UNIT 3- MACHINING

OPERATIONS
MACHINE SHOP
Lecture plan for unit 3
machining section
L8
Unit-III Machining and Welding Operations and their Applications
introduction
Machining: Basic principles of Lathe-machine and operations
performed on it.
L9
Shaper and planer machine, Basic operations performed on shaper &
planer
L10
 Milling machine and basic operations performed on milling machine
L11
 Grinding machine and basic operations performed on grinding
machine
Machining

It is a metal removing operation

from the work piece with the help
of machine tools and cutting tools.
Metal is removed in the form of
chip from the workpiece.
MACHINE AND MACHINE TOOL
Machine is device which is used to produce
required output by supplying necessary input but
without application of  cutting tool.
e.g.- Fan
Machine tool is device which produces output in
terms of  required shape or size by the application
of cutting tool  and supplying necessary input.
e.g.-Lathe
What is a Machine Tool?

In Mechanical Engineering, ‘Machine’ is

nothing but an assembly of mechanisms
that are clustered to perform certain
operations by utilizing electrical,
mechanical, hydraulic, and/or pneumatic
power.
MACHINE TOOL
Whereas, a Machine Tool is a machine having following characteristics:
It must be power driven.
It must be non-portable.
It must have sufficient value.
It can perform more than one type of machining operations.
It utilizes a cutting tool to remove material.
If and only if all the above four conditions are satisfied then a Machine
can be called as a Machine Tool. In fact Machine Tool is the necessary
(sometime mandatory) term to designate such machines which qualify
all four conditions.
Example of machine tool includes Lathe, Milling, Shaping, etc. The
concept of Machine Tool is usually restricted within the metal-working
(or Machining) field.
What is Cutting Tool?

Cutting tool, also called “Tool” only in

metal-working field, is a small wedge-
shaped sharp-edged device that removes
excess material by shearing while
machining. 
Cutting tool is mounted on the machine
tool using some tool holding
arrangements.
Each cutting tool may have one or more sharp edges,
and accordingly cutting tools are classified into three
groups, namely,
Single-point tool (turning tool, shaping tool, etc.),
Multi-point tool (drill bit,milling tool, broaching tool,
etc.).
Material removal by machining requires relative
motion between cutting tool and workpiece. The
required motion either on tool or on job or on both are
provided by the machine-tool.
Cutting tool and machine tool
Cutting tool- Single point cutting and
multiple point cutting tool
Single point cutting tool like lathe tool,
shaper tool
Multiple point cutting tool like drill bit,
milling cutter, reamer
Multiple point cutting tool- drill bit, reamer,
milling cutter
Milling cutter
Single point cutting tool
Names of commonly used machine tools:

1. Lathe machines, 6. Milling Machines

2. Drilling machines, 7. Boring Machines
3. Grinders, 8. Metal Cutting Saws
4. Shaping machines, 9. Slotting machines etc.
5. Planning Machines,
Lathe Machines
Lathe machine parts
Headstock- it consists of spindle and chuck
Tailstock
Carriage- it consists of following parts like apron,
saddle, cross slide, compound rest, tool post
Bed
Lathe machine
Basic principle of a lathe machine :
Lathe machines are normally used to produce
cylindrical surfaces. The job is held in the chuck
attached to the head stock or between the centers
provided at the head stock or tail stock. The tool is
held on the compound rest. Job is rotated at the
predetermined speed by the head stock. The tool is
moved relative to the workpiece with the help of
carriage, cross slide or compound rest. Desired
quantity of metal is removed in the form of chip from
the work piece.
Specification of a lathe machine
A lathe machine is specified by the following
Height of the centers measured from the lathe bed.
Swing diameter over bed- This the largest diameter
of work piece which will revolve without touching
the bed. It is equal twice the height of centers from
the bed.
Swing diameter over carriage. It is the largest
diameter that can revolve over the cross-slide. This
always less than the swing diameter over the bed.
Maximum bar diameter-This is the
maximum diameter that will pass
through the head stock spindle.
Length of the bed.
Fig.- Specifications of lathe machine
Classification of Lathe machines

Lathes can be classified into following three types

Engine Lathes
Light weight bench engine lathe
Precision Tool Room lathes
Gap lathes
Turret Lathes
Special Purpose lathes
Basic Operations Performed on a Lathe Machine :

1. Turning –Plain turning , Step turning

2. Facing
3. Taper Turning
4. Drilling :
5. Boring :
6. Reaming :
7. Knurling :
8. Forming :
9. Chamfering :
10. Parting Off:
11. Threading or thread cutting
Turning
Plain turning on lathe machine
Fig.- step turning on lathe machine
Fig.- Facing on lathe machine
Turning on lathe machine
FIG.- TAPER TURNING BY COMPOUND REST
METHOD
Taper turning by set over method
Taper turning by swiveling the compound
rest
Taper turning by form tool
Eccentric turning on lathe machine
FIG.- KNURLING
Knurling on lathe machine
Knurling on lathe using knurling tool
Knurling tool
FIG.- DRILLING AND BORING
Drilling on lathe machine
Boring on lathe machine
Drilling on lathe
Boring on lathe
Reaming on lathe machine
Reaming on lathe using reamer tool
Reamers
FIGURE – GROOVING AND PARTING
Parting on lathe machine
Grooving on lathe
Forming on lathe machine
Chamfering on lathe machine
Threading on lathe
Threading on lathe machine
Shaping Machines

