the bed and vertical travel of
the bed / tool
 Maximum length of the stroke (of the ram / tool)
 Range of number of strokes per minute
 Range of table feed
 Power of the main drive
 Space occupied by the machine
 Milling machine

Its major parts are

➢ Milling arbour: to hold and rotate the
cutter
➢ Ram: to support the arbour
➢ Machine table: on which job and job
holding devices are mounted to provide
the feed motions to the job.
➢ Power drive with Speed and gear boxes: to
provide power and motions to the tool-
work
➢ Bed: which moves vertically upward and
downward and accommodates the
various drive mechanisms
➢ Column with base: main structural body
to support other parts. Schematic view of a milling machine
Milling machines are also quite
versatile and can do several
operations like
➢ making flat surfaces
➢ grooving, slitting and parting
➢ helical grooving

Milling Machine Tool

Cutting Tool for Milling
Some common milling operation
Components Manufactured by Milling Operation
 Specification of Milling machine
 Size of the work table
 Range of travels of the table in X-Y-Z directions
 Arbour size (diameter)
 Power of the main drive
 Range of spindle speed
 Range of table feeds in X-Y-Z directions
 Floor space occupied.
 Drilling machine

▪ The major parts are

▪ Column with base: it is the basic
structure to hold the other parts
▪ Drilling head: this box type
structure accommodates the power
drive and the speed and feed gear
boxes.
▪ Spindle: holds the drill and
transmits rotation and axial
translation to the tool for providing
cutting motion and feed motion –
both to the drill

Schematic view of a drilling machine

 Specification of Drilling Machine
 Maximum drill size (diameter) that can be used
 Size and taper of the hole in the spindle
 Range of spindle speeds
 Range of feeds
 Power of the main drive
 Range of the axial travel of the spindle / bed
 Floor space occupied by the machine
Machine Tool Drives
 For the desired tool-work motions with power, machine
tools are driven by electric motors and use of some
mechanisms like belt-pulley, gears etc.
 Machine tool drives:
 Refers to source and transmission of motion and power
 Sources of motion and power
 Electric motors
 Hydraulic power drive
 Machine tools need wide ranges of speed and feed for:
➢ Machining different jobs (material and size)
➢ Using different cutting tools (material, geometry and size)
➢ Various machining operations like high speed turning to low
speed thread cutting in lathes
➢ Degree of surface finish desired.
 Machine Tool drive may be
 Stepped drive (common in conventional machine tools
where a discrete number of speeds and feeds are available
 Step pulley
 Gear boxes
 Chain drive
 Stepless drive (modern CNC machine tools are provided
with stepless drives enabling optimum selection and
flexibly automatic control of the speeds and feeds)
 Cone pulley drive
 Variable speed AC or DC motors
 Stepper and servo-motors
 Hydraulic drive
Kinematic System And Working
Principle Of Lathes
 Kinematic System means the arrangement or the
system of mechanisms or the chain of structure of
mechanisms which enable transform and transmit
motions from the power source to the job and the
cutting tool for the desired machining action.
 Kinematic system deals with transmission and
transformation of motion at the cutting tool and job.
Norton
Drives

Meander
Drives

Schematic diagram of a centre lathe

 The job gets rotation (and power) from the motor through the belt-pulley, clutch and
then the speed gear box which splits the input speed into a number (here 12) of
speeds by operating the cluster gears.
 The cutting tool derives its automatic feed motion(s) from the rotation of the spindle
via the gear quadrant, feed gear box and then the appron mechanism where the
rotation of the feed rod is transmitted
- either to the pinion which being rolled along the rack provides the longitudinal feed
- or to the screw of the cross slide for cross or transverse feed.
 While cutting screw threads the half nuts are engaged with the rotating lead screw to
positively cause travel of the carriage and hence the tool parallel to the lathe bed i.e.,
job axis.
 The feed-rate for both turning and threading is varied as needed by operating the
Norton gear and the Meander drive systems existing in the feed gear box (FGR). The
range of feeds can be augmented by changing the gear ratio in the gear quadrant
connecting the FGB with the spindle
 As and when required, the tailstock is shifted along the lathe bed by operating the
clamping bolt and the tailstock quil is moved forward or backward or is kept locked
in the desired location.
Kinematics of Drilling Machine Tool

RM- Reversal Mechanism

 Cutting motion:
 attained by rotating the drill at different speeds (r.p.m.)
 large number of spindle speeds to cover the useful ranges of work material,
tool material, drill diameter, machining and machine tool conditions
 the drill gets its rotary motion from the motor through the speed gear box
(SGB) and a pair of bevel gears.
 For the same motor speed, the drill speed can be changed to any of the 12
speeds by shifting the cluster gears in the SGB.
 The direction of rotation of the drill can be changed, if needed, by operating
the clutch in the speed reversal mechanism.

