Machining Process

Machining Process
It is one of the secondary manufacturing processes by which excess

material is removed in form of chips by using a wedge shaped cutting
tool in order to get desired shape and size with tolerance.
Classifications of machining process
1. Electro
1. Turning 1. Polishing 1. Abrasive jet chemical
2. Milling 2. Buffing machining machining
3. Drilling 3. Lapping 2. Ultrasonic 2. Electro
4. Planning 4. Grinding machining discharge
5. Shaping 5. Honing 3. Water jet machining
6.Broaching 6. Super machining 3. Laser beam
7. Gear finishing 4. Magnetic machining
cutting abrasive 4. Plasma beam
8. Boring finishing machining
Machine Tools
• Machine tools are
defined as a tool which
while holding the cutting
tool would be able to
remove metal from the
workpiece.
• Material is removed from
the workpiece in order to
generate desired shape.
Some examples of M/C
tools are milling cutter,
drill bit, shaper etc.
Classification of Machine
Tools
General purpose machine tools
• It is designed to perform a variety of operations on a wide range of components.
• They can be used for almost any type of application but, the speed of production
is very low.
• Exp. Lathe, shaper and milling machine
Production machine tools

• A number of function are automated.
• Slightly more productive than general purpose M/C tools and are used for
production purposes.
• Exp. Capstan and turret Lathe
Special purpose machine tools
• They are specially made for mass production and are designed for particular
application.
• Exp. Cam shaft grinding machine and piston turning lathe
Single purpose machine tools
• These are designed for single operations on the job.
• They are used for highly automated production processes, where the production
rate is very high.
• They are least flexible.
• Exp. Transfer lines for complete machining of a product
Classification of Machine
Tools
Machine tool producing the flat
surface
Shaper, slotter planner, milling,
broaching
Machine tool producing revolved
surface
Lathe, drilling and boring machine
Miscellaneous machine tool
• Gear cutting machine tool
• Thread milling machine tool
Classification of Machine Tools
3. Lathe cutting tools ( Materials: HSS)
4. Grinding wheels
Lathe Machine
• A lathe is a machine tool that rotates a work piece about an axis of rotation to
perform various operations such as cutting, knurling, drilling, facing, turning
with tools that are applied to the work piece to create an
object with symmetry about that axis.
Parts of Lathe Machine
• Bed
• Head stock
• Tail stock
• Carriage (cross slide, compound rest,
tool post and apron)
• Feed Mechanism
• Legs
Parts of lathe machine
1.Headstock: Clamped on left-hand end of bed.

 Headstock spindle – Hollow cylindrical shaft supported by bearings.
Provides drive through gears to work - holding devices.
 Live centre, faceplate, or chuck fitted to spindle nose to hold and drive
work.
 Driven by stepped pulley or transmission gears
2.Lathe bed:
 Heavy, rugged casting.
 Made to support working parts of lathe.
3.Cross slide: Mounted on top of saddle

 Provides manual or automatic cross
movement for cutting tool.
 Compound rest (fitted on top of cross- slide)
4.Apron:
 Fastened to saddle
 Houses gears and mechanism required to move carriage or cross-slide
automatically
 Locking-off lever inside apron prevents engaging split-nut lever and automatic
feed lever at same time
 Apron hand wheel turned manually to move carriage along lathe bed
5.Tailstock:
 Adjusted for taper or parallel turning by
two screws set in base
 Tailstock clamp locks tailstock in any
position along bed of lathe.
 Tailstock spindle has internal taper to
receive dead centre – Provides support
for right-hand end of work.
6.Tool post: There are three main types of tool post used for
holding lathe cutting tools:
 Ring and rocker
 Four-way turret
 Quick -change
7.Compound slide/top slide: It is fixed on top of the cross-slide, and can be

turned (set) to any desired angle. The compound slide is useful for turning
and boring short tapers and chamfers.
8. Chucks: Used extensively for holding work
for machining operations. Most commonly
used lathe chucks.
• Three-jaw universal
• Four-jaw independent
• Collet chuck
9.Carriage: Used to move cutting tool along

