Unit 5 MACHINE TOOLS

15ME202 Manufacturing Technology

By

V. THULASIKANTH
Assistant Professor
Mechanical Engineering Department

SRM Nagar, Kattankulathur 603 203

V.Thulasikanth, Asst.Prof, SRM University
 Syllabus
MACHINE TOOLS

Milling Machine specification, Types, Types of cutters, operations,

Indexing methods simple problems.
Shaping, Planning and Slotting Machine description, Operations, Work
and tool holding Devices. Boring machine Specification, operations, Jig
boring machine. Broaching machine operations, Specification, Types,
Tool nomenclature.

TEXT BOOKS
1. Sharma, P.C., A textbook of Production Technology Vol I and II, S. Chand & Company Ltd., New
Delhi, 1996.
2. Rao, P.N., Manufacturing Technology, Vol I & II, Tata McGraw Hill Publishing Co., New Delhi, 1998.

REFERENCE BOOKS
1. Chapman W. A. J., Workshop Technology Vol. I and II, Arnold Publisher, New Delhi, 1998.
2. Hajra Choudhary, S. K. and Hajra Choudhary, A. K., Elements of Manufacturing Technology, Vol II,
Media Publishers, Bombay, 1988.
3. Jain. R. K., Production Technology, Khanna Publishers, New Delhi, 1988.
4. Kalpakjian, Manufacturing Engineering and Technology, Addision Wesley Congmen Pvt. Ltd.,
Singapore, 2000.
V.Thulasikanth, Asst.Prof, SRM University
 Milling Process
A machine operation in which a work part is fed past a rotating cylindrical tool with
multiple edges. (milling machine)

Milling is the removal of metal by feeding the work past a rotating multitoothed
cutter.

In this operation the material removal rate (MRR) is enhanced as the cutter rotates
at a high cutting speed.

The surface quality is also improved due to the multicutting edges of the milling
cutter.

The action of the milling cutter is totally different from that of a drill or a turning
tool.

In turning and drilling, the tools are kept continuously in contact with the material
to be cut, whereas milling is an intermittent process, as each tooth produces a chip
of variable thickness.

Milling operations may be classified as peripheral (plain) milling or face (end)

millingV.Thulasikanth, Asst.Prof, SRM University
 Types
Peripheral milling
Slab, slotting, side and straddle milling Up Milling (Conventional) & down milling
(Climb)

Facing milling
Conventional face, Partial face, End, Profile, Pocket & contour millings

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V.Thulasikanth, Asst.Prof, SRM University
 Peripheral milling
The cutting occurs by the teeth arranged on the periphery of the milling cutter,
and the generated surface is a plane parallel to the cutter axis.

Peripheral milling is usually performed on a horizontal milling machine.

For this reason, it is sometimes called horizontal milling.

The appearance of the surface and also the type of chip formation are affected by
the direction of cutter rotation with respect to the movement of the WP.

In this regard, two types of peripheral milling are differentiable, namely, up-milling
and down-milling.
Up-milling Down-milling

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 Up-milling
Up-milling is accomplished by rotating the cutter against the direction of the feed
of the WP.

The tooth picks up from the material gradually; that is, the chip starts with no
thickness and increases in size as the teeth progress through the cut.

This means that the cycle of operation to remove the chip is first a sliding action
at the beginning and then a crushing action takes place, which is followed by the
actual cutting action.

In some metals, up-milling leads to strain hardening of the machined surface, and
also to chattering and excessive teeth blunting.

Advantages of up-milling
It does not require a backlash eliminator.
It is safer in operation (the cutter does not climb on the work).
Loads on teeth are acting gradually.
Built-up edge (BUE) fragments are absent from the machined surface.
TheV.Thulasikanth,
milling cutter is not SRM
Asst.Prof, affected by the sandy or scaly surfaces of the work.
University
 Down-Milling (Climb Milling)
It is accomplished by rotating the cutter in the direction of the work feed.

In climb milling, as implied by the name, the milling cutter attempts to climb the
WP.

Chips are cut to maximum thickness at initial engagement of cutter teeth with the
work, and decrease to zero at the end of its engagement.

The cutting forces in down milling are directed downward.

Down-milling should not be attempted if machines do not have enough rigidity and
are not provided with backlash eliminators.

