MACHINE TOOLS

Definition of Machining

 Machining is an essential process of finishing by which jobs are

produced to the desired dimensions and surface finish by

gradually removing the excess material from the preformed

blank in the form of chips with the help of cutting tool(s)

moved past the work surface(s).

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 Machining to high accuracy and finish essentially
enables a product

 fulfill its functional requirements

 improve its performance

 prolong its service

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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 the

following.
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.
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 Machine Tool - definition
 A machine tool is a non-portable power operated and reasonably
valued device or system of devices in which energy is expended
to produce jobs of desired size, shape and surface finish by
removing excess material from the preformed blanks in the
form of chips with the help of cutting tools moved past the work
surface(s).

 A machine which performs the material removal operation with

tools, to produce desired shape and size of the work piece is
known as machine tool.

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  Machine tools are used

 To improve production rates.

 To reduce cost of production.

 To achieve better quality.

 To reduce wastage.

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 The various types of machine tools used in the workshops
are

 Lathe

 Shaping machine

 Drilling machine

 Milling machine

 Grinding machine

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 Lathe is the most general purpose machine tool in which the work piece
is held and rotated against suitable cutting tool for the purpose of
producing surface of revolution.
 Lathes are classified on the basis of drive mechanisms, processes,
purpose etc.
 The main types are
 Centre lathes(Engine lathe)

 Speed lathes

 Tool room lathes

 Production lathes (Capston And Turret Lathe)

 Special purpose lathes

 Automatic lathes

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 Centre lathe

 These are power driven general purpose lathes. Here the

cutting tool is fed in the longitudinal as well as in the lateral
direction automatically.
 As these support the work piece between a live center and a
dead center, these are named as lathes.
 As the early versions of these were used to machine the parts
of watt's steam engine and later driven by steam engines, they
derived the name 'Engine lathes'.
 These are widely used in machine shops. These can perform
various operations at different speeds.

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 Central Lathes are classified on the basis of their power source as

 Belt driven Lathe

 Motor driven Lathe

 Gear-head Lathe.

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 Working Principle

 The main function of Lathe is to provide suitable means to hold

a work-piece and to rotate it about the axis.

 A cutting tool either fed perpendicular or parallel to the axis of

work removes material from the rotating work to give the
require size and shape.

 If the tool is moved parallel to the axis of rotation of the work

then a cylindrical surface is produced.

 If the tool is moved perpendicular to the axis of rotation of the

work, then a flat surface is produced.
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 Fig Principal parts of the Lathe

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 Fig Schematic view of a Centre Lathe

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Specifications of a Lathe (Size of Lathe)
A lathe size is mainly specified as follows :
 Height of lathe centre’s from top of bed.

 Swing over bed and carriage. (Maximum distance from the bed,
that the work-piece can be rotated between the centre’s with out
with touching the bed).

 Distance between the centers.

 Length and types of bed with or without gap.

 Lead screw details.

 Motor details.
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 1 Bed

 The bed is the base of foundation of the Lathe.

 The headstock, tailstock, carriage etc. are mounted on the bed.

 The bed also provides the required strength and rigidity to the
machine.

 The top of the bed is planed to form 'guides' or 'ways'.

 Ways are accurate rails which support carriage and tailstock.

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 2 Headstock:
 The headstock is mounted on the bed at the left end.

 Spindle is supported in headstock. Spindle is a hollow cylindrical

shaft supported by bearings.

 Work-holding attachments such as, face plate, driving plate or

chucks are mounted on the spindle nose.

 The spindle along with the work-piece is rotated by a combination

of gears and cone pulleys or by gears alone driven by the motor.

 The head stock has a gear box for changing the speed of rotation of
spindle and thereby the speed of rotation of work-piece

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 3 Tailstock:
 The tailstock is mounted on the bed at the right end and can be
clamped at any convenient position.

 It supports one end of the work-piece.

 It is also used for holding tool for performing operations such as

drilling, reaming etc.

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 4 Carriage:
 The carriage of a lathe consists of several parts that serves to
support the cutting tool and to control the action of the cutting
tool.
 It can be moved along the bed ways provided at the top of the
bed. Carriage has five major parts :
 Saddle
 Cross slide
 Compound rest
 Tool post
 Apron
 Lead screw
 Lathe centers
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 a) Saddle:
Saddle is the base of the carriage. Saddle slides along the
guide ways.

 b) Cross slide: Cross Slide is mounted on Saddle.

 Saddle can be moved along the guide ways so that tool can
be moved towards and away perpendicular to centre line of
lathe.
c) Compound rest:
 Compound Rest is mounted on the top of cross slide. Tool
post is fixed on Compound Rest.
Compound Rest can be swiveled (rotated) about the saddle,
which makes positioning of cutting tool at the desired angle.
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d) Tool post:
 Tool post is mounted on Compound Rest and slides in T-
Slot. Cutting Tool can be firmly held on it.

e) Apron:
 Apron is fixed below the saddle. Apron contains gears and
levers for manual and automatic motion of carriage.
 For manual motion of carriage along the bed there is a hand
wheel in front of the apron.
 For thread cutting operation automatic motion of the
carriage is made possible by engaging hand wheel shaft of
Apron with a lead screw.

