ME3493
INTRODUCTION
MANUFACTURING TECHNOLOGY
Dr.V.Rajkumar
1 Associate Professor
Mechanical Engineering
SYLLABUS
UNIT – I MECHANICS OF METAL CUTTING 9
Mechanics of chip formation, forces in machining, Types of chip, cutting tools – single
point cutting tool nomenclature, orthogonal and oblique metal cutting, thermal aspects,
cutting tool materials, tool wear, tool life, surface finish, cutting fluids and
Machinability.
UNIT – II TURNING MACHINES 9
Centre lathe, constructional features, specification, operations – taper turning methods,
thread cutting methods, special attachments, surface roughness in turning, machining
time and power estimation. Special lathes - Capstan and turret lathes- tool layout –
automatic lathes: semi-automatic – single spindle: Swiss type, automatic screw type –
multi spindle
UNIT – III RECIPROCATING MACHINE TOOLS 9
Reciprocating machine tools: shaper, planer, slotter: Types and operations- Hole
making: Drilling, reaming, boring, tapping, type of milling operations-attachments-
types of milling cutters– machining time calculation - Gear cutting, gear hobbing and
gear shaping – gear finishing methods Abrasive processes: grinding wheel–
specifications and selection, types of grinding process – cylindrical grinding, surface 2
grinding, centerless grinding, internal grinding - micro finishing methods
UNIT – IV CNC MACHINES 9
Computer Numerical Control (CNC) machine tools, constructional details, special
features – Drives, Recirculating ball screws, tool changers; CNC Control systems –
Open/closed, point-to-point/continuous - Turning and machining centres – Work
holding methods in Turning and machining centres, Coolant systems, Safety features.
UNIT – V PROGRAMMING OF CNC MACHINE TOOLS 9
Coordinates, axis and motion, Absolute vs Incremental, Interpolators, Polar
coordinates, Program planning, G and M codes, Manual part programming for CNC
machining centers and Turning centers – Fixed cycles, Loops and subroutines,
Setting up a CNC machine for machining
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Production Engineering covers two domains:
(a) Production or Manufacturing Processes
(b) Production Management
(a) Manufacturing Processes
This refers to science and technology of manufacturing products effectively,
efficiently, economically and environment-friendly through:
• Application of any existing manufacturing process and system
• Proper selection of input materials, tools, machines and environments.
• Improvement of the existing materials and processes
• Development of new materials, systems, processes and techniques
All such manufacturing processes, systems, techniques have to be:
• Technologically acceptable
• Technically feasible
• Economically viable
• Eco-friendly 4
(b) Production Management
It mainly refers to planning, coordination and control of the entire
manufacturing in most profitable way with maximum satisfaction to
the customers by best utilization of the available resources like men,
machine, materials and money (MMM)
The various process routes may differ regarding principle, technique,
quality of products and time requirement and cost of manufacture.
Achieving manufacturing goals requires fulfillment of one or more of the
following objectives:
• reduction of manufacturing time
• increase of productivity
• reduction of manufacturing cost
• increase in profit or profit rate
Production management integrates and accomplishes all such essential
activities leading to maximum benefits by best utilization of the resources
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and strategies.
(b) Production Management
The most significant and ultimate objective, i.e., “Increase in Profit, Pr”, can
be attained by
(i) reducing the overall manufacturing cost, Cm
(ii) increase in revenue, R by increasing quality and reliability of the
products
(iii) enhancement of saleable products
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BROAD CLASSIFICATION OF ENGINEERING MANUFACTURING PROCESSES.
(a) Shaping or forming
Subtractive
(b) Joining process Manufacturing
(c) Removal process
(d) Regenerative manufacturing
Production of solid products in layer by layer
from raw materials in different form:
• liquid – e.g., stereo lithography Additive
• powder – e.g., selective sintering Manufacturing
• sheet – e.g., LOM (laminated object
manufacturing)
• wire – e.g., FDM. (Fused Deposition
Modelling)
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MANUFACTURING PARADIGMS
In an industry, metal components are made into different shapes and dimensions by
using various metal working processes.
Metal working processes are classified into two major groups. They are:
1. Non-cutting or chips less or metal forming process - forging, rolling, etc.
2. Cutting/shaping or metal cutting or chip forming process - turning, drilling, milling,
etc.
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MACHINING - DEFINITION AND REQUIREMENTS
“Machining is an essential process of finishing by which work pieces are produced to
the desired dimensions and surface finish by gradually removing the excess material
from the preformed blank in the form of chips with the help of cutting tool(s) moved
past the work surface(s).”
