COMPUTER

INTEGRATED
MANUFACTURING
TECHNOLOGIES
3RD YEAR SEM-1 BTECH MECHANICAL ENGINEERING (R18A0312)

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COURSE OBJECTIVES
UNIT - 1 CO1: Learn about geometry of metal cutting theory,
mechanism of chip formation and mechanism of
orthogonal cutting and merchants force diagram
UNIT - 2 CO2: Learn about ways to reduce the surface
roughness by using different machining process
UNIT - 3 CO3: To write APT and CNC programming concepts

UNIT - 4 CO4: Learn the concepts of DNC Systems and Post

Processors

UNIT - 5 CO5: To know about Computer aided process

planning and computer aided inspection and Quality
control

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT 1

METAL CUTTING THEORY

CO1: Learn about geometry of metal cutting theory,

mechanism of chip formation and mechanics of orthogonal
cutting and merchants force diagram

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UNIT – I (SYLLABUS)

ELEMENTS OF CUTTING PROCESS

• Geometry of Single point tool and angles, chip formation.
• Types of chips, built up edge and its effects.
• Mechanics of orthogonal cutting-cutting forces, cutting
speeds, feed, depth of cut, tool life, coolants and
Machinability

Lathe Machine
• Principle of working, specification of lathe and types of
lathe, operations of lathe and work holding devices.

DEPARTMENT OF MECHANICAL ENGINEERING

 COURSE OUTLINE-UNIT 1
LECTUR LECTURE TOPIC KEY ELEMENTS Learning objectives
E

1 Metal cutting theory, elements of cutting Cutting in manufacturing ● understand the imp
process, Geometry of single point tool and of cutting, tool points of cutting in
angles and angles manufacturing
● cutting process

2 Chip formation, types of chips theory of chip formation ● understand types of

in cutting process chips
3 Mechanics of orthogonal cutting, Cutting forces orthogonal cutting and ● understand
and speeds speeds difference between
orthogonal & oblique
cutting
4 Depth of cut, feed, tool life, coolants and tool life,coolants ● understand relative
machinability movement of tool
● imp of cooling in
manufacturing
5 Lathe machine-principle of working Lathe principles ● working of lathe in
brief and its principle
6 Types of lathe and its specifications Types of lathe machines ● understanding types
of lathe like speed,
centre lathe
7 Operations of lathe, work holding and tool operation of lathe ● Understanding basic
holding devices machines and tool operations of lathe
holding devices and various tool
holding devices

DEPARTMENT OF MECHANICAL ENGINEERING

 LECTURE 1
METAL CUTTING THEORY- ELEMENTS OF
CUTTING PROCESS

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TOPICS TO BE COVERED
LECTURE 1
Metal Cutting Theory
• Metal cutting theory Introduction
• Material removal process
• Metal cutting features
• Elements of cutting process
• Geometry of single point tool and
angles
• Single point cutting tool types

DEPARTMENT OF MECHANICAL ENGINEERING

Metal Cutting Theory

• INTRODUCTION- 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: Non-cutting shaping or chips less or metal
forming process - forging, rolling, pressing, etc. Cutting shaping or
metal cutting or chip forming process - turning, drilling, milling, etc

• Machining: Term applied to all material-removal processes. Metal

cutting: The process in which a thin layer of excess metal (chip) is
removed by a wedge-shaped single-point or multipoint cutting tool
with defined geometry from a work piece, through a process of
extensive plastic deformation.

DEPARTMENT OF MECHANICAL ENGINEERING

Metal Cutting Theory

DEPARTMENT OF MECHANICAL ENGINEERING

MATERIAL REMOVAL PROCESSES

• 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).
• Principle of machining - the fig illustrates 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.

DEPARTMENT OF MECHANICAL ENGINEERING

MATERIAL REMOVAL PROCESSES

DEPARTMENT OF MECHANICAL ENGINEERING

Metal Cutting: features

• Closer dimensional accuracy

• Surface texture/finish
• Economical
• Complex shape
• Size
• Material loss (~50%)
• Scarcity of materials
• Special equipment
• Skilled operators
• Time required
• All materials cannot be machined

DEPARTMENT OF MECHANICAL ENGINEERING

Essentials of Metal Cutting Operation

• Machine Tool
• Cutting Tool
• Method
• Operator

DEPARTMENT OF MECHANICAL ENGINEERING

ELEMENTS OF CUTTING PROCESS

Principle Elements of Metal Machining:

1: Cutting Speed:
The cutting speed can be defined as the relative surface speed between the tool and the
job. It is a relative term since either the tool or the job or both may be moving during cutting.
It is expressed in m/min.
2: Feed:
It may be defined as the relatively small the cutting tool relative to the work piece in a
direction which is usually perpendicular to the cutting speed direction. It is expressed in
mm/rev or mm/stroke.
It is more complex element as compare to the cutting speed. It is expressed differently for
various operations.
3:Depth of cut:
The depth of cut is the thickness of the layer of the metal remove in one cut or pass
measured in a direction perpendicular to the machine surface. The depth of cut is always
perpendicular to the direction feed motion.

DEPARTMENT OF MECHANICAL ENGINEERING

ELEMENTS OF CUTTING PROCESS

DEPARTMENT OF MECHANICAL ENGINEERING

Single-point cutting tool

● Single Point Cutting Tool is a tool that helps to perform several

operations (like Turning, Facing, Producing Flat surface) on Lathe,
Shaper, Planer Machine.
● This tool consists of a sharpened cutting part called its point and the
shank.
● The point of the tool is bounded by the face (along which the chips
slides as they are cut by the tool), the side flank or major flank the end
flank or minor flank and the base.
● As we know we perform several operations on the lathe (like turning,
facing) from the single-point cutting tool.
● Design and fabrication are very easy for this tool.This tool can be made
at a very cheaper rate as compared to others

DEPARTMENT OF MECHANICAL ENGINEERING

Single-point cutting tool

DEPARTMENT OF MECHANICAL ENGINEERING

Single Point Cutting Tool Types

There are only two types of tool:

1. Single and
2. Multi-Point cutting tool.

1. Single Point cutting tool:

● One cutting point or tip is available
● Example: Lathe Machine, Planning Machine tool

2. Multi-Point cutting tool:

● More than One cutting point or tip is available
● Example: Milling cutter, Grinding wheel, drill tool, extra.

DEPARTMENT OF MECHANICAL ENGINEERING

Single point cutting tool angle

Angle:
1. Side Cutting edge angle
2. End cutting edge angle
3. Side relief angle
4. End relief angle
5. Back Rack angle
6. Side rack angle

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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LECTURE 2
Introduction - Resultants of Force System

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TOPICS TO BE COVERED
LECTURE 2
Chip formation
● Chip formation
● Mechanism of chip formation
in machining ductile
materials
● Mechanism of chip formation
in machining brittle materials
● types of chips formation

DEPARTMENT OF MECHANICAL ENGINEERING

CHIP FORMATION

Mechanism of chip formation

• Machining is a semi-finishing or finishing process essentially done
to impart required or stipulated dimensional and form accuracy
and surface finish to enable the product to:
1. Fulfill its basic functional requirements.
2. Provide better or improved performance.
3. Render long service life
Machining is a process of gradual removal of excess material from
the preformed blanks in the form of
chips

DEPARTMENT OF MECHANICAL ENGINEERING

CHIP FORMATION

The form of the chips is an important index of machining because it

directly or indirectly indicates:
❖ Nature and behavior of the work material under machining
condition.
❖ Specific energy requirement (amount of energy required to
remove unit volume of work material) in machining work.
❖ Nature and degree of interaction at the chip-tool interfaces

DEPARTMENT OF MECHANICAL ENGINEERING

CHIP FORMATION

• The form of machined chips depends mainly upon:

1. Work material.
2. Material and geometry of the cutting tool.
3. Levels of cutting velocity and feed and also to some extent on
depth of cut.
4. Machining environment or cutting fluid that affects temperature
and friction at the chip-tool and work-tool interfaces.
• Knowledge of basic mechanism(s) of chip formation helps to
understand the characteristics of chips and to attain favorable
chip forms.

DEPARTMENT OF MECHANICAL ENGINEERING

Mechanism of chip formation in machining ductile
materials

• During continuous machining the uncut layer of the work material

just ahead of the cutting tool (edge) is subjected to almost all
sided compression Compression of work material (layer) ahead
of the tool tip.
• The force exerted by the tool on the chip arises out of the normal
force, N and frictional force, F as indicated in Fig. 1.10. Due to
such compression, shear stress develops, within that
compressed region,in different magnitude, in different directions
and rapidly increases in magnitude.
• Whenever and wherever the value of the shear stress reaches or
exceeds the shear strength of that work material in the
deformation region, yielding or slip takes place resulting shear
deformation in that region and the plane of maximum shear
stress.

DEPARTMENT OF MECHANICAL ENGINEERING

Mechanism of chip formation in machining ductile
materials

• But the forces causing the shear stresses in the region of the
chip quickly diminishes and finally disappears while that region
moves along the tool rake surface towards and then goes
beyond the point of chip-tool engagement.
• As a result the slip or shear stops propagating long before total
separation takes place. In the meantime the succeeding portion
of the chip starts undergoing compression followed by yielding
and shear.
• This phenomenon repeats rapidly resulting in formation and
removal of chips in thin layer by layer. This phenomenon has
been explained in a simple way by Piispannen*1 using a card
analogy

DEPARTMENT OF MECHANICAL ENGINEERING

Mechanism of chip formation in machining ductile
materials

DEPARTMENT OF MECHANICAL ENGINEERING

Mechanism of chip formation in machining brittle
materials

• The basic two mechanisms involved in chip formation are:

➢ Yielding - generally for ductile materials.
➢ Brittle fracture - generally for brittle materials.
● During machining, first a small crack develops at the tooltip as
shown in Fig due to wedging action of the cutting edge. At the
sharp crack-tip stress concentration takes place.
● In case of ductile materials immediately yielding takes place at
the crack-tip and reduces the effect of stress concentration and
prevents its propagation as crack.
● But in case of brittle materials the initiated crack quickly
propagates, under stressing action, and total separation takes
place from the parent workpiece through the minimum resistance
path as indicated in Fig.

DEPARTMENT OF MECHANICAL ENGINEERING

Mechanism of chip formation in machining brittle
materials

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF CHIPS

• Different types of chips of various shape, size, colour etc. are

produced by machining depending upon:
• Type of cut, i.e., continuous (turning, boring etc.) or
intermittent cut (milling).
• Work material (brittle or ductile etc.).
• Cutting tool geometry (rake, cutting angles etc.).
• Levels of the cutting velocity and feed (low, medium or high).
• Cutting fluid (type of fluid and method of application).

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF CHIPS

Discontinuous chips
• This is also called as segmental chips. This mostly occurs
while cutting brittle material such as cast iron or low ductile
materials.
• Instead of shearing the metal as it happens in the previous
process, the metal is being fractured like segments of
fragments and they pass over the tool faces.
• Tool life can also be more in this process.
• Power consumption as in the previous case is also low.

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF CHIPS

Continuous chips without BUE

• When the cutting tool moves towards the work piece, there
occurs a plastic deformation of the work piece and the metal
is separated without any discontinuity and it moves like a
ribbon.
• The chip moves along the face of the tool. This mostly occurs
while cutting a ductile material.
• It is desirable to have smaller chip thickness and higher
cutting speed in order to get continuous chips.
• Lesser power is consumed while continuous chips are
produced.
• Total life is also mortised in this process.

DEPARTMENT OF MECHANICAL ENGINEERING

ASSIGNMENT QUESTIONS

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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LECTURE-3

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TOPICS TO BE COVERED
LECTURE 3

● Mechanics of orthogonal Cutting forces and

speeds
cutting
● Orthogonal and oblique
cutting
● pure orthogonal cutting
● cutting force components
and its significance
● Development of equations
for estimation of cutting
forces
● Cutting speeds

DEPARTMENT OF MECHANICAL ENGINEERING

Orthogonal Cutting

• It is appears from the diagram shown in Fig (a and b) that

while turning ductile material by a sharp tool
• The continuous chip would flow over the tool’s rake
surface and in the direction apparently perpendicular to the
principal cutting edge, i.e., along orthogonal plane which is
normal to the cutting plane containing the principal cutting
edge.
• But practically, the chip may not flow along the orthogonal
plane for several factors like presence of inclination angle,
λ, etc.

DEPARTMENT OF MECHANICAL ENGINEERING

ORTHOGONAL CUTTING

DEPARTMENT OF MECHANICAL ENGINEERING

ORTHOGONAL CUTTING AND OBLIQUE CUTTING

• The role of inclination angle, λ on the direction of chip flow is

schematically shown in Fig which visualizes that:
When λ = 00, the chip flows along orthogonal plane, i.e, ρc = 00.
When λ ≠ 00, the chip flow is deviated from πo and ρc = λ where ρc
is chip flow deviation (from πo) angle.

DEPARTMENT OF MECHANICAL ENGINEERING

ORTHOGONAL AND OBLIQUE CUTTING

DEPARTMENT OF MECHANICAL ENGINEERING

ORTHOGONAL AND OBLIQUE CUTTING

• Orthogonal cutting: When chip flows along orthogonal plane,

πo, i.e., ρc = 00.
• Oblique cutting: When chip flow deviates from orthogonal
plane, i.e. ρc ≠ 00.
• But practically ρc may be zero even if λ = 00 and ρc may not be
exactly equal to λ even if λ ≠ 00.
• Because there is some other (than λ) factors also may cause
chip flow deviation

DEPARTMENT OF MECHANICAL ENGINEERING

Pure orthogonal cutting

• This refers to chip flow along πo and φ = 900 as typically

shown in Fig. 1.9. Where a pipe like job of uniform thickness
is turned (reduced in length) in a center lathe by a turning tool
of geometry; λ = 00 and φ = 900 resulting chip flow along πo
which is also πx in this case.

DEPARTMENT OF MECHANICAL ENGINEERING

PURE ORTHOGONAL CUTTING

DEPARTMENT OF MECHANICAL ENGINEERING

ORTHOGONAL METAL CUTTING

• Benefit of knowing and purpose of determining cutting forces

The aspects of the cutting forces concerned:
❖ Magnitude of the cutting forces and their components.
❖ Directions and locations of action of those forces.
❖ Pattern of the forces: static and / or dynamic.
❖ Knowing or determination of the cutting forces facilitate or are
required for:
❖ Estimation of cutting power consumption, which also enables
selection of the power source(s) during design of the machine
tools.
❖ Structural design of the machine - fixture - tool system.
.

