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Systems In Mechanical
Engineering

UNIT 5
Manufacturing Processes

Casting

Mr. Girish G Khope

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 Manufacturing Process

It involves transforming a raw material from it’s original state to a

finished state by changing it’s shape or the properties of the
material in a series of steps.

Manufacturing Process

Raw Material Machine Tool Finished Product

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 •Turning
•Facing
•Drilling
•Milling
•Shaping
•Reaming

•Joining Processes
•Welding
•Soldering
•Brazing
•Screwing
•Riveting
•Adhesive Bonding

•Surface Finishing Processes

•Honing
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•Lapping
 Metal Casting
• Casting: It is a manufacturing process in which
part of desired shape is obtained by pouring
molten metal into cavity of required shape

• It is one of the oldest manufacturing process (around

6000 year old, Egyptians were first to use castings)
•Castings
•Sand Casting

•Die Casting

•Investment casting
c •Centrifugal casting

•Slush Casting

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Metal Casting: Sand Casting

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 Metal Casting: Sand Casting
• Steps in Sand Casting:
1. Pattern Making:
• Pattern is replica of the part to be casted.
• Initially pattern has to be made using different manufacturing
process other than casting.
• Draft/Taper is provided on pattern for its easy removal from sand
mould
• Commonly used materials for pattern making are- Wood, Plastic
and metal

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 Metal Casting: Sand Casting
• Steps in Sand Casting:
2. Mould Making:
• Mould is a container made from green sand and which has
cavity in which molten metal can poured.
• Mould box has two halves, the upper halve is called cope and
lower halve is called drag
• Arrangement for metal pouring has to be made inside the
mould

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 Metal Casting: Sand Casting
• Steps in Sand Casting:
3. Core Making:
• Core is a device used in sand casting to produce hollow
castings
• Generally core is made from same material as that of the
mould i.e. sand
• Supporting elements called chaplets are used to support core

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 Metal Casting: Sand Casting
• Steps in Sand Casting:
4. Metal Melting and Pouring:
• The raw material is melted using furnace. Furnace may be
operated on electricity or fuel
• The molten metal is poured into mould using ladle
• Pouring basin, sprue, runner, gate are used to guide molten
metal into the cavity

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 Metal Casting: Sand Casting
• Steps in Sand Casting:
5. Solidification
• Metal is allowed to cool to room temperature
• During solidification the metal shrinks and the extra metal
required compensate this shrinkage is obtained from the riser

6. Finishing
• Undesired part which corresponds to gating system and riser
has to be cut from main casting
• The casted surface generally is rough and some finishing
operation like grinding, machining, polishing are required

7. Inspection
• Before dispatching the casted part has to be checked for
desired dimensions. The part which doesn’t meet expected
dimensions has to be scraped
• Castings are also checked for various undesirable defects
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E:\GK\BME study material\Unit 3 v\RELATED
VIDEOS\2Sand Casting Simulation.flv

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Other Subjects: https://www.studymedia.in/fe/notes
 Metal Casting: Sand Casting
• Terminology in Sand Casting:
1. Mould Box:
• It is metallic or wooden box in which sand mould is
created.
• Upper part of mould box is called cope and lower part is
called drag
2. Pouring Basin/Cup:
• It is a shallow part at the entry of gating system through
which metal is poured

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 Metal Casting: Sand Casting
• Terminology in Sand
Casting:

3. Sprue:
• A conical vertical portion
immediately after pouring cup is
called sprue

• Diameter of free falling liquid

under gravity will be decreasing.
If straight sprue is used, a
vacuum will be created in
between sprue wall and the
metal stream.

• This vacuum will be responsible

for suction of atmospheric gases
which will create voids in casting

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 Metal Casting: Sand Casting
• Terminology in Sand Casting:
4. Runner:
• The horizontal portion immediately after the sprue is called
runner
5. Gate:
• A narrow entry through which metal enters mould cavity is called
gate

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 Metal Casting: Sand Casting
• Terminology in Sand Casting:
4. Skim Bob:
• A small hollow spherical bulge above the top runner surface which is
used to separate light floating impurities is called skim bob

5. Well:
• A deep portion immediately below the sprue which acts as cushion to
molten metal so that the sand is not washed off into the casting is
called well

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 Metal Casting: Sand Casting
• Terminology in Sand Casting:
6. Riser:
• It is a cavity cut into the sand mould which
permits the molten metal to rise above the
casting cavity

• Main function of riser is to supply molten

metal during the shrinkage which happens
during the solidification

• The riser shape has to be designed in such a

way that its solidification time is more than
that of the casting

• Riser can be through or blind. Through riser

also serves as an exit to the entrapped gases
in mould cavity
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 Metal Casting: Sand Casting
• Terminology in Sand Casting:
7. Chills:
• Chills are the metallic element which are used to enhance solidification rate

• As metals have higher thermal conductivity than sand, heat transfer rate will be
higher in the vicinity of chills hence the molten metal solidifies faster there

• Using chill we can control solidification direction as well as grain size ( Faster
cooling rate will result in finer grain size)

• Chills can be internal as well as external. Internal chills have to be made from
same material as that of casting

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 Metal Casting: Sand Casting
• Terminology in Sand Casting:
8. Chaplet:
• It is a supporting element which used to hold core in correct position
• Chaplet has to be made from same material as that of the casted part

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 Metal Casting: Sand Casting
• Terminology in Sand Casting:
9. Machining Allowance:
• Casted products require finishing operation because of poor surface finish. After finishing
operation, size of the casted part reduces.
• In order to compensate this reduction, size of ‘casting pattern’ is increased . This increase
in size of pattern with respect base size is called machining allowance
10. Shrinkage Allowance:
• When the casted product cools from its melting point to room temperature , size of
component reduces. In order to compensate this reduction pattern of bigger size than
product size are used.
• The percentage increase in size of casted product at its melting point with respect its size
at room temperature is called shrinkage allowance.

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 Metal Casting: Sand Casting
Advantages of Sand Casting:
– It is one of the cheapest manufacturing process. Operating as well
as initial cost of equipment is much lower as compared to other
manufacturing processes

– Casting can be used to create complicated shapes

– Casting can be used to manufacture components made from

brittle as well as ductile material

– Casting can be used economically to create small as well as large

components

– Casting is a primary manufacturing process. Raw material supplied

to various other manufacturing process is obtained through the
casting
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 Metal Casting: Sand Casting
Disadvantages of Sand Casting:
– Casting can not be used to create very thin components (thickness < 6mm)

– Casting contains various defects such cracks, voids, foreign particle inclusions
which reduces strength of the component

– Casted components are brittle in nature as compared forged components

– Surface finish of sand casted component is poor

– Man power and space requirement is high

– Pollution during the casting process is high

– Risk of injury in metal handling is high

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 Metal Casting: Sand Casting
Applications of Sand Casting:
– Machine beds for various machines (Lathe, Drilling, Shaping, Milling)

– Automobile parts (Pistons, cylinder block, clutch and brake plates, Gearbox casing)

– Aircraft parts (Turbine and compressor blades, Engine casing)

– Casings used in various machines (Turbine, Generator, Compressors, Motors, Gear box,
Pumps)

– Pulleys, Railway wagon wheels, Valves

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Casting

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 Systems In Mechanical
Engineering

Unit 5

SHEET METAL WORKING

Mr. Girish G Khope

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 SHEET METAL WORKING

Sheet metal working

is the process of manufacturing the components
from the sheet metal of thickness ranging from 0.1
mm to about 8 mm.