A shaper is used for producing relatively

small flat surfaces. A single point tool is
mounted on a tool box fitted to a
reciprocating ram. The job is clamped in a
vice. There is a cutting action in the forward
motion of the tool while the return stroke is
idle. Job is given indexed feed.
Working of shaper
FIG.- SHAPER
Shaper machine
Shaper operations

Horizontal cutting
Vertical cutting
Inclined cutting
Irregular cutting
HORIZONTAL AND VERTICAL CUTTING ON
SHAPER
INCLINED CUTTING ON SHAPER
PLANNING MACHINE OR PLANNER
Planning machines are used for generating large flat
surfaces. These flat surfaces may be horizontal, vertical
or inclined. Planing machines also perform all the
functions that a shaping machine does. The planning
machines handle larger and heavy jobs.
In planning machines the job is mounted on a table
which moves forward and backward. The tool is held
firmly on the cross rails in the middle of the machine.
FIGURE- PLANNER
Planer machine
FIG.- MACHINING BED ON PLANNER
Diff. between shaper and planer
Planing Machine Shaping Machine
1. Machine is heavy and is used for 1. Machine is light and only small job
producing large surfaces can be produced.
2. Cutting takes place by 2. Cutting takes place by
reciprocating the work piece reciprocating the tool.
3. Heavier cuts can be given 3. Only light cuts can be given.
4. Several tools can be mounted and 4. Only one tool is used at a time.
employed at a time 5. Only one job can be taken up at a
5. Several jobs requiring similar time.
operations can be machined at a 6. Indexed feed is given to the job
time during idle stroke of the ram.
6. Indexed feed is given to the tool
during idle stroke of the work table.
Milling Machine
In milling machine , milling operation is done. Milling
is a metal removing process by the help of a
multitooth (multi edge) revolving cutting tool. The
cutting tool is held on a spindle called arbour and the
work piece is fixed on a table.
The table reciprocates past the cutting tool and metal
removal takes place. Feed for the next cut and the
depth of the cut are given by the movement of the
table. Each tooth has the same profile. Each tooth after
taking a cut comes in operation after some interval.
This allows the tool to cool down before the next cut
takes place.
FIG.- UP MIILNG AND DOWN
MILLING
Horizontal milling machine
FIG.- HORIZONTAL MILLING MACHINE
FIG.- VERTICAL MILLING MACHINE
Milling machine
Horizontal milling machine
Vertical milling machine
MILLING OPERATIONS
1. Plain or Slab Milling
2. Face Milling
3. Angular Milling
4. Form Milling
5. Straddle Milling
6. Gang Milling
PLAIN MILLING
FACE MILLING
ANGULAR MILLING
FORM MILLING
STRADDLE MILLING
GANG MILLING
Drilling Machine

Drilling is an operation
through which a drilled hole is
produced in a job. The machine
tool used in this case is called
drilling machine and the
cutting tool used is called a drill
bit or drill.
FIG.- DRILLING
PARTS OF TWIST DRILL
Parts of twist drill
1. Point- It is the cone shaped end and it does the
cutting. The point angle depends upon the workpiece
material. E.g.- for steel it is 118 to 135 degree.
2. Shank- it is the portion of drill by which it is
clamped in the spindle. The shank may be either
straight or tapered
3. Body- It is the portion between the ppint and the
shank. It consists of flutes( spiral grooves), margin and
body clearance.
FIG.- TWIST DRILL
Hand drill, drill bit
Hand drill
Bench drilling machine
Fig.- Radial drilling machine
FIG.- RADIAL DRILLING MACHINE
Radial drilling machine
Radial milling machine
Operation performed on a drill machine

Drilling : Operation of producing a cylindrical hole in

a solid body by means of a drill.
Reaming : Operation of finishing the drilled hole
(that is achieving the closer tolerances and desired
surface finish) by means of a reamer.
Boring : A drilled hole can be enlarged also by means
of boring tool on the drill machine.
Counter Boring : Enlarging the diameter of the
drilled hole only upto certain depth. For this counter
boring tool is used.
Counter Sinking : It is enlarging the top end
of a drilled hole and giving it a conical shape by
the help of a counter sinking tool.
Spot Facing : Squaring the surface at the top
end of a hole to provide a true seat for the bolt
head or collar.
Tapping : A tap can be rotated inside an
already drilled hole to produce internal
threads.
FIG.- DRILLING OPERATIONS
Grinding

It is the process of removing material by the abrasive

action of a revolving wheel from the surface of a work
piece, in order to achieve required dimension and
surface finish of the work piece. The wheel used for
this purpose is called grinding wheel. Grinding wheel
consists of sharp crystals called abrasives held together
by a bonding material.
Types of grinding machines

Grinding machines are normally put in two categories :

Roughing Grinders
Bench , pedestral or floor grinders
Swing frame grinders
Portable and flexible shaft grinders
Belt grinder

Precision Grinders
Cylindrical Grinders (three types)
Surface Grinders
Horizontal spindle, reciprocating table surface grinders
Vertical spindle , reciprocating table surface grinders
Internal Grinders
Common Grinding Operations :-
FIG.- INTERNAL GRINDING AND CENTERLESS
GRINDING
FIG.-GRINDING OPERATIONS
FIG.- SURFACE GRINDING
Hand grinder
Bench grinder
Bench grinder or pedestal grinder
Surface grinder
Cylindrical grinder
Center less grinding machine