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5 Machining Process

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14 views26 pages

5 Machining Process

Uploaded by

BASKAR
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Introduction to Production Engineering

Presented By
Dr. Vasu. M
Assistant Professor
Department of Production Engineering

NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 1


Introduction to Machining

NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 2


Machining
• A material removal process in which a sharp cutting tool is used to mechanically cut away
material so that the desired part geometries are obtained.

• Most common application: to shape metal parts.

• Machining is the most versatile and accurate of all manufacturing processes in its capability
to produce a diversity of part geometries and geometric features.

• Casting can also produce a variety of shapes, but it lacks the precision and accuracy of
machining.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 3


Classification of Machined Parts

1. Rotational - cylindrical or disk-like shape


2. Non-rotational (also called prismatic) – it is in the
form of block or plate.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 4


Various Machining operations

• Turning
• Drilling
• Milling
• Grinding
• Shaping & Planning

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 5


Block Diagram of Lathe Machine

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 6


Turning
A single point cutting tool removes material from a rotating workpiece to generate a cylindrical
shape. Performed on a machine tool called a lathe.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 7


Lathe machine operations
Chamfering: The tool is used to cut an angle on the corner of a cylinder.
Parting: The tool is fed radially into rotating work at a specific location along its length to cut off
the end of a part.
Threading: A pointed tool is fed linearly across the outside or inside surface of rotating parts to
produce external or internal threads.
Boring: Enlarging a hole made by a previous process. A single-point tool is fed linearly and
parallel to the axis of rotation.
Drilling: Producing a hole by feeding the drill into the rotating work along its axis. Drilling can be
followed by reaming or boring to improve accuracy and surface finish.
Knurling: Metal forming operation used to produce a regular cross-hatched pattern in work
surfaces.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 8


Facing
Facing is an operation which produces flat surfaces. Tool is fed radially
inward direction.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 9


Contour Turning
In Contour turning, the tool movement follows contour instead of feeding
the tool parallel to the axis of rotation, thus creating a contoured form.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 10


Chamfering

Cutting edge cuts an angle on the corner of the cylinder, forming a


"chamfer"

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 11


Cutoff or Parting

Tool is fed radially into rotating work at some location to cut off end of part.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 12


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.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 13


Holding the work at lathe machine

Three Jaws Chuck Four Jaws Chuck

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 14


Drilling

Creates a round hole in a workpiece.


Contrasts with boring which can
only enlarge an existing hole
Cutting tool called a drill or drill bit.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 15


Types of holes
Through-holes - drill exits the opposite side of work

Blind-holes –drill does not exit work on opposite side

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 16


Milling

It is a process performed with a machine in which the cutters rotate to remove the material from
the work piece.

Axis of tool rotation is perpendicular to feed direction.

Milling Machine are used to manufacture high precision products and parts in different shapes
and sizes.

With the help of the milling machines can perform many operations and functions starting from
small objects to large ones.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 17


Block Diagram of Milling (Horizontal Knee and column)

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 18


Block Diagram of Milling (Vertical Knee and column)

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 19


Types of Milling Machine
Face milling

Peripheral milling Cutter axis is perpendicular to workpiece.

Cutter axis is parallel to workpiece.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 20


Types of Milling Machine
Slot milling

Slab milling Width of cutter is less than workpiece width,


creating a slot in the work.
The basic form of peripheral milling in which the cutter
width extends beyond the workpiece on both sides

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 21


Grinding

In grinding, the cutting tools are the sharp


edges of the abrasive grains of the
grinding wheel.

• These grains are very large in number


and have a random orientation and
distribution.

• The size of the chips removed by grain


is exceedingly small.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 22


Shaping & Planning

Both are similar kind of operation, a straight, flat surface is created in both operations.

•Both use a single point cutting tool moved linearly relative to the workpiece.

•Low cutting speeds due to start-and-stop motion.

• Usual tooling: single point high speed steel tools.

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 23


Continued…

Components of shaper

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 24


Continued…

Open Side Planer

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 25


THANK YOU

09-09-2024 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI 26

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