Under such circumstances, the cutter climbs up on the WP and the arbor and
spindle may be damaged.
Advantages
Fixtures are simpler and less costly, as cutting forces are acting downward.
Flat WPs or plates that cannot be firmly held can be machined by down-milling.
Cutter with higher rake angles can be used, which decreases the power
requirements.
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 Face Milling
In face milling, the generated surface is at a right angle to the cutter axis.

When using cutters of large diameters, it is a good practice to tilt the spindle
head slightly at an angle of 13 to provide some clearance, which leads to an
improved surface finish and eliminate tool blunting.

Face milling is usually performed on vertical milling machines; for this reason, the
process is called vertical milling, which is more productive than plain milling.

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 Milling Machines

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V.Thulasikanth, Asst.Prof, SRM University
 Milling Cutters
The milling cutters are selected for each specified machining duty.

The milling cutter may be provided with a hole to be mounted on the arbor of the
horizontal milling machines, or provided with a straight or tapered shank for mounting
on the vertical or horizontal milling machine.

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1. Plain milling cutters are either straight or helical ones. Helical milling cutters are
preferred for large cutting widths to provide smooth cutting and improved surface
quality (Figure .a). Plain milling cutters are mainly used on horizontal milling
machines.

2. Face milling cutters are used for the production of horizontal (Figure .b), vertical
(Figure .c), or inclined (Figure .d) flat surfaces. They are used on vertical milling
machines, planer type milling machines, and vertical milling machines with the
spindle swiveled to the required angle , respectively.

3. Side milling cutters are clamped on the arbor of the horizontal milling machine
and are used for machining of the vertical surface of a shoulder (Figure .e) or cutting
a keyway (Figure .f).

4. Interlocking (staggered) side mills (Figure .g) mounted on the arbor of the
horizontal milling machines are intended to cut wide keyways and cavities.

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5. Slitting saws (Figure .h) are used on horizontal milling machines.

6. Angle milling cutters, used on horizontal milling machines, for the production of
longitudinal grooves (Figure .i) or for edge chamfering.

7. End mills are tools of a shank type, which can be mounted on vertical milling
machines (or directly in the spindle nose of horizontal milling machines). End mills
may be employed in machining keyways (Figure .j) or vertical surfaces (Figure .k).

8. Key-cutters are also of the shank type that can be used on vertical milling machines.

They may be used for single-pass milling or multipass milling operations (Figures l and
m).
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9. Form-milling cutters are mounted on horizontal milling machines. Form cutters
may be either concave as shown in Figure .n or convex as in Figure .o.

10. T-slot cutters are used for milling T-slots and are available in different sizes. The
T-slot is machined on a vertical milling machine in two steps:
Slotting with end mill (Figure .j) and Cutting with T-slot cutter (Figure .p)

11. Compound milling cutters are mainly used to produce compound surfaces. These
cutters realize high productivity and accuracy (Figure .q).

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12. Inserted tool milling cutters have a main body that is fabricated from tough and
less expensive steel.

The teeth are made of alloy tool steel, HSS, carbides, ceramics, or cubic boron
nitride (CBN) and mechanically attached to the body using set screws and in some
cases are brazed.

Cutters of this type are confined usually to large-diameter face milling cutters or
horizontal milling cutters (Figure .q).

13. Gear milling cutters are used for the production of spur and helical gears on
vertical or horizontal milling machines (Figures .r and .s). Gear cutters are form-
relieved cutters, which are used to mill contoured surfaces. They are sharpened at
the tooth face.

Hobbing machines and gear shapers are used to cut gears for mass production and
high accuracy demands.
Materials for Milling Cutters

High Carbon Steel, High Speed Steel, Stellite, Cemented Carbides and ceramics

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 Milling Operations
1. Plain or Slab Milling 1. Slot and groove milling

2. Face Milling 2. Keyway milling

3. Angular Milling 3. Slitting or saw milling

4. Form Milling 4. Side Milling

5. Straddle Milling 5. End Milling

6. Gang Milling 6. Profile Milling

7. Gear Milling
8. Cam Milling
9. Thread Milling
10. Helical Milling

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 Horizontal type

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 Vertical type

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 Milling Cutters

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 Milled Components

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 Indexing or Dividing Heads
Dividing Heads
Heads help in changing the angular position of the component in relation to the
cutter.
They are mainly employed on knee-type milling machines to enhance their
capabilities toward milling straight and helical flutes, slots, grooves, and gashes
whose features are equally spaced about the circumference of a blank (and less
frequently unequally spaced).