DEPARTMENT OF MECHANICAL ENGINEERING

ORTHOGONAL METAL CUTTING

❖ Evaluation of role of the various machining parameters (process

- VC, fo, t, tool - material and geometry, environment - cutting
fluid) on cutting forces.
❖ Study of behaviour and machinability characterization of the work
materials.
❖ Condition monitoring of the cutting tools and machine tools

DEPARTMENT OF MECHANICAL ENGINEERING

Cutting force components and their significances

• The single point cutting tools being used for turning, shaping,
planing, slotting, boring etc. are characterized by having only one
cutting force during machining.
• But that force is resolved into two or three components for ease
of analysis and exploitation. Fig visualizes how the single cutting
force in turning is resolved into three components along the three
orthogonal directions; X, Y and Z.
• The resolution of the force components in turning can be more
conveniently understood from their display in 2-D as shown in
Fig.

DEPARTMENT OF MECHANICAL ENGINEERING

Cutting force components and their significances

DEPARTMENT OF MECHANICAL ENGINEERING

Cutting force components and their significances

The resultant cutting force, R is resolved as, R = PZ + PXY

and PXY = PX + PY
where, PX = PXY sinφ
and PY = PXY cosφ
PZ - Tangential component taken in the direction of Zm axis.
PX - Axial component taken in the direction of longitudinal feed or
Xm axis.
PY - Radial or transverse component taken along Ym axis.

DEPARTMENT OF MECHANICAL ENGINEERING

Significance of PZ, PX and PY

PZ: Called the main or major component as it is the largest in

magnitude. It is also called power component as it being acting along
and being multiplied by VC decides cutting power (PZ.VC)
consumption.
PY: May not be that large in magnitude but is responsible for causing
dimensional inaccuracy and
vibration.
PX: It, even if larger than PY, is least harmful and hence least
significant.

DEPARTMENT OF MECHANICAL ENGINEERING

Development of equations for estimation of cutting
forces

The two basic methods of determination of cutting forces and their

characteristics are:
(a) Analytical method: Enables estimation of cutting forces.
Characteristics:
• Easy, quick and inexpensive.
• Very approximate and average.
• Effect of several factors like cutting velocity, cutting fluid action
etc. are not revealed.
• Unable to depict the dynamic characteristics of the forces

DEPARTMENT OF MECHANICAL ENGINEERING

Development of equations for estimation of cutting
forces

(b) Experimental methods: Direct measurement.

Characteristics:

• Quite accurate and provides true picture.

• Can reveal effect of variation of any parameter on the forces.
• Depicts both static and dynamic parts of the forces.
• Needs measuring facilities, expertise and hence expensive.

DEPARTMENT OF MECHANICAL ENGINEERING

Cutting Speeds for Turning and Threading with HSS Tool Bits

DEPARTMENT OF MECHANICAL ENGINEERING

ASSIGNMENT QUESTIONS

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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LECTURE-4

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TOPICS TO BE COVERED LECTURE-4

● Depth of cut Tool life and

● feed rate coolants
● tool life
● coolants
● machinability

DEPARTMENT OF MECHANICAL ENGINEERING

DEPTH OF CUT

• Cutting speed is defined as the speed at which the work moves

concerning the tool (usually measured in feet per minute).
• The cutting speed, expressed in FPM, must not be confused with
the spindle speed of the lathe which is expressed in RPM.
• To obtain uniform cutting speed, the lathe spindle must be
revolved faster for workplaces of small diameter and slower for
workplaces of large diameter.

DEPARTMENT OF MECHANICAL ENGINEERING

DEPTH OF CUT

DEPARTMENT OF MECHANICAL ENGINEERING

DEPTH OF CUT

• The proper cutting speed for a given job depends upon the hardness of
the material being machined, the material of the tool bit, and how much
feed and depth of cut is required.
• Cutting speeds for metal are usually expressed in surface feet per
minute, measured on the circumference of the work

DEPARTMENT OF MECHANICAL ENGINEERING

DEPTH OF CUT

DEPARTMENT OF MECHANICAL ENGINEERING

DEPTH OF CUT

• The depth of cut is the distance that the tool bit moves into the work. usually
measured in thousandths of an inch or millimeters.
• General machine practice is to use a depth of cut up to five times the rate of
feed, such as rough cutting stainless steel using a feed of 0.020 inches per
revolution and a depth of cut of 0.100 inch.
• Which would reduce the diameter by 0.200 inch.
• If chatter marks or machine noise develops, reduce the depth of cut.
• It is the total amount of metal removed per pass of the cutting tool. It is
expressed in mm.
• It can vary and depend upon the type of tool and work material.
Mathematically, it is half of the difference of diameters.

DEPARTMENT OF MECHANICAL ENGINEERING

DEPTH OF CUT

Depth of cut (t) = D-d/2 mm

where, D = outer diameter, (mm)

d = Inner diameter (mm)

DEPARTMENT OF MECHANICAL ENGINEERING

FEED RATE

● Feed Rate is one of the most important factors to consider

when implementing any CNC strategy.
● Simply put, feed rate is the speed at which the cutter
engages the part and is typically measured in units/minute.
● Suggested cut feed rates will vary depending on the type
of material you are cutting (i.e., aluminum, steel, wood,
acrylic, etc.), the material of the cutter (carbide, high speed
steel, ceramic, etc.) and many other cutting factors
including desired surface and the characteristics of the
CNC machine itself.

DEPARTMENT OF MECHANICAL ENGINEERING

TOOL LIFE

• Every device or tool has its functional life. At the expiry of

which it may function, but not efficiently.
• So it is also true with a cutting tool.
• During use, the tool losses its material, i.e., it gets worn
out.
• As the wear increases, the tool losses its efficiency.
• So its life has to be defined and on expiry of its life, it
should be reground for fresh use.

DEPARTMENT OF MECHANICAL ENGINEERING

TOOL LIFE

The tool life can be defined in following different ways:

(i) The time elapsed between two successive grindings.

(ii) The period during which a tool cuts satisfactory.

(iii) The total time accumulated before tool failure occurs.

DEPARTMENT OF MECHANICAL ENGINEERING

COOLANTS

• Machine coolants have been used extensively in metal

cutting operations for the last 200 years.
• In the beginning, machine coolants consisted of simple oils
applied with brushes to lubricate the machine tool.
Occasionally, lard, animal fat or whale oil was added to
improve the oil's lubricity.
• As cutting operations became more severe, machine
coolant formulations became more complex.
• Today's machine coolants are special blends of chemical
additives, lubricants and water formulated to meet the
performance demands of the metalworking industry.

DEPARTMENT OF MECHANICAL ENGINEERING

The Importance of Coolants in Machining

The critical functions of coolant in the machining process

include:

● Reducing and removing the heat build-up in the cutting

zone and workpiece
● Provides lubrication to reduce friction between the tool and
removal of the chips
● Flushes away chips and small abrasive particles from the
work area
● Protects against corrosion

DEPARTMENT OF MECHANICAL ENGINEERING

Types of Coolants

Coolants are grouped into four main categories and have a variety of
different formulations. Selecting coolant should be based on the
overall performance it provides centered around your machining
application and materials used.

Soluble Oils: The most common of all water-soluble cutting fluids and
a great option for general purpose machining. The drawback is that
they are prone to microbiological growth of fungus and bacteria if the
coolant sump is not correctly maintained.

Synthetic Fluids: These types of fluids tend to be the cleanest of all

cutting fluids because they contain no mineral oil and reject tramp oil.
However, they provide the least lubrication.

DEPARTMENT OF MECHANICAL ENGINEERING

Types of coolants

Semi-synthetic Fluids: Considered to be the best of both

worlds, they have less oil than emulsion-based fluids, a less
stinky smell, and retain much of the same lubricating
attributes. This makes them usable for a broader range of
machining.

Straight Oils: These are not water-miscible and have a

composition of a mineral or petroleum oil base and contain
lubricants like vegetable oils, fats, and esters. They provide
the best lubrication but have the poorest cooling
characteristics.

DEPARTMENT OF MECHANICAL ENGINEERING

MACHINABILITY

• The condition and physical properties of the work material

have a direct influence on the machinability of a work
material.
• The various conditions and characteristics described as
"condition of work material," individually and in
combinations, directly influence and determine the
machinability.
• Operating conditions, tool material and geometry and
workpiece requirements exercise indirect effects on
machinability and can often be used to overcome difficult
conditions presented by the work material.
• On the other hand, they can create situations that increase
machining difficulty if they are ignored

DEPARTMENT OF MECHANICAL ENGINEERING

Condition of Work Material

The following eight factors determine the condition of the work

material:
• microstructure,
• grain size
• heat treatment
• chemical composition
• fabrication
• hardness
• yield strength
• tensile strength

DEPARTMENT OF MECHANICAL ENGINEERING

MACHINABILITY

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING
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LECTURE-5

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TOPICS TO BE COVERED
LECTURE-5

● Lathe Machine LATHE MACHINE

● Types of lathe
● Description and function of
lathe parts
● Lathe machine working
● Principle of working

DEPARTMENT OF MECHANICAL ENGINEERING

LATHE MACHINE

• One of the oldest machine tools is a lathe machine. In

1797, an Englishman, Henry Maudslay, designed the first
screw-cutting lathe which is the forerunner of the present
day high speed, heavy duty production lathe.
Functions of the Lathe :
• To remove metal from a piece of work to give it the
required shape and size is the main function of the lathe.
• This is accomplished by holding the work securely and
rigidly on the machine.
• Then turning it against cutting tool which will remove metal
from work in the form of chips.

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF LATHE

1. Speed Lathe

● Woodworking

● Centring

● Polishing

● Spinning

2. Engine Lathe

● Belt drive

● Individual motor drive

● Gear head lathe

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF LATHE

3. Bench Lathe

4. Toolroom Lathe

5. Capstan and Turret Lathe

6. Special purpose

● Wheel lathe

● Gap bed lathe

● T-lathe

7. Automatic Lathe

DEPARTMENT OF MECHANICAL ENGINEERING

Description and function of lathe parts

1. The bed
The lathe bed forms the base of the machine, the headstock and tailstock are located
at either end of the bed and the carriage rests over the lathe bed and slides over it.

1. The Headstock
The headstock is secured permanently on the inner ways at the left-hand end of the
lathe bed.

1. The Tailstock
The tailstock is located on the inner ways at the right-hand end of the bed.

1. Carriage
The carriage of a lathe has various parts which serve to support, move and control the
cutting tool.

1. Feed Mechanism
Feed is the movement of the tool relative to the work

DEPARTMENT OF MECHANICAL ENGINEERING

Lathe machine working

• The lathe is a machine tool which holds the work piece between two rigid

and strong supports called centers or in a chuck or face plate which

revolves.

• In a tool post which is fed against the revolving work, the cutting tool is

rigidly held and supported.

• With the cutting tool fed either parallel or at right angles to the work axis, the

normal cutting operations are performed.

DEPARTMENT OF MECHANICAL ENGINEERING

LATHE MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

Working principle of Lathe

• A lathe is a machine tool which use to removes unwanted materials from a

workpiece in the form of chips with the help of a tool that travels across the
work piece and can be fed deep in work.
• When the tool is moved parallel to the work-piece then the cylindrical
surface is formed.
• If the tool is moved inclined to the axis then it produces a tapered surface and
so calls as taper turning.

DEPARTMENT OF MECHANICAL ENGINEERING

Working

● It holds the work between two supports so call as centers.

● Face plate or Chuck are using for holding the work.
● Face plate or Chuck are mounted on the machine spindle.
● The cutting tool is holding with the help of Tool post.
● The movement of the job is rotating about the spindle axis.
● Against the revolving work, the tool is feed.
● The tool moves either parallel or inclination to the work axis.

DEPARTMENT OF MECHANICAL ENGINEERING

WORKING

DEPARTMENT OF MECHANICAL ENGINEERING

ASSIGNMENT QUESTIONS

DEPARTMENT OF MECHANICAL ENGINEERING

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LECTURE-6

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TOPICS TO BE COVERED LECTURE-6

● Types of lathe Lathe machine-Types

● Center or Engine Lathe

● Speed Lathe
● Capstan and Turret Lathe
● Tool Room Lathe
● Bench Lathe
● Automatic Lathe
● Special Purpose and
● CNC Lathe Machine
● Its specifications

DEPARTMENT OF MECHANICAL ENGINEERING

Lathe Machine

• A lathe machine is a machine tool that is used to remove

metals from a workpiece to give a desired shape and size.
• Lathe Machines are used in metalworking, woodturning,
metal spinning, thermal spraying, glass working, and parts
reclamation.
• The various other operations that you can perform with the
help of Lathe Machine can include sanding, cutting,
knurling, drilling, and deformation of tools that are
employed in creating objects which have symmetry about
the axis of rotation.

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF LATHE

Lathe machine tool which is used for removing the excess material from
the workpiece to give required shape and size to the workpiece

Lathe machine has been categorized into the following types:

● Center or Engine Lathe
● Speed Lathe
● Capstan and Turret Lathe
● Tool Room Lathe
● Bench Lathe
● Automatic Lathe
● Special Purpose and
● CNC Lathe Machine

DEPARTMENT OF MECHANICAL ENGINEERING

Center or Engine Lathe Machine

• Center or Engine Lathe Machine is the most widely used lathe machine and
still, it is, in every workshop, this machine is present.
• The operation like Turning, facing, grooving, Knurling, threading and more, such
operations are performed on this type of machine.
• Engine lathe machine has all the parts such as bed, Saddle, headstock, and
tailstock, etc. The headstock of an engine lathe is rigid and tailstock is moveable
which is further used to support an operation like knurling.
• It can easily feed the cutting tool in both directions i.e. longitudinal and lateral
directions with the help of feed mechanisms.
• Center Lathe machines are driven by the gear mechanism or pulley
mechanism.
• It has three types of driven mechanisms, and those are Belt-driven, Motor-
driven, Gearhead type.

DEPARTMENT OF MECHANICAL ENGINEERING

CENTER OR ENGINE LATHE MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

Speed Lathe

• Speed lathe is also called as Wood Lathe.

• As the name indicates “Speed” the machine works with high speed. The
headstock spindle is rotating at a very high speed.
• The parts having like headstock, tailstock, but it’s not having feed
mechanism like center or engine lathe having.
• The feed we provide is manually operated.
• The speed ranges of this machine operated between 1200 to 3600
RPM.
• Speed lathe is used for spinning, centering, polishing and machining of
wood.

DEPARTMENT OF MECHANICAL ENGINEERING

SPEED LATHE

DEPARTMENT OF MECHANICAL ENGINEERING

Capstan and Turret Lathe

• This is an advanced technology of the manufacturing industry.

• The capstan and turret lathe machine used for Mass production (large
Quantity) and it is a modified version of the engine lathe machine
• This machine is used where their sequence of operation is performed on the
workpiece, there is no alternative operation performed on this machine.
• These machines provided by hexagonal turret head instead of the tailstock
in which multiple operations (Turning, facing, boring, reaming) performed in
a sequence without changing its tool manually, after each operation the
turret rotated.
• It also consists of three tool post. It requires more floor space than other
lathe machines.
• Capstan and turret lathe is using for only large jobs.
• The main advantage of using capstan and turret lathe is even less skilled
operators can do a job.