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 Lead screw
 The lead screw is a long threaded shaft which is brought into
action only when threads have to be cut.
 The rotation of lead screw is used to move the tool along the
work to produce screw thread.

f) Lathe centers
 Lathe centers are tapered components fit into spindles provided
in the headstock and tailstock.

 The center connected to the head stock is called live centre

since this centre rotates with the spindle.

 The center connected to the tailstock is called dead centre

since it does not rotate and its function is only to support the
work piece
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 Operations performed on a Lathe
 Various operations performed in the lathe are discussed below
 Turning
 Turning is the removal of material from the periphery of a
work piece to obtain a cylindrical surface.

 Turning can be carried out by holding the work in a chuck or

by supporting the work in between lathe centers.

 The cutting tool, fed parallel to the axis of rotation of the

work, removes material from the rotating work.

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 Turning operation

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 Single point cutting tool

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 The following procedure is adopted in turning.
 i) Hold the work piece in a chuck with a short length
projecting out. Rotate it at a constant speed.
 ii)Face the end of the work by feeding the tool perpendicular
to the axis of rotation
 iii) Drill a small hole at the centre of this faced surface. This
can be done by fixing the drill bit in the tailstock and feeding
it into the rotating work piece.
 iv) Remove the drill bit from the tailstock and fix the dead
centre.
 v) Set the work piece between the chuck and the dead centre.

 vi) Fix a tool in the tool post in such a way that the tip of the
tool is in level with the axis of rotation of work piece.
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 vii) Adjust the depth of cut by moving the tool perpendicular to the
axis of work.
 After giving the depth of cut, the tool is moved parallel to the axis
of the rotating work.
 For further reduction in diameter of the work, apply further depth
of cut and traverse the tool again.
 For final finish the speed of rotation must be increased and a fine
depth of cut must be given.
 The traversing of tool must also be slow and steady.

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Taper turning
 A taper is a conical shape.
 Tapers can be cut with lathes quite easily. Some machine elements
and other parts are required to be turned with a taper.
 Taper is expressed as the ratio of the difference in the end
diameters to the length of tapered job, measured parallel to the
axis.
 Taper turning means producing a conical surface by gradual
reduction in diameter from a cylindrical work piece.
The following methods are used for taper turning.
 Forming tool method
 Tail stock set over method
 Compound rest method

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 Forming tool method
 The tool having a straight cutting edge is set at correct angle and
is fed straight into work to generate the tapered surface.
 This method is limited to turn short external tapers only.

Turning using forming tool

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 Tailstock set over method.

 In this method the normal rotating part of the lathe still drives the
work piece (mounted between centers), but the centre at the
tailstock is offset towards/away from the cutting tool.
 Then, as the cutting tool passes over, the part is cut in a conical
shape. This method is limited to small tapers over long lengths. The
tailstock offset h is defined by h = Lsinα,
 where L is the length of work piece, and α is the half of the taper
angle. This method is limited to the production of small taper on
long jobs.

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 Tail stock set over method.

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 Compound rest method
 The principle of turning taper by this method is to rotate the work
piece on the lathe axis and feeding the tool at an angle to the axis of
rotation of the work piece.
 The compound rest, on which the tool is mounted, has a circular
base graduated in degrees.
 By swiveling compound rest, it can be set at any desired angle. For
taper turning this angle must be half the taper angle.
 Once the compound rest is set at the desired angle, rotation of the
compound slide screw will cause the tool to be fed at that angle and
generate a corresponding taper.

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 Taper Turning by Compound rest method.

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  Thread Cutting
 Thread cutting is one of the most important operations performed in
a lathe. Threads can be cut either on outside or inside surface of an
object.
 A thread on the outside surface of an object such as a bolt is called
external thread. Thread on the inside surfaces of an object such as a
nut is called internal thread.
 For cutting a thread, it is necessary that there should be a relation
between the movement of the tool and rotation of work.
 This is obtained by means of a lead screw. The lead screw is driven
by a set of gears from the spindle. The lead screw, through which
the saddle receives its motion along the bed, has a definite pitch.
 For each turn of the screw the saddle moves along the bed a distance
equal to the pitch of the lead screw.

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 The tool which is held in the tool post also moves the same
distance.
 Thus there is rotation of work, combined with a fixed
longitudinal movement of the tool for each turn of work.
 The gears connecting the headstock spindle with the lead screw
can be selected to cut a thread of any desired pitch.
 For example, suppose the pitch of a lead screw is l2 mm and it is
required to cut a screw of 4 mm pitch, then the gears are to be so
selected that the spindle rotates 3 times the speed of the lead
screw.

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 Fig Thread Cutting operation

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  Knurling

 Knurling is the process of roughening a smooth surface of a

cylindrical work piece.
 The purpose of knurling is to get grip over the surface. For
knurling process, the work piece is held between the chuck and
the dead centre and rotated at the required speed.
 The knurling tool, which consists of a set of hardened steel
rollers with the teeth cut on the surface in a definite pattern, is
held rigidly in the tool post.
 The knurling tool is pressed against the revolving work piece
and is traversed along the length be knurled

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 Fig Knurling Operation

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 Drilling
 Drilling is the operation of producing a circular hole
using a drill by removing metal from the work piece.

