MANUFACTURING PROCESSES

(22446)
UNIT I
Fundamentals of Machining and Machining
Operations

Ms. Patil Snehal S.

Department of Mechanical Engineering
Rajarshi Shahu College of Engineering (Polytechnic),
Tathawade, Pune.
 INTRODUCTION

• Machining is the process used to remove material,

typically metal, to create parts for machines, tools,
transportation, and more. Machine shops and machinists
use equipment like lathes, mills, and drill presses to turn
material into useful tools using precise cuts.
• Machining is most commonly used to manufacture metal
objects, parts, and tools. Metals that can be machined are
stainless steel, aluminum, brass, titanium, and copper.
Stainless steel is commonly used for precision machining,
offering the advantages of strength and resistance to
corrosion.
 MECHANICS OF CHIP FORMATION

• A wedge shaped tool is made to move relative to the

workpiece.
• As the tool makes contact with the workpiece it exerts
pressure on it resulting in compression of the metal
near the tool tip.
• This induces shear – type deformation within the metal
and it starts moving upward along the face of the tool.
• As the tool advances this process of shearing goes on
increasing and material is removed.
MECHANICS OF CHIP FORMATION
 MECHANICS OF CHIP FORMATION

• As the tool makes contact with the workpiece it Results in

exerting pressure on the material in front of it.
 CHIP FORMATION IN BRITTLE MATERIALS

• Cracks develop in the workpiece near the tool tip.

• This crack results in stress concentration.
• Hence, crack propagation intensity increases.
• The chip detaches itself from the base material.
• This results in a discontinuous, irregular shape and sized
chip.
 FACTORS FOR CHIP TYPES

1. Nature of work piece

2. Nature of tool
3. Dimension of tool
4. Feed rate
5. Cutting speed
6. Cutting environment like temperature, friction, etc
7. Friction between tool and work piece.
 CHIPS TYPES

• Continuous chips
• Discontinuous chips
• Continuous chips with built up edges (BUE)
 CONTINUOUS CHIPS

• If the metal chips are formed during machining is without

segments i.e. without breakage, than it is called as
continuous types of chips.
• Continuous chips are formed when the ductile material is
machined with high cutting speed and minimum friction
between the chip and tool face.
 DISCONTINUOUS CHIPS

1. If the chip is formed during machining is not continuous i.e.

formed with breakage is called discontinuous chips.
2. Discontinuous types of chips are formed when hard and
brittle metals like brass, bronze and cast iron is machined.
 CONTINUOUS CHIP WITH BUILT UP EDGE

• Continuous chips with built up edge is formed by machining

ductile material with high friction at the chip-tool interface.
• It is similar to the continuous types of chips but it is of less
smoothness due to the built up edge.
 CUTTING TOOLS

• A cutting tool or cutter is any tool that is used to remove

material from the work piece by means of shear
deformation.
• One of most important components in machining process.
• Success in metal cutting depends on selection of proper
cutting tool for a given work material.
• Performance will determine efficiency of operation
• Two basic types (excluding abrasives)
• Single point and multiple point
 SINGLE POINT CUTTING TOOL

• It is simpler form of cutting tool that have only one cutting

edge.
• Shear tools, lathe tools, planner tools, boring tools etc. are
the examples of single point cutting tool.
• Boring Turning
GEOMETRY OF SINGLE POINT
CUTTING TOOL
 GEOMETRY OF SINGLE POINT
CUTTING TOOL

• Shank: the shank is used as a tool holder. It is a main body of the

tool. It is generally gripped in the tool frame.
• Flank: It is a surface of the cutting edge or the surface adjacent to
the cutting edge of the tool.
• Face: It is the surface of the tool where the chip slides along the
top of this surface.
• Base: Base is a bearing surface of the tool. This base is held in
a tool holder or it is directly clamped in the tool post.
• Heel: Heel is an intersection to the flank and base of the cutting
tool. It is a curved portion at the bottom of the tool.
• Nose: This is a point where the base cutting edge and the side
cutting edge gets intersected.
 GEOMETRY OF SINGLE POINT
CUTTING TOOL

• Cutting edges: It is a face edge on the face of the tool that

removes the material from the work piece. There are two cutting
edges as side cutting edge and end cutting edge, where the side
cutting edge is major cutting edge and the end cutting edge is
minor cutting edge.
• Tool angles: Tool angle splay a vital role in the tool cutting
action. The tool that comes with proper angles will reduce
failures as tool breaking due to high work forces on the work
piece. The metal cutting is done more efficiently with generation
of little heat.
• Noise radius: The nose radius will provide long life and also
good surface finish with it sharp point on the nose. It has high
stress and leaves in its path of cut. Longer nose radius will give
raise to chatter.
 METHODS OF MACHINING

• Orthogonal Cutting- The cutting edge of wedge shaped

cutting tool is perpendicular to the direction of tool motion.
 METHODS OF MACHINING

• Oblique Cutting -The cutting edge of wedge shaped cutting

tool makes an angle except right angle to the direction of
tool motion. This will affect the cutting conditions.
 LATHE

• Working principle of lathe: The lathe is a machine tool

which holds the work piece between two rigid and strong
supports called centers or in a chuck or face plate which
revolves. The cutting tool is rigidly held and supported in a
tool post which is fed against the revolving work.
SPECIFICATION OF LATHE
CLASSIFICATION OF LATHE
BASIC PARTS OF CENTER LATHE
 LATHE ACCESSORIES

• Work Holding Devices-

• Three jaws chuck - For holding cylindrical stock centered.
- For facing/center drilling the end of your aluminum stock
• Four jaws chuck - This is independent chuck generally has
four jaws , which are adjusted individually on the chuck
face by means of adjusting screws
Work Holding Devices
 Work Holding Devices

• Thin jobs can be held by means of magnetic chucks.