DEPARTMENT OF MECHANICAL ENGINEERING

Capstan and Turret Lathe

DEPARTMENT OF MECHANICAL ENGINEERING

Tool Room Lathe

• The toolroom lathe machine operates to speed up to 2500

rpm.
• The parts are almost the same similar to engine lathe
machine but the parts are built very accurately and should
be arranged in proper sequence because this lathe is used
for highly precious work with very fewer tolerances.
• It is mainly used in grindings, working on the tool, dies
gauges and in machining work where accuracy is needed.

DEPARTMENT OF MECHANICAL ENGINEERING

Tool Room Lathe

DEPARTMENT OF MECHANICAL ENGINEERING

Bench Lathe

• Bench lathe machines are mounted on the bench.

• This type of lathe machine is small in size and use for
very small precision work.
• It has all the similar parts of engine lathe and speed
lathe.

DEPARTMENT OF MECHANICAL ENGINEERING

Bench Lathe

DEPARTMENT OF MECHANICAL ENGINEERING

Automatic Lathe

• As the name indicates “Automatic lathe” performs work

automatically.
• Standard lathes have some drawbacks i.e. they are not used for
mass production.
• But automatic lathes are used for mass production. Some
mechanisms are responsible for the automation in it.
• Here there is no need to change the tool manually because it
changes automatically.
• Having this machine the main advantage is that a single operator
can handle machines more than 4 to 5 machines at a time.
• These types of lathes are high speed and heavy-duty.

DEPARTMENT OF MECHANICAL ENGINEERING

Automatic Lathe

DEPARTMENT OF MECHANICAL ENGINEERING

Special Purpose Lathe

• As the name indicates “special purpose lathe” the machine performs the
special types of operation which can not be performed on standard and
other machines.
• It is known for the heavy-duty production of identical parts.
• Some examples of special lathes include Vertical lathes, Wheel lathes,
T-lathe, Multi Spindle lathes, Production lathes, Duplicate or tracer
lathes, etc.
• Wheel lathe is used for machining of journals and rail rods.
• It is also used for turning the threads on locomotive wheels.
• The “T -lathe” is used for machining rotors for jet engines.
• The axis of the lathe bed is at right angles to the axis of the headstock
spindle in the form of a T.

DEPARTMENT OF MECHANICAL ENGINEERING

Special Purpose Lathe

DEPARTMENT OF MECHANICAL ENGINEERING

CNC Lathe Machine

• CNC stands for Computerized numerically controlled.This is widely used as a

lathe in the present time because of its fast and accurate working. It is one of the
most advanced types.
• It uses computer programs to control the machine tool. Once the program is fed
into the computer as per the program it starts operation with very high speed and
accuracy.
• Even do preplanned programmed machine is there in which once code is set for
the various operations it can starts operation without changing code in the next
time.
• A semi-skilled worker can easily operate this after the initial setup is done.These
types of lathes are also used for mass production like capstan and turret but
there is no programmed fed system.
• The components manufactured by these lathes are very accurate in dimensional
tolerances.

DEPARTMENT OF MECHANICAL ENGINEERING

CNC Lathe Machine

DEPARTMENT OF MECHANICAL ENGINEERING

ASSIGNMENT QUESTIONS

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

www.mrcet.ac.in
LECTURE-7

www.mrcet.ac.in
TOPICS TO BE COVERED
LECTURE-7

● Operations of lathe Work and tool holding devices

● Work Holding Devices

● Carriers and catch plates
● Face plates
● Angle plates
● Mandrels
● Rests
● Tool Holding devices

DEPARTMENT OF MECHANICAL ENGINEERING

Operations of Lathe

A Lathe Machine consists of the following operation:

● Centering
● Facing
● Turning
● Chamfering
● Knurling
● Thread cutting
● Drilling
● Boring
● Reaming
● Spinning
● Tapping
● Parting off

DEPARTMENT OF MECHANICAL ENGINEERING

Centering operation in the lathe
• We use this operation for producing a conical hole in the face of the job to make
the bearing support of the lathe center when the job is to hold between two
centers. (Head-stock and Tail-stock).

DEPARTMENT OF MECHANICAL ENGINEERING

Facing operation in the lathe

Facing operation is for making the ends of the job to produce a smooth flat surface
with the axis of operation or a certain length of a job.

In this operation,
1. Hold the job on Head-stock spindle using Three or four-jaw chuck.
2. Start the machine on desire RPM to rotate the job.
3. Give a desirable feed on the perpendicular direction of the axis of the job

DEPARTMENT OF MECHANICAL ENGINEERING

Facing operation in the lathe

DEPARTMENT OF MECHANICAL ENGINEERING

Turning operation in the lathe

The operation by which we remove the excess material from the workpiece to produce
a cone-shaped or a cylindrical surface.

There are several types of turning operations, those are:

1. Straight turning
2. Shoulder turning
3. Rough turning
4. Finish turning
5. Taper turning
6. Eccentric turning

DEPARTMENT OF MECHANICAL ENGINEERING

Turning operation in the lathe

DEPARTMENT OF MECHANICAL ENGINEERING

Chamfering operation

Chamfering is used for beveling the end of a job to remove burrs, to look better, to
make a passage of the nut into the bolt.

This operation is done after thread cutting, knurling, rough turning

DEPARTMENT OF MECHANICAL ENGINEERING

Knurling operation

• It is the process of producing a rough surface on the workpiece to provide

effective gripping.
• Knurling tool is held rigidly on the tool post and pressed against the rotating job
so that leaving the exact facsimile of the tool on the surface of the job

DEPARTMENT OF MECHANICAL ENGINEERING

Thread cutting operation

• It is the operation that is used to produce a helical groove

on a cylindrical or conical surface by feeding the tool
longitudinally when the job revolved between the two
centers.

Tool setting for thread cutting operation:

• The tool should be set exactly to the height of the

centerline of the job and at 90 degrees to the job.
• Tool setting gauge is used for this purpose.

DEPARTMENT OF MECHANICAL ENGINEERING

THREAD CUTTING OPERATION

DEPARTMENT OF MECHANICAL ENGINEERING

Drilling operation

• Drilling is an operation by which we can make holes in a job.

• In this operation, the job is rotated at the turning speed on the lathe axis and the
drilling tool fitted on the tail-stock spindle. And the tail-stock is moved towards the
job by hand feed.

DEPARTMENT OF MECHANICAL ENGINEERING

Boring operation

• In this operation, we can enlarge the diameter of the existing hole on a job by
turning inside with some farm tool known as a boring tool.The boring tool is also
fitted on tail-stock

DEPARTMENT OF MECHANICAL ENGINEERING

Reaming operation

Reaming is the operation for sizing or finishing a drilled hole to the required size by a
tool called reamer.This tool is fitted on tail-stock.

DEPARTMENT OF MECHANICAL ENGINEERING

Spinning operation

• In this operation, the job of this sheet metal is held between the former and the
tail-stock center rotates at high speed with the former.
• The long round nose forming tool rigidly fixed on special tool post presses the job
on the periphery of the former.
• So the job is taken exactly the shape of the former.This is a chipless machining
process.

DEPARTMENT OF MECHANICAL ENGINEERING

Tapping operation

We use this operation for creating internal threads within a hole by means of a tool
called tap.

Three taps are generally used in an internal thread.

1. Taper Tap
2. Second Tap
3. Plug Tap

DEPARTMENT OF MECHANICAL ENGINEERING

Parting-off operation

• It is the operation of cutting off a bar type job after complete the machining
process. In this operation a bar type job is held on a chuck, rotates at turning
speed, a parting off tool is fed into the job slowly until the tool reaches the center
of the job.

DEPARTMENT OF MECHANICAL ENGINEERING

Specification of a Lathe

A Lathe is generally specified by:

1. Swing- the largest work diameter that can be swung for the lathe bed.
2. The distance between the headstock and tailstock center.
3. Length of the bed in a meter.
4. The pitch of the lead screw.
5. Horsepower of the machine.
6. Speed range and the number of speeds of HS spindle.
7. The weight of the machine in a tonne.

DEPARTMENT OF MECHANICAL ENGINEERING

Work Holding Devices Being used on Lathe

As we know the lathe is one of the oldest and highly important

machine tool. There is vast number of applications of this
machine tool. So for facilitating the easy machining of the
workpiece it should be held tightly and securely. For this
purpose many types of accessories are being used for
facilitating easy holding of the worKpiece.
Some of the work holding devices are
1) Carriers and catch plates
2) Face plates
3) Angle plates
4) Mandrels
5) Rests
DEPARTMENT OF MECHANICAL ENGINEERING
Carriers and catch plates

These are in general used for driving the work piece when it is
held in between two centers namely head stock and tail stock.
Carriers are also called as the driving dogs. These are attached
to the work piece by the help of setscrews. Where as the catch
plates are pinned to the headstock.

DEPARTMENT OF MECHANICAL ENGINEERING

Angle plates

These are used along with faceplates for maintaining the given
work piece horizontal i.e. perpendicular to the tool used. Angle
plates consist of two faces, which are highly machined, and these
also have the provision of holes for the easy clamping of the work
piece to it.

DEPARTMENT OF MECHANICAL ENGINEERING

Mandrels

This type of work holding devices are employed for holding previously drilled
or bored hole so as to facilitate effective outer surface machining. The work
is loaded over the mandrels between the centers. The ends of the mandrels
are made slightly smaller than the original diameter. This is done for effective
gripping of the mandrel in the chuck or any other holding device. In general
the material used for the manufacturing of the mandrels is plain carbon steel.
Various types of mandrels are in usage. Various types of mandrels are
1) Plain mandrels
2) Step mandrels
3) Collar mandrels
4) Screwed mandrels
5) Cone mandrels
6) Gang mandrels
7) Expansion mandrels

DEPARTMENT OF MECHANICAL ENGINEERING

Plain mandrels

This type of mandrels finds a numerous number of

applications in shops where identical pieces are to be
generated. The body of these mandrels has generally a
tapered shape. The difference in the tapped diameter is of 1 to
2 mm and the length varies between 55mm to 430mm. the
tapper is provided for facilitating high end gripping for holding
the work piece.

DEPARTMENT OF MECHANICAL ENGINEERING

Step mandrel

A special type of mandrel, which facilitates faster processing

by holding various sized jobs without replacing the mandrel.
This type of mandrels finds applications in repair shops and
generally used for turning collars, washers and odd sized jobs.

DEPARTMENT OF MECHANICAL ENGINEERING

Collar mandrel

A collar mandrel has a collar arrangement, which is fixed and

may have size larger than that of the 100mm. this type of
construction is a type of optimizing the material being used.

DEPARTMENT OF MECHANICAL ENGINEERING

Screwed mandrels

These mandrels have a thread cut engraved on one side along

with a collar. Such type of mandrels is called as screwed
mandrels. Screwed mandrels are used when work pieces
having internal threads are to be machined. The size of the
threads to be engraved on the screwed mandrels depends on
the type of work piece, which is going to fit over it.

DEPARTMENT OF MECHANICAL ENGINEERING

Cone mandrel

Cone mandrels have a cone shaped piece attached at one of

the mandrel. This type of arrangement allows the mandrel to
handle a variety of work pieces having a varying internal cross
sectional diameter. The workpiece is held tightly by fixing a nut
at the other end of fixing the work piece to the mandrel. Too
tight fitting of the workpiece over the cone may damage the
internal surface finish of the workpiece along with the damage
to the cone shape of the mandrel.

DEPARTMENT OF MECHANICAL ENGINEERING

Gang mandrel

Gang mandrel is generated by some of the optimizers so as to

reduce the material. This type of mandrel can facilitate
machining for work pieces of various diameters. The gang
mandrels consist of a fixed collar at one end and removable
mandrels at the other end which is fixed by the help of the
threads engraved both on the mandrel and also on the internal
surface of a hallow mandrel. This mandrel can be used for
machining various diameter pieces by just removing and fixing
various collars over the thread. The friction between the walls
of collar and sides of work piece is enough to hold the work
piece tightly and hence facilitating is a high end machining.

DEPARTMENT OF MECHANICAL ENGINEERING

Expansion mandrel

This is a special type of mandrel, which has a central

tapered pin. Over this tapered pin a sleeve is arranged
when this sleeve is moved over it form one corner to other
the size increases or decreases. This type of mandrels is
best used when a varying diameter pieces are to be hold
without much difficulty.

DEPARTMENT OF MECHANICAL ENGINEERING

Chucks

A chuck is a work holding device. It is used for holding work

over a lathe machine, which is having large length and small
diameter, and also for jobs, which are unable to mount on
between the centers i.e., head stock and tail stock centers. A
chuck is also employed when a non-axis symmetrical object is
to be mounted over the lathe. The chucks are most commonly
used work holding devices. These are fixed directly to the
spindle of the lathe by means of screws and a back plate. In
general there are various types of chuck, which have their own
importance and unique applications

DEPARTMENT OF MECHANICAL ENGINEERING

Types of chucks

• Four jaw chuck or independent chuck

• Three jaw chuck or self-centering chuck
• Air or hydraulic operated chuck
• Magnetic chuck
• Collet chuck
• Combination chuck
• Drill chuck

DEPARTMENT OF MECHANICAL ENGINEERING

Rests

Rest is a work holding device, which is used to hold the work

piece when the work piece of very long length are to be held.
In general when a long piece is to be held it may have directly
held then there arises deflection in the work piece due its own
weight. So to prevent the deflection in the work piece rests of
various types are used. Some of the rests being used are
1) Steady rest
2) Follower rest

DEPARTMENT OF MECHANICAL ENGINEERING

TOOL HOLDING DEVICES

Workpieces are held in lathe with the assistance of chucks,

faceplates, or lathe centers. A lathe chuck is a device that exerts
pressure on the workpiece to hold it secure to the headstock
spindle or tailstock spindle. Commonly used with the lathe are the
independent chuck (4 Jaw),the universal scroll chuck (3 Jaw), and
the collet chuck.

DEPARTMENT OF MECHANICAL ENGINEERING

Independent Chuck - (4 Jaw)

• The independent chuck has four jaws which are adjusted

individually on the chuck face by means of adjusting screws.
• The chuck face is scribed with concentric circles which are used
for rough alignment of the jaws when chucking round
workpieces.
• The final adjustment is made by turning the workpiece slowly
and using dial indicators to determine its concentricity and to the
desired tolerances.
• The jaws of the independent chuck may be used as in the figure
shown, or may be reversed so that the steps face in the opposite
direction; thus, workpieces can be gripped either externally or
internally.

DEPARTMENT OF MECHANICAL ENGINEERING

Independent Chuck - (4 Jaw)

• The independent chuck can he used to hold square, round,

octagonal, or irregular shaped workpieces in either a concentric
or eccentric position due to the independent operation of each
jaw.
• Because of its versatility and capacity for fine adjustment, the
independent chuck is commonly used for mounting workpieces
that require extreme accuracy.