Fig Drilling Operation

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 Fig Drilling in Lathe

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Reaming
 It is the operation of sizing and finishing a hole by
means of a reamer (reaming tool) having several cutting
edges. A reamer cannot produce a hole in a solid job. It
can accurately size and finish the already drilled holes.

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 Reamer

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 Boring
 Boring is the process of enlarging the hole by means of an
adjustable single point tool.

Fig Boring operation

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 Lathe Accessories
 The devices which are used for holding and supporting the
work and the tool on the lathe are called the lathe accessories.
The various accessories are the following.
 Chucks
 These are used for holding and rotating the work piece in the
lathe. It is attached to the lathe spindle by means of two bolts.
There are many types of chucks, but the following are
commonly used.
 Three jaw chuck:
 This chuck is called as Self Centering Chuck or Scroll Chuck.
During working all jaws of three chuck come towards the
center or away from the centers respectively in equal
distances. It is used for holding round and hexagonal work-
piece.
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 Fig. Three jaw chuck:

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 Four jaw chuck:
 It has four reversible jaws, each of which may be
independently adjusted to accommodate the work.
 Since movement of work is independent, it can be used
for holding square, round or irregular shape.

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 Four jaw chuck

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  Centers:
 It is a hardened steel device with a taper shank at one end and
60o point at other end.
 Drive plate:
 It is a plain disc which is bored and threaded so as to attach it
to spindle nose.
 Face plate
 Face plate is similar to Drive plate except that it is larger in
diameter.
 Mandrel
 Mandrel is a steel shaft used to hold hollow work-pieces.

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 For turning, facing, boring, threading and similar operations, jobs
of odd shape and size are usually mounted on large face plate
(instead of chuck) being fitted on the spindle nose as shown in Fig.
4.5.2. The job may be (b) directly clamped on the face plate or (c)
in case of batch or small lot production, in a fixture which is
clamped on the face plate.

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 Collet Chuck

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DRILLING MACHINES
  DRILLING MACHINE

 Drilling is the process of making holes in a work piece by forcing

a rotating tool called drill against it.
 Drilling is a process of producing round holes in a solid material
or enlarging existing holes with the use of multi tooth cutting
tools called drills or drill bits.
 Various cutting tools are available for drilling, but the most
common is the twist drill.

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  Basic purposes of use of drilling machines
 Drilling machines are generally or mainly used to originate
through or blind straight cylindrical holes in solid rigid bodies
and/or enlarge (coaxially) existing (premachined) holes

of different diameter ranging from about 1 mm to 40 mm

of varying length depending upon the requirement and the

diameter of the drill

in different materials excepting very hard or very soft

materials like rubber, polythene etc.

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 Fig Radial Drilling Machine

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 Fig Radial Drilling Machine

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 The principal parts of the radial drilling machine are the
following
 Base
 Column
 Table
 Drill head
 Base
 Base is the of the drilling machine is a rectangular casting on
which the column is mounted.
 Column
 The column is the vertical member of the machine which
supports the table. The head supporting the motor and the
spindle is mounted on the top of the column.
 Table
 The table of the drilling machine supports the work piece or
other work holding devices. It can be moved up and down on
the column. Also it can be set at various positions in the
6 horizontal plane.
 Drill head
 It is mounted on the top of the column and supports the spindle
head and motor. The spindle head houses drill houses drill holding
the rotating devices.
 A hand wheel is provided for the upward and downward movement
of the spindle.
 A drill chuck is mounted on the spindle for holding the drill.
 The spindle receives power from the motor through belt and pulley
arrangement.
 The speed of the spindle can be varied by shifting the belt on the
different steps of the step of the cone pulley.

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 Drilling
lt is the operation of producing a circular hole using a drill in the
work-piece.

Fig Drilling Operation

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  Reaming operation
 It is the operation of sizing and finishing a hole by means
of a Reamer (reaming tool) having several cutting edges.
 A reamer cannot produce a hole in a solid job.
 It can accurately size and finish the already drilled holes.

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  Boring
 Boring is the operation of enlarging a hole by means of an
adjustable single point tool.

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  Counter boring:
 Counter-boring operation differs from differs from boring
operation in the sense that where as boring enlarges a hole for
its full length, the counter boring does so only for a small
length to accommodate the heads of bolts, studs etc.

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  Tapping
 Tapping is the operation of cutting threads in a drilled
hole.

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 Counter Sinking
It is an operation to produce, cone shaped enlargement
at the end of hole.

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GRINDING MACHINES
 Grinding is a process of metal removal in which cutting tool used
is an abrasive (abrasive is a material, often a mineral, that is used
to shape or finish a work-piece eg.bauxite, diamond etc.) wheel.
 Grinding wheels are made of abrasive particles bonded together by
some bond.
 Grinding is mainly used for the following purposes

 To remove small amount of metal from the work-piece to

bring its dimensions within very close tolerance of the size
desired.
 To obtain better finish on the surface.
 To sharpen the cutting tools.
 To machine hard surfaces which are otherwise difficult to be
machined by other methods.
 Types of Grinding.

 According to the type of surface to be ground, grinding

is classified as
 Cylindrical grinding

 Surface grinding

 Form grinding
 Cylindrical Grinding

 Cylindrical grinding produces cylindrical surfaces on a work-piece.