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MACHINE TOOL - DEFINITION
“A machine tool is a non-portable power operated and reasonably valued
device or system of devices in which energy is expended to produce jobs of
desired size, shape and surface finish by removing excess material from the
preformed blanks in the form of chips with the help of cutting tools moved past
the work surface(s).“
BASIC FUNCTIONS OF MACHINE TOOLS
Machine Tools produce geometrical surfaces like flat, cylindrical or any contour on
the preformed blanks by machining work with the help of cutting tools.
The physical functions of a Machine Tool in machining are:
• firmly holding the blank and the tool
• transmit motions to the tool and the blank
• provide power to the tool-work pair for the machining action.
• control of the machining parameters, i.e., speed, feed and depth of cut. 10
PURPOSE OF MACHINING
❑Most of the engineering components such as gears, bearings, clutches, tools, screws and
nuts etc. need dimensional and form accuracy and good surface finish for serving their
purposes.
❑Pre-forming like casting, forging etc. generally cannot provide the desired accuracy and
finish.
❑Such preformed parts, called blanks, need semi-finishing and finishing and it is done by
machining and grinding.
❑ Machining to high accuracy and finish essentially enables a product to :
✔ Fulfil its functional requirements.
✔ Improve its performance.
✔ Prolong its service.
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PRINCIPLE OF MACHINING
A metal rod of irregular shape, size and surface is converted into a finished
product of desired dimension and surface finish by machining by proper relative
motions of the tool-work pair.
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CLASSIFICATION OF MACHINE TOOLS
According to direction of major axis:
✔ Horizontal - center lathe, horizontal boring machine etc.
✔ Vertical - vertical lathe, vertical axis milling machine etc.
✔ Inclined - special (e.g. for transfer machines).
According to purpose of use:
✔ General purpose - e.g. center lathes, milling machines, drilling m/c etc.
✔ Single purpose - e.g. facing lathe, roll turning lathe etc.
✔ Special purpose - for mass production.
According to degree of automation:
✔ Non-automatic - e.g. center lathes, drilling machines etc.
✔ Semi-automatic - capstan lathe, turret lathe, hobbing machine etc.
✔ Automatic - e.g., single spindle automatic lathe, swiss type automatic lathe, CNC
milling machine etc.
According to blank type:
✔ Bar type (lathes).
✔ Chucking type (lathes).
✔ Housing type 13
CLASSIFICATION OF MACHINE TOOLS ………CONTD
According to number of spindles:
✔ Single spindle - center lathes, capstan lathes, milling machines etc.
✔ Multi spindle - multi spindle (2 to 8) lathes, gang drilling machines etc.
According to type of automation:
✔ Fixed automation - e.g., single spindle and multi spindle lathes.
✔ Flexible automation - e.g., CNC milling machine.
According to configuration:
✔ Stand alone type - most of the conventional machine tools.
✔ Machining system (more versatile) - e.g., transfer machine, machining center, FMS etc.
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CLASSIFICATION OF MACHINE TOOLS
According to size:
✔ Heavy duty - e.g., heavy duty lathes (e.g. ≥ 55 kW), boring mills, planning machine,
horizontal boring machine etc.
✔ Medium duty - e.g., lathes - 3.7 ~ 11 kW, column drilling machines, milling machines
etc.
✔ Small duty - e.g., table top lathes, drilling machines, milling machines.
✔ Micro duty - e.g., micro-drilling machine etc.
According to precision:
✔ Ordinary - e.g., automatic lathes.
✔ High precision - e.g., Swiss type automatic lathes.
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SPECIFICATION OF MACHINE TOOLS
Centre lathe:
✔ Maximum diameter and length of the jobs that can be accommodated.
✔ Power of the main drive (motor).
✔ Range of spindle speeds and range of feeds.
✔ Space occupied by the machine.
Shaper:
✔ Length, breadth and depth of the bed.
✔ Maximum axial travel of the bed and vertical travel of the bed / tool.
✔ Maximum length of the stroke (of the ram / tool).
✔ Range of number of strokes per minute.
✔ Range of table feed.
✔ Power of the main drive.
✔ Space occupied by the machine. 16
SPECIFICATION OF MACHINE TOOLS
Drilling machine (column type):
✔ Maximum drill size (diameter) that can be used.
✔ Size and taper of the hole in the spindle.
✔ Range of spindle speeds.
✔ Range of feeds.
✔ Power of the main drive.
✔ Range of the axial travel of the spindle / bed.
✔ Floor space occupied by the machine..
Milling machine (knee type and with arbor):
Type; ordinary or swiveling bed type.
✔ Size of the work table.
✔ Range of travels of the table in X - Y - Z directions.
✔ Arbor size (diameter).
✔ Power of the main drive.
✔ Range of spindle speed.
✔ Range of table feeds in X - Y - Z directions.
✔ Floor space occupied. 17
