Module-4

CONTENT

◦Turning
◦ Drilling
◦ Boring

◦ Milling

◦ Grinding and Finishing Processes

LATHE DEFINITION
• A lathe machine is a machine tool which is used to remove metals from a workpiece to give a desired shape and size.

• In other words it is a machine that is used to hold the workpiece to perform various metal removing operations such as turning, grooving, chamfering,
knurling, facing etc. with the help of tools. It is also called as mother of machine.

• Lathe is one of the most important machine tools in the metal working industry. A lathe operates on the principle of a rotating workpiece and a fixed
cutting tool.
• The cutting tool is feed into the workpiece, which rotates about its own axis, causing the workpiece to be formed to the desired shape.

Working principle of Lathe

◦ If the tool moves parallel to work piece cylindrical surface is formed.

 ◦ If the tool moves inclined to the axis it produces a taper surface
and is called taper turning.
Working principle of lathe

◦ It holds the work between two supports called centers.

◦ Chuck or Face plate is also used for holding the work.

◦ Chuck or face plate is mounted on machine spindle ◦ Cutting tool is held and supported
on a tool post.
◦ Movement of the job is rotation about spindle axis

◦ Tool is fed against the revolving work

◦ Movement of the tool is either parallel to or at any inclination to the work axis
Schematic diagram of lathe machine
PARTS OF LATHE
◦ Bed : Supports all major components

◦ Carriage: Slides along the ways and consists of the cross-slide, tool post, apron

◦ Headstock : Holds the jaws for the work piece, supplies power to the jaws and has various drive speeds

◦ Tailstock : Supports the other end of the workpiece

◦ Feed Rod and Lead Screw : Feed rod is powered by a set of gears from the headstock
LATHE OPERATIONS

knurling
TURNING
◦A single point cutting tool removes material from a rotating workpiece to generate a rotationally symmetric shape.

◦Types of cuts:
•Facing
•Contour turning
•Chamfering
•Parting (Cut-off) / Grooving
•Threading
FACING
• Facing is the process of removing metal from the end of a workpiece to produce a
flat surface.

• Feed: in direction perpendicular to workpiece axis

• Length of Tool Travel = radius of workpiece

• Depth of Cut: in direction parallel to workpiece axis

COUNTER TURNING
◦ Instead of feeding the tool parallel to the axis of rotation, tool follows a contour that is not necessarily straight (thus creating a contoured form).

CHAMFERING

• Chamfering is the operation of beveling the extreme end of the workpiece.

• Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer“.
THREADING
Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotation at a large feed rate, thus creating threads.

PARTING (CUTOFF) / GROOVING

• The term grooving usually applies to a process of forming a narrow cavity of a

certain depth, on a cylinder, cone, or a face of the Part.

• Tool is fed radially into rotating work at some location to cut off end of part, or provide a groove.

• Shape of tool shape of groove

 Drilling

◦ The drilling machine or drill press is one of the most common and useful machine employed in industry for producing forming and finishing holes in a
work piece. The unit essentially consists of:

1. A spindle which turns the tool (called drill) which can be advanced in the work piece either automatically or by hand.
2. A work table which holds the work piece rigidly in position.
Working principle:
The rotating edge of the drill exerts a large force on the work piece and the hole is generated. The removal of metal in a drilling operation is by shearing
and extrusion.

Use:- Drilling machine is used to drill blind and through holes in work pieces.

◦ Drilling is the process of producing holes by using multipoint cutting tool.

◦ If the required large size of the hole is produced directly by using corresponding size of drill bit because the force induced are higher, vibrations are
higher and it produces large error in the position., i.e. the positional accuracy of hole produced is very poor.
◦ To avoid this problem it is always recommended to produce the smallest diameter hole first, enlarge it slowly by using different sixes of drill bits until
the required diameter of the hole can be produced.
 ◦ By using the above method in stages maximum size of the hole produced will be 50mm only. Because if larger holes are produced by using this
method, the time taking for machining is high and cost of manufacturing increases.

Drilling machine diagram:

CONSTRUCTION
◦ The machine has only a hand feed mechanism for feeding the tool into the work piece.
◦ This enables the operator to feel how the drill is cutting and accordingly he can control the down feed pressure.
◦ Sensitive drill presses are manufactured in bench or floor models, i.e., the base of machine may be mounted on a bench or floor.
◦ The main operating parts of a sensitive machine/drill press are Base, Column, Table, and Drill Head.

