Me 2252 - Manufacturing Technology - Ii II Year Mechanical Engg. B-Sec Notes On Lesson Unit - I: Theory of Metal Cutting
Me 2252 - Manufacturing Technology - Ii II Year Mechanical Engg. B-Sec Notes On Lesson Unit - I: Theory of Metal Cutting
Notes on Lesson
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Material removal process
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Turning machines
Drilling machines
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Boring machines
Milling machines
Grinding machines pa
Shaping and planing machines
Gear cutting machines
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Unconventional machining machines
Special machines like automats, copy turning machines, reaming ,
copy milling machines, centreless grinding machine, broaching
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machine etc.
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Chip formation
Discontinuous chip
Continuous chip
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Orthogonal cutting
Mechanics of orthogonal cutting
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Requirement of a cutting tool material
Cutting tool materials
Carbon tool steels
High speed steel
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Cast cobalt alloys
Cemented carbides
Coated carbides
Ceramics
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Diamond
Cubic boron nitride(CBN