 LATHE CENTERS

• Lathe Centers
• Work to be turned between centers must have center
hole drilled in each end
• Provides bearing surface
• Support during cutting
• Most common have solid Morse taper shank 60º
centers, steel with carbide tips
• Care to adjust and lubricate occasionally
LATHE CENTERS
 MANDRELS

• Mandrels is used to held the hollow/drilled w/p.

 RESTS

• Long w/p need extra support that tend to spring away from
the tool bit. We use the rest for provide support. Jaws hinge
work work jaws lathe bed guideways carriage
 FACE PLATES

• A lathe face plate is a flat round plate that threads to the

headstock spindle to the lathe.
• The faceplate is used for irregularly shaped w/p that cannot
succesfully held by chucks.
LATHE OPERATIONS
 Turning

• A single point cutting tool removes material from a rotating

workpiece to generate a cylindrical shape
• Performed on a machine tool called a lathe
• Variations of turning that are performed on a lathe:
• Facing
• Contour turning
• Chamfering
• Cutoff
• Threading
 Turning

Turning is the removal of metal from the outer diameter of a

rotating cylindrical work piece. Turning is used to reduce the
diameter of the work piece, usually to a specified dimension,
and to produce a smooth finish on the metal. Often the work
piece will be turned so that adjacent sections have different
diameters.
 Facing

Facing is the process of removing metal from the end of a

work piece to produce a flat surface. Most often, the work
piece is cylindrical, but using a 4-jaw chuck you can face
rectangular or odd-shaped work to form cubes and other non-
cylindrical shapes.
Knurling
GROOVING
CHAMFERING
 DRILL MACHINE- CLASSIFICATION

• Portable Drilling Machine

• Sensitive or Bench Drill
• Upright Drilling Machine(Single Spindle)
• Upright Drilling Machine(Turret Type)
• Radial Drilling Machine
• Multiple Spindle Drilling Machine
• Deep Hole Drilling Machine
• Gang Drilling Machine
• Horizontal Drilling Machine
• Automatic Drilling Machine
 CONSTRUCTION OF RADIAL DRILLING
MACHINE

 The setup essentially consists of

• Base
• Column
• Radial Arm
• Motor for elevating the arm
• Elevating screw
• Guideways
• Motor for driving drill spindle
• Drill head
• Drill spindle
• Table
CONSTRUCTION OF RADIAL DRILLING
MACHINE
 CONSTRUCTION OF RADIAL DRILLING
MACHINE

• Base: It is made up of Cast Iron which possesses high

compressive strength and good wear resistance. The base is
used to support the assembly of parts on it and also absorbs
the vibrations induced by the machine parts.
• Column: It is exactly placed at one end of a bed which can
act as a support for rotating the radial arm in 360 degrees.
• Radial Arm: It is the arm which is connected to Column.
The Drill head is slide from one end to another end by the
guideways.
• Motor: It is placed on the drill head for driving the work
unit(Spindle of the Drill bit)
 CONSTRUCTION OF RADIAL DRILLING
MACHINE
• Table: The machine vice is connected to a swivel table which
can hold the workpiece for further operation.
• Flywheel or Hand wheel: It is connected to the spindle
arrangement which is used to move up and down w.r.t. the
workpiece.
• Drive Head: It generally consists of two levers which by
varying can increase or decrease the speed of chuck.
• Chuck: One end of the chuck is connected to the spindle
arrangement and another end is connected to the drill bit(tool).
• Tool-Drill bit: The drill bit is used to drill the holes on the
specimens.
• Workpiece: It has to be fixed in the machine vice provided on
the table.
 SENSITIVE DRILLING MACHINE

• This type of drilling machine is used for very light work.

• Its construction is very simple and so is the operation .
• It consists of as shown in fig. of a cast iron having a fixed
table over it.
 DRILLING OPERATIONS

• Drilling
• Reaming
• Boring
• Counter Boring
• Counter Sinking
• Spot Facing
• Tapping
 DRILLING OPERATIONS

• Drilling :- It is the main operation done on this

machine. It is the operation of producing a circular hole
in a solid metal by means of a revolving tool called
drill.
• Boring :- It is an operation used for enlarging a hole to
bring it to the required size and have a better finish.
• Counter sinking :- It is the operation used for
enlarging the end of a hole to give it a conical shape for
a short distance
 DRILLING OPERATIONS

• Reaming :- It is the operation of finishing a hole to

bring it to accurate size and have a fine surface finish .
This operation is performed by means of a multi tooth
tool called reamer.
• Counter boring :- This operation is used for enlarging
only a limited portion of the hole is called counter
boring .
• Tapping:- It is the operation done for forming internal
threads by means of the tool called tap.
 VIDEO LINKS
 Machining process-
• https://www.youtube.com/watch?v=KR8v633uQ_M

 Lathe-
• https://www.youtube.com/watch?v=yOFGu9rpaZk

 Drill machine-
• https://www.youtube.com/watch?v=f5HfRpeT7Fg
THANK YOU