Bench Drilling Machine :- The simplest type of sensitive drilling machine is shown in figure. This is used for light duty drilling work. This machine is
capable to drill hole up to 12.5mm diameter.
1.Motor :- An electric motor supplies the required driving force to stepped pulley.

2.Base :- Base is the bottom part of machine in which the column is fitted upright.

3.Feed handle :- Handle is provided to feed the drill in to the work piece. A rake and pinion mechanism is provided to drive the chuck.

4.Column:- Column is the main cylindrical part of drill machine on which the other components are mounted.
5.Belt guard:- Belt guard is provided to cover the belt and pulley drive mechanism to minimize the hazard of accident.
6.Chuck:- Chuck is provided to hold the drill of different sizes up to 6.5 mm. Drill size of more than 6.5 mm are to be fitted directly in the Morse taper
of spindle.
7.Work Table:- Work pieces are mounted and held in position by the table. This table can be tilted for drilling at an angle.
TYPES OF DRILLING MACHINE

1. Portable Drilling Machine

2. Sensitive or Bench Drill

3. Upright Drilling Machine(Single Spindle)

4. Upright Drilling Machine(Turret Type)

5. Radial Drilling Machine

6. Multiple Spindle Drilling Machine

7. Deep Hole Drilling Machine 8. Gang Drilling Machine

9. Horizontal Drilling Machine

10. Automatic Drilling Machine

PORTABLE DRILLING MACHINE:
◦ It is a very small, compact and self contained unit carrying a small electric motor inside it.

◦ It is very commonly used for drilling holes in such components that cannot be transported to the shop due to their size or weight or where lack of space
does not permit their transportation to the bigger type of drilling machine.
◦ In such cases, the operation is performed on the site by means of the portable electric drill.

SENSITIVE OR BENCH DRILLING MACHINE:

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

◦ Its construction is very simple and so is the operation .

RADIAL DRILLING MACHINE
◦ This machine is very useful because of its wider range of action. (shown in the fig.)

◦ Its principal use is in drilling

holes on such work is difficult
to be handled frequently.

◦ With the use of this machine,

the tool is moved to the desired
position instead of moving the
work to bring the latter in
position for drilling.

GANG DRILLING
MACHINE:
◦ It is nothing but a type of
multiple spindle drilling
machine, in which the spindles are arranged in a row.

◦ These spindles may be driven either separately or collectively.

◦ This machine is very useful when the nature of work is such that a number
of operations like drilling, reaming, counter boring and tapping, etc. are to
be performed in succession on it.
OPERATION OF DRILLING MACHINE:
1. Drilling, 2. Reaming, 3. Boring, 4. Counter Boring, 5. Counter Sinking, 6. Spot Facing, 7. Tapping

DRILLING:It is the main operation done on this machine. It is the operation of producing a circular hole in a solid metal by means of a revolving tool
called drill.
BORING :- It is an operation used for enlarging a hole to bring it to the required size and have a better finish. It’s an internal turning operation.

COUNTER SINKING :- It is the operation used for enlarging the end of a hole to give it a conical shape for a short distance.
REAMING :- It is the operation of finishing a hole to bring it to accurate size and have a fine surface finish . This operation is performed by
means of a multi tooth tool called reamer.
 COUNTER BORING :- This operation is used for enlarging only a limited portion of the hole is called counter boring .

TAPPING:- It is the operation done for forming internal screw threads by means of the tool called tap.
TREPANNING:- When large diameter holes are required in a sheet metal, then trepanning operation is carried out. By using trepanning any size of
holes can be produced.

But only through holes can be produced not blind holes.

Milling machine
◦ Milling: is a metal cutting operation in which the excess material from the work piece is
removed by rotating multipoint cutting tool called milling cutter.
◦ A milling machine is a machine tool that removes metal as the work is fed against a rotating
multipoint cutter. The milling cutter rotates at high speed and it removes metal at a very fast
rate with the help of multiple cutting edges. One or more number of cutters can be mounted
simultaneously on the milling machine. This is the reason that a milling machine finds wide
application in production work.
◦ Used for machining flat surfaces, contoured surfaces, external and internal threads.