DEPARTMENT OF MECHANICAL ENGINEERING

Universal Scroll Chuck - (3 Jaw)

• The universal scroll chuck has three jaws which move in unison
as an adjusting pinion is rotated.
• The advantage of the universal scroll chuck is its ease of
operation in centering the work for concentric turning.
• This chuck is not as accurate as the independent chuck but,
when in good condition, it will centre the work automatically
within 0.003 of an inch of complete accuracy.
• The jaws are moved simultaneously within the chuck by means
of a scroll or spiral threaded plate.

DEPARTMENT OF MECHANICAL ENGINEERING

Universal Scroll Chuck - (3 Jaw)

• The jaws are threaded to the plate and move an equal distance
inward or outward as the scroll is rotated by means of the
adjusting pinion.
• Since the jaws are individually aligned on the scroll, the jaws
cannot be reversed.
• However, the chuck is usually supplied with two sets of jaws
which can be interchanged.
• The universal scroll chuck can be used to hold and automatically
centre round or hexagonal workpieces.
• Having only three jaws, the chuck cannot be used effectively to
hold square, octagonal, or irregular shapes.

DEPARTMENT OF MECHANICAL ENGINEERING

Collet Chuck

• The collet chuck is the most accurate means of holding small

workpieces in the lathe.
• The collet chuck consists of a spring machine collet and a collet
attachment which secures and regulates the collet on the
headstock spindle of the lathe.
• The spring machine collet is a thin metal bushing with an
accurately machined bore and a tapered exterior.
• The collet has three lengthwise slots to permit its sides to be
sprung slightly inward to grip the workpiece.
• To grip the workpiece accurately, the collet must be no more
than 0.001 inch larger or smaller than the diameter of the piece
to be chucked.

DEPARTMENT OF MECHANICAL ENGINEERING

Collet Chuck

• For this reason, spring machine collets are generally supplied in

sets with various capabilities in 1/16, 1/32, or 1/64 inch
increments.
• For general purposes, the spring machine collets are limited in
capacity to 1 inch in diameter.
• The collet attachment which, with the spring machine collet,
forms the collet chuck and consists of a collet sleeve, a draw bar,
and a handwheel or hand lever to move the draw bar.
• The collet is fitted to the right end of the headstock spindle. The
draw bar passes through the headstock spindle and is threaded
to the spring machine collet.
• When the draw bar is rotated by means of the handwheel, the
collet is pulled inward and the collet walls are cammed together
by contact with the collet sleeve, tightening the chuck to the
workpiece
DEPARTMENT OF MECHANICAL ENGINEERING
ASSIGNMENT QUESTIONS

DEPARTMENT OF MECHANICAL ENGINEERING

IMP QUESTIONS FOR UNIT-1

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

www.mrcet.ac.in
 COMPUTER
INTEGRATED
MANUFACTURING
TECHNOLOGIES
3RD YEAR SEM-1 BTECH MECHANICAL ENGINEERING (R18A0312)

www.mrcet.ac.in
COURSE OBJECTIVES
UNIT - 1 CO1: Learn about geometry of metal cutting theory,
mechanism of chip formation and mechanism of
orthogonal cutting and merchants force diagram
UNIT - 2 CO2: Learn about ways to reduce the surface
roughness by using different machining process
UNIT - 3 CO3: To write APT and CNC programming concepts

UNIT - 4 CO4: Learn the concepts of DNC Systems and Post

Processors

UNIT - 5 CO5: To know about Computer aided process

planning and computer aided inspection and Quality
control

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT 2

SHAPING, SLOTTING AND

PLOTTING MACHINES
CO2: Learn about ways to reduce the surface using different
Machining Processes.

www.mrcet.ac.in
UNIT – II (SYLLABUS)
SHAPING, SLOTTING AND PLANING MACHINES

• Principles of working
• Classifications

Drilling and Boring machines

• Principles of working
• Classifications
• Types

DEPARTMENT OF MECHANICAL ENGINEERING

 COURSE OUTLINE

LECTU
UNIT LECTURE TOPIC​
-2 KEY ELEMENTS​ Learning Objectives​
RE​
1​ Shaping, slotting and planning machines. Shaping, slotting and • Learn the working
Principles of working​ planning machines​ principles of shaping,
slotting and plotting
machines​

2​ Classifications, operations performed Classifications of Shaping, • Understanding

& machining time calculations​ slotting and planning the types and uses
machines​ of Shaping, slotting
and planning
machines​

3​ Drilling machine working principle, Drilling machine​ • Working of drilling

specifications and types​ machine and its types​

4​ Drilling and Boring machines Operations performed • Understand

operations performed, tool holding devices ​ using drilling and boring the main uses of
machines​ drilling and boring
machines​
5​ Boring machines-Fine boring, jig boring​ Types of boring machines​ • Operations of fine
and jig boring and its
uses​
6​ Deep hole drilling machine​ Deep hole drilling machine • Operations of
concepts​ deep hole drilling
machines and its uses​

DEPARTMENT OF MECHANICAL ENGINEERING

LECTURE 1
Shaping machines

www.mrcet.ac.in
TOPICS TO BE COVERED
LECTURE 1
Shaping Machine
• Principles of working
• classifications
• operations performed

DEPARTMENT OF MECHANICAL ENGINEERING

Shaping Machine

• A shaping machine is used to machine surfaces. It can cut

curves, angles and many other shapes.
• The tool feed handle can be turned to slowly feed the cutting tool
into the material as the 'ram' moves forwards and backwards.
• In a standard shaper, cutting takes place during the forward
stroke of the ram and the backward stroke remains idle.
• The forward and backward motion is obtained by “Quick Return
Mechanism”.
• The depth of the cut is adjusted by moving the tool downwards
towards the work piece

DEPARTMENT OF MECHANICAL ENGINEERING

PRINCIPLE OF WORKING

The shaper is a machine tool used primarily for:

1. Producing a flat or plane surface which may be in a
horizontal, a vertical or an angular plane.
2. Making slots, grooves and keyways
3. Producing contour of concave/convex or a combination of
these

DEPARTMENT OF MECHANICAL ENGINEERING

SHAPER MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

WORKING PRINCIPLE

• The job is rigidly fixed on the machine table. The single

point cutting tool held properly in the tool post is mounted
on a reciprocating ram.
• The reciprocating motion of the ram is obtained by a quick
return motion mechanism.
• As the ram reciprocates, the tool cuts the material during
its forward stroke.
• During return, there is no cutting action and this stroke is
called the idle stroke.
• The forward and return strokes constitute one operating
cycle of the shaper.

DEPARTMENT OF MECHANICAL ENGINEERING

CONSTRUCTION

The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column), Cross rail,
Ram and tool head (Tool Post, Tool Slide, Clamper Box Block).
Base: The base is a heavy cast iron casting which is fixed to the shop floor. It supports the
body frame and the entire load of the machine. The base absorbs and withstands vibrations
and other forces which are likely to be induced during the shaping operations.
Body (Pillar, Frame, Column): It is mounted on the base and houses the drive mechanism
compressing the main drives, the gear box and the quick return mechanism for the ram
movement. The top of the body provides guide ways for the ram and its front provides the
guideways for the cross rail.
Crossrail: The cross rail is mounted on the front of the body frame and can be moved up
and down. The vertical movement of the cross rail permits jobs of different heights to be
accommodated below the tool. Sliding along the cross rail is a saddle which carries the work
table.
Ram and tool head: The ram is driven back and forth in its slides by the slotted link
mechanism. The back and forth movement of ram is called stroke and it can be adjusted
according to the length of the workpiece to be-machined.

DEPARTMENT OF MECHANICAL ENGINEERING

CLASSIFICATIONS OF SHAPER MACHINE

The shaper machine is a reciprocating type of machine basically used for

producing the horizontal, vertical or flat surfaces. The shaper holds the
single point cutting tool in ram and workpiece is fixed in the table.

During the forward stroke, the ram is holding the tool is reciprocating over
the workpiece to cut into the required shape. During the return stroke, No
metal is cutting. In the shaper machine, the rotary motion of the drive is
converted into reciprocating motion of ram holding the tool.

Therefore in order to reduce the total machine time, It allows the ram
holding the tool should move slower during forwarding cutting stroke
and it comes faster in return stroke. This can be achieved by a
mechanism called a quick return mechanism.

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF SHAPER MACHINE

Types of Shaper Machines

Following are the different types of shaper machine

1. Based on the type of driving mechanism.

1. Crank type shaper.
2. Geared type shaper.
3. Hydraulic type shaper.
2. Based on ram travel.
1. Horizontal shaper
2. Vertical shaper.
3. Based on the table design.
1. Standard shaper.
2. Universal shaper.
4. Based on cutting stroke.
1. Push cut type
2. Draw cut type

DEPARTMENT OF MECHANICAL ENGINEERING

Crank Type Shaper Machine

• These are very common types of shaper machines, which is using to

hold the workpiece on the table.
• The tool is reciprocating in motion equal to the length of the stroke
desired while the work is clamped in position on an adjustable table.
• In construction, the crank shaper employs a crank mechanism to
change the circular motion of a large gear called “bull gear” incorporated
in the machine to reciprocation motion of the ram.
• It uses a crank mechanism to convert the circular motion of the bull gear
into reciprocating motion of the ram.
• The ram carries a tool head at its end & provides the cutting action.

DEPARTMENT OF MECHANICAL ENGINEERING

Crank Type Shaper Machine

DEPARTMENT OF MECHANICAL ENGINEERING

Gear Type Shaper Machine

• In these types of shaper machines, the ram is reciprocating. The ram is

affecting due to reciprocating motion with the rack and pinion.
• The rack teeth are cut directly below the ram mesh with the spur gear.
• The speed and the direction in which the machine will traverse depend
on the number of gears in the gear train.
• This type of shaper machines is not widely using in any industry.

DEPARTMENT OF MECHANICAL ENGINEERING

Hydraulic Shaper Machine

• In these types of shaper machines, the reciprocating motion of the ram is provided by
the hydraulic mechanism.
• The Hydraulic shaper uses the oil under high pressure. The end of the piston rod is
connected to the ram.
• The high-pressure oil first acts on one side of the piston and then on the other causing
the piston to reciprocating and the motion is transmitted to the ram.
• The main advantages of this type of shaper machine are that the cutting speed and
force of the ram drive are constant.
• From start to end of the cut without making noise and operates quietly.

DEPARTMENT OF MECHANICAL ENGINEERING

Horizontal Shaper Machine

In these types of shaper machines, the ram is reciprocating. The ram holding
the tool in a horizontal axis and reciprocate. This type of shaper is using for
the production of flat surfaces, external grooves, keyways etc.

DEPARTMENT OF MECHANICAL ENGINEERING

Vertical Shaper Machine

In these types of shaper machines, the ram reciprocating in verticle plane. In this, the table
holds the workpiece. Verticle shapers maybe crank driven, rack-driven, screw-driven or
hydraulic power-driven.The vertical shaper is very convenient for machining internal
surfaces, keyways, slots or grooves. The workpiece can move in any given directions such
as the cross, longitudinal or rotary movements.

DEPARTMENT OF MECHANICAL ENGINEERING

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LECTURE 2
Introduction - Resultants of Force System

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TOPICS TO BE COVERED
LECTURE 2
Slotting Machine
• Principle of working
• classifications

DEPARTMENT OF MECHANICAL ENGINEERING

Slotting Machine

The slotting machine is a reciprocating machine tool in which,

the ram holding the tool reciprocates in a vertical axis and the
cutting action of the tool is only during the downward stroke.

The slotter can be considered as a vertical shaper and its main

parts are:
1. Base, column and table
2. Ram and tool head assembly
3. Saddle and cross slide
4. Ram drive mechanism and feed mechanism.

DEPARTMENT OF MECHANICAL ENGINEERING

SLOTTING MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

CONSTRUCTION

• The base of the slotting machine is rigidly built to take up all the
cutting forces.
• The front face of the vertical column has guide ways for Tool the
reciprocating ram. The ram supports the tool head to which the
tool is attached.
• The workpiece is mounted on the table which can be given
longitudinal, cross and rotary feed motion.
• The slotting machine is used for cutting grooves, keys and slotes
of various shapes making regular and irregular surfaces both
internal and external cutting internal and external gears and
profiles.
• The slotter machine can be used on any type of work where
vertical tool movement is considered essential and
advantageous.

DEPARTMENT OF MECHANICAL ENGINEERING

CONSTRUCTION

The different types of slotting machines are:

1. Punch slotter: a heavy duty rigid machine designed for
removing large amount of metal from large forgings or castings
2. Tool room slotter: a heavy machine which is designed to
operate at high speeds. This machine takes light cuts and
gives accurate finishing.
3. Production slotter: a heavy duty slotter consisting of heavy
cast base and heavy frame, and is generally made in two
parts.

DEPARTMENT OF MECHANICAL ENGINEERING

Slotter Machine Mechanism

Hydraulic Drive (Greater speed Flexibility, Smoother operation,

Stroke length can be adjusted )

Variable Speed Motor Drive (In this Multi-speed arrangement)

Hydraulic Drive:
A speed motor drives a hydraulic pump that delivers oil at a constant
pressure to the line.

A regulating valve admits oil under pressure to each end on the

piston alternately.
At the same time allowing oil from the opposite end of the piston to
return to the reservoir.

DEPARTMENT OF MECHANICAL ENGINEERING

Working Principle of Slotter Machine

The working of the Slotter machine is similar to the shaper machine do but the main
difference between them is the Shaper machine works horizontally whereas Slotter
machines work vertically.
Now the ram is connected to the crank and crank connected to the gears. So what
happened here is when we increase or decrease the gear speed, the rotation of crank
increases and decreases. And as per these, the ram moves up and down.

We have attached the workpiece into the work table and manually we bring the ram near to
the workpiece and according to the ram we adjust the worktable and then we have to clamp
it.

Now we supply the power as per gear the crank rotates and the crank is connected to the
ram so ram moves up and down.

During down (ram moves down) the cutting stroke takes place and while moving up or
return stroke there is no cut.

If we have to cut at the different sections then manually we give feed to the work table and
as per requirement, it cuts.

DEPARTMENT OF MECHANICAL ENGINEERING

Slotter Machine Operations

It is used for various operations like:

● Internal and external Flat surface Machining.
● The internal recess of circular, semi-circular, concave and convex
surfaces.
● Internal and External Circular surfaces Machining.
● Blind Holes Internal machining.
● For shaping internal and external forms or profiles.
● The machine operates vertical, Horizontal and at Some angle too
(Inclined Surfaces).
● Irregular surface machining.
● Machining operation of Dies and Punches.
● The operation like slots, grooves, splines, and keyways for both
internal and external surfaces.
● Internal and external gear teeth machining.