The work-piece is rotated about the axis and is traversed across the
face of a rotating abrasive wheel.

Fig Cylindrical grinding process

 Surface grinding

Surface Grinding produces flat surfaces.

The grinding wheel is rotated about the axis and the work-piece
is traversed (pass through) under the revolving grinding wheel.

Fig Surface grinding

 Form grinding

 Form grinding produces surfaces on the revolving

cylindrical work-piece depending up on the shape of
the grinding wheel.
Types of Grinding Machines based on type of Grinding
 Grinding Machines are classified into

 Surface Grinding Machine

 Internal Grinding Machine

 Cylindrical Grinding Machine

 Tool and Cutter Grinding Machine

 Surface Grinding Machine

 Surface Grinding Machines are used to produce and finish flat

surfaces.
 It consists of a base- table, column and wheel head.
 One end of the base has a column for supporting wheel head.
 The wheel head can be lowered or raised and the table can be
moved along the ways to provide longitudinal feed.
 Table can be moved along with ways.
 In some cases table can be raised and lowered.
 Surface grinders can be manually operated or have CNC
controls.
Fig Surface Grinding Machine
Production Machines and
Processes

LATHE
Working Principle
• Apron - Front part of the carriage assembly on which the
carriage handwheel is mounted.
• Bed - Main supporting casting running the length of the lathe.
• Carriage - Assembly that moves the toolpost and cutting
tool along the ways
• Carriage Handwheel - A wheel with a handle used to
move the carriage by hand by means of a rack and pinion drive.
• Chuck - A clamping device for holding work in the lathe or
for holding drills in the tailstock.
• Compound - Movable platform on which the toolpost is
mounted; can be set at an angle to the workpiece. Also known
as the compound slide and compound rest.
• Cross Slide - Platform that moves perpendicular to the
lathe axis under control of the cross-slide handwheel.
• Headstock - The main casting mounted on the left end of the
bed, in which the spindle is mounted. Houses the spindle speed
change gears.
• Leadscrew - Precision screw that runs the length of the bed.
Used to drive the carriage under power for turning and thread
cutting operations. Smaller leadscrews are used within the
cross-slide and compound to move those parts by precise
amounts.
• Spindle - Main rotating shaft on which the chuck or other work
holding device is mounted. It is mounted in precision bearings
and passes through the headstock.
• Tailstock - Cast iron assembly that can slide along the ways
and be locked in place. Used to hold long work in place or to
mount a drill chuck for drilling into the end of the work.
• Tailstock Handwheel - A wheel with a handle used to
move the tailstock ram in and out of the tailstock casting.
Bed & Leadscrew
Carriage
Cross Slide and Compound
Toolpost
Tailstock, Centers and Drill Chuck
 Lathe Specifications
• A lathe is specified by its
– Swing – maximum diameter of the workpiece
– Distance from headstock and tailstock centers
– Length of the bed
• Lathes are available in a variety of styles and types of construction
power
• Types of lathes
– Bench lathe:
• Placed on a bench
• Low power
• Hand feed operated
– Toolroom lathes: High precision
– Engine lathes
• Available in a wide variety of sizes
• Used for a variety of turning operations
 Various Cutting Operations
• Turing – produces straight, conical, curved, or grooved workpieces

• Taper Turning- produces a taper

• Facing – produces a flat surface at the end of the part

• Drilling - to produce a hole

• Boring – to enlarge a hole

• Cutting off – to cut off a workpeiece

• Threading – to produce threads

• Knurling – produces a regularly shaped roughness

 Turning Operations
• Turning is the removal of metal from the
outer diameter of a rotating cylindrical
workpiece. Turning is used to reduce the
diameter of the workpiece, usually to a
specified dimension, and to produce a
smooth finish on the metal.
 Turning Operations
• Turning operations performed on a lathe
include:
– Straight turning
– Taper turning
– Facing
 Taper turning
• A taper is a conical shape.
• Taper is expressed as the ratio of the difference in
the end diameters to the length of tapered job,
measured parallel to the axis.
• Taper turning means producing a conical surface
by gradual reduction in diameter from a cylindrical
work piece
• Different methods
– Forming tool method
– Tail stock set over method
– Compound rest method
Forming tool method
Tailstock set over method
Compound rest method
 Facing Operation
• Facing is the process of removing
metal from the end of a workpiece to
produce a flat surface.
Drilling Operation
 Boring
• Boring is an operation in which a hole is
enlarged with a single point cutting tool.
Thread Cutting
Knurling
 Workholding on a Lathe
• Chuck
– 3,4, or 6 jaw
– Soft jaws
 Shaping Machine
• A shaping machine is used to machine
surfaces.
• It can cut curves, angles and many other
shapes.
• The work is held in a vice, fastened to a
work table and the tool reciprocated over
the work.
Shaping Machine
• Base. Base supports the whole machine and is rigidly bolted
to the floor
• Column: The column is mounted on the base. All the other
parts of shaper are attached to column. The top of the
column is machined to form guide ways for ram reciprocation.
The front vertical face of the column is also machined to
enable the table to be raised or lowered.
• Ram: It is the reciprocating part of the shaper. It reciprocates
on the guide ways provided on the top of the column. It
carries the tool head at the extreme front end. The ram is
connected to the quick return mechanism which allows the
ram to move at a slower speed during the cutting stroke and
at a faster speed during the return stroke.
• Tool head: It is mounted at the front of the ram. It can be
swiveled to any angle to enable the tool to take angular cuts.
• Table: Vice is clamped on the table. Vice is a device to-hold
work on the table of the shaper.
 Operations performed on a shaper

• Machining horizontal surface

• Machining Vertical Surface
• Machining Angular Surface
• Machining Irregular surface
Machining Horizontal Surface Machining Vertical Surface
Machining Angular Surface
 Drilling
• The drilling machine (drill press) is a single
purpose machine for the production of holes.