lathe bed
 Consists of three main parts –
 Saddle: H-shaped casting mounted
on top of lathe ways, provides means
of mounting cross-slide and apron
 Cross-slide
 Apron
Operation on lathe machine
1. Turning:
o Excess Material is removed to reduce
Diameter.
o Cutting Tool: Turning Tool.
o Work is held in either chuck or between
centres.
o Longitudinal feed is given to the tool
either by hand or power.
2. Facing:
o Flat surface or to Reduce Length of Job.
o Turning Tool
o Feed: in direction perpendicular to
workpiece axis. Length of Tool Travel =
radius of workpiece.
o Depth of Cut: in direction parallel to
workpiece axis
3. Knurling:
 Produce rough textured
surface.
 For Decorative and/or
Functional Purpose
 No MRR.
4. Grooving:
 Produces a Groove on
workpiece
 Shape of tool = shape of
groove
 Carried out using
Grooving Tool.
5. Parting:
 Cutting workpiece into two parts
similar to grooving Parting Tool
 Tool rides over – at slow feed
 Coolant use
6. Chamfering:
 Bevelling sharp machined edges
 Similar to form turning
 Chamfering tool – 45°
 Used to avoid sharp edges, make
assembly easier and improve
aesthetics
7. Drilling:
Cutting tool is held in Tailstock
and feed from Tailstock
8. Taper Turning
• Form Tool
• Swivelling Compound Rest
• Taper Turning Attachment
• Simultaneous Longitudinal
and Cross Feeds
Taper turnung
• Using the compound rest
• By using the form tools
• Offsetting of tailstock
• Using taper turning attachment
Parameters are used in machining
Material Removal Rate (MRR):

Volume of materials removed per second
Cutting speed
It is defined as the speed at which the work moves with
respect to the tool (usually measured in feet per minute).
Feed rate
It is defined as the distance the tool travels during one
revolution of the part.
Depth of Cut
Depth of cut is the distance that the tool bit moves into the
work.
Conventional Vs Unconventional
CONVENTIONAL MACHINING UNCONVENTIONAL MACHINING

PROCESS PROCESS
1. Generally macroscopic chip formation by 1. Material removal may occur with chip
shear deformation. formation or even no chip formation. For
example, in AJM chip are of microscopic
size.
2. It involves the direct contact of tool and 2. It does not require the direct contact of
workpiece. tool and work piece.
3. Lower accuracy and surface finish. 3. Higher accuracy and surface finish.
4. Suitable for every type of material 4. Not suitable for every type of material.
economically.
5. Tool life is less due to high surface 5. Tool life is more.
contact and wear.
6. Higher waste of material due to high 6. Lower waste of material due to low or no
wear. wear.
7. Lower capital cost. 7. Higher capital cost.
8. Easy setup equipment. 8. Complex setup equipment.
9. Manual to operate. 9. Fully automated process.
10. Skilled or unskilled operator required. 10 Skilled operator required.
.
Specification of Lathe
1. Distance between centres
2. Swing over the bed
3. Swing over the carriage
4. Maximum diameter of w/p through spindle
5. Length of bed
6. Width of bed
7. Power rating of electric motor
8. Number of spindle speed
9. Range of spindle speed
THANK YOU

Machining Process

Uploaded by

Copyright:

Available Formats

Machining Process

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Machining Process

Uploaded by

Copyright:

Available Formats

Machining Process

It is one of the secondary manufacturing processes by which excess

Production machine tools

1.Headstock: Clamped on left-hand end of bed.

 Made to support working parts of lathe.

3.Cross slide: Mounted on top of saddle

7.Compound slide/top slide: It is fixed on top of the cross-slide, and can be

9.Carriage: Used to move cutting tool along

Material Removal Rate (MRR):

CONVENTIONAL MACHINING UNCONVENTIONAL MACHINING

You might also like