DEPARTMENT OF MECHANICAL ENGINEERING

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LECTURE 3
Introduction - Resultants of Force System

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TOPICS TO BE COVERED
LECTURE 3

o INTRODUCTION PLANING MACHINE

o CLASSIFICATION
o WORKING PRINCIPLE
o OPERATIONS
PERFORMED

DEPARTMENT OF MECHANICAL ENGINEERING

PLANER MACHINE

The planer machine is similar to a shaper machine. It intended to

produce plane and flat surfaces by a single-point cutting tool. A
planer machine is very large and massive compared to a shaper
machine. It is capable of a machining heavy workpiece, which cannot
be fit on a shaper table.

DEPARTMENT OF MECHANICAL ENGINEERING

PLANER MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

PLANER MACHINE

The fundamental difference between a shaper and a planer is that

● In a planer, the work which is supported on the table

reciprocates over the stationary cutting tool and the feed is
provided by the lateral movement of the tool.
● In a shaper, the tool which is mounted upon the ram
reciprocates. And the feed is given by the crosswise movement
of the table.

DEPARTMENT OF MECHANICAL ENGINEERING

CLASSIFICATION

Types of Planer Machine

Following are the five types of planer machine:

1. Standard or Double housing type planer machine

2. open side type planer machine
3. Pit planer machine
4. Edge or plate type planer
5. Divided table planer

DEPARTMENT OF MECHANICAL ENGINEERING

PARTS

Parts of Planer Machine

Following are the six main parts of the planer machine:

1. Bed
2. Table
3. Housing or Column
4. Cross rail
5. Tool head
6. Driving and Feed Mechanism

DEPARTMENT OF MECHANICAL ENGINEERING

. Standard or Double Housing Planer Machine

The standard or double housing planer is the most widely used types of planer machine
in workshops. A double housing planer has a long heavy base on which a table
reciprocates on accurate guideways.

DEPARTMENT OF MECHANICAL ENGINEERING

Openside Planer Machine

An openside planer has a housing only on one side of the base. And the Crossrail is suspended from the
housing as a cantilever. This feature of the machine allows the large and wide workpiece to be clamped
on the table and reciprocated over the cutting tool.

DEPARTMENT OF MECHANICAL ENGINEERING

Pit Planer Machine

A pit type planer is massive in construction. It differs from an ordinary planer. In this the
table is stationary and the column carrying the Crossrail reciprocates on massive horizontal
rails mounted on both sides of the table.

DEPARTMENT OF MECHANICAL ENGINEERING

Edge or Plate Planer

The design of a plate or edge planer is totally unlike that of an ordinary planer. It is specially intended for
squaring and bevelling the edges of steel plates. Also used for different pressure vessels and shipbuilding
works.

DEPARTMENT OF MECHANICAL ENGINEERING

Divided Table Planer

This type of planer has two tables on the bed which may be reciprocated separately or together.

This type of design saves much of idle time while setting the work. The setting up of a large number of
identical workpieces on the planing machine table takes quite a long time. It may require as much time for
setting up as may necessary for machining.

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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LECTURE 4

www.mrcet.ac.in
TOPICS TO BE COVERED
LECTURE 4

o INTRODUCTION
o CLASSIFICATION
o WORKING PRINCIPLE
o OPERATIONS TO BE
PERFOMED

DEPARTMENT OF MECHANICAL ENGINEERING

DRILLING MACHINE

A drilling machine is one of the important machine tools in the

workshop

Drilling is a material-removing or cutting process in which the

tool uses a drill bit to cut a hole of circular cross-section in solid
materials.

This is the most common machining process, one estimate is that

75% of all metal cutting material removed comes from the drilling
operation.

DEPARTMENT OF MECHANICAL ENGINEERING

DRILLING MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

Drilling Machine Main Parts

A drilling machine consists of the following parts:

● Base
● Column or Pillar
● Arm
● Worktable
● Drill head
● Feed Mechanism
● Spindle
● Drill jigs
● Chuck
● Electric Motor
● Pully or gears

DEPARTMENT OF MECHANICAL ENGINEERING

DRILLING MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

Base

It is one of the main parts of a drilling machine, it carries the entire weight of the
machine, and transfer the weight to the ground.

The base of a drilling machine is generally made of cast iron or steel, and it is very
rigid.

At the top of the base, there are some slots provided to support the big jobs.

And on one side of the base, a radial column or a pillar is situated.

The base is generally bolted with the ground or in some case the base is supported by
two or four legs.

DEPARTMENT OF MECHANICAL ENGINEERING

Column or pillar

The column or pillar is situated on one side of the base. In general, we use a radial
column so that the movement of the arm is possible in a clockwise or anti-
clockwise direction.

The column is also made of cast iron or steel and is also very rigid so that it can carry
the load of the arm as well as a drill head.

DEPARTMENT OF MECHANICAL ENGINEERING

Upper arm

At the top of the column, there is an upper arm, which carries the drill head and also
the house of the driving mechanism. The upper arm is also made of the same
material as the base. To make the structure rigid.

In some drilling machine, a guideway is provided so that the drill head can slide over
this.

DEPARTMENT OF MECHANICAL ENGINEERING

Worktable

The worktable is generally made of cast iron and it is mounted on the column. T-slots
are provided at the top surface of the table may be in some table there is a vice
which also helps to hold the job.

The table can move up and down as also right or left according to the job and tool
arrangement. The up and down motion of the table can be given by hand as well as by
some electrical mechanism. We use a rack and pinion mechanism for a vertical
moment of the table.

The shape of the table can be rectangular or also circular.

DEPARTMENT OF MECHANICAL ENGINEERING

Drill head

One side of the arm a drill head is mounted, a drill head is consist of various feed
and driving mechanism.

A drill chuck is mounted over it. A drill head can slide up and down as per the
requirement of the job.

A V-types belt is provided to transfer the power from the motor to the pulley and from
pulley, the mechanical power is transferred to the drill head.

DEPARTMENT OF MECHANICAL ENGINEERING

Feed Mechanism

In a drill machine, we use an electric motor, V-belt, and pulley to transfer the
power from the motor to the spindle.

For the up and down motion of the drill head, we use hand and as well as automatic
feed by an electrical motor. Here also a rack and pinion are used to convert the
rotational movement from electrical motor or by hand to the straight-line movement.

DEPARTMENT OF MECHANICAL ENGINEERING

Spindle

It is a circular taper shaft which helps to hold the drill chuck. It is made of high carbon
chromium steel or stainless steel or steel alloys.

It transfers the rotary motion from drill head to drill jigs.

There is a keyhole provided on the spindle to change the drill chuck.

The spindle also can move up and down with the help of rack and pinion mechanism.

DEPARTMENT OF MECHANICAL ENGINEERING

Chuck

The chuck is mounted on the lower end of the spindle, it holds the drill jig. Here also
a keyhole is provided to change the drill jigs.

Drill chucks are generally self-centering. In a drill machine, we use three-jaw chuck.
And it is made of special alloy steel

DEPARTMENT OF MECHANICAL ENGINEERING

How does Power Transmission happen in the Drilling machine?

The power transmission in the drilling machine used to transmit power for its
working.

This power is supplied from the electric motor.

The process of transmission takes place with the help of the v-bolt and the pair of
pulley stacks opposite to each other.

The speed of the spindle is fixed or controlled with the help of the pulley stacks.

Let’s jump to the types of Drill machine section.

DEPARTMENT OF MECHANICAL ENGINEERING

Drilling Machine Types

In the market there are various types of Drilling machine available, here I mention
some of the popular types of drilling machines.
● Sensitive Drilling Machine
● Vertical or Pillar
● Radial Arm
● Gang Type
● Multi-Spindle
● Numerically control
● Special Purpose Drilling Machine

DEPARTMENT OF MECHANICAL ENGINEERING

Sensitive Drilling Machine

The sensitive drilling machine has only a hand-feed mechanism for feeding the tool
into the workpiece. This enables the operator to feel how the drill is cutting and
accordingly he can control the down feed pressure.

DEPARTMENT OF MECHANICAL ENGINEERING

Vertical or Pillar Drilling Machine

Vertical or Pillar Drilling Machine is free standing and is of a far heavier

construction able to take larger drills.

It has a heavy frame to support a wider range of work.

The table height is adjustable and power speed and feeds are available.

The larger drills normally have a taper shank located within taper bore in the spindle
end. These tapers are standardized as Morse tapers.

DEPARTMENT OF MECHANICAL ENGINEERING

Vertical or Pillar Drilling Machine

DEPARTMENT OF MECHANICAL ENGINEERING

Radial Arm Drilling Machine

The radial drill machine is free-standing and the workpiece is clamped in the position
on the base. It is used for heavy large and heavy work.

The arm is power-driven for the height location. The drill head is positioned using
motorized drives and it transverse the swinging arm.

The workpiece remains stationary o the machine base or worktable.

The machine spindle is moved to the location required.

DEPARTMENT OF MECHANICAL ENGINEERING

Radial Arm Drilling Machine

DEPARTMENT OF MECHANICAL ENGINEERING

Gang Type Drilling Machine

In the Gang type Drilling Machine, several spindles/ or stations are mounted on one
long table as shown in the figure.

DEPARTMENT OF MECHANICAL ENGINEERING

Multi-spindle Drilling Machine

In the Multi-spindle drilling machine, there are many spindles mounted on one head
to allow many holes to be drilled simultaneously.

DEPARTMENT OF MECHANICAL ENGINEERING

Numerical Control Drilling Machine

Numerical control drilling machine can automatically change tooling with a turret
or automatic tool changer.

Speeds, feeds, and table position is controlled using a computer program.

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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LECTURE-5

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TOPICS TO BE COVERED
LECTURE-5

o TWIST DRILL DRILLING MACHINE

CONTEXT
NOMENCLATURE

DEPARTMENT OF MECHANICAL ENGINEERING

Twist drill nomenclature

It is designed with cones like internal structure, narrow at the top of the web with a
gradually increasing thickness to the shank.

It is a multi-point cutting tool. I also wrote an article on the single-point cutting tool you
can check that too.

DEPARTMENT OF MECHANICAL ENGINEERING

Properties of twist drill

Axis:

The imaginary straight line which forms the longitudinal centerline of the drill.

Back taper:

A slight decrease in diameter from front to back in the body of the drill.

Body:

The portion of the drill extending from the sank or next to the outer corners of the cutting lips.

Body Diameter clearance:

That portion of the land that has been cut away so it will not rub against the wall of the hole.

Chisel Edge:

The edge at the end of the web that connects the cutting lips.

DEPARTMENT OF MECHANICAL ENGINEERING

Properties of twist drill

Chisel Edge Angle:

The angle included between the chisel angle and the cutting lips as viewed from the
end of the drill.

Clearance Diameter:

The diameter over the cutaway portion of the drill lands.

Drill Diameter:

The diameter over the margins of the drill measured at the point.

Flutes:

Helical or Street grooves cut or formed in the body of the drill to provide cutting lips, to
permit removal of chips and to allow cutting Fluids to reach the cutting lips.

DEPARTMENT OF MECHANICAL ENGINEERING

Properties of twist drill

Flute Length:

The length from the outer corners of the cutting lips to the extreme back and of the
flutes; it includes the sweep of the tool used to generate the flutes and, therefore does
not indicate the usable length of the flutes.

Helix Angle:

The angle made by the leading edge of the land with a plane containing the axis of the
drill.

Land:

The peripheral portion of the body between adjacent flutes.

Land Width:

The distance between the leading edge and the hill of the land measured at the right
angle to the leading edge.

DEPARTMENT OF MECHANICAL ENGINEERING

Properties of twist drill

Lead:

The axial advance of the leading edge of the land in one turn around the circumference.

Lips:

The cutting edge of a two-flute drill extending from the chisel edge to the periphery.

Lip Relief:

The axial relief on the drill point.

Lip Relief Angle:

The axial relief angle at the outer corner of the lip; it is measured by projection onto a plane
tangent to the Periphery at the outer corner of the lip.

Margin:

The cylindrical portion of the land which is not cut away to provide clearance.

DEPARTMENT OF MECHANICAL ENGINEERING

TWIST DRILL NOMENCLATURE

DEPARTMENT OF MECHANICAL ENGINEERING

Drilling Machine Operation

These are the following operations that can be performed in the Drilling machine.
● Plane drilling operation
● Core drilling operation
● Step drilling operation
● Boring operation
● Counter boring operation
● Reaming operation
● Countersinking operation
● Spot facing operation
● Tapping operation
● Trepanning operation

DEPARTMENT OF MECHANICAL ENGINEERING

Drilling operation

When we need a circular hole in a workpiece of any size there, we can use drilling
operation, by a drilling operation you can form any size of holes in a workpiece.
Although you can use a lathe for drilling operation too, drill machine is an appropriate
machine to do holes in a workpiece.

The cutting tool we used for this type of operation is drill bit. A drill bit is a multipoint
rotary cutting tool which helps to remove material from a workpiece

DEPARTMENT OF MECHANICAL ENGINEERING

Core Drilling

• When sand castings are made, cores are used to displace the metal
where holes are desired. When cast the molten metal flows around the
core.
• After the metal solidifies the casting is removed from the mold and the
core disintegrates leaving the desired holes.
• The holes are usually quite rough and require heavy body drill to clean
up the sidewall of the whole.

DEPARTMENT OF MECHANICAL ENGINEERING

Step Drilling

More than one diameter can be ground on the drill body which saves an extra
operation.

DEPARTMENT OF MECHANICAL ENGINEERING

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LECTURE-6

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TOPICS TO BE COVERED
LECTURE-6

o BORING
o WORKING PRINCIPLE
o TYPES
o DEEP HOLE DRILLING
MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

BORING

• Boring machine, device for producing smooth and accurate

holes in a workpiece by enlarging existing holes with a bore,
which may bear a single cutting tip of steel, cemented carbide, or
diamond or may be a small grinding wheel.
• Single-point tools, gripped in a boring head attached to a rotating
spindle, are moved circularly against the sides of the existing
holes.
• The diameter of the hole swept out by the tool is controlled by
adjustment of the boring head.

DEPARTMENT OF MECHANICAL ENGINEERING

BORING MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING

BORING MACHINE

• There are various types of boring. The boring bar may be supported on both ends
(which only works if the existing hole is a through hole), or it may be supported at one
end (which works for both, through holes and blind holes).
• Line boring (line boring, line-boring) implies the former.
• Backboring (back boring, back-boring) is the process of reaching through an existing
hole and then boring on the "back" side of the workpiece (relative to the machine
headstock).
• Because of the limitations on tooling design imposed by the fact that the workpiece
mostly surrounds the tool, boring is inherently somewhat more challenging than
turning, in terms of decreased toolholding rigidity, increased clearance angle
requirements (limiting the amount of support that can be given to the cutting edge),
and difficulty of inspection of the resulting surface (size, form, surface roughness).
application.