• Drilling is generally the best method of

producing holes.

• The drill is a cylinderical bar with helical flutes

and radial cutting edges at one end.

• The drilling operation simply consist of rotating

the drill and feeding it into the workpiece being
drilled.
 Principal Parts of Drilling Machine
Base
Base is the rectangular casting on which the column is mounted.
Column
The column is the vertical member of the machine which supports the
table. The head supporting the motor and the spindle is mounted on the
top of the column.
Table
The table of the drilling machine supports the work piece or other work
holding devices. It can be moved up and down on the column. Also it can
be set at various positions in the horizontal plane.
Drill head
It is mounted on the top of the column and supports the spindle head
and motor.. A hand wheel is provided for the upward and downward
movement of the spindle. A drill chuck is mounted on the spindle for
holding the drill. The spindle receives power from the motor through belt
and pulley arrangement. The speed of the spindle can be varied by
shifting the belt on the different steps of the step of the cone pulley.
 Different operations performed on the
Drilling machine
• Drilling- lt is the operation of producing a circular hole using a
drill in the work-piece.

• Reaming operation- It is the operation of sizing and finishing

a hole by means of a Reamer (reaming tool) having several
cutting edges. A reamer cannot produce a hole in a solid job
• Boring - Boring is the operation of enlarging a hole by means of
an adjustable single point tool.

• Counter boring- Counter-boring operation differs from boring

operation in the sense that where as boring enlarges a hole for
its full length, the counter boring does so only for a small length
to accommodate the heads of bolts, studs etc.
• Tapping- Tapping is the operation of cutting threads in a
drilled hole

• Counter Sinking- It is an operation to produce, cone

shaped enlargement at the end of hole.
 Milling Direction

• Up Milling • Down/Climb Milling

•Starts with a small cut and finishes •Starts with a large cut and finishes
with a large cut with a small cut
•Pushes the material away from the •Pulls the material into from the
cutter cutter
•Used for rough cutting •Better surface finish
•Used for deep cuts •Uses less Power
Up and Down Milling
 Milling machines
• Two Major Classifications - Knee & Column
and Bed
– Knee & Column (Bridgeport type)
• Basic job shop type mill
• Column mounted to the base which is the major support
frame.
• Construction provides controlled motion of the worktable
in three mutual perpendicular directions.
• Knee moves vertically on the ways in the front of the
machine
• Table moves longitudinally on the ways on the saddle
• Saddle moves transversely on the ways on the knee
• Quill moves parallel in Z axis or, if head is rotated, X axis
• Versatile general purpose machine
1.Face milling cutter 2.Spindle 3.Spindle head 4.Column 5.Table 6.Saddle 7.Knee 8.Base
9.Spindle switch 10.Spindle speed gear lever 11.Spindle speed control lever 12.Oil tank
13.Table manual wheel 14.Table lock bar 15.Saddle automatic moving bar 16.Saddle
automatic moving control dial 17.Saddle manual wheel 18.Knee manual wheel 19.Quick
button
 Milling Machines
– Bed
• Used extensively in production milling operations
• Rigid construction capable of heavy cuts
• Table is mounted directly to the bed
• Spindle head moves vertically to set depth of cut
• Head locks into position for cut
• Base of machine functions as a coolant reservoir
Horizontal Milling
Vertical Milling M/c
Machines
Conventional

Computer
Numerical
Control
Milling Machines
• A milling machine is a machine tool that cuts metal with a
multiple-tooth cutting tool called a milling cutter. The
workpiece is fastened to the milling machine table and is fed
against the revolving milling cutter. The milling cutters can
have cutting teeth on the periphery or sidesor both. The
cutting teeth can be straight or spiral.

Milling machines can be classified under three main headings:..