◦ As the workpiece moves against the cutting edges of milling cutter, metal is removed in form chips. Machined surface is formed in one or more passes
of the work.
◦ The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head, in a special fixture or bolted to machine table.
◦ In many applications, due to its higher production rate and accuracy, milling machine has even replaced shapers and slotters.
MILLING METHODS:
◦ Up-milling or conventional milling

◦ Down-milling or climb milling

1.Up-milling or conventional milling:-

◦ Metal is removed by cutter rotating against the direction of travel of the workpiece.

◦ Needs stronger holding of the job.

◦ Chip thickness is minimum at the start of cut and maximum at the end of the cut.

◦ Because of opposite direction of movement, the force acting on tool tips is very high, tool wear is higher and tool life lower.

◦ Disadvantage- tendency to lift work from the fixtures and poor surface finish.

2. Down-milling or climb milling:-

◦ Metal is removed by cutter rotating in the same direction of travel of the workpiece.

◦ Chip thickness is maximum at the start of cut and minimum at the end of cut.

◦ Because of same direction of movement the force are lower, tool wear is lower and tool life higher.

◦ Teeth cut downward instead of upwards.

 ◦ Less friction involved .

◦ Better surface finish.

◦ Less power consumption.

TYPES OF MILLING MACHINE

◦ The milling machine may be classified in
several forms, but the choice of any particular
machine is determined primarily by the size of
the workpiece.

◦ According to general design, the distinctive

types of milling machines are:

1. Column and knee type milling machines

2. Planer milling machine

3. Fixed-bed type milling machine

4. Special types of milling machines

1. COLUMN AND KNEE TYPE
◦ It is the most commonly used milling machine used for general shop work.

◦ The table is mounted on the knee which in turn is mounted on the vertical slides of the main column.

◦ The knee is vertically adjustable on the column so that the table can be moved up and down to accommodate work of various heights.
◦ Principal parts of the milling machine: Base, Column, Knee, Saddle, Table, Spindle

A. COLUMN AND BASE:

Column including base is the main casting that supports all other parts of milling machine.

◦ The column contains an oil reservoir and a pump which lubricates the spindle.

◦ The column rests on the base and base contains coolant reservoir and a pump which is used during machining operation that requires coolant.

B. KNEE:

It is a casting that supports the saddle and table. All gearing mechanism is enclosed within the knee.

◦ It is fastened to the column by dovetail ways.

◦ The knee is supported and adjusted by a vertical positioning screw (elevating screw).
 ◦ The elevating screw is used to adjust the knee up and down by raising or lowering the lever either with the help of hand or power feed.

C. SADDLE AND SWIVEL TABLE

◦ The saddle is present on the knee and supports the table. It slides on a horizontal dovetail on the knee and dovetail is parallel to the axis of the spindle
( in horizontal milling m/c).
◦ The swivel table (in universal machines only) is attached to the saddle that can be swiveled (revolved) horizontally in either direction.

D. POWER FEED MECHANISM:

It is the knee which contains the power feed mechanism. It is used to control the longitudinal ( left and right), transverse ( in and out) and vertical (up and
down) feeds.
◦ To get the desired rate of feed on the machine, the feed selection lever is positioned as indicated on the feed selection plates.
◦ On some universal knee and column milling machine, the feed is obtained by turning the speed selection handle until the desired rate of feed is indicated on
the feed dial.
◦ Most of the milling machines have a rapid traverse lever that can be engaged when a temporary increase in the speed of the longitudinal, transverse or
vertical feeds is required. For example this lever would be engaged when the operator is positioning or aligning the work. E. TABLE:
It is a rectangular casting which is present on the top of the saddle.
◦ It is used to hold the work or work holding devices.
◦ It contains several T-slots for holding the work and work holding devices (i.e. jigs and fixtures).
◦ The table can be operated by hand or by power. To move the table by hand, engage and turn the longitudinal hand crank. To move it through power, engage
the longitudinal direction feed control lever.

F. SPINDLE

It is the shaft that is used to hold and drives the cutting tools of the milling machine.

◦ The spindle is mounted on the bearings and supported by the column.

◦ Spindle is driven by the electric motor through gear trains. The gear trains are present within the column.

