MANUFACTURING TECHNOLOGY-2

1.Cutting Speed (C.S): The speed at which the

cutting edge of the tool moves relative to the
workpiece, usually measured in meters per
minute (m/min) .
2.RPM (n): The number of revolutions the
spindle or workpiece makes per minute,
measured in revolutions per minute (RPM).
3. Feed Rate: The distance the cutting
tool advances per revolution of the
workpiece.
4. Turning Time: The total time required
to complete a turning operation.
5. Length of Cut: The total length the
tool travels while cutting.
6. Number of Cuts: The total passes the
tool makes to achieve the desired
dimension.
Turning operations in a lathe include:
1. Straight Turning – Reducing the
diameter along the workpiece length.
 2. Taper Turning – Producing a conical
shape by gradually changing the diameter.
3. Step Turning – Creating different
diameters in steps along the length.
4. Facing – Cutting the end of the
workpiece to make it flat.
5. Grooving – Cutting a narrow groove
on the workpiece.
6. Parting-off – Cutting through the
workpiece to separate it.
7. Thread Cutting – Producing external
or internal threads.
8. Knurling – Creating textured patterns
for better grip.
9. Boring – Enlarging an existing hole.
10. Chamfering – Beveling the edges for
smoothness.
Types of lathe machines:
1. Engine Lathe – Most common,
manually operated.
2. Turret Lathe – Used for mass
production with a turret tool holder.
3. Capstan Lathe – Similar to a turret
lathe but smaller and lighter.
 4. Bench Lathe – Small, used for
precision work in workshops.
5. Toolroom Lathe – High-precision
lathe for fine work.
6. CNC Lathe – Computer-controlled for
automation and precision.
7. Speed Lathe – High-speed, used for
polishing and woodturning.
8. Automatic Lathe – Fully automated
for high-volume production.
9. Special Purpose Lathe – Designed for
specific tasks like wheel lathes or
crankshaft lathes.
10. Vertical Lathe – Used for large and
heavy workpieces in a vertical position.
UNIT-2
Drilling and Milling
 Drilling is the process of creating round
holes in a material using a rotating cutting
tool.
 Milling is a machining process where a
rotating cutter removes material from a
 workpiece to create shapes, slots, or
profiles.
Drilling Tools
 Twist Drill – Most common, used for
general drilling.
 Center Drill – Used for centering holes
before further machining.
 Step Drill – For drilling different-sized
holes with a single tool.
 Countersink Drill – Used for chamfering
holes.
 Reamer – For finishing and sizing drilled
holes.
Drilling Machines
 Bench Drill – Small machine for light-
duty drilling.
 Pillar Drill – Heavy-duty machine with a
vertical column.
 Radial Drill – Large machine with an
adjustable drilling head.
 Gang Drill – Multiple spindles for high-
volume drilling.
  CNC Drill – Computer-controlled for
precision drilling.
Fundamentals of Milling
 Uses a rotating cutter to remove material
from a workpiece.
 Can produce flat, curved, slotted, or
contoured surfaces.
 Involves up milling (conventional) and
down milling (climb).
Types of Milling Operations
 Plain Milling – Flat surface machining.
 Face Milling – Producing flat surfaces
using a facing cutter.
 Angular Milling – Cutting at an angle to
the surface.
 Form Milling – Creating complex shapes
with special cutters.
 Slot Milling – Producing slots or grooves.
 Gear Milling – Creating gears using form
cutters or hobbers.
Milling Machines
  Column & Knee Type – Common, with
vertical and horizontal movement.
 Universal Milling Machine – Versatile
with adjustable table.
 Horizontal Milling Machine – Cutter is
mounted horizontally.
 Vertical Milling Machine – Cutter is
mounted vertically.
 CNC Milling Machine – Computer-
controlled for precision.
Work Holding Devices
 Vice – Holds the workpiece firmly.
 Clamps – Used for irregular workpieces.
 Rotary Table – For precise angular
movement.
 Collet – Holds cylindrical workpieces.
 Chuck – Used for holding round parts.
Gear Hobbing
 A machining process for gear cutting using
a rotating hob.
 Produces gears with high accuracy and
efficiency.
Types of Hobs
 Single-thread hob – One cutting edge per
revolution.
 Multi-thread hob – Multiple cutting
edges for faster production.
 Straight hob – Straight tooth profile.
 Helical hob – Used for helical gears.
 Serrated hob – Produces worm gears.
Machining Parameters
 Cutting Speed – Speed of the cutting tool
in meters/min.
 Feed Rate – Distance the tool advances
per revolution.
 Depth of Cut – The thickness of material
removed per pass.
 Coolant – Used to reduce heat and wear.
UNIT-3
Introduction to Forming Process
Forming is a manufacturing process in which
material, usually metal, is reshaped without
adding or removing material. It is achieved
through plastic deformation under the
influence of external forces such as
compressive, tensile, or shear forces.
Principles of Metal Forming
 Plastic Deformation: The material is
deformed beyond its elastic limit but
without breaking.
 Flow Stress: The stress required to sustain
plastic deformation.
 Friction and Lubrication: Essential to
control material flow and reduce tool wear.
 Temperature Influence: Forming can be
done in hot, warm, or cold conditions,
affecting material properties.
Types of Forming Processes
1. Bulk Forming: Processes involving
large plastic deformation (e.g., forging,
rolling, extrusion, drawing).
2. Sheet Metal Forming: Processes that
shape thin sheets without altering
thickness significantly (e.g., bending,
stamping).