It is carried out by a machine tool called press

(Press working).

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•Sheet Metal Working
•Sheet Metal Cutting (Shearing) Operations
•Piercing
•Punching
•Blanking
•Perforating
•Notching
•Lancing
•Slitting

•Sheet Metal Forming Operations

•Bending
•Drawing & Deep Drawing
•Embossing
•Forming
•Coining (Squeezing)

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 Metal Cutting (Shearing ) Processes:
Piercing- Producing a hole of any desired shape in metal sheet.

Punching- Producing a circular hole in metal.

Blanking-
The metal punched out is the required component, called blank.
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Difference between punching and blanking

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Other Subjects: https://www.studymedia.in/fe/notes
Notching- removal of a small part of a metal sheet of any desired shape.

Perforating- Producing no of evenly spaced holes in a metal sheet.

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7
 Slitting- Cutting a metal sheet in a straight line along a length .

Lancing- Cutting a part of metal sheet through some portion of its length and then
bending of cut portion .

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 Metal Forming processes
• It is a process in which flat plate metal sheet is converted into
a desired shape without wasting the material.

• Drawing and deep drawing

• Bending
• Forming
• Coining
• Embossing

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Bending Methods-

U Bending

V Bending
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Angle Bending

Bending and wiping/

Edge bending

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Drawing
process of forming a flat metal
sheet into a three dimensional hollow
shape.

Drawing

Deep drawing
If the depth of hollow cup exceeds the
diameter of formed cup, the process is
called Deep Drawing.

Deep Drawing
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Forming-
Process of flat metal sheet into a surface of a desired profile.

Curling
an edge of circular cross section is formed along a sheet or at the end of
the tube.

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Other Subjects: https://www.studymedia.in/fe/notes
 Embossing
is the process of producing depressed or
raised impression of letters figures or designs
on metal sheet.

Embossing

Coining
is the process of cold squeezing of
metal sheet in which all the surface are
confined within a set of dies.

Coining (Squeezing)
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Advantages:
•Components produced are light in weight.
•Cheap
•Rate of production is high
•High dimensional accuracy
•Not required skilled man power

Limitations:
•Limitation of thickness of metal sheet
•Components have low strength.
•Vibrations are more during operations
•Noisy in operation.
•Dies are costly.

Applications:
– Automobile body parts (bike , car , buses etc), aircraft
body parts.
– Steel furniture, Utensils
– Electronics appliances
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Kitchen Tools

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 Industrial Components
Machine Parts

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Automobile bodies

Aircraft bodies

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Sheet metal Working

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 Systems In Mechanical
Engineering

UNIT 5

METAL FORMING PROCESS

Mr. Girish G Khope

Other Subjects: https://www.studymedia.in/fe/notes 1
• Metal forming process
is the process in which the component of desired shape and size is
obtained through the plastic deformation of the metal under the action
of extremely applied force.

FORGING PROCESS
is a metal forming process in which metal is first heated and then
plastically deformed to the desired shape and size by the application of
compressive force using hand hammer, or a press.

Ductile materials are required. (ability of material to sustain plastic

deformation without failure.)

•Alloy Steel, Low Carbon Steel, Medium Steel, Stainless steel

•Copper Alloys
•Aluminum Alloys etc.

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 Forging Process:
• Forging is the process of shaping heated metal by the
application of sudden blows (hammer forging) or steady
pressure (press forging) and makes use of the characteristic
plasticity of the material.

• In forging process the material is heated to a temperature at

which its elastic properties completely disappear. This
temperature is known as forging temperature and it varies
from material to material.

• Similar to casting the forging is also one of the oldest process

of manufacturing metallic components. In ancient days the
forging was in use for making the implements of war such as:
swords, knives, arrows, protective armour, helmets etc.
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 Working principle:
• In forging process, the material (billet) is
deformed into the desired shape between two
parts called dies.

• The shape of the dies matches with desired

shape of the forged component.

• The forging press shown in figure consists of a

lower die fixed to the frame (Anvil) while upper
die is connected to the ram.

• The hot material is kept on the lower die.

• In mechanical press the ram is driven by the

crank shaft through the connecting rod where
as in hydraulic press the ram is driven by the
hydraulic cylinder.

• During the downward stroke of the ram, the

upper die exerts sudden compressive force on
the hot material.

• Due to this sudden compressive force the hot

material is converted into the desired shape.

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Forging

[Heated] metal is beaten with a heavy hammer to give it the required

shape

Hot forging,

open-die

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 Classification
Based on types of dies used, forging process are classified as:

1. Open die forging

2. Closed die forging

Open Die Forging process:

•In open die forging, the material or work

piece is deformed between two flat dies
or dies of very simple shape.

Closed Die Forging process:

•In closed die forging, the material or work

piece is deformed between two dies
which have the impression of the desired
shape.

• when the two cavities are closed, the

cavity formed is of the desired final shape.
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 Based on mode of application of compressive force, forging processes are
classified as:
1. Hand forging
2. Drop forging
3. Press forging
4. Upset or machining forging

Hand forging:
• It is the process of deforming the hot
material or work piece into desired
shape by applying repeated blows of
hand held hammer.

• In case of hand forging, hammering is

done by hand; whereas forging by m/c
involves the use of dies and it is
mostly used in mass production.

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Other Subjects: https://www.studymedia.in/fe/notes
 Drop forging:
• It is the process of deforming the hot
material or work piece into a desired shape
by raising the die with the help of
arrangement like pneumatic cylinder and
allowing it to fall so as to impart the blow or
impact on the material.

• In this process the lower die is fixed to the

frame while the upper die is attached to the
ram which reciprocates in a guide.

• The ram is connected to the piston through

the piston rod.

• It is important to note that the purpose of

pneumatic cylinder is mainly to lift the ram
and upper die unit to the required height.
The pneumatic cylinder does not control but
assist the fall ofOther
ramSubjects:
and upper die unit.
https://www.studymedia.in/fe/notes
 press forging:
• It is the process of deforming the hot
material or work piece into a desired
shape by slow squeezing action.

• The gradual motion of the upper die

transfers the compressive force
uniformly and gradually to the hot
material so as to deform it to the
desired shape.

• Unlike hand forging and drop forging

processes, in press forging process
there is no blow or impact.

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 Machine or Upset forging
– The cross section of the hot material or workpiece is
increased locally with a corresponding reduction in
it’s length by slow squeezing action.

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• Roll Forging-
– long cylindrical products- axle, leaf spring, tapered
levers.

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 Mechanical working of metals
• Mechanical working of metals is simply plastic deformation of metal performed to change the
dimension, properties and surface condition with the help of mechanical pressure.

• Depending upon the temperature and strain rate, mechanical working may be either Hot working
or Cold working.

• Process of formation of new grains is called as recrystallisation and the corresponding temperature
is the recrystallisation temperature.

• Recrystallisation temperature is the point which differentiates hot working and cold working.