G. OVER ARM / OVERHANGING ARM

◦ It is a horizontal beam present at the top face of the column. It may be a single casting which slides on the dovetail ways present on the top face of
the column.
◦ The overarm is used to fastened arbor support. It may consist of one or two cylindrical bars which slide through the holes in the column.

H. RAM
◦ The overhanging arm in the vertical machine is called ram. One end of the ram is mounted on the top of the column and on the other end milling
head is attached.
 CLASSIFIACTION OF COLUMN & KNEE TYPE MILLING MACHINE:

(a) Hand milling m/c.

(b) Horizontal milling m/c.

(c) Universal milling m/c.

(d) Vertical milling m/c.

MILLING OPERATIONS
❑Plain or slab milling

❑Face milling ❑End milling

❑Side milling

❑Slot milling

❑Angular milling

❑Form milling

❑Straddle milling
1. PLAIN/SURFACE/ SLAB MILLING:
Process to get the flat surface on the work piece in which the cutter axis and work
piece axis are parallel. The primary motion is the rotation of the cutter. The feed is
imparted to the work piece.

◦ Cutter: Plain milling cutter.

◦ Machine: Horizontal Milling m/c.

2. FACE MILLING:
Operation carried out for producing a flat surface, which is perpendicular to the axis
of rotating cutter.
◦ Cutter: Face milling cutter.

◦ Machine: Vertical Milling Machine

3. END MILLING:
Operation performed for producing flat surfaces, key slots, grooves or finishing the
edges of the work piece.
◦ Cutter: End milling cutter. ◦ Machine: Vertical Milling Machine

4. SIDE MILLING:
Operation performed for producing flat surfaces, slots, grooves or finishing the edges of the work
piece.

◦ Cutter: End milling cutter.

◦ Machine: Horizontal Milling Machine

5. SLOT MILLING:
Operation of producing slots like T-slots, plain slots etc.,

◦ Cutter: End milling cutter, T-slot cutter, side milling cutter

◦ Machine: Vertical Milling Machine
6. ANGULAR MILLING:
Operation of producing all types of angular cuts like V-notches and grooves, serrations and angular surfaces.
◦ Cutter: Double angle cutter.

◦ Machine: Horizontal Milling Machine

7. STRADDLE MILLING
Operation of machining two parallel surfaces simultaneously on a work piece.

◦ Cutter: 2 or more side & face milling cutters

◦ Machine: Horizontal Milling Machine

8. GANG MILLING:
Process to get different profiles on the work piece simultaneously with two or more cutters at one stretch.

◦ Cutter: Different cutters as required.

 ◦ Machine: Horizontal Milling Machine

Grinding and finishing process

◦ It is a conventional finish machining where very thin layer of material is removed in the
form of fine dust particles. (thickness 0.25-0.5mm).
◦ Grinding can be defined as a material removal process by the abrasive action between
rotating abrasive wheel & the work piece.
◦ Grinding machine is a power operated machine tool where, the work piece is fed against a constantly rotating abrasive wheel which is also called as
Grinding wheel so that a thin layer of material is removed from the work piece.
Working principle:
◦ Generally it removes small amount of material only each and every abrasive particle present on surface of Grinding wheel is acting like a single point
cutting tool for removal of material from workpiece.
◦ As the grinding is progressing the abrasive particles are wearing out slowly. The worn out particles are started rubbing on to the workpiece producing
rubbing forces.
◦ These rubbing forces are more than sufficient to pull out the blunt abrasive particles so that fresh and new abrasive particles present behind will come
in contact with workpiece and started removing material. This is called as Self sharpening of grinding wheel.
GRINDING PROCESS
◦ It is the only economical method of cutting hard material like hardened steel.
 ◦ It produces very smooth surface , suitable for bearing surface.

◦ Surface pressure is minimum in grinding. It

is suitable for light work, which will spring
away from the cutting tool in the other
machining processes.
CONSTRUCTION OF GRINDING
WHEEL
Grinding wheel consists of i. Abrasives ii.
Bond iii. Grit/grain size iv. Grade
v. Structure of wheels
1. ABRASIVE
◦ An abrasive is a hard and tough substance,
having sharp edges. It cuts or wears away
materials softer than itself.
◦ Important properties of abrasives are
penetration hardness, fracture resistance and
wear resistance.