• General Purpose machines - these are mainly the column

and knee type (horizontal & vertical machines)
• High Production types with fixed beds- (horizontal types)
• Special Purpose machines such as duplicating, profiling, rise
and fall , rotary table ,planetary and double end types
• Milling attachments can also be fitted to other machine tools
including lathes planing machines and drill bench presses
can be used with milling cutters.
Boring
Chamfering
Counter Boring
Countersinking
Drilling
End Milling Tool
End Milling
Face Miiling Cutter
Face milling
Pocket Milling
Reaming
Tapping
Plain milling
 Workholding on a Lathe
• Between centers
– Live-tailstock
– Dead-headstock
– Face plate
– Drive dog
 Workholding on a Lathe
• Chuck
– 3,4, or 6 jaw
– Soft jaws
 Workholding on a Lathe
• Collect system
 Workholding on a Lathe
• Others
– Face driver system
– Sub-spindle system
 Shaping Machine
• A shaping machine is used to machine
surfaces. It can cut curves, angles and
many other shapes. It is a popular
machine in a workshop because its
movement is very simple although it can
produce a variety of work.
• The shaping process was used in the early days of
machine tools. Shaping machines are not widely
used now. Shaping produces flat surfaces by moving
a single point cutting tool in a recprocating motion.
The forward stroke is the cutting stroke the backward
movement is completed at a faster velocity and
includes the sideways feed motion.
The shaping machine is a versitile machine able to
produce flat surfaces , grooves, T-Slots, dovetails,
and may be used to produce curved surfaces.
The size of components that may be machined is
normally limited by the length of the stroke of the
shaping machine which can vary up to a maximum of
about 1500mm. (750mm is normally the maximum
stroke. The shaping machine is not generally used
as a production tool because of its slow cutting speed
and the unproductive return stroke.
• The tool feed handle can be turned to slowly
feed the cutting tool into the material as the
'ram' moves forwards and backwards. The
strong machine vice holds the material
securely. A small vice would not be suitable as
the work could quite easily be pulled out of
position and be damaged. The vice rests on a
steel table which can be adjusted so that it ca
be moved up and down and then locked in
position. Pulling back on the clutch handle
starts the 'ram' moving forwards and
backwards.
 The tool post and the tool slide can be angled as seen
below. This allows the shaper to be used for different
types of work

• DIA A: The tool post has been turned • DIA B: The tool post is not angled
at an angle so that side of the material so that the tool can be used to
can be machined level a surface.

• DIA C: The top slide is slowly feed into the material so that a ‘rack’ can be
machined for a rack and pinion gear system.
 Drilling Process
• The drilling machine (drill press) is a single
purpose machine for the production of
holes. Drilling is generally the best method of
producing holes. The drill is a cylinderical bar
with helical flutes and radial cutting edges at
one end. The drilling operation simply consist
of rotating the drill and feeding it into the
workpiece being drilled.
• The process is simple and reasonably accurate
and the drill is easily controlled both in cutting
speed and feed rate. The drill is probably one
of the original machining processes and is the
most widely used.
Typical Drilling Processes
 Abrasive Machining

• Abrasive machining uses hard non-

metallic particles to machine the work
surface. Relevant processes include
grinding, honing, superfinishing / abrasive
belt machining and honing. The first three
processes uses abrasive particles (grit),
rigidly held in a wheel, stone, or
belt. Lapping is based on the abrasive
particles being retained in a fluid.
 Grinding
• The grinding process is used to produce a high surface finish
with a close tolerance and for machining hard materials. The
process is a variation of polishing using abrasive materials
held together by an adhesive generally in the form of a solid
wheel. The wheel is rotated at high speeds and the
circumferential surface of the rotating wheel is brought into
contact with the material being machined.
Reasons for grinding:
• Removal of surplus material
• Production of high quality surface finishes
• Machining very hard materials
The two main abrasives used for grinding wheels are
• Aluminium Oxide (for use on materials with a high tensile
strength.
• Silicon Carbide (for use on materials with a low tensile
strength
 Welding
• A weld occurs when pieces of metal are joined by causing the
interface to melt and blend prior to solidifying as a uniform
metal joint. This process may be caused by heat, pressure
or a combination of both. When heat alone is used the
process is called fusion welding.

Pressure welding usually involves heating the surfaces to a

plastic state and then forcing the metal together. The
heating can be by electric current of by friction resulting from
moving one surface relative to the other.

The methods and equipment used for welding metal are also
associated with cutting metal. There are a large number of
welding and allied processes including the following.
 Welding Processs
• Gas Welding
• Arc Welding
• Brazing
• Soldering
• Resistance Welding
• Solid State Welding
• Other Welding
 Arc Welding
• Basically, an electric arc is used to heat base metals
and a consumable filler rod.

• This is the most common form of welding and is used

in about half of all applications.

• A power supply is used to create a high potential

between an electrode (guided by the welder) and a
metal work piece. When moved close enough
electrodes break down the air and start to flow. The
local current of the flow is so high that it heats metals
up to 30000C or 54000F.
• Material is added during this welding process.
This material can come from a consumable
electrode, or from a rod of material that is fed
separately.

• The electrodes/rods are often coated. This

coating serves a number of functions,
• - it protects the welder from contact
• - it deoxidizes and provides a gas shield
• Basically, filler and base materials are heated to the point
of melting by a burning a gas.
The common type is - oxygen-acetylene
These are suited to a few applications, but they produce
by-products that can contaminate the final weld.
Typically the flame is adjusted to give a clean burn, and
this is applied to the point of the weld.
• A welding rod will be fed in separately to melt and join
the weld line.Flux can be used to clean the welds.
 MILLING MACHINE
• Milling is a process of removal of meal by feeding
the work piece against rotating multipoint cutter.
• As the cutter rotates, each cutting edge removes
small amount of material from the advancing
work-piece.
• The rate of metal removal is rapid as the cutter
rotates at very high speed and has many cutting
edges.
• Milling Machine based on spindle position is
classified into
– Horizontal Milling Machine
– Vertical Milling Machine.
 Horizontal Milling Machine
The principal parts of a horizontal milling machine are
• Base
• Column Knee
• Saddle
• Table,
• Elevating Screw
• Spindle
• Over arm
• Arbor.
 Vertical Milling Machine
The principal parts of a Vertical Milling Machine are
• Spindle head
• Elevating screw
• Base
• Column
• Knee
• Saddle
• Table
• Over arm
 Milling Operations
• Plain milling Face Milling