DEPARTMENT OF MECHANICAL ENGINEERING

BORING MACHINE

• These are the reasons why boring is viewed as an area of machining practice in its
own right, separate from turning, with its own tips, tricks, challenges, and body of
expertise, despite the fact that they are in some ways identical.
• The first boring machine tool was invented by John Wilkinson in 1775.[1]
• Boring and turning have abrasive counterparts in internal and external cylindrical
grinding.
• Each process is chosen based on the requirements and parameter values of a
particular

DEPARTMENT OF MECHANICAL ENGINEERING

Features of Boring Machines

i. Headstock:

This is most important unit of the machine. The entire machine is built around it. It
supports, drives and feeds the tool. It may contain one or two spindles. One spindle
is heavy and slow moving for the heavier operations of boring, or drilling.

The other spindle is lighter and faster for drilling and tapping small holes and end mill
work. Spindle rotation is reversible in either case for backing out tools and for right
and left hand cutters.

ii. Column:

The column provides support for the headstock and guides it up and down accurately
by means of ways. It is heavily constructed and is hollow to house the
counterweights which balance the headstock and make it easier to move. Columns
are keyed, dowelled, and bolted to bases. Some columns are stationary whereas
others move with their bases.

DEPARTMENT OF MECHANICAL ENGINEERING

Features of Boring Machines

iii. The Column Base:

The base supports and secures the column. It houses the various gears and driving mechanisms. On floor type
machines the column base is mounted so that the spindle is at right angle to the ways of the run way. On planer type
machines, the spindle is parallel to the ways of the run way.

iv. End Support:

For operations involving the use of long boring bars and heavy tools, an out board bearing is utilised to support the end
of the bar. There is an open and a closed type of end support. On table and planer type machines, the bearing block
travels in synchronism with the headstock of the machine. When such an end support is used with floor type machines,
it is adjusted separately from the headstock and aligned by means of an accurate scale and vernier.

v. Run Ways:

These are used on floor or planer type machines to carry the main column, end-support column, and in some cases, a
rotary table. When the column base, column and headstock are traversed as a complete unit, the member upon which it
travels is called a run way and not a bed.

DEPARTMENT OF MECHANICAL ENGINEERING

Features of Boring Machines

vi. Table and Saddle:

The chief function of the table is to provide a support for holding the workpiece. It also provides a means of locking and
clamping the work. It is equipped with suitable ranges of feeds as well as rapid traverse.

The table usually traverses at right angles to the axis of the spindles unless provided with saddle. The function of the
saddle is to provide a compound movement of the table, so that it can move axially as well as transversely to the
spindle.

vii. Bed:

It may be cast in one or several pieces. It serves to support the column and headstock, the end supports, the table, the
saddle and the various feed and control shafts. It contains all the necessary feeding mechanisms for the table as well as
a coolant tank.

DEPARTMENT OF MECHANICAL ENGINEERING

Types of Boring Machines

A. Horizontal Boring Machine:

The horizontal boring mill is also known as horizontal boring, drilling and milling machine, and is intended to perform
operations on relatively large pieces which cannot be rotated easily, are irregular and unsymmetrical, and require
operations on many surfaces.

Fig. shows the main features of a horizontal boring machine. It also indicates the relative movements of its sliding and
rotating elements. It may be noted that the main spindle can be rotated in either direction. It is possible to feed the main
spindle axially. The work table can be traversed along and across the machine bed.

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF BORING MACHINE

B. Vertical Boring Machine:

There are two types of vertical boring machines, viz.,

i . Standard vertical boring mill and

ii. Vertical turret lathe.

Standard vertical boring mill is the largest of the machine tools. It is used to machine inside and outside diameters and
facing large pieces which are more or less symmetrical such as large ring-gear blanks, steam turbine castings, water
turbine runners, locomotive tires, tables for machine tools, flanges for large pipes and pressure vessels. The size of
such a machine is given by the diameter of the largest workpiece which can be machined.

Vertical turret lathe is basically a vertical boring mill and has turrent arrangement of holding the tools. It can do
essentially the same jobs, but on a smaller scale. The machine looks like a turrent lathe, with its head stock resting on
the floor and its axis vertical. The table is usually called a chuck because of its adjusting jaws for work clamping.

The distinguishing feature of the machine, however, is its five sided turrent, or tool holder mounted on the cross rail. It
has five tool positions which enable successive tools to be brought into position without demounting. The typical jobs
which can be machined include boring and turning rail road wheels, locomotive cross-heads, large pistons, rings and
gear blanks, bowls and many other similar round and symmetrical pieces.

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF BORING MACHINE

C. Other Boring Machines:

Two-spindle vertical way type drilling and boring machine

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF BORING MACHINE

Double Ended Machine

DEPARTMENT OF MECHANICAL ENGINEERING

TYPES OF BORING MACHINES

Fine Boring Machines

These are precision boring machines designed for high accuracy and surface finish. Boring
spindle is very precisely supported on ball, roller, hydrostatic or air bearings. Often, diamond
tools are used. These are available in horizontal (single end or double end type) and vertical
spindle fashions. Axial feed is given by cam or hydraulic cylinder. Recirculating ball screw drive
is used for feeding to achieve higher position accuracy in numerically controlled boring
machines.

DEPARTMENT OF MECHANICAL ENGINEERING

Boring Tools

Boring tools are held in boring tool holders which may be either fixed or rotating type. Fixed holders are used in work-
rotating machines and rotating holders in tool rotating machines. Size of boring bar should be such as to provide
maximum rigidity and also permit sufficient clearance for disposal of chips. Normally boring bar diameter is taken as 0.7
x bore diameter. It should have minimum overhang.

Various types of boring tool holders are:

i. Adjustable Boring Bars:

These are built with cartridges (to hold throwaway type inserts) adjustable in axial and radial directions by set screws.

ii. Damped Boring Bars:

In it, dampers are provided at the feed end to absorb vibrations.

iii. Line Boring Bars:

These are used for long bores and can accommodate fly cutters, tool blocks, cartridges etc. These are supported at the
feed end in suitable bearings.

DEPARTMENT OF MECHANICAL ENGINEERING

BORING TOOLS

iv. Boring Head:

It is more rigid boring tool holder and is used for roughing and finishing of large bore (100 to 500 mm).
Provision to offset cutting axially and radially exists. Two cutters can be mounted radially at 180° to
have balanced cutting.

v. Boring and Facing Heads:

This enables boring of large bores and facing of seating surfaces at right angles to the bore. Radial
tool feeding facility also exists.

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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 COMPUTER
INTEGRATED
MANUFACTURING
TECHNOLOGIES
3RD YEAR SEM-1 BTECH MECHANICAL ENGINEERING (R18A0312)

www.mrcet.ac.in
COURSE OBJECTIVES
UNIT - 1 CO1: Learn about geometry of metal cutting theory,
mechanism of chip formation and mechanism of
orthogonal cutting and merchants force diagram
UNIT - 2 CO2: Learn about ways to reduce the surface
roughness by using different machining process
UNIT - 3 CO3: To write APT and CNC programming concepts

UNIT - 4 CO4: Learn the concepts of DNC Systems and Post

Processors

UNIT - 5 CO5: To know about Computer aided process

planning and computer aided inspection and Quality
control

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT 3

COMPUTER AIDED
PROGRAMMING
CO3:.To write APT and CNC programming concepts

www.mrcet.ac.in
UNIT – III (SYLLABUS)

APT PROGRAMMING

• General Information
• Examples of Apt programming
• NC programming

CAD/CAM SYSTEMS
• Tooling
• Inter changeble tooling system

DEPARTMENT OF MECHANICAL ENGINEERING

COURSE OUTLINE

LECTU LECTURE TOPIC​ KEY ELEMENTS​ Learning Objectives​

RE​

1​ Computer aided Programming-Basics​ Concepts of CAP​ • Understanding various

programming languag
es and codes used for
manufacturing​

2​ APT Programming and examples​ Automatically • Write a program using

programmed tool​ APT and few examples
on drilling and milling​

3​ NC programming and examples​ Numerical control • Programs for drilling,

programming​ milling and cutting
using NC codes ie G
and M codes​

4​ Automatic tool path generation, CNC basics​ • Understanding tool

tooling for CNC,Interchangeable path and automated
tooling systems​ tool path generation​
• Tooling for CNC​

5​ Preset and Qualified tools, coolant fed Preset and Qualified • Understand the
tooling system, Modular featuring​ tools​ concepts of
coolants in CNC​
• Importance of preset
and Qualified tools​

6​ Quick change tooling system and Automatic head • Understanding the

automatic head changer​ changer​ automatic
tool changing
DEPARTMENT OF MECHANICAL ENGINEERING phenomenon​
LECTURE 1

www.mrcet.ac.in
TOPICS TO BE COVERED
LECTURE 1
• COMPUTER AIDED • COMPUTER AIDED
PROGRAMMING BASICS PROGRAMMING
BASICS

DEPARTMENT OF MECHANICAL ENGINEERING

COMPUTER AIDED PROGRAMMING

Computer-aided design (CAD) is the use of computers (or workstations) to aid in the creation, modification, analysis, or
optimization of a design.[1] CAD software is used to increase the productivity of the designer, improve the quality of design, improve
communications through documentation, and to create a database for manufacturing.[2] CAD output is often in the form of
electronic files for print, machining, or other manufacturing operations. The term CADD (for Computer Aided Design and Drafting) is
also used.[3]
Its use in designing electronic systems is known as electronic design automation (EDA). In mechanical design it is known as
mechanical design automation (MDA) or computer-aided drafting (CAD), which includes the process of creating a technical
drawing with the use of computer software.[4]
CAD software for mechanical design uses either vector-based graphics to depict the objects of traditional drafting, or may also
produce raster graphics showing the overall appearance of designed objects. However, it involves more than just shapes. As in the
manual drafting of technical and engineering drawings, the output of CAD must convey information, such as materials, processes,
dimensions, and tolerances, according to application-specific conventions.

DEPARTMENT OF MECHANICAL ENGINEERING

COMPUTER AIDED PROGRAMMING

CAD may be used to design curves and figures in two-dimensional (2D) space; or curves, surfaces, and solids in three-dimensional
(3D) space.[5]
CAD is an important industrial art extensively used in many applications, including automotive, shipbuilding, and aerospace
industries, industrial and architectural design, prosthetics, and many more. CAD is also widely used to produce computer animation
for special effects in movies, advertising and technical manuals, often called DCC digital content creation. The modern ubiquity and
power of computers means that even perfume bottles and shampoo dispensers are designed using techniques unheard of by
engineers of the 1960s. Because of its enormous economic importance, CAD has been a major driving force for research in
computational geometry, computer graphics (both hardware and software), and discrete differential geometry.[6]

DEPARTMENT OF MECHANICAL ENGINEERING

COMPPUTER AIDED PROGRAMMING

Computer Aided Manufacturing (CAM) is the use of software and computer-controlled

machinery to automate a manufacturing process.

Based on that definition, you need three components for a CAM system to function:

● Software that tells a machine how to make a product by generating toolpaths.

● Machinery that can turn raw material into a finished product.
● Post Processing that converts toolpaths into a language machines can understand.

These three components are glued together with tons of human labor and skill. As an industry we’ve
spent years building and refining the best manufacturing machinery around. Today, there’s no design
too tough for any capable machinist shop to handle.

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

www.mrcet.ac.in
LECTURE 2
Introduction - Resultants of Force System

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TOPICS TO BE COVERED
LECTURE 2
APT PROGRAMMING
• APT PROGRAMMING
• EXAMPLES

DEPARTMENT OF MECHANICAL ENGINEERING

INTRODUCTION TO APT

• APT is a form of text code that was invented in the 1950s and is used to control CNC cutting
tools.
• It programs the tools to cut complex parts, by creating the geometric points that create a path
that the tool must follow in order to make the correct cuts.
• It utilizes a purpose-built language to program these points and to determine the specifics of the
machine that will follow the path.

DEPARTMENT OF MECHANICAL ENGINEERING

APT

• APT (automatically programmed tools) is a form of coding that is used for CNC (computer

numerical control) tools.

• It was created in the 1950s at MIT by Douglas T. Ross and was partially funded by the U.S. Air

Force.

• It was designed specifically for use in aeronautics, to be able to accurately cut the complex

pieces needed for machinery.

• It creates the form that the tools must cut, by calculating all of the necessary geometric points.

The code itself is non-proprietary, but the compilers that translate the code into the target

language for the CNC tools are almost all proprietary.

DEPARTMENT OF MECHANICAL ENGINEERING

APT

• APT was created in response to the swift developments in CNC technology.

• It was impossible for individuals to be able to calculate the movements needed to create
complex parts – something that these new machines were capable of doing.
• The program helped to utilize these machines at their maximum potential, where human ability
was limited.
• APT takes English statements and uses a process to convert them into instructions for CNC
tools. These instructions are the code geometric points on a path for the tool to follow.
• These coordinates are also known as cutter location data (CLD).
• This information is then fed into a computer that controls the numerically controlled tool, which
then follows the set paths to create the appropriate cuts.

DEPARTMENT OF MECHANICAL ENGINEERING

APT

• When using APT, the programmer has two main tasks.

• Firstly, they must define the geometric points that will be used to create the tools’ path and

specify this path as well as the operational sequence (what order the cuts should be placed in).

The rest is done by the computer.

• Apt is seen as the predecessor to more commonly used forms of CAM (computer-aided

manufacturing). CAM is far more capable of using computer-assisted tools to accurately

manufacture pieces of machinery but was also initially created to provide services in the

aerospace industry.

DEPARTMENT OF MECHANICAL ENGINEERING

FEATURES OF APT

• One of the main features of APT is that it is completely text-based.

• It was created before the advent of graphic interfaces, therefore required a method of creating
complex toolpaths that was alternative to the one that is far more commonly used today.

• The text commands utilize English to specify the geometry and toolpaths needed to create the

cuts to form the machine part.

• The code language is comprised of over 400 different words, to create all of the possible unique

tool paths that are necessary.

DEPARTMENT OF MECHANICAL ENGINEERING

APT is comprised of four different types of statements

● Geometry statements/Definition statements – Used to determine the geometric

elements of the part, by defining the points and lines that the machine will follow. These

statements are characterized by up to six alpha-numeric characters (always at least one

alpha character), which is used to refer to a specific geometric feature. It can also be used

to define the size and location of the feature, in relation to other parts.

● Motion commands – These specify the direction of the tools’ movements that form the

path. FROM is always the code for the starting point, and GOTO and GODLA are the

commands used to continue on a tool path from point to point.

DEPARTMENT OF MECHANICAL ENGINEERING

APT is comprised of four different types of statements

● Postprocessor statements – The aspects of the code that control the capabilities of the
machine being used. This can include the speed of the tool (measured in revolutions per
minute), sizing (whether things are measured in inches or millimeters), the tolerance value
for circular interpolation (both inward and outward values), and the values pertaining to the
cutter itself (such as the diameter and length, but these calculations can also be done in
3d). It also determines what tool, and what specific controller should be used for each cut,
and this is the final postprocessor statement in a task. The tool can be defined by using up
to 7 different variables and comes with its own language to denote the various tool shapes,
including “bell end” and “chamfer”.