Such jobs include milling of spur and helical gears, spline shafts, twist drills,
reamers, milling cutters, and others.

Dividing heads are capable of indexing the WP through predetermined angles. In

addition to the indexing operation, the dividing head continuously rotates the WP,
which is set at the required helix angle during milling of helical slots and helical
gears.
3-Types
1. Plain dividing Head
2. Universal Dividing Head
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3. Optical Dividing Head
Indexing Methods

Simple Indexing
Compound Indexing

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Simple Indexing
This method of indexing involves the use of crank, Worm, Worm wheel and
indexing plate.

Worm wheel contains 40 teeth and the worm is single start and it is directly
mounted in spindle.

Worm has single start thread and the worm wheel 40 teeth, with one turn of the
crank, the worm wheel will rotate through one pitch distance equal to 1/40 of the
revolution.

For two divisions on the work, the crank will make 40/2 = 20turns for each divisions

Similarly for n divisions on the work 40/n

Example: 23 teeth
Crank movement = 40/23 = (1 (17/23))

In the fraction the numerator denotes the number of holes to be moved and the
denominator the number of holes on the circle to be used.

ForV.Thulasikanth,
each division on theSRM
Asst.Prof, job University
the crank will make on complete revolution and will
move further through 17 holes on 23 holes circle
 Compound Indexing
This method of indexing used when number of divisions required is outside the
range of simple indexing.

In compound indexing, a plunge (5) is inserted in the bore of the work spindle while
the index plate is unlocked.

The spindle drives the plate through change and bevel gears while the crank
through the worm is driving the spindle.

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Hence, the required turn of the work spindle is obtained as sum of two turns

A turn of the index crank (2) relative to the index plate (1)

A turn of the index plate itself, which is driven from the work spindle through
change gears (a/b) (c/d) to provide the correction

Depending on the setup, the index plate rotates either in the same direction with
the index crank or in the opposite direction.

An idler gear should be used if the crank and plate move in opposite directions to
each other

Consider crank turned 3 holes on a 18 holes circle and the index plate and crank
both turned further 5 holes on 20 holes circle.
(3/18) + (5/20) = 5/12

Since 40 turns of the worm will turn the work through 1 revolution.

Therefore 5/12 turns of the worm will turn the work through (5/(12x40)) revolution
= 1/96 of a revolution ( this will enable 96 divisions on the work)
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V.Thulasikanth, Asst.Prof, SRM University
V.Thulasikanth, Asst.Prof, SRM University
These processes are used for machining horizontal, vertical, and inclined flat and
contoured surfaces, slots, grooves, and other recesses by means of special single-
point tools.

The difference between these three processes is that in planing, the work is
reciprocated and the tool is fed across the work, while in shaping and slotting, the
tool is reciprocating and the work is fed across the cutting tool.

Moreover, the tool travel is horizontal in shaping and planing and vertical in case
of slotting
It is the same as of turning, where metals are removed by singlepoint tools similar
in shape to lathe tools.

However, these operations differ from turning in that the cutting action is
intermittent, and chips are removed only during the forward movement of the tool or
the work.

Moreover, the conditions under which shaping, planing, and slotting tools are less
favorable than in turning, even though the tools have the opportunity to cool during
the return stroke, when no cutting takes place.

That is because these tools operate under severe impact conditions for these
conditions, the related
V.Thulasikanth, machine
Asst.Prof, and tools are designed to be more rigid and strongly
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dimensioned, and the cutting speed in most cases does not exceed 60 m/min
Consequently, tools used in these processes should not be shock-sensitive, such
as ceramics and CBN.

It is sufficient to use low-cost and easily sharpened tools such as HSS and
carbides.

The limited cutting speed and the time lost during the reverse stroke are the main
reasons behind the low productivity of shaping, planing, and slotting compared to
turning.

However, in planing, not only the productivity but also the accuracy are enhanced
due to the possibility of using multiple tooling in one setting.

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Shapers
A shaper machine is commonly used in single-piece and small-lot production as
well as in repair shops and tool rooms.

Owing to its limited stroke length, it is conveniently adapted to small jobs and best
suited for surfaces comprising straight-line elements and contoured surfaces when
the shaper is equipped with a tracing attachment.

It is also applicable for cutting keyways and splines on shafts.

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Planers
Planers are intended for machining large-size WPs because of their capacity for
long table travel (115 m) and robust construction.