• Mechanical working of metals above the recrystallisation temperature, but below the melting or
burning point is known as hot working, whereas below the recrystallisation temperature is known as
cold working.
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 Hot Forging(Isothermal Forging)
• Hot Forging is accomplished at a temperature above the
recrystallisation temperature but below the melting or burning
point of the metal, because above the melting point, the metal will
burn and become unsuitable for use.

• Material is heated extremely at high temp.

– (For Steel-up to 1200 0c, Al Alloys- 525 0c)

• Every metal has a characteristic hot working temperature range

over which hot working may be performed.

• The changes in structure from hot working improves mechanical

properties such as ductility, toughness, resistance to shock and
vibration, % elongation, % reduction in area, etc.
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 Cold Forging
▪ The working of metals at temperatures below their recrystallisation temperature is called as
cold working.

▪ Most of the cold working processes are performed at room temperatures.

▪ Unlike hot working, it distorts the grain structure and does not provide an appreciable
reduction in size.

▪ Cold working requires much higher pressure than hot working.

▪ If the material is more ductile, it can be more cold worked.

▪ Residual stresses are setup during the process, hence to neutralize these stresses a suitable heat
treatment is required.

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Difference between Cold &Hot Working
Forging
Parameters Hot Working Forging Cold Working Forging

Definition It is Defined as the It is Defined as the

deformation of the material deformation of the material
into predetermined shape into predetermined shape
carried out at a temperature carried out at a
above its recrystallation temperature below its
temperature. recrystallation temperature.

Force & Low High

Energy
required

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Parameters Hot Working Forging Cold Working Forging

Dimensional accuracy Poor (due to thermal Good

contraction during
cooling)

Machine requirement Light Heavier and Powerful

Ductility of component Increases Decreases

Type of materials Need not be soft Soft like Aluminum

Strain Hardening effect Absent Present

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 Materials used for forging:

• Must be ductile material.

• Examples: low and medium carbon steels,

alloy steels, stainless steels, copper alloys,
aluminum alloys etc

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Advantages:
• Forging process gives high dimensional accuracy and good surface
finish.

• As the forging process gives high dimensional accuracy it reduces the

material removal during machining and finishing operations.

• This process reduces the grain size, which results in improving the
strength and toughness of the forged components.

• It produces components without shrinkage cavities, blow holes and

machining scratches which increases the endurance strength of the
parts.

• Forged components offer better resistance to shock and vibrations.

• Welding of forged parts is easier.

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 Limitations:
• Brittle like cast iron can not be forged.

• Difficult to produce complex components with intricate

shapes by forging process.

• Normal forged components cost more than cast components.

• The cost of forged dies is high.

• Forging process is mostly suitable for large parts.

• More noise and vibrations are produced during the process.

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 Applications of Forging process:

1. Car axles, crankshafts, connecting rods, leaf springs,

crane hooks, jet engine turbine dies and blades.

2. Levers, flanges, propellers, hollow bodies, railway

wheel disks, tank bottoms.

3. Aircraft and rocket parts, knife blades, bolts, nuts,

washers, collars, gear blanks, etc.

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 Applications of Forging process:
1. Car axles, crankshafts, connecting rods, leaf springs, crane hooks, jet
engine turbine dies and blades.
2. Levers, flanges, propellers, hollow bodies, railway wheel disks, tank
bottoms.
3. Aircraft and rocket parts, knife blades, bolts, nuts, washers, collars, gear
blanks, etc.

Other Subjects: https://www.studymedia.in/fe/notes 25

 Systems In Mechanical
Engineering

UNIT 5
METAL JOINING PROCESSES

Mr. Girish G Khope

Other Subjects: https://www.studymedia.in/fe/notes
 Welding
• Welding is the process of joining two plastic or metal parts by melting them, with
or without using a further molten material.

• Welding is a process of joining two metal pieces by the application of heat.

• The heat produced by an arc is used in welding to melt metal rods, which solidify
to provide a strong joint between two metal surfaces.

• Special helmets must be worn when doing welding to protect the eyes

• Welding is the least expensive process and widely used now a days in fabrication.

• Welding joints different metals with the help of a number of processes in which
heat is supplied either electrically or by mean of a gas torch.

• Different welding processes are used in the manufacturing of Auto mobiles bodies,
structural work, tanks, and general machine repair work.
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 Welding
Filler material
(Optional)

Application of Heat
pressure
(Essential)
(Optional)

Welding

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TYPES OF WELDING

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 Pressure Welding (Plastic Welding):-
• Pressure welding is a process in which external
pressure is applied to produce welded joints either at
temperatures below the melting point, which is solid
state welding, or at a temperature above the melting
point, which is fusion state welding.

• In this process, metal pieces to be welded are heated

to a temp. so as to make them plastic and then
forced together by external pressure.

• This process does not require additional metal for

completing the weld.
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Pressure Welding (Plastic Welding):-

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 Fusion Welding (Non-Pressure Welding):-
• In this process, metal pieces to be welded are heated
to molten (fusion) state & allowed to solidify.

• No pressure is required in this process.

• Additional metal is generally supplied by filler rod

(welding rod) to complete the joint.

• The material at the joint is heated to a molten state

and allowed to solidify

• (Ex) Gas welding, Arc welding

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Fusion Welding (Non-Pressure Welding)

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 Electric Arc Welding
• It is a fusion welding process, in which welding heat is obtained from an
electric arc between electrode & work.

• The electrode is first allowed to touch the work to form an electric circuit
and then separated by a small distance ( 4 to 6 mm), so that current
continuously flow through the gaseous medium.

• The temp. produced by an electric arc is about 6000°C to 7000°C.

• The base metal is melted by the temp. of the arc, forming a pool of molten
metal which is forced out of the pool by blast from the arc.

• Metal of the electrode also gets melted & deposited at the weld.

• Either A.C. or D.C. is used for arc welding.

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 Electric Arc Welding

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 Electric Arc Welding

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 Metal Inert Gas Welding (MIG)
• The workpiece to be welded and the consumable electrode (in the
form of wire) are connected to the Power Supply (D.C or A.C).

• Whenever the consumable electrode is brought near the

workpiece (with a small air gap), an arc is produced. This arc
melts the electrode.

• The melted electrode fills uniformly over the required regions of

the workpiece.

• An inert gas supply is provided around the electrode (hence the

name ‘Metal Inert Gas Welding’). During the welding process ,it
forms a gas shield around the arc and the weld This is
intended to protect the weld from the external atmosphere.
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Shielded Metal Arc Welding (SMAW)
• The arc temperature produce
immense heat with temp. ranging
from 24000C to 40000C
• The electrodes are coated with a
shielding flux (Borax flux) of a
suitable composition.
• Heat is generated by an electric arc
between flux coated consumable
metal electrode and the work piece.

• Consumable electrodes
usually have a coating on its outer
surface which on melting release
gases like hydrogen or carbon dioxide
to form a protective covering around
the molten pool from atmosphere
contamination.
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Other Subjects: https://www.studymedia.in/fe/notes
Advantages of Welding:
• Gives light weight construction.
• High strength joint.
• High rate of production.
• Ability to produce complicated shapes.
• Used effectively for repairing broken parts.
• Low cost process.
• Ability to produce fluid tight joints.