● Auxiliary statements – The statements that are grouped together to accomplish a certain
task. An ATP program begins with the code APTO, and ends with FINI – everything in
between these two phrases is part of a single part program.

DEPARTMENT OF MECHANICAL ENGINEERING

APT

APT for CNC tools are fully capable of utilizing 5-axis control, to create precise paths for the cutter to

follow anywhere in 3d space, at any angle. It is also capable of creating instructions for 3d surfacing

and 2.5d contouring.

It is very similar to other programming languages such as FORTRAN, which also converts statement

text into instructions for a computer to then follow. In the case of APT, the computer then feeds the

instructions specifically to CNC tools that perform cutting tasks.

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

www.mrcet.ac.in
LECTURE 3
Introduction - Resultants of Force System

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TOPICS TO BE COVERED
LECTURE 3

o NC PROGRAMMING NC PROGRAMMING

o EXAMPLES

DEPARTMENT OF MECHANICAL ENGINEERING

Numerical Control(NC) Part Programming Using CAD/CAM

• A CAD/CAM system is a computer interactive graphics system equipped with software is

accomplish certain tasks in design and manufacturing and to integrate the design and
manufacturing functions.
• A CAD/CAM system is a computer interactive graphics system equipped with software is accomplish
certain tasks in design and manufacturing and to integrate the design and manufacturing functions.
• In this method of part programming, portions of the procedure usually done by the part programmer
are instead done by the computer.
• Recall that the two main tasks of the part programmer in computer assisted programming are (1)
defining the part geometry and (2) specifying the tool path. Advanced CAD/CAM systems automate
portions of both of these tasks.

DEPARTMENT OF MECHANICAL ENGINEERING

Numerical Control(NC) Part Programming Using CAD/CAM

Geometry Definition Using CAD/CAM.

• A fundamental objective of CAD/CAM is to integrate the design engineering and
manufacturing engineering functions.
• Certainly one of the important design functions is to design the individual components of the
product.
• If a CAD/CAM system is used, a computer graphics model of each part is developed by the
designer and stored in the CAD/CAM database.
• That model contains all of the geometric, dimensional, and material specifications for the
part.

DEPARTMENT OF MECHANICAL ENGINEERING

Numerical Control(NC) Part Programming Using CAD/CAM

• When the same CAD/CAM system, or a CAM system that has access to the same CAD data
base in which the part model resides, is used to perform NC part programming, it makes little
sense to recreate the geometry of the part during the programming procedure.
• Instead, the programmer has the capability to retrieve the part geometry model from storage
and to use that model to construct the appropriate cutter path.
• The significant advantage of using CAD/CAM in this way is that it eliminates one of the
tirneconsurning steps in computerassisted part programming: geometry definition.
• After the part geometry has been retrieved, the usual procedure is to lahel the geometric
elements that will be used during part programming.
• These labels are the variable names (symbols) given to the lines, circJe~ and surfaces that
comprise the part. Most systems have the capacity to automatically label the geometry
clements of the part and to display tbe labels on the monitor. The programmer can then refer
to those labeled elements during tool path construction.

DEPARTMENT OF MECHANICAL ENGINEERING

G-Code: The CNC Programming Language

G-code was first established in the 1960s by the Electronics Industry Association (EIA). While
the official language was documented as RS-274D, you’ll hear everyone refer to it as G-code.
Why? Many of the words, or individual pieces of code, that make up this machine-based
language start with the letter G.

While G-code is supposed to be a universal standard, you’ll find that many CNC machine
companies have developed their own unique flavor. We’re all be eating ice cream at the end of
the day, but a Haas might be strawberry, and a Tormach chocolate. Because of this difference
in G-code flavors, it’s really important to understand how your own machine uses G-code

DEPARTMENT OF MECHANICAL ENGINEERING

G-Code: The CNC Programming Language

Why the difference in G-code flavors? It really comes down to the capabilities of each machine.
Take one machine that can process a coordinate system rotation based on probe inputs. You’ll
need a set of G-code commands that can enable or disable this rotation. Another machine
without this adjustment capability won’t require that G-code.

When in doubt, always refer to the documentation of your CNC machine as you work through
the rest of this article. We’ll be walking through the basics, but you never know if your machine
might have taken a slightly different path to the same end destination.

DEPARTMENT OF MECHANICAL ENGINEERING

G-Code Blocks

The G-code standard was published back in the days when machines had small amounts of memory.
Because of this memory limitation, G-code is an extremely compact and concise language that might almost
seem archaic at first glance. Take for example this line of code:

G01 X1 Y1 F20 T01 M03 S500

In this single line we’re giving the machine a series of instructions:

● G01 – Perform a linear feed move

● X1/Y1 – Move to these X and Y coordinates
● F20 – Move at a feed rate of 20
● T01 – Use Tool 1 to get the job done
● M03 – Turn the spindle on
● S500 – Set a spindle speed of 500

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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LECTURE 4

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TOPICS TO BE COVERED
LECTURE 4

o AUTOMATIC TOOL PATH TOOL PATH GENERATION

GENERATION
o TOOLING FOR CNC

DEPARTMENT OF MECHANICAL ENGINEERING

AUTOMATED TOOL PATH GENERATION

• The first step in specifying the tool path is La select the cutting tool for the operation. Most
CADICAM systems have tool libraries that can be called by the programmer to identify what
tools arc available in the tool crib.
• The programmer must decide which of the available tools is must appropriate for the
operation under consideration and specify it for the tool path.
• This permits the tool diameter and other dimensions to be entered automatically for tool
offset calculations.
• If the desired cutting tool is not available in the library, an appropriate tool can be specified by
rhc programmer. It then becomes part of the library for future use

DEPARTMENT OF MECHANICAL ENGINEERING

AUTOMATED TOOL PATH GENERATION

• The next step is tool path definition.

• There are differences in capabilities of the various CAD/CAM systems, which result in
different approaches for generating the tool path.
• The most basic approach involves the use of the interactive graphics system to enter the
motion commands One by one.
• Simiilar to computer assisted part programming.
• Individual statements in APT or other part programming language are entered. and the
CAD/CAM system provides an immediate graphic display of the action resulting from the
command. thereby validating the statement.

DEPARTMENT OF MECHANICAL ENGINEERING

AUTOMATED TOOL PATH GENERATION

• A moreadvanced approach for generating tool path commands is to use one of the automatic
software modules available on the CAD/CAM system.
• These modules have been developed to accomplish a number of common machining cycles for
milling, drilling, and turning. They are subroutines in the NC programming package that can be
called and the required parameters given to execute the machining cycle.
• When the complete part program has been prepared, the CAD/CAM system can provide an
animated simulation of the program for validation purposes.
• Computer Automated Part Programming. In the CAD/CAM approach to NC part programming,
several aspects of the procedure are automated.
• In the future, it should be possible to automate the complete NC part programming procedure. We
are referring to this fully automated procedure as computer automated part programming.
• Given the geometric model of a part that has been defined during product design, the computer
automated system would possess sufficient logic and decision making capability to accomplish NC
part programming for the entire part without human assistance.

DEPARTMENT OF MECHANICAL ENGINEERING

Tool path generation

• This can most readily be done for certain NC processes that involve well defined, relatively
simple part geometries. Examples are point to point operations such as NC drilling and
electronic component assembly machines.
• In these processes, the program consists basically of a series of locations in an xy
coordinate system where work is to be performed [e.g .. holes arc to be drilled or components
are to be inserted).
• These locations are determined by data that are generated during product design. Special
algorithms can be developed to process the design data and generate the NC program for
the particular system. "fe contounag systems will eventually be capable at a similar level of
automation. Automatic programming of this type is closely related to computer-automated
process planning (CAPP), discussed in later pages.

DEPARTMENT OF MECHANICAL ENGINEERING

Nc modules

DEPARTMENT OF MECHANICAL ENGINEERING

Machining in nc

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

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LECTURE-5

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TOPICS TO BE COVERED
LECTURE-5

o Preset tools and qualified Preset and qualified tools

tools
o Coolant fed systems

DEPARTMENT OF MECHANICAL ENGINEERING

Preset and qualified tools

• Ideally, tooling should attach to a machine like the bayonet on the end of a rifle -- quick, sure, and precise.
Preset, quick-change, and adjustable tooling can achieve this ideal to a greater or lesserextent, depending
on the specific application. Use of this tooling can result in cost savings through such things as:
● Reduced labor hours
● Increased machine hours available for production
● Reduced skill and training requirements for shop people
● Improved quality
● Reduced operator error
● Reduced scrap

DEPARTMENT OF MECHANICAL ENGINEERING

Preset Tooling

• The key attribute of preset tooling is that its location in the machine is known with a high degree of precision.
Once such a tool has been attached to a machine, it will produce the desired predetermined dimension
without adjustment.
• Presetting is done off the machine, and requires that tools have a means of adjustment. In addition, the
method of attaching them to the machine must be repeatable and highly accurate.
• Presetting is often employed on end-working tools, but can also be used for cross-working applications.
• Preset tooling saves time during setup, as well as when tools are changed during the job’s run, by reducing
or eliminating test cuts, measurements, and adjustments.
• On screw machines in particular, where the “brass hammer method” is often used, these adjustments require
either substantial skill or substantial time.
• The amount of time saved through the use of this tooling has to be balanced against the time required for
presetting

DEPARTMENT OF MECHANICAL ENGINEERING

Preset tooling

• However, even if there is no apparent reduction in labor hours, there will be an increase in the number of
hours available for production on the machine.
• This is because presetting is part of “external” setup or operating time. That is, it can be done while the
machine continues to make pieces.
• Whether the benefits of this type of tooling come in the form of reduced labor or increased uptime, they may
be most significant on newer, more expensive, advanced technology machines which carry a higher machine
hour rate.
• In this report, preset tooling has been handled separately from “quick-change,” which has been handled
separately from “adjustable,” etc.
• The purpose of this is to be clear about exactly which benefits are inherent in each type of tooling. However,
in actual practice these types are commonly combined, with examples such as “preset, quick-change
tooling,” or “quick-change, adjustable tooling” coming to mind.

DEPARTMENT OF MECHANICAL ENGINEERING

Preset tooling

• There is a question regarding the feasibility of this tooling on some cam machines, since the end points of
tool slides are not necessarily predictable on a given job, or repeatable from one run to the next.
• In some cases this is due to small differences between “identical” cams which are used interchangeably. In
addition, on single spindle machines the high and low points on the lead cam may not be exact, although
some presetting systems can correct for this.
• These problems can be overcome by purchasing new cams to closer tolerances; but for the shop with a
large inventory of existing cams, this may not be cost effective.
• Another option is to provide a means of making a graduated fine adjustment on the machine, either with an
adjustable tool holder or with an integral adjustable slide, although this will reduce the benefits of this tooling
somewhat.

DEPARTMENT OF MECHANICAL ENGINEERING

Pre gaged tooling

• Pre-gaged tooling is a variation of preset tooling, but lacks its ability to be adjusted off the machine. It is
made to close tolerances with only small differences between “identical” tools.
• Prior to being set up, this type of tool is gaged and variations from its nominal dimensions are noted.
• Generally it is used on CNC machines, and adjustments for these variations are handled by the tool
compensation offsets, in many cases without the need for trial cuts and subsequent adjustments.
• While not common, this concept can be applied on cam machines as long as there is a way to make
graduated fine adjustments, either within the tool holder system, or on the machine itself.

DEPARTMENT OF MECHANICAL ENGINEERING

Qualified tooling

• Qualified tooling is another variation of preset tooling.

• All of the components that comprise a qualified tool are made to close tolerances; and because of this, it will
cut very near to the desired dimension.
• One of the most common types is the carbide insert/insert tool holder combination. Installed in the machine,
any combination of “identical” inserts and tool holders will generally be located within ?.005” of their nominal
dimension.
• Like the pre-gaged type above, this tooling is not adjustable; and there must be a way on the machine to
compensate for these small variations, following a trial cut and measurement.

DEPARTMENT OF MECHANICAL ENGINEERING

QUICK CHANGING TOOLS

• The primary characteristic of quick-change tooling is the ease, speed, and convenience it provides in terms
of removal and replacement.
• In addition, it generally fastens to the machine in a repeatable fashion. The very fact that it is quick acting
allows this tooling to save time both during setup, and when it needs to be changed during a run.
• Unlike quick-change collets, most quick-change tooling can also be preset, pre-gaged, adjusted, etc. With
this combination of qualities it is possible to exchange a new or “renewed” tool with one that needs
sharpening, and have the machine producing again in a moment or two.
• In some instances it may even make sense to replace a slightly worn tool in this way, rather than taking time
from production for a trial-and-error, on-machine adjustment.

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

www.mrcet.ac.in
COMPUTER INTREGRATED
MANUFACTURING
TECHNOLOGIES (R18A0312)

3rd Year B. Tech I- sem, Mechanical Engineering

www.mrcet.ac.in
 UNIT 4

DNC SYSTEMS AND ADAPTIVE CONTROL

CO4: To understand APT & CNC Programming Concepts

www.mrcet.ac.in
PROBLEMS WITH CONVENTIONAL NC

o Part programming mistakes

o Nonoptimal speeds and
feeds
o Punched tape
o Tape reader
o Controller
o Management information

DEPARTMENT OF MECHANICAL ENGINEERING

COMPUTER NUMERICAL CONTROL

o Conventional hard- wired NC

controller unit replaced by computer.
o NC system that utilizes stored programs
in a dedicated computer to perform some
or all NC functions
o Soft-wired
o Flexibility

DEPARTMENT OF MECHANICAL ENGINEERING

CNC

DEPARTMENT OF MECHANICAL ENGINEERING

FUNCTIONS OF CNC

Machine tool control

o Hybrid CNC –Hard-wired logic circuits for
functions like feed rate generation , circular
interpolation etc. in addition to computer
mass production of circuits and less
expensive computer
o Straight CNC – Computer to perform all NC
functions

DEPARTMENT OF MECHANICAL ENGINEERING

HYBRID CNC

DEPARTMENT OF MECHANICAL ENGINEERING

STRAIGHT CNC

DEPARTMENT OF MECHANICAL ENGINEERING

 FUNCTIONS OF CNC

In-process compensation –
Dynamic correction of machine tool motion for
changes or errors that occur during processing
o Adjustment of errors sensed by in-process inspection
o probes and gauges
o Recomputation of axis positions when an inspection
probe is used to locate a datum reference on the
work part
o Offset adjustments for tool radius and length
o Adaptive control adjustments to sped and feed
o Computation of predicted tool life and selection
of alternate tooling when indicated.