They are used to machine plane surfaces that may be horizontal, vertical, or at
an angle. Angular surfaces are often easier to machine on planers.

Some of the work formerly done on planers is done now on planer-type milling
machines using large face milling cutters.

However, it is found that milling cutters tend to be glazed and the machined
component is work-hardened and hence becomes difficult to be hand-scraped.

Therefore, plane surfaces that required hand-scraping are preferably machined

on planers.

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V.Thulasikanth, Asst.Prof, SRM University
Slotters

Slotters are commonly used for internal machining of blind holes, or vertical
machining of complicated shapes that are difficult to machine on horizontal
shapers.

Useful for machining keyways, and cutting of internal and external teeth on large
gears.

The job is generally supported on a round table (3) that has a rotary feed in
addition to the usual table movement in cross-directions.

The ram (1) travels vertically along the ways of the column (2). The ram stroke of
a slotter ranges from 300 to 1800 mm.

The slotters are generally very robust machines and there is a possibility of tilting
the ram up to 15 from vertical to permit machining of dies with relief.

The rams are either crank-driven or hydraulically driven. Ram speeds are usually
from 2 to 40 m/min.

Longitudinal andAsst.Prof,
V.Thulasikanth, transverse feeds range from 0.05 to 2.5 mm/stroke. Cutting
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action takes place on downward stroke.
V.Thulasikanth, Asst.Prof, SRM University
V.Thulasikanth, Asst.Prof, SRM University
V.Thulasikanth, Asst.Prof, SRM University
Boring is the machining process in which internal diameters are generated in true
relation to the centerline of the spindle by means of single-point tools.

It is the most commonly used process for enlarging and finishing holes or other
circular contours.

Although most boring operations are performed on simple straight-through holes,

the process may be also applied to a variety of other configurations.

Tooling can be designed for boring blind holes, holes with bottle configurations,
circular-contoured cavities, and bores with numerous steps undercuts and
counterbores.

The process is not limited by the length-to-diameter ratio of holes.

Boring is sometimes used after drilling to provide drilled holes with greater
dimensional accuracy and improved surface finish.

It is used for finishing large holes in castings and forgings that are too large to be
produced by drilling.

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V.Thulasikanth, Asst.Prof, SRM University
a. Single-point cutter mechanically secured to a boring bar. When the tool becomes
worn, it is removed for sharpening and reset again. Resetting sharpened tools is
tedious and requires a fair degree of skill.

b. Adjustable single-point cutter is advanced for wear compensation.

c. Boring tools are clamped in a universal boring head that is attached to the end of
the boring bar. The head is designed to accommodate a variety of tool confi
gurations.

d. A fixed cutter, held by a stub boring bar, is simple and widely used.

e. A blade-type boring tool, where the cutter is inserted through the body, thus
providing two cutting edges that enable a substantially higher increase of feed rate
than that is possible when only one cutting edge is used.

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 BORING MACHINES
General-Purpose Boring Machines

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Jig Boring Machines

Jig borers are extra-precise vertical boring machines intended for precise boring,
centering, drilling, reaming, counterboring, facing, spot facing, and so on in addition
to lay out work.

They are mainly designed for use in tool making, jigs and fi xtures, and machining
of other precisions parts.

The jig boring machines are rigid enough to perform heavy cuts and sensitive
enough for prcising.

They are equipped with special devices ensuring accurate positioning of the
machine operative units including a precision lead screw-and-nut and are
supplemented by vernier dials and precision scales in combination with optical
read-out devices, inductive transducers, and also optical and electrical measuring
devices.

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 BROACHING
Broaching is performed using a multiple-teeth cutting tool by moving the tool
linearly relative to the work in the direction of the tool axis.

The machine tool is called a broaching machine, and the cutting tool is called a
broach.

Advantages include good surface finish, close tolerances, and a variety of work
shapes.

There are two principal types of broaching: external (also called surface broaching)
and internal.

External broaching is performed on the outside surface of the work to create a

certain cross-sectional shape on the surface.

Internal broaching is accomplished on the internal surface of a hole in the part.

V.Thulasikanth, Asst.Prof, SRM University

V.Thulasikanth, Asst.Prof, SRM University
V.Thulasikanth, Asst.Prof, SRM University
V.Thulasikanth, Asst.Prof, SRM University
 Broaching Machines.