Types of Abrasive:
 ◦ Natural abrasives- they are obtained from nature. Natural abrasives are sand stone, emergy/corundum, diamond and garnet.
◦ Artificial/synthetic abrasives- they are manufactured to have well defined and controlled properties of hardness, roughness and type of structure.
Artificial o synthetic abrasives are silicon carbide(SiC), aluminium oxide(Al2O3)
2. BOND
◦ The bond is an adhesive substance which cements or holds the abrasive grains together to form a grinding wheel.

◦ Depending upon the application, bond imparts the qualities of hardness or softness to the grinding wheel.

◦ The choice or selection of the bond depends upon the accuracy, the required surface finish and the nature of grinding operation.

Name of the bonding material and their characteristics:

a. Vitrified bond: out of different bonding materials vitrified is the most commonly used bonding material between the abrasive particle in grinding
wheel, because it produces higher bonding strength, high temp withstanding capability and high thermal conductivity.

b. Silicate bond: waterproof, used for large diameter wheels. Grinding of fine edge tool etc.

c. Shellac bond: Thin wheels, high elasticity, not suitable for heavy duty application.

d. Rubber: Thin wheels, fine finishing and polishing. Ex- ball bearing races.

e. Resinoid bond: Rough grinding, high speed grinding.

3. GRIT/GRAIN SIZE
◦ Size of grain grit is determined by sorting or grading the material by passing through screens with the no. of meshes per linear inch.

◦ The grain size influences stock removal rate and the generated surface finish. ◦ The selection of grain size is determined by i. Nature
of grinding operation ii. Material to be grinded iii. Material removal rate iv. Surface finish required

SR. NO. SIZE TYPE APPLICATIONS

1. 10,12,14,16,20,24 Coarse Rapid material removal

2. 30,36,46,54,60 Medium Stock removal and finish both

3. 80,100,120,150,180 Fine Less stock removal, high surface finish

4. 220,240,280,320,400,500, 600 Very fine Very high surface finish, grinding hard materials
4. GRADE OF THE WHEEL:
◦ Structure of the grinding wheel represents to the grain spacing or the manner in which the abrasive grains are distributed throughout the wheel.
◦ The entire volume is occupied by abrasive grains, bonding material and pores.

◦ The primary purpose of structure is to provide chip clearance and it may be open medium or dense.
SR. NO. TYPE DESIGNATION APPLICATION

1. Dense 1,2,3,4 Cutting and snagging, hard and brittle materials

2. Medium 5,6,7,8 90%grinding wheels

3. Open 9,10,11,12,13,14 Soft, tough, ductile materials e.g.

ball bearings, brass, bronze
 4. WHEEL SHAPE AND SIZE
◦ The shape of grinding wheel should be such that it permits proper contact between the wheel and all of the permits proper contact between the
wheel and all of the surface must be ground.
◦ They are classified in the following groups:

i. Straight side grinding wheel ii. Cylindrical wheels iii. Cup wheels iv. Dish wheels

(WHEEL DESIGNING):
◦ It consists of 6 symbols representing following properties of grinding wheel:
i. Manufacturer’s symbol ii. Type of abrasive iii. Grain size
iv. Grade v. Structure vi. Type of bond vii. Manufacture symbol (optional) for reference ◦ Example of wheel specification:
51 A 36 L 5 V 40
51Manufacturer’s symbol indicating type of abrasive
A Abrasive (aluminium oxide)
36Grain size(medium)
L Grade(medium)
5 Structure(dense)
V Bond(vitrified)
40Manufacture symbol (suffix) optional

BORING
◦ Boring is a process of producing circular internal profiles on a hole made by drilling or another process. It uses single point cutting tool
called a boring bar. In boring, the boring bar can be rotated, or the work part can be rotated. Machine tools which rotate the boring bar
against a stationary workpiece are called boring machines (also boring mills).
◦ Boring can be accomplished on a turning machine with a stationary boring bar positioned in the tool post and rotating workpiece held in the lathe chuck as
illustrated in the figure. In this section, we will consider only boring on boring machine.
◦ Difference between boring and turning:
 -Boring is performed on the inside diameter of an existing hole. -Turning is performed on the outside
diameter of an existing cylinder -In effect, boring is an internal turning operation.
◦ Types of Boring machines

– Horizontal: The rotational axis of w/p is horizontal

– Vertical - The rotational axis of w/p is vertical