DEPARTMENT OF MECHANICAL ENGINEERING

FUNCTIONS OF CNC

Improved programming and operating features

o Use of tape and tape reader only once
o On-line editing of part programs at the machine
o Special canned cycles.
o Graphic display of tool path to verify the tape
o Various types of interpolation: circular, parabolic, cubic
o Support of various units. Conversion from one unit to another
unit.
o Use of specially written subroutines or macros
o Manual data input (MDI)
o Several part programs in bulk can be stored.

DEPARTMENT OF MECHANICAL ENGINEERING

FUNCTIONS OF CNC

Diagnostics – Equipped with diagnostic

capability to assist in maintaining and
repairing the system
o Identification of reason for downtime
o Indication of imminent failure of certain
component
o Redundancy of components

DEPARTMENT OF MECHANICAL ENGINEERING

DIRECT NUMERICAL CONTROL
o A manufacturing system in which no. of machines
are controlled by a computer through direct
connection and in real time.

DEPARTMENT OF MECHANICAL ENGINEERING

DNC WITH SATELLITE COMPUTER

DEPARTMENT OF MECHANICAL ENGINEERING

DNC – DRIP FEEDING

Very complex part shapes 🡺 very large NC

program
NC controller memory may not handle HUGE part program

computer feeds few blocks of

NC program to controller

When almost all blocks executed,

controller requests more blocks

DEPARTMENT OF MECHANICAL ENGINEERING

BEHIND THE TAPE READER (BTR)

o Computer is linked directly

to regular NC controller unit
o The connection is made
behind the tape reader
o Two temporary
storage buffers
o Less cost

DEPARTMENT OF MECHANICAL ENGINEERING

SPECIAL MACHINE CONTROL UNIT

o Regular NC controller is
o replaced by special MCU
o More accuracy in circular
interpolation and fast
material removal rates than
BTR systems
o Most CNC machines are
sold with computer

DEPARTMENT OF MECHANICAL ENGINEERING

NC, CNC AND DNC

DEPARTMENT OF MECHANICAL ENGINEERING

FUNCTIONS OF DNC
o NC without punched tape
o NC part program storage
o Programs must be made available for downloading to CNC machine tools
o Part program can be uploaded after editing from CNC machine
o Entry of new programs. Editing of programs , deletion of programs
o Tool management
o Tool offsets can be downloaded in to MCU
o Postprocessor
o Data processing and management functions
o Primary storage and secondary storage
o Syntax checking and graphic proving of programs on CNC computer
o CNC can be operated directly from DNC computer
o Flexibility in shop floor scheduling
o Part program preparation
o Machinability database for calculating speed/feed

DEPARTMENT OF MECHANICAL ENGINEERING

FUNCTIONS OF DNC
o Data collection, Processing and reporting
o Monitor production in the factory
o Data processing and report generation by DNC computer
o Getting the data about health of the machine in the form of
sensor signals or diagnostic messages which can be used for
preventive/predictive maintenance
o Metrological data in the form of dimensional acceptance
o Communications
o Central computer and machine tools
o Central computer and NC part programmer terminals
o Central computer and bulk memory, which stores the NC
o programs
o CAD system
o Shop floor control system
o Corporate data processing
o Remote maintenance diagnostics system
DEPARTMENT OF MECHANICAL ENGINEERING
JUSTIFICATION OF DNC
o Interconnected CNC machines are large in
number
o Very large program size. Can not be
accommodated in the part program
memory of MCU
o Large variety of part programs and small
batch sizes
o Frequent changes in program designs

DEPARTMENT OF MECHANICAL ENGINEERING

 ADVANTAGES OF DNC
o Elimination of punched tape and tape reader
o Greater computational capability and flexibility
o Convenient storage of NC part programs in computer
files
o Programs stored as CLFILE
o Reporting of shop performance
o Establishes the framework for evolution of future
computer automated factory (CIM)
o 2-5 % increase in operational efficiency of CNC
machine tools. Cost of DNC installation can be
recovered quickly.

DEPARTMENT OF MECHANICAL ENGINEERING

COMBINED CNC/DNC SYSTEMS

o Development of hierarchical computer systems in

o manufacturing
o Flexibility
o Ability to gradually build the system
o More versatile and economic approach
o Distributed Numerical System
o Part program downloaded only once
o Redundancy
o Improved communication between central computer and
shop floor

DEPARTMENT OF MECHANICAL ENGINEERING

ADAPTIVE CONTROL
o A control system that measures certain output process
variables like spindle deflection, force, torgue, cutting
temperature, vibration amplitude, horse power and
uses them to control speed or feed
o NC reduces non productive time in a
machining operation
o AC determines proper speeds and feeds during
machining as a function of variation in work
piece hardness, width or depth of cut, air gaps in
part geometry etc.
o Increased metal removal rate and reduced cost
per volume of metal removed

DEPARTMENT OF MECHANICAL ENGINEERING

WHERE TO USE ADAPTIVE CONTROL?

o In-process time consumes significant

portion of the machining cycle time. (>40%)
o Significant sources of variability in the job
o Higher cost of operation of machine tool
o Work material – steel, titanium, high
strengh alloys

DEPARTMENT OF MECHANICAL ENGINEERING

SOURCES OF VARIABILITY IN MACHINING

o Variable depth/width of cut

o Variable workpiece hardness and variable machinability
o Variable workpiece rigidity
o Toolwear
o Air gaps during cutting

DEPARTMENT OF MECHANICAL ENGINEERING

ADAPTIVE CONTROL OPTIMIZATION (ACO)

o Index of performance is a measure of overall process

performance such as production rate or cost per
volume of metal removed.
o Objective is to optimize the index of performance by
manipulating speed or feed in the operation
o IP = MRR/TWR
MRR – Material removal rate
TWR – Tool wear rate
o Sensors for measuring IP not available

DEPARTMENT OF MECHANICAL ENGINEERING

ADAPTIVE CONTROL CONSTRAINT (ACC)

o Nearly all AC systems is of this type

o Less sophisticated and less expensive
than research ACO systems
o Objective is to manipulate speed or feel so that
measured process variables are maintained at
or below their constraint limit values.

DEPARTMENT OF MECHANICAL ENGINEERING

OPERATION OF ACC SYSTEM

o Profile or contour milling on NC machine tool

o Feed is controlled variable
o Cutter force and horsepower are used as measured
variables
o Hardware components
o Sensors mounted on the spindle to measure cutter
force
o Sensors to measure spindle motor current
o Control unit and display panel to operate the system
o Interface hardware to connect the AC system to
existing NC/CNC system

DEPARTMENT OF MECHANICAL ENGINEERING

RELATIONSHIP OF AC SOFTWARE TO APT PROGRAM

DEPARTMENT OF MECHANICAL ENGINEERING

OPERATION OF ACC SYSTEM DURING MACHINING
PROCESS

DEPARTMENT OF MECHANICAL ENGINEERING

BENEFITS OF AC
o Increased production rate
o Increased tool life
o Greater part protection
o Increases machine life
o Less operator intervention
o Easier part programming

DEPARTMENT OF MECHANICAL ENGINEERING

WHAT IS A CNC POST PROCESSOR?

• Say you are going to manufacture a part on a mill, lathe or multi-

axis machining center. To do this, you create the tool paths in
your CAM system, and then you “post it.” That means you send the
instructions for making your part to the post processor, an
intermediary piece of software that translates the tool motions
calculated by your CAM software into NC code that can be
executed by your particular machine.

DEPARTMENT OF MECHANICAL ENGINEERING

CONT…

• A good post is also capable of “flavoring” this information in ways

that best suit your shop’s workflow, data handling procedures, and
most importantly, the requirements of your machine tool and
control. For example, your control will expect information such as
work offsets, tool offsets and canned cycles to be formatted and
presented in a specific way. Examples of machine shop-specific
customization might include your standards for safety blocks or
required comments. The post can also generate additional outputs
such as alarms or signals to equipment performing secondary
operations. Some posts can be programmed to deliver functionality
beyond what is currently available in your CAD system.

DEPARTMENT OF MECHANICAL ENGINEERING

OPEN VS. CLOSED POST PROCESSORS

• CAM vendors offer post processors that are either open or closed.
Closed post processors allow no one but authorized parties (that
is, the post vendor) to customize the post. Open post processors
have an architecture that allows anyone—vendors, resellers and
customers—to make modifications to customize the post
processor’s behavior.
• The benefit of the closed approach lies in its simplicity and safety.
Users get what they pay for, and ideally, the CAM software will
give them everything they need in functionality and performance. If
not, the vendor will create customizations for a fee.

DEPARTMENT OF MECHANICAL ENGINEERING

CONT…

• Open post processors give their users more options to make this
software fit their preferences and requirements. Today, there is a large
community of experts who know how to develop post customizations,
and they share their knowledge with each other. Open post processors
provide their own layer of safety, too. Because extensive modifications
can be made entirely outside the main CAM program routines, it is less
likely that a user’s CAM software code might be corrupted by poorly
developed customizations.
• The ready availability of customization expertise means that resellers
and users can be more involved in flavoring the post so that the user’s
preferences are realized sooner. In addition, users with the right
expertise can continue to make modifications as needed so that the
post’s contribution to quality and productivity may increase substantially
over the years.
• As a software engineer deeply involved in the development of open post
processors, I will keep my observations mainly to that arena.

DEPARTMENT OF MECHANICAL ENGINEERING

VARIETY OF POST PROCESSOR USERS

• The first customers for new posts are the machine tool builders. When a new
machine tool is being developed, leading CAM software developers work
closely with the machine builder and controller suppliers to develop an initial
“generic” post that satisfies a majority of output requirements for the new
machine tool. The typical CAM software developer is likely to have
relationships with many machine tool vendors. These relationships enable the
software developer to create and test posts on new machine tools. Mastercam,
for example, works with nearly a hundred machine tool companies.
• These generic posts can be used as written, with little (if any) customization, to
put the new machine tools through initial testing by shops that are early
adopters. There has to be enough functionality in the generic post so that the
new users can operate the equipment productively. However, flavoring of the
post should be kept to a minimum at this point. Otherwise, some customers
may be satisfied, while others may find the post totally contrary to the way they
structure their CNC manufacturing workflow. This approach enables the final
configuration to be tailored closely to the specific needs of each end user.

DEPARTMENT OF MECHANICAL ENGINEERING

CONT…

• End users generally fall into one of three categories. A great many will
find that the generic post (with or without some minor modifications by
the reseller) meets their needs. Others will need some specific
customization, which could be minimal or extensive. In most cases, the
cost of customization will only be a small fraction of what it would take to
develop a completely custom post, because a generic version that
already covers all or most of the end user’s requirements is likely to be
the starting point.
• The third type of end user includes CNC programmers and machine
operators who have learned to go into the post and change lines of code
to change its functionality. For example, most machinists who need to
make a minor variation on a part that has already been programmed will
simply modify the G and M code at the machine. However, if such part
variations are made frequently, then it is far more efficient to edit the
post processor to generate the code automatically by prompting for
some dimensional variables.

DEPARTMENT OF MECHANICAL ENGINEERING

FUNCTIONALITY OF POST PROCESSORS

• Additional functionality for their equipment even when the desired routines are
not supported in the CAM system itself, as these two examples show:
• Canned Pocket Cycles: Many CAM packages have canned drilling cycles but
few have canned pocketing. This is not a problem if you have an open post.
You can customize the post to take data from a CAM drilling cycle and
output a canned pocket routine instead.

• Programming Robots: Although Mastercam does not support robots, enough

data is available in the CAD file to drive one. The developers of RobotMaster
(Jabez Technologies Inc.) grasped this fact and used the Mastercam post
processor to create a specialized module to drive a wide variety of six-axis
robots. Robot trajectories are programmed graphically within
the CAM package. Then the RobotMaster module uses the CAM software’s
machine definitions to define the outputs for particular robots.
• The lesson here is simple: If the requisite data is in the CAD file, you can use a
good CAM system and an open post processor to program a CNC machine to
its full capability.

DEPARTMENT OF MECHANICAL ENGINEERING

THANK YOU

www.mrcet.ac.in
 UNIT 5

COMPUTER – AIDED PROCESS PLANNING (CAPP)

CO3: To understand about tooling of CNC machines

www.mrcet.ac.in
WHAT IS CAPP

DEPARTMENT OF MECHANICAL ENGINEERING

PROCESS PLAN

DEPARTMENT OF MECHANICAL ENGINEERING

PROCESS PLANNING

DEPARTMENT OF MECHANICAL ENGINEERING

BASIC PROCESS IN DEVELOPING A PROCESS PLAN

DEPARTMENT OF MECHANICAL ENGINEERING

PROCESS PLANNING APPROACHES

• Manual Systems
• Computer Aids
– Variant System
– Experimental Generative System

DEPARTMENT OF MECHANICAL ENGINEERING

MANUALLY PREPARED PROCESS PLANS

DEPARTMENT OF MECHANICAL ENGINEERING

COMPUTER AIDS

DEPARTMENT OF MECHANICAL ENGINEERING

VARIANT (RETRIEVAL) CAPP METHODOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

VARIANT CAPP

DEPARTMENT OF MECHANICAL ENGINEERING

VARIANT CAPP

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING
VARIANT CAPP

DEPARTMENT OF MECHANICAL ENGINEERING

GENERATIVE CAPP METHODOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

KNOWLEDGE BASED PROCESS PLANNING

DEPARTMENT OF MECHANICAL ENGINEERING

DECISION TABLES
• A table of rows and columns, separated into four quadrants
– Conditions
– Condition alternatives
– Actions to be taken
– Rules for executing the actions

DEPARTMENT OF MECHANICAL ENGINEERING

FIGURE BELOW IS THE STANDARD FORMAT USED FOR
PRESENTING A DECISION TABLE

DEPARTMENT OF MECHANICAL ENGINEERING

DEVELOPING DECISION TABLES

• Determine conditions that affect the decision

• Determine possible actions that can be taken
• Determine condition alternatives for each condition
• Calculate the maximum number of columns in the
decision table
• Fill in the condition alternatives
• Complete table by inserting an X where rules suggest
actions
• Combine rules where it is apparent
• Check for impossible situations
• Rearrange to make more understandable

DEPARTMENT OF MECHANICAL ENGINEERING

FIGURE BELOW CONSTRUCTING A DECISION TABLE FOR DECIDING
WHICH CATALOG TO SEND TO CUSTOMERS WHO ORDER ONLY
FROM SELECTED CATALOGS

DEPARTMENT OF MECHANICAL ENGINEERING

CHECKING FOR COMPLETENESS AND
ACCURACY
• Four main problems
– Incompleteness
– Impossible situations
– Contradictions
– Redundancy

DEPARTMENT OF MECHANICAL ENGINEERING

CHECKING THE DECISION TABLE FOR INADVERTENT
CONTRADICTIONS AND REDUNDANCY IS IMPORTANT

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING
TYPES OF DECISION TABLE

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
THANK YOU

www.mrcet.ac.in