Gear cutting.
• Side Milling T-Slot Milling

• End Milling Angular milling

 Up Milling and Down Milling
Up Milling
In Up Milling also known as conventional
Milling, the cutter rotates against the
direction in which the work is being fed.
Job-tool motion is opposite.
Cutting forces vary from zero to maximum
ie. cutting starts with zero thickness.
Cutter tends to lift the work-piece.
Poor surface finish.
More power consumption.
Down Milling
Cutter rotates in same direction as that in
which the work is being fed.
Job-tool motion is opposite.
Cutting forces vary from maximum to
minimum i.e. chip thickness is maximum
at the beginning.
Cutter tends to press the work-piece
firmly against the table.
Good surface finish.
Less power consumption
 GRINDING MACHINE
• Grinding is a process of metal removal in which
cutting tool used is an abrasive wheel.
• Grinding wheels are made of abrasive particles
bonded together by some bond.
• Grinding is mainly used for the following purposes
– To remove small amount of metal from the work-piece
to bring its dimensions within very close tolerance of
the size desired.
– To obtain better finish on the surface.
– To sharpen the cutting tools.
– To machine hard surfaces which are otherwise difficult
to be machined by other methods.
 Types of Grinding
According to the type of surface to be ground, grinding
is classified as
• Cylindrical grinding
• Surface grinding
• Form grinding
Cylindrical grinding
Surface Grinding
Form Grinding
 MILLING MACHINE

1
 MILLING MACHINE

 Milling is a process of removal of metal by feeding the work

piece against rotating multipoint cutter.
 As the cutter rotates, each cutting edge removes small amount
of material from the advancing work-piece.
 The rate of metal removal is rapid as the cutter rotates at very
high speed and has many cutting edges.
 Milling Machine based on spindle position is classified into

Horizontal Milling Machine

Vertical Milling Machine.

2
 Fig Horizontal Milling machine

3
4
  The principal parts of a horizontal milling machine are the

 Base,
 Column Knee
 Saddle
 Table,
 Elevating Screw
 Spindle
 Over arm
 Arbor.

5
 Base :
 It is the foundation for all other parts of the milling machine. It gives the
machine the required rigidity and strength. It also acts as a reservoir for
the coolant.
 Column:
 It is the main supporting frame mounted vertically on the base. The front
face of the column has vertical guide ways.
 Knee
 The knee is a rigid casting that slides up and down on the vertical guide
ways of the column. It has horizontal guide ways on its top surface. It
supports the saddle and table and is partially supported by the elevating
screw for adjusting the height of the knee.
 Saddle:
 The saddle supports and carries the table. Saddle is adjustable on guide
ways on the knee
 Table
 The table rests on guide ways on the saddle and can be moved
longitudinally. It supports the work piece.

6
 Elevating screw
 The height of the knee is adjusted by the elevating screw. It also
supports the knee.
 Spindle
 The spindle obtains the power from the motor and transmits it to
an arbor. The spindle has a tapered socket for inserting the arbor.
 Over arm
 The over arm is mounted on the top of the column. The over arm
support provided at the free end of over arm can be moved
horizontally on the guide ways provided at the bottom surface of
the over arm

7
  Arbor
 It is the rod on which cutter is mounted. It is tapered at one
end to fit into the spindle. The other end of the arbor is
mounted in a bearing provided in the over arm support.

8
 Vertical Milling Machine
 In vertical milling machine the spindle axis is kept vertical.
The principal parts of the vertical milling machines are
 Base
 Column
 Knee
 Saddle
 Table
 Elevating screw
 Spindle head and
 Over arm

9
 Fig Vertical Milling machine

10
11
  Base
 It is the foundation member for all other parts of the milling machine. It
gives the machine the required rigidity and strength.
 Column
 It is the main supporting frame mounted vertically on the base. The
front face of the column has vertical guide ways.
 Knee
 The knee is a rigid casting that slides up and down on the vertical guide
ways of the column face. It has horizontal guide ways on its top surface.
It supports the saddle and the table and is partially supported by the
elevating screw which adjusts the height of the knee.
 Saddle
 The saddle supports and carries the table and is adjustable on guide
ways on the top of the knee.
 Table
 The table rests on guide ways on the saddle and can be moved
longitudinally. It supports the work piece.
12
  Elevating screw
 The height of the knee is adjusted by elevating the screw. It also
supports the knee.
 Spindle head
 The spindle head is mounted on the top of the column. It has a
swivel base and hence the spindle head can be swiveled at an
angle for machining angular surfaces

13
  Milling Operations
 Plain milling
 Plain milling is also called surface milling or slab milling is
the production of flat surfaces with the milling cutter axis
parallel to the surface being milled.
 The work piece is generally clamped directly to the table.
 Flat surfaces may be milled with a plain milling cutter
mounted on the arbor.