 Feed motion
 the drill receives its feed motion from the output shaft of the SGB through
the feed gear box (FGA), and the clutch.
 The feed rate can be changed to any of the 6 rates by shifting the gears in the
FGB.
 And the automatic feed direction can be reversed, when required, by
operating the speed reversal mechanism, RM-s as shown.
 Applications of Drilling Machine
 Drilling through or blind holes
 Centering
 Slotting
 Boring
 Counterboring and countersinking
 Reaming (finishing)
 Tapping (Cutting internal thread)
Kinematics of Milling Machine Tool

Schematic views of conventional up and down milling

 Difference between upmilling and downmilling

UP MILLING MACHINE DOWN MILLING MACHINE

The cutting forces act upward in Here the cutting forces act opposite
the UP Milling as you can see in the to the up milling or you can say
diagram. downward.

Down Milling or Climb Milling

The UP Milling process is used for
Process is used for the final or
rough purposes.
finishing operation.

Surface finishing is not good. Here surface finishing is great.

It is used for cutting of brass, But This one is applicable to

bronze, and ferrous materials. aluminum and aluminum alloys.

The cutter rotates against the the cutter rotates in the same
direction of the feed. direction of feed.
Kinematic diagram of a milling machine
Kinematic system and working principles of
Shaping Machine
• Control of stroke
length & position
• Quick return ratio
(QRR) =
(2l+S)/(2l-S)
where l = length of
lever, S = stroke
length
• Control of cutting
speed and feed
• Speed can be
control by
number of
stokes/min
• Feed can be
control by
changing the
eccentricity of
rod.
Kinematic diagram of a shaping machine
Gears Manufacturing
Basic Purpose Of Use Of Gears
 Gears are widely used in various mechanisms and devices
to transmit power and motion positively (without slip)
between parallel, intersecting ( axis) or non-intersecting
non parallel shafts,
 without change in the direction of rotation
 with change in the direction of rotation
 without change of speed (of rotation)
 with change in speed at any desired ratio
General Applications Of Gears
 Speed gear box, feed gear box and some other kinematic units of
machine tools
 Speed drives in textile, jute and similar machineries
 Gear boxes of automobiles
 Speed and / or feed drives of several metal forming machines
 Machineries for mining, tea processing etc.
 Large and heavy duty gear boxes used in cement industries,
sugar industries, cranes, conveyors etc.
 Precision equipments, clocks and watches
 Industrial robots and toys.
Types Of Gears
 (a) According to configuration
 External gear
 • Internal gear

a) Straight toothed (b)Helical and (c) Double helical gears

 (b) According to axes of transmission
 Spur gears

a) Straight toothed (b)Helical and (c) Double helical gears

 • Bevel gears – transmitting motion between
intersecting shafts

Bevel gear straight toothed

 Gears transmitting motion and power between non-
parallel nonintersecting
 shafts (Fig. 7.2.5)
 o Worm and worm wheel
 o Spiral gears
 o Skewed or hypoid bevel gears

(a) worm and worm wheel, (b) hypoid gear and (c) spiral gears.
Specification Of Gears
 Type: e.g. spur, bevel, spiral etc.
 Material: metal (Fe, non Fe), non metals, composite
 Size or dimensions: module, number of teeth, width
 Geometry: pressure angle, Addendum, dedendum
 Special features:
 Tooth bevelling for safe handling,
 Tooth crowning for uniform wear,
 Tooth rounding for easy engagement
 Manufacture Of Gears
 Manufacture of gears needs several processing operations in sequential
stages depending upon the material and type of the gears and quality
desired.
 Those stages generally are :
⎯ Preforming the blank without or with teeth
⎯ Annealing of the blank, if required, as in case of forged or cast steels
⎯ Preparation of the gear blank to the required dimensions by
machining
⎯ Producing teeth or finishing the preformed teeth by machining
⎯ Full or surface hardening of the machined gear (teeth), if required
⎯ Finishing teeth, if required, by shaving, grinding etc.
⎯ Inspection of the finished gears.