Limitations of Welding:
• Not possible to disassemble the parts.
• Joints weak against vibrations.
• Quality and strength of joint is operator dependant.
• Gives harmful radiations.
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Applications :
• Fabrications of Bridges, Electric and Transmission Towers.
• Manufacturing of Automobile bodies.
• Building of Ships and Aircrafts.
• Manufacturing of Boiler, Pressure Vessels, Storage Tanks, Pipelines
• Manufacturing of Steel Furniture, Window and Door Frames,
Window Grills. etc

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Soldering
is a process in which two or more metal items are
joined together by melting and flowing a nonferrous
filler metal into the joint. (below 450oC) tin-lead alloy

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Brazing
is a metal joining process whereby a filler metal is
heated above and distributed between two or more close
fitting parts by capillary action. (above 450oC) copper
alloys

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 Comparison b/w Brazing and Soldering
Parameters Brazing Soldering

Heating Temperature Above 450oC Below 450oC

Filler Material Alloys of copper, silver Tin- Lead alloy Zinc-

or Nickel Aluminum

Surface Finish Good Not good

Strength of Joint Lower than welded Very Low

joint but relatively
good

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Comparison b/w Welding Brazing and Soldering
Parameters Welding Brazing Soldering

Process of joining Process of joining Process of joining

the two metallic two work piece two work piece
parts together by made of similar or made of similar or
heating them to a dissimilar dissimilar materials
plastic or semi materials by by heating them
molten state with heating them below 4500C as
Definition or without above 4500C but well as the below
pressure and filler below melting the melting
material temperature of temperature of work
work piece and piece and using non
using non ferrous ferrous filler
filler material. material.

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Heating of work By electric arc or By gas flame or in By gas flame or
piece by gas flame or by furnace by electric
chemical reaction soldering iron.

Strength of joints High Lower than Very Low

welded joints but
good

Surface finish Not very good Good Not very good

Thickness of sheet Thin sheets can not Can be joined Can be joined
be joined

Cost Costly Costly Cheap

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 Fabrication of Fabrication of Electric circuits,
bridges, electric heat exchangers,
towers, Pipe Fitting,
Transmission Electrical repair
powers, etc. work, etc

Applications Manufacturing of Joining of Carbide In electrical

two and four tips with metal equipments,
wheeler bodies shanks in cutting Joining Wires., etc
Building of ships tools, etc
and aircrafts,
Boiler, Pressure
Vessel, Storage
tanks etc.

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 Systems In Mechanical
Engineering

Unit 5

Lathe, Drilling & milling

Machine

Mr. Girish G Khope

Other Subjects: https://www.studymedia.in/fe/notes
 Introduction
Machine Tool

• It is defined as the machines used for carrying out

metal cutting processes & surface finishing
processes.

• Machine tool is a power driven machine used for

producing the components of required shape & size
with desired accuracy & surface finish by removing
the material from the workpieces.
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•Machine Tools
•According to size of chip removed
•Larger sized chips like lathe machine, drilling machine etc.
•Smaller sized chips like grinding machine ,lapping machine etc

•According to desired purpose

•Single-purpose , Multi –purpose & Special purpose machine tool

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Lathe Machine(Turning Machine)
• It is known as the mother of all the machine
tools & most widely used machine tool.
• Lathe was first machine tool which came into
being as a useful machine for metal cutting.

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Block Diagram of Lathe Machine

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Other Subjects: https://www.studymedia.in/fe/notes
 Working Principle
• Lathe is a machine tool which holds workpiece
securely between two rigid & strong supports, called
as centres or in a chuck or face plate, while workpiece
revolves.

• The cutting tool is rigidly held & supported in a tool

post & fed against revolving workpiece.

• While workpiece revolves about its own axis, tool is

made to move in parallel or at an inclination with axis
of material to be cut.

• So the metal is removed to give desired shape & size.

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 Lathe Machine

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 Basic Elements of Lathe Machine
a) Bed :
It acts as a base of machine on which, different fixed &
operating parts of lathe are mounted.
It is made up of cast alloy with nickel & chromium. And used
to support all elements of lathe.

b) Headstock :
It is a box-like casting mounted permanently on bed to left
hand end of machine. It supports spindle & contains a
gear-box.
Spindle is hollow rotating shaft used for holding workpiece.
work holding device chuck is mounted on spindle.
Gear box is used to drive spindle & change spindle speed.
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c)Tailstock : It is also called as loose or puppet
head & situated at right hand end of bed & can
be moved on innerways of bed.
It hold a tool for performing operations such as
drilling, reaming, tapping etc.

d)Carriage : It is located between headstock &

tailstock of lathe. It carries cutting tool &
precisely controls its movements.
It is used for supporting, guilding & feeding tool
against workpiece during the operation on the
lathe.
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e)Feed Mechanism : The movement of tool
relative to workpiece is known as feed. Feed
mechanism has various units through which
motion is transmitted from headstock spindle to
the carriage. It is used to transmit motion from
headstock spindle to carriage by using various
units.

f)Thread cutting mechanism(Lead Screw) : It is a

long threaded shaft which is used as a master
screw & it is brought into operation only when
threads to be cut. It gives mechanised motion to
carriage for cutting threads on workpiece.
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Other Subjects: https://www.studymedia.in/fe/notes
 Specifications of Lathe Machine
a)Length of bed : It is total length of lathe bed.

b)Distance between centres : It is maximum length of

workpiece that can be mounted between centres.
Distance between live centre & dead centre.

c)Swing:-It is maximum diameter of workpiece that

can revolve between centres without touching bed.

d) Maximum & Minimum spindle speeds:-Maximum

& minimum speed at which spindle rotates.
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• E:\GK\BME study material\Unit 4 v\RELATED
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EKALASALA_com.flv

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 Lathe Machine Operations
1. Straight turning : Operation is performed for
producing a cylindrical surface by removing
excess material from workpiece. The cutting tool
is held in tool post & fed into rotating work
parallel to lathe axis. It may be rough turning.
Tool used in this operation is called as turning
tool.

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Operations on Lathe .. Turning ..
Cylindrical job

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 Turning

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2.Step turning : It is also called as Shoulder
turning. When workpiece of different diameters
are turned, the surface formed from one
diameter to the other is called as shoulder.

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Other Subjects: https://www.studymedia.in/fe/notes
3.Eccentric turning : If cylindrical workpiece has
two separate axis of rotation one being out of
centre to other, then workpiece is called as
Eccentric & turning of these different surfaces
of workpiece is known as Eccentric Turning.
Axis of workpiece is offset from axis of lathe
spindle.

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Other Subjects: https://www.studymedia.in/fe/notes
4.Taper turning : In taper turning, workpiece is
rotated on lathe axis & tool is fed at an angle to
axis of rotation of workpiece. Tool is mounted on
compound rest which is attached to circular base.
Base is graduated in degrees which can be
swivelled & clamped at any required angle.

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Other Subjects: https://www.studymedia.in/fe/notes
 Taper Turning

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5.Facing : It is operation of machining ends of a
workpiece to produce a flat surface with axis & it
involves feeding of tool perpendicular to axis of
rotation of workpiece. The tool used for facing is
properly ground & mounted in a tool holder of
tool post.

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Operations on Lathe .. Facing
Flat Surface/Reduce length

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 Facing

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• E:\GK\BME study material\Unit 4 v\RELATED
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tool.flv

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6.Drilling : This is process of producing cylindrical
hole in the workpiece. In operation, workpiece is
held in a chuck & drill is held in a tailstock. During
operation drill is fed by rotating handwheel of
the tailstock in clockwise direction.