The machines for broaching are relatively simple in construction, have only linear
motions, and usually are actuated hydraulically, although some are moved by crank,
screw, or rack.
Many styles of broaching machines are available, and sizes range from machines
for making needle-like parts to those used for broaching gun barrels, including rifled
(With internal spiral grooves) gun barrels.

Broaching machines either pull or push the broaches and are either horizontal or
vertical.

Push broaches usually are shorter, generally in the range from 150 to 350 mm.

Pull broaches tend to straighten the hole, Whereas pushing permits the broach to
follow any irregularity of the leader hole.

Horizontal machines are capable of longer strokes. The force required to pull or
push the broach depends on the (a) strength of the workpiece material, (b) total
depth and Width of cut, (c) cutting speed, (d) tooth profile, and (e) use of cutting
fluids.
The pulling force capacities of broaching machines are as high as 0.9 MN.
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Roughing Semi Finishing Finishing
broach
Broach Broach

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 Broaches

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Introduction :

Broaching speeds vary from 20 to 120 surface feet per

minute (SFPM).

This results in a complete cycle time of 5 to 30 seconds.

Most of the time is consumed by the return stroke, broach

handling, and work piece loading and unloading.

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 Classification
of broaching Machines :

According to nature and direction of cutting

Horizontal Broaching Machine
Vertical Broaching Machine
Continuous Broaching Machine

According to the purpose

Internal Broaching Machine
External Broaching Machine

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 Classification
of broaching Machine :
According to the construction of the broach tool
Solid Broaching Machine
Inserted tooth Broaching Machine
Progressive Cut Broaching Machine
Built-up Broaching Machine

According to the function

Keyway Broaching Machine
Burnishing Broaching Machine
Splining Broaching Machine
Round-Hole Broaching Machine
Surface Broaching Machine
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 Classification
of broaching Machine :
According to the number of main slides
Single Broaching Machine
Double Broaching Machine
Multiple slides Broaching Machine

According to the motion of Broach tool

Straight-line Broaching Machine
Stationery Broach tool Broaching Machine

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Broach tool :

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 broaches

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Kinds of broaches :

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 Broaching
samples :

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 Suitable materials :
BRASS
BRONZE
COPPER ALLOYS
ALUMINIUM
GRAPHITE
HARD RUBBERS
WOOD
COMPOSITES
PLASTIC.

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 Broaching machines :
Horizontal Broaching Machine :
In this type, the broach moves in horizontal direction
relatively with the workpiece. Otherwise, the workpiece is
set in horizontal motion relative to the broach.
Both internal and surface broaching can be performed using
HBM.

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Horizontal Broaching Machine :

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 Vertical Broaching Machine :

The working of vertical broaching machine is similar to

that of horizontal broaching machine.
Here, either the broach is set in vertical motion instead of
horizontal motion.
It is further classifies into 3 types, namely
Pull up type
Pull down type
Push down type

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Vertical Broaching Machine :

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 Continuous broaching machine :
Continuous type :

This type is used for mass production of smaller parts.

The broaches are fitted into a belt driven by a set of pulleys,

such that the workpiece is held normal to the broach.

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CONTINOUS BROACHING MACHINE

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 rotary broaching machine :
Rotary type :
This machine has a rotary table and vertical column. The
broach is fitted horizontally above the table.

A series of fixtures are mounted on the rotay table for

locating and holding work pieces. They move past the
stationarey broaches.

Rotary broaching machines are limited to small parts. They

are used for squaring distributor shaft, slotting and the facing
of smaller parts.

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ROTARY BROACHING MACHINE

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 Broaching specifications :
Broaching speeds vary from 20 to 120 surface feed per
minute (SFPM). This results in a complete cycle time of 5
to 30 seconds. Most of the time is consumed by the return
stroke, broach handling, and workpiece loading and
unloading.
Common internal holes can range from 0.125 to 6 in (3.2
to 150 mm) in diameter but it is possible to achieve a
range of 0.05 to 13 in (1.3 to 330 mm).

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 Broaching specifications :
Surface broaches' range is usually 0.075 to 10 in (1.9 to
250 mm), although the feasible range is 0.02 to 20 in
(0.51 to 510 mm).
Tolerances are usually 0.002 in (0.05 mm), but in
precise applications a tolerance of 0.0005 in
(0.01 mm) can be held. Surface finishes are usually
between 16 and 63 microinches (in), but can range from
8 to 125 in.[10] There may be minimal burrs on the exit
side of the cut.

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