Sheet Metal Forming Processes
 1. Bending: A sheet is deformed along a
straight axis to a required angle.
2. Shearing: Cutting of sheet metal along
a straight line using shear forces.
3. Stretch Forming: The sheet is
stretched and shaped using a die.
4. Spinning: A sheet is rotated and
formed into axisymmetric shapes.
5. Stamping: A combination of
processes like punching, embossing, and
blanking to create detailed shapes.
Applications of Forming Process
 Automotive (body panels, chassis
components)
 Aerospace (aircraft skin panels, structural
components)
 Construction (roofing sheets, metal doors)
 Electronics (heat sinks, enclosures)
 Packaging (metal cans, containers)
Tooling and Equipment
 Dies: Shaping tools that define the final
form of the product.
  Punches: Apply force to deform the
material into the die cavity.
 Forming Presses: Machines (mechanical,
hydraulic, pneumatic) used to apply force
for forming operations.
UNIT-4
Introduction & Classification of Advanced
Manufacturing Processes
Advanced Manufacturing Processes (AMP)
involve modern techniques that enhance
precision, efficiency, and material utilization
in production. These processes often use non-
conventional energy sources such as
mechanical, thermal, electrical, or chemical
energy for material removal or shaping.
Classification of Advanced Manufacturing
Processes:
1. Mechanical Energy-Based
Processes: AJM (Abrasive Jet
Machining), USM (Ultrasonic Machining)
 2. Thermal Energy-Based Processes:
EDM (Electrical Discharge Machining),
LBM (Laser Beam Machining)
3. Chemical & Electrochemical
Processes: ECM (Electrochemical
Machining), CHM (Chemical Machining)
4. Additive Manufacturing Processes:
3D Printing, Selective Laser Sintering
(SLS), Fused Deposition Modeling (FDM)
AJM (Abrasive Jet Machining)
 Uses a high-velocity stream of abrasive
particles mixed with air to remove
material.
 Suitable for brittle and heat-sensitive
materials.
 Applications: Micro-drilling, cutting,
deburring, and cleaning.
USM (Ultrasonic Machining)
 Uses ultrasonic vibrations with an abrasive
slurry to remove material.
 Best for hard and brittle materials like
ceramics and glass.
  Applications: Precision machining of non-
conductive materials.
EDM (Electrical Discharge Machining)
 Uses electrical sparks to erode material
from the workpiece.
 Works on electrically conductive
materials.
 Applications: Die making, intricate hole
drilling, and aerospace components.
LBM (Laser Beam Machining)
 Uses a high-energy laser beam to remove
material through melting and vaporization.
 Suitable for cutting, welding, and
engraving.
 Applications: Aerospace, electronics, and
medical devices.
Additive Manufacturing Processes
 Involves layer-by-layer material deposition
to create a 3D object.
 Types: Stereolithography (SLA), FDM,
Selective Laser Sintering (SLS).
  Used for prototyping, rapid manufacturing,
and complex geometries.
Introduction to 3D Printing
 A subset of additive manufacturing that
builds objects by adding material in layers.
 Common materials: Plastics, metals,
ceramics, and composites.
 Methods: FDM, SLA, and SLS.
Applications of Advanced Manufacturing
 Aerospace: Lightweight and high-
precision components.
 Automotive: Rapid prototyping and
customized parts.
 Medical: Implants, prosthetics, and
surgical tools.
 Electronics: Micro-components, PCB
fabrication.
 Defense: Advanced weapon systems,
drones.
UNIT-5
Overview of CNC (Computer Numerical
Control)
CNC (Computer Numerical Control) is an
advanced manufacturing technology where
pre-programmed computer software controls
machining tools and processes. It enables
precise, automated, and efficient production of
complex parts with minimal human
intervention.
Basic Concepts of CNC
 G-Code & M-Code: Programming
languages for CNC operations.
 Axis Movements: Defined by X, Y, and Z
coordinates for precise machining.
 Closed-Loop & Open-Loop Systems:
Feedback mechanisms to control
positioning accuracy.
 Automation & Repeatability: Ensures
consistent quality and efficiency in mass
production.
CNC Milling Machines
 Uses rotary cutting tools to remove
material.
 Capable of multi-axis machining (3-axis,
4-axis, 5-axis).
  Used for contouring, slotting, drilling, and
complex part fabrication.
CNC Lathes/Turning Centers
 Rotates the workpiece while a stationary
cutting tool removes material.
 Used for cylindrical parts like shafts, bolts,
and threaded components.
 Can include live tooling for milling,
drilling, and tapping operations.
Coordinate Systems in CNC
 Cartesian Coordinate System (X, Y, Z):
Defines tool movement in 3D space.
 Machine Zero & Work Zero: Reference
points for precise positioning.
 Incremental vs. Absolute Positioning:
Determines movement references based on
previous points or fixed coordinates.
Applications of CNC Machines
 Automotive: Engine components, gears,
and chassis parts.
 Aerospace: Turbine blades, structural
frames, and landing gear.
  Medical: Surgical tools, implants, and
prosthetics.
 Electronics: Circuit board drilling and
micro-component fabrication.
 Defense: High-precision weaponry and
military equipment.
CNC Operation and Setup
 Workpiece and Tool Setup: Proper
clamping and alignment.
 Tool Calibration: Ensuring correct tool
offsets and lengths.
 Program Execution: Loading and
verifying CNC programs.
 Quality Control: Inspection of machined
parts for accuracy.
 Maintenance: Regular cleaning,
lubrication, and software updates.