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7.Reaming :
It is a finishing operation because a very small
amount of material is removed during this
operation.
A reamer is a type of rotary cutting tool used in
metalworking.
Precision reamers are designed to enlarge the
size of a previously formed hole by a small
amount but with a high degree of accuracy to
leave smooth sides. ... The process of enlarging
the hole is called reaming.
For performing reaming a multi teeth tool is
used, which is called as reamer.
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Other Subjects: https://www.studymedia.in/fe/notes
8.Boring : It is an operation which is employed for
machining surfaces, hence also called as Internal
Turning. It is done to enlarge the already drilled
hole & bring them to the exact required size.
Generally, used for a single point solid boring
tool.

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• E:\GK\BME study material\Unit 4 v\RELATED
VIDEOS 4\1ITI Vocational Courses - Turner -
Drilling Operation Lathe Machine.flv

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9.Knurling : It is a process of embossing a diamond
shape regular pattern on surface of workpiece
using a tool called knurling tool. It consists of a
straight shank fitted with one or two knurling
wheels.(grip).

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Operations on Lathe ..
Knurling

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 Knurling

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10.Thread Cutting : It is a process of producing a
helical groove of V or square shape on a
cylindrical surface. Tool motion is parallel to axis
of lathe.For one rotation of workpiece tool
automatically travels distance equal to pitch of
thread.

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Other Subjects: https://www.studymedia.in/fe/notes
Other Subjects: https://www.studymedia.in/fe/notes
11.Parting Off : It is a process of cutting a
workpiece into two parts.Tools used for this
operation is known as Parting Tool which is a
longer point as they are required to cut from the
outside surface right upto centre of the job.

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Operations on Lathe .. Parting Off/cutting off ..

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12.Chamfering : It is an operation of bevelling the
extreme end of a workpiece. Chamfering is done
to remove the burrs & to protect end of
workpiece from being damaged & to have better
appearance. And it is generally performed at the
end of all the operations.

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13.Grooving : It is an operation through which a
groove of approximately same width is
produced on the job as that of cutting edge of
the tool. Hence this process is also known as
form turning operation.

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Other Subjects: https://www.studymedia.in/fe/notes
Operations on Lathe .. Grooving ..

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Other Subjects: https://www.studymedia.in/fe/notes
14.Forming : Some components having neither
cylindrical nor tapered surfaces are said to have
shaped or formed surfaces. For machining such
shapes, special tools are used which are called as
Form Tools.

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Drilling Machine

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 DRILLING MACHINES

•Drilling is an operation through

which cylindrical holes are
produced in a solid material by
using a revolving tool which is
called as drill.

•The machine tool used for

producing the holes in workpiece
by forcing rotating tool into
stationary workpiece is called as
drilling machine.

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 Drilling
• Drilling is the operation of originating a
cylindrical hole
• Hole is generated by rotating cutting edges
of drill, which exerts large force on the WP
to originate a hole

Drill

WP

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 1. WORKING PRINCIPLE
•The work piece is clamped firmly on the work table by using
nuts and bolts.

•The tool used to produce holes in solid material called as drill

is press fitted in drill chuck.

•The rotating drill is made of harder material than that of the

workpiece and it is fed against the stationary work piece.

•During the operation, the material is removed in the form of

chips.

•It is important to note that during the process high amount of

heat is generated, hence continuous supply of coolant is
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Other Subjects: https://www.studymedia.in/fe/notes
Other Subjects: https://www.studymedia.in/fe/notes
1)BASE:-

•It is the part of machine which supports the entire structure.

•Generally, the machine base is made from casting.

2) COLUMN:-

•It is the vertical member of the machine which supports the

table and head containing all the driving mechanisms.

•It may be made of round section or box section.

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3) WORK TABLE:-

•The table is mounted on the column, it may be round or rectangle

in shape.

•The table has following type of motion

(i) vertical motion ( up and down)
(ii) circular motion (swing)
out its own axis.

4) DRILL HEAD:-

•The drill head carries driving and feeding mechanism for the
spindle, the driving mechanism is used for driving the drill spindle.
The drill head is mounted on the top of the column

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5) SPINDLE DRIVE:-

•Spindle is a hollow part in which drill( tool) is inserted.

•During the operation spindle rotates, as well as move up and

down. Hence the drill also rotates as well as moves up and down.

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Other Subjects: https://www.studymedia.in/fe/notes
TYPES OF DRILLING MACHINES:-

Drilling machine are manufactured in different sizes and varieties

to suit different types of workpieces. They are classified as follows:

1) Portable drilling machine

2) Sensitive or Bench drilling machine
3) Upright drilling machine
4) Radial drilling machine
5) Gang drilling machine
6) Multi-spindle drilling machine
7) Deep hole drilling machine
8) Automatic drilling machine

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1. Portable Drilling Machine:-
•Portable drilling machine is very small, compact and self
contained unit carrying a small electric motor inside it.

•It is generally used for drilling holes in components which

cannot be transported to the workshop, because of their size or
weight.In such cases, the drilling operations is performed on the
site by using portable electric drill.

•Portables drills are light in weight and manufactured in different

sizes and capacities.

•One of the major advantage of portable drill is that, the holes

can be drilled at any desired inclination.

•As small size of drill is used, the machine is operated at high

speed. Other Subjects: https://www.studymedia.in/fe/notes
Portable Drilling Machine

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2. Sensitive or Bench Drilling Machine
• This type of drilling machine is designed for drilling small holes at
high speed in light workpieces.

• It is small machine having simple construction and operation.

Fig., shows sensitive drill machine which consist of a base,
which may be mounted on a bench or on the floor.

• The vertical column carries a swivelling table, the height of which can
be adjusted along the column. Also, the table can be swung to any
required position.

• At the top, the column is provided with belt-pulley arrangement. One

of the pulley is mounted on the motor shaft and other on the machine
spindle.

• Different spindle speed can be obtained by shifting a V-belt to

different pairs of driver and driven pulleys,while the motor continues
to rotate at the same speed.
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 Sensitive Drilling Machine
• Drill holes
from 1.5 to
15mm

• Operator
senses the
cutting action
so sensitive
drilling
machine
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• There is no arrangement for automatic feed of the drill
spindle and hence the drill is fed into the work by hand
control.

• For drilling small holes, high speed and hand feed are
necessary.

• Hand feed enables the operator to feel the gradual

penetration of the drill into the work piece and sense
obstruction, if any.

• As the operator sense the cutting action at any instant, it is

known as sensitive drilling machine.

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3. Upright or Pillar Drilling Machine

Upright drilling machine is similar to sensitive drilling machine

but differs in the following manners:-

• Upright drilling machine is larger and heavier then sensitive

drilling machine.

•Upright drilling machine is used for handling medium sized

work pieces.

•In this machine, large no. of spindles speeds and feeds are
available for drilling different types of work pieces .The spindle
feed is power feed or automatic.

•The table of the machine has different types of adjustments

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Up-Right Drilling Machine

• Drill holes
upto
50mm

• Table can
move
vertically
and radially

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4. Radial Drilling Machine
• Radial drilling machine is designed for drilling medium to large
and heavy work pieces.