14
15
  Face Milling
 Face milling is a process by which the flat horizontal
surfaces perpendicular to the axis of cutter is produced.

16
 Conventional face milling operation. The face-milling
cutter machines the entire surface. The cutter diameter is
greater than the workpart width.

17
 Partial face milling operation. The face milling cutter machines only
one side of the work piece.

18
  Side Milling
 Side milling is the process by which flat surfaces is
produced at the side of the work piece.

19
  End Milling
 End milling is the process by which a flat surface which
may be vertical or horizontal.

20
 End milling operation used to cut a pocket in
an aluminum workpart.

21
  T-Slot Milling
 A T-Slot is produced using a T-Slot cutter. First of all a
plain slot is cut on the work piece using an end milling
cutter.
 Then the T-Slot cutter is fed from one end of the work
piece.
 The neck portion of the cutter passes through the already
milled plain slot.

22
  Angular milling, or angle milling, is milling flat surfaces which
are neither parallel nor perpendicular to the axis of the milling
cutter. A single angle milling cutter is used for angular surfaces.
The usual angle of the cutter is 45o,50o,55o, or 60o based on
designs.

23
  Gear cutting.
 Gear teeth are cut on the milling machine using formed milling
cutters called involute gear cutters. These cutters are
manufactured in many pitch sizes and shapes for different
numbers of teeth per gear.

24
  Up Milling and Down Milling:
Milling can be classified as either up milling or down
milling. These operations are shown in fig below

Fig Up Milling Process Fig Down Milling Process

25
 Up Milling Down Milling
In Up Milling also known as Cutter rotates in same direction
conventional Milling, the cutter as that in which the work is
rotates against the direction in being fed.
which the work is being fed.
Job-tool motion is opposite. Job-tool motion is in same
direction.
Cutting forces vary from zero to Cutting forces vary from
maximum ie. cutting starts with maximum to minimum i.e. chip
zero thickness. thickness is maximum at the
beginning.
Cutter tends to lift the work-piece. Cutter tends to press the work-
piece firmly against the table.
Poor surface finish. Good surface finish.
More power consumption. Less power consumption
26
27
28
29
SHAPING MACHINE
 SHAPING MACHINE

 Shaping Machine or the shaper is used for the production of

flat surfaces.

 It uses a single point cutting tool for machining.

 The work is held in a vice, fastened to a work table and the

tool reciprocated over the work.

 During the forward stoke of the tool it removes metal from the
work-piece.

 At the end of the return stroke the feed operates to move the
table and work to the desired amount.
2
 Fig shaping machine

3
4
5
6
 Base. Base supports the whole machine and is rigidly bolted
to the floor
 Column: The column is mounted on the base. All the other
parts of shaper are attached to column. The top of the column
is machined to form guide ways for ram reciprocation. The
front vertical face of the column is also machined to enable
the table to be raised or lowered.
 Ram: It is the reciprocating part of the shaper. It reciprocates
on the guide ways provided on the top of the column. It
carries the tool head at the extreme front end. The ram is
connected to the quick return mechanism which allows the
ram to move at a slower speed during the cutting stroke and
at a faster speed during the return stroke.

7
  Tool head: It is mounted at the front of the ram. It can be
swiveled to any angle to enable the tool to take angular
cuts.

 Table: Vice is clamped on the table. Vice is a device to-

hold work on the table of the shaper.

8
 Operations performed on a shaper
 Even though shaper is primarily designed to generate a flat
surface, it may also be used to perform many other
operations.

 The different operations performed on a shaper are

 Machining horizontal surface
 Machining Vertical Surface
 Machining Angular Surface
 Machining Irregular surface

9
  Machining horizontal surface

 The work piece is held in the vise provided on the table of

the shaper.
 The bed is raised so that the work piece is just near to the
tool fitted in the tool holder.
 The tool is fed on to the work by lowering the tool head.
 The tool is lowered by rotating the down feed screw of the
tool head.
 The tool as it moves forward removes the metal from the
work.
 The work is moved laterally a little when it is ready for
the cut during the forward stroke.
10
 Fig Machining horizontal surface

11
  Machining Vertical Surface

 The work is mounted in the vise.

 The vertical slide is set exactly at the zero position and
the apron is swiveled in a direction away from the surface
being cut.
 The down feed is given by rotating the down feed screw
of the tool head.

12
 Fig Machining Vertical Surface

13
  Machining Angular Surface

 The work is set on the table

 the vertical side of the tool head is swiveled to the

required angle from the vertical position.

 The apron is further swiveled away from the work.

 The down feed is given by rotating the down feed screw

of the tool head

14
 Fig Machining Angular Surface

15
 TYPES OF SHAPERS
 Shapers are classified under the following headings:
 According to the type of mechanism used for giving reciprocating
motion to the ram
 Crank type
 Geared type
 Hydraulic type
 According to the type of design of the table:
Standard shaper
 Universal shaper
 According to the position and travel of ram;
Horizontal type
 Vertical type
 Travelling head type
 According to the type of cutting stroke:
Push type
 Draw type.

16