• It consists of a heavy, round and vertical column mounted on a

large base.

• To accommodate work pieces of different heights, the column

supporting a radial arm can be raised or lowered.

• When several holes are to be drilled on a larger work piece, the

position of the arm and the work head is changed, so that the
drill spindle may be moved from one position to another position
without changing the setting of the work piece.

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 Radial Drilling Machine

• It is the
largest and
most
versatile
used for
drilling
medium to
large and
heavy work
pieces.
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 DRILLING MACHINE OPERATIONS
1. DRILLING
Drilling is the operation of producing a circular hole in a solid metal
by using revolving tool which is called drill.

2. REAMING
• Reaming is the operation of finishing a hole which has been
previously drilled and has a coarse surface finish.
• The operation is performed by using a multitooth tool called as
reamer.

3. BORING
• The boring is the process of enlarging a drilled hole by using an
adjustable cutting tool which is called as boring tool.
• It is important to note that the boring tool is having only one
cutting edge.
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4. COUNTER SINKING
• Counter sinking operation is used for enlarging the end of
a hole and to give it a conical shape for a short distance.

• The standard countersinks have the included angles of

60, 82 or 90 degrees and cutting edges of tool are at the
conical surface.

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5. SPOT FACING
• It is the operation of smoothing and squaring the surface around a hole for the
seat of a nut or the head of a screw.
• For spot facing counterbore or special spot facing tool is used.

6. TAPPING
• Tapping is an operation of cutting internal threads by using a cutting tool called as
tap.
• For tapping purpose, the machine should be equipped with a reversible motor or
some other reversing mechanism.

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7. COUNTER BORING OPERATION:

It is the operation of enlarging the end of a hole

cylindrically. The enlarged hole forms a square shoulder
with the original hole. This is necessary in some cases to
accommodate the heads of bolts, studs and pins.

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8. TREPANNING

• When large diameter holes are required in a sheet metal,

then trepanning operation is carried out by using trepanning
tool.

• A small hole , to suit the pilot is drilled at the center of the

required position, the adjustable arm is extended so that the
edge of the high speed steel cutting tool produces the
required hole size.

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 Trepanning
Cutting Edges
Guide

WP

• Trepanning is the operation of producing a

hole by removing metal along the
circumference of a hollow cutting tool
• Trepanning is performed for producing large
holes which can not be produced by any
drilling operations
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Milling Machine

It is a machine which removes excess materials from

the work pieces by a cutting tool called as milling
cutter.

It is one of the important machines of a tool room since

almost all the operation can be performed on it very
accurately.

The milling cutter has multiple cutting edges, so it

removes metal at a very fast rate.

The machine can be mounted with a number of cutter at

a time. So milling machine finds wide application in
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production work.
 Milling machine can be used to obtain:
A) Flat surfaces
B) Countoured surfaces
C) Slots
D) Internal and external threads
E) Gear cutting

Types of milling machine

• vertical milling machine
• Horizontal milling machine
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Basic Elements of Milling Machine

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 Basic Elements of Milling Machine
• Base:

It is the foundation part of a milling machine. All other parts are jointed on it. It
carries the entire load so it should have high compressive strength so it is made by
cast iron. It also works as reservoir of cutting fluid.

• Column:

Column is another foundation part of milling machine. It is mounted vertically on the

base. It supports the knee, table etc. Work as housing for the all the other driving
member.it is a hollow member which contains driving gears and sometimes motor for
spindle and the table.

• Knee:

Knee is the first moving part of milling machine. It is mounted on the column and
moves along the slideways situated over the column. It is made by cast iron
and moves vertically on slideways It moves up and down on sideways which change
the distance between tool and workpiece It is driven by mechanically or
hydraulically.

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 Basic Elements of Milling Machine
• Saddle:

It is placed between table and the knee and work as intermediate part between them. It can moves
transversally to the column face. It slides over the guide ways provided situated on the knee which is
perpendicular to the column face. The main function of it is to provide motion in horizontal direction to
work piece. It is also made by cast iron.

• Table:

Table is situated over the knee. It is the part of machine which holds the work piece while machining. It is
made by cast iron and have T slot cut over it. The work piece clamp over it by using clamping bolts. The
one end of clamping bolt fix into this slot and other is fix to work piece which hold the work piece. It can
provide three degree of freedom to work piece.

• Overhanging arm:

It is situated over the column on horizontal milling machine. It is overhang over the column surface and
other end supports the arbor. It is made by cast iron.

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 Basic Elements of Milling Machine
• Spindle:

Spindle is the main part of the machine which hold tool at right place in
vertical milling machine and hold arbor in horizontal milling machine. It is a
moving part which is in rotary motion. It is motor driven and drives the tool. It
has a slot on the front end of it. The cutting tool fix in that slot.

• Arbor:

It is a mechanical part on which is used as extension part of the spindle in

horizontal milling machine. It is fitted on the spindle whenever required. It
holds the tool and moves it in correct direction.

• Arbor Supports:

This are used to support arbor at right place. One end of this support is
jointed at the overhanging arm and another is jointed with arbor.
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Other Subjects: https://www.studymedia.in/fe/notes
 Milling Machine Operations
1. Plain Milling

The plain milling is the most common types of milling

machine operations. Plain milling is performed to
produce a plain, flat, horizontal surface parallel to the
axis of rotation of a plain milling cutter. The operation is
also known as slab milling.

2. Side Milling

The side milling is the operation of producing a flat

vertical surface on the side of a workpiece by using a side
milling cutter. The depth of cut is set by rotating the
vertical feed screw of the table.
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 Milling Machine Operations
3. Face Milling
Face milling is the simplest milling machine operations. This
operation is performed by a face milling cutter rotated about
an axis perpendicular to the work surface.

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 Milling Machine Operations
4. Straddle Milling

The straddle milling is the operation of producing a flat

vertical surface on both sides of a workpiece by using two side
milling cutters mounted on the same arbor.

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 Milling Machine Operations
5. Angular Milling

The angular milling is the operation of producing an angular

surface on a workpiece other than at right angles of the axis of
the milling machine spindle.

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 Milling Machine Operations
6. Saw Milling
• The saw-milling is the operation of producing
narrow slots or grooves on a workpiece by using
a saw-milling cutter.

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 Milling Machine Operations
7. Slot & Groove Milling:
The operation of producing of keyways, grooves and slots of
varying shapes and sizes can be performed in a milling
machine. It is done by using a plain milling cutter, a metal
slitting saw, an end mill or by a side milling cutter.

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 Milling Machine Operations
8. End milling:
• This operation is also used to get plain surface. In this
operation, the cutting tool axis is perpendicular to the
machining surface or the face of the machining surface.
It is also used to slot cutting on the milling axis.

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 Systems In Mechanical
Engineering

UNIT 5
ADVANCED MANUFACTURING
PROCESSES

Mr. Girish G Khope

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 Micromachining
• Removal of material in the form of chips or
debris having the size in the range of microns.

• Creating micro features or surface characteristics

(especially surface finish) in the micro/nano
level.

• Definition: material removal at micro/nano level

with no constraint on the size of the component
being machined.
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 Micromachining
• The term micromachining usually refers to the
fabrication of micromechanical structures with
the aid of etching techniques to remove part of
the substrate or a thin film.

• Silicon has excellent mechanical properties

making it an ideal material for machining.

• Micromachining usually refers to the fabrication

process of MEMS(Micro Electro Mechanical
System) , microsensors and microstructure in
general.
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 Different Micromachining
Techniques
• Photolithography

• Etching

• Silicon Micromachining

• LIGA

• Mechanical Micromachining

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Steps Involved in Photolithography

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 Photolithography Process Description
• The wafers are chemically cleaned to remove particulate matter,
organic, ionic, and metallic impurities.

• High-speed centrifugal whirling of silicon wafers known as "Spin

Coating" produces a thin uniform layer of photoresist (a light
sensitive polymer) on the wafers

• Photoresist is exposed to a set of lights through a mask often made

of quartz

•Wavelength of light ranges from 300-500 nm (UV) and X-rays

(wavelengths 4-50 Angstroms)

• Two types of photoresist are used:

– Positive: whatever shows, goes
– Negative: whatever shows, stays

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 Abrasive Jet Machining
Definition:

In abrasive jet machining, a focused stream of

abrasive particles, carried by high pressure air or
gas is made to impinge on the work surface
through a nozzle and work material is removed
by erosion by high velocity abrasive particles.

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 Additive manufacturing
• Additive manufacturing, also known as 3D printing, is a process
that creates a physical object from a digital design.

• Additive manufacturing, also known as 3D printing, is a

transformative approach to industrial production that enables
the creation of lighter, stronger parts and systems.

• It is yet another technological advancement made possible by

the transition from analog to digital processes.

• Additive manufacturing uses data computer-aided-design (CAD)

software or 3D object scanners to direct hardware to deposit
material, layer upon layer, in precise geometric shapes.

• As its name implies, additive manufacturing adds material to

create an object.
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 Additive manufacturing
• The term “additive manufacturing” references technologies
that grow three-dimensional objects one superfine layer at a
time.

• Each successive layer bonds to the preceding layer of melted

or partially melted material.

• It is possible to use different substances for layering material,

including metal powder, thermoplastics, ceramics,
composites, glass and even edibles like chocolate.

• The journey from .stl file to 3D object is revolutionizing

manufacturing. Gone are the intermediary steps, like the
creation of molds or dies, that cost time and money.
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Fig. of additive manufacturing -3D Printer

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 Additive manufacturing processes
• Material Extrusion
Material extrusion is one of the most well-known additive
manufacturing processes.
Spooled polymers are extruded, or drawn through a heated nozzle
mounted on a movable arm.
The nozzle moves horizontally while the bed moves vertically,
allowing the melted material to be built layer after layer.
Proper adhesion between layers occurs through precise temperature
control or the use of chemical bonding agents

• Directed Energy Deposition

The process of directed energy deposition (DED) is similar to
material extrusion, although it can be used with a wider variety of
materials, including polymers, ceramics and metals.
An electron beam gun or laser mounted on a four- or five-axis arm
melts either wire or filament feedstock or powder.
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•Material Jetting
With material jetting, a print head moves back and forth, much like the
head on a 2D inkjet printer.
However, it typically moves on x-, y- and z-axes to create 3D objects.
Layers harden as they cool or are cured by ultraviolet light.

• Binder Jetting

The binder jetting process is similar to material jetting, except that the
print head lays down alternate layers of powdered material and a liquid
binder.

• Powder Bed Fusion

Powder Bed Fusion (PBF) technology is used in a variety of AM

processes, including direct metal laser sintering (DMLS), selective
laser sintering (SLS), selective heat sintering (SHS), electron beam
melting (EBM) and direct metal laser melting (DMLM).
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 Additive manufacturing materials

AM technology fabricates jet engine parts from advanced metal alloys,

and it also creates chocolate treats and other food items.
• Thermoplastics
• Metals
• Ceramics
• Biochemicals

• Additive manufacturing applications-

• Aerospace
AM excels at producing parts with weight-saving, complex geometric designs.
Therefore, it is often the perfect solution for creating strong aerospace parts.

• Automotive
• CNN reported that the McLaren racing team is using 3D-printed parts
in its Formula 1 race cars.
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Healthcare
At the New York University School of Medicine, a clinical study of 300 patients
will evaluate the efficacy of patient-specific, multi-colored kidney cancer models
using additive manufacturing

Product Development
As the potential for AM's design flexibility is realized, once impossible design
concepts are now being successfully re-imagined. Additive manufacturing
unleashes the creative potential of designers who can now operate free of the
constraints under which they once labored.

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 Rapid Prototyping (RP)
• Rapid prototyping is the fast fabrication of a physical
part, model or assembly using 3D computer aided
design (CAD).

• The creation of the part, model or assembly is usually

completed using additive manufacturing, or more
commonly known as 3D printing.

• Rapid prototyping (RP) includes a variety of

manufacturing technologies, although most utilise
layered additive manufacturing.

• However, other technologies used for RP include

high-speed machining, casting, moulding and extruding.
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 Types of Rapid Prototyping (RP)
• Fused Deposition Modelling (FDM) or Material Jetting
This inexpensive, easy-to-use process can be found in most
non-industrial desktop 3D printers.

It uses a spool of thermoplastic filament which is melted inside a

printing nozzle barrel before the resulting liquid plastic is laid down
layer-by-layer according to a computer deposition program.

While the early results generally had poor resolution and were weak,
this process is improving rapidly and is fast and cheap, making it ideal
for product development.

• Stereolithography (SLA) or Vat Photopolymerization

This fast and affordable technique was the first successful method of
commercial 3D printing. It uses a bath of photosensitive liquid which
is solidified layer-by-layer using a computer-controlled ultra violet
(UV) light.
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 Types of Rapid Prototyping (RP)
• Selective Laser Sintering (SLS)
Used for both metal and plastic prototyping, SLS uses a powder bed to build a
prototype one layer at a time using a laser to heat and sinter the powdered
material.

However, the strength of the parts is not as good as with SLA, while the surface
of the finished product is usually rough and may require secondary work to
finish it.

• Selective Laser Melting (SLM) or Powder Bed Fusion

Often known as powder bed fusion, this process is favoured for making
high-strength, complex parts. Selective Laser Melting is frequently used by the
aerospace, automotive, defence and medical industries.

This powder bed based fusion process uses a fine metal powder which is
melted in a layer by layer manner to build either prototype or production parts
using a high-powered laser or electron beam.

Common SLM materials used in RP include titanium, aluminium, stainless steel

and cobalt chrome alloys.
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 Types of Rapid Prototyping (RP)
• Laminated Object Manufacturing (LOM) or Sheet Lamination
This inexpensive process is less sophisticated than SLM or SLS, but it does not
require specially controlled conditions.

LOM builds up a series of thin laminates that have been accurately cut
with laser beams or another cutting device to create the CAD pattern design.

Each layer is delivered and bonded on top of the previous one until the part is
complete.

• Digital Light Processing (DLP)

Similar to SLA, this technique also uses the polymerisation of resins which are
cured using a more conventional light source than with SLA.

While faster and cheaper than SLA, DLP often requires the use of support
structures and post-build curing, it crosses a light barrier that alters its
configuration to create the desired cross-sectional pattern on the plastic.
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 CNC MACHINE
• The use of computers to control machine tools
like lathe, mills, shaper etc is called CNC machine.

• The operations which can be carried out by CNC

(Computerised Numerically Controlled) machines are
mounting the job or machine, rotation of spindle,
movement and operations of different tools in sequence as
per the requirements of the job, tool changing, ON and
OFF operations and releasing the finished job.

• For the operations as mentioned above, a programme is

done on a tape and fed to the machine through computer.

• This method helps to change the programme if required

with minimum time and cost
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Block Diagram of CNC Machine

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 Main Parts of CNC Machine
(i) Input Devices:
These are the devices which are used to input the part program in the CNC machine. There
are three commonly used input devices and these are punch tape reader, magnetic tape
reader and computer via RS-232-C communication.

(ii) Machine Control Unit (MCU):

It is the heart of the CNC machine. It performs all the controlling action of the CNC machine,
the various functions performed by the MCU are
• It reads the coded instructions fed into it.
• It decodes the coded instruction.
• It implements interpolation ( linear, circular and helical ) to generate axis motion commands.
• It feeds the axis motion commands to the amplifier circuits for driving the axis mechanisms.
• It receives the feedback signals of position and speed for each drive axis.
• It implements the auxiliary control functions such as coolant or spindle on/off and tool
change.

(iii) Machine Tool:

A CNC machine tool always has a slide table and a spindle to control of the position and
speed. The machine table is controlled in X and Y axis direction and the spindle is controlled in
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 Main Parts of CNC Machine
iv ) Driving System:
The driving system of a CNC machine consists of amplifier circuits, drive motors and ball lead
screw.

The MCU feeds the signals (i.e. of position and speed) of each axis to the amplifier circuits.
The control signals are than augmented (increased) to actuate the drive motors.

And the actuated drive motors rotate the ball lead screw to position the machine table.

(v) Feedback System:

This system consists of transducers that acts like sensors. It is also called as measuring
system.

It contains position and speed transducers that continuously monitor the position and speed
of the cutting tool located at any instant.

The MCU receives the signals from these transducers and it uses the difference between the
reference signals and feedback signals to generate the control signals for correcting the
position and speed errors.

(vi) Display Unit:

A monitor is used to display the programs, commands and other useful data of CNC
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 Working of CNC Machine
• First, the part program is inserted into the MCU of the CNC.
In MCU all the data process takes place and according to the program
prepared, it prepares all the motion commands and sends it to the driving
system.

• The drive system works, as the motion commands are sent by MCU. The
drive system controls the motion and velocity of the machine tool.

• The feedback system records the position and velocity measurement of the
machine tool and sends a feedback signal to the MCU.

• In MCU, the feedback signals are compared with the reference signals and if
there are errors, it corrects it and sends new signals to the machine tool for
the right operation to happen.

• A display unit is used to see all the commands, programs and other
important data. It acts as the eye of the machine.

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 Advantages of CNC
1. It can produce jobs with the highest accuracy and precision than any other manual
machine.

2. It can be run for 24 hours a day.

3. The parts produced by it have the same accuracy. There is no variation in the parts
manufactured by a CNC machine.

4. A highly skilled operator is not required to operate a CNC machine. A semi-skilled

operator can also operate accurately and more precisely.

5. Operators can easily make changes and improvements and reduces the delay time.

6. It has the capability to produce complex designs with high accuracy in minimum
possible time.

7. The modern design software, allows the designer to simulate the manufacturer of
his/her idea. And this removes the need for making a prototype or model and saves
time and money.

8. Fewer workers are required to operate a CNC machine and save labor cost.

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 Disadvantages of CNC
1. The cost of the CNC machine is very high as
compared with a manually operated machine.

2. The parts of the CNC machines are expensive.

3. The maintenance cost in the case of CNC is

quite high.

4. It does not eliminate the need for costly tools.

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 Classification of CNC-Controlled Systems

According to the operations carried out, the systems are

classified as follows :
1. Point to Point System :

In this system, the operation is carried out at selected point on the job. During
operation, it has no effect on the work-piece during its motion from one point to
another point. It is generally used for drilling and reaming operations.

2. Straight Cut System :

In this operation, the tool is moved continuously along a straight path for required cut
and for required time. The example of this system is turning on the lathe. The finishing
of the job depends upon the speed of the job and feed rate.

3. Continuous Path System :

In this system, simultaneous movement of tool along different axes takes place to
produce desired contour. This is used for curved surfaces and different profiles (as cam
profile). The motion of the tool is controlled on more than one axis simultaneously and
continuously.

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Fig. Continuous Path System

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 CNC Programming
• The most common codes used when programming CNC
machines tools are G-codes (preparatory functions), and M codes
(miscellaneous functions).

• Other codes such as F, S, D, and T are used for machine functions

such as feed, speed, cutter diameter offset, tool number, etc.

• G-codes are sometimes called cycle codes because they refer to

some action occurring on the X, Y, and/or Z axis of a machine tool

• M or miscellaneous codes are used to either turn ON or OFF

different functions which control certain machine tool operations

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 G Codes

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 G Codes

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 M Codes

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 M Codes

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 Internet Of Things (IoT)
• The internet of things, or IoT, is a system of interrelated computing devices,
mechanical and digital machines, objects, animals or people that are provided
with unique identifiers (UIDs) and the ability to transfer data over a network
without requiring human-to-human or human-to-computer interaction.

• A thing in the internet of things can be a person with a heart monitor implant,
a farm animal with a biochip transponder, an automobile that has
built-in sensors to alert the driver when tire pressure is low or any other
natural or man-made object that can be assigned an IP address and is able to
transfer data over a network.

• IoT is simply the network of interconnected things/devices which are

embedded with sensors, software, network connectivity and necessary
electronics that enables them to collect and exchange data making them
responsive.

• More than a concept Internet of Things is essentially an architectural

framework which allows integration and data exchange between the physical
world and computer systems over existing network infrastructure.

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 Working of IoT
• An IoT ecosystem consists of web-enabled smart devices that
use embedded processors, sensors and communication
hardware to collect, send and act on data they acquire from
their environments.

• IoT devices share the sensor data they collect by connecting to

an IoT gateway or other edge device where data is either sent to
the cloud to be analyzed or analyzed locally.

• Sometimes, these devices communicate with other related

devices and act on the information they get from one another.

• The devices do most of the work without human intervention,

although people can interact with the devices -- for instance, to
set them up, give them instructions or access the data.

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 IoT

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 QUESTION BANK
• What is casting? Explain with sketch sand casting.
• What is forging? State its advantages and disadvantages
• Write short notes on drawing and extrusion metal forming process.
• Explain with sketch different types of sheet metal working processes.
• What is welding? Write short notes on arc welding.
• Compare TIG and MIG welding.
• Explain with sketch shielded metal arc welding.
• Draw the block diagram of lathe machine.
• Write short notes on different parts of lathe machine.
• Explain with sketch different operation performed on lathe machine.
• Draw block diagram of sensitive drilling machine.
• Draw sketches of different operation performed on drilling machine.
• Write a short notes with figure On Horizontal milling & Vertical
milling.
• Explain with sketch different operation performed on milling
machine.
• Write short notes on Micromachining, Additive manufacturing,3D
printing, IOT, Rapid prototyping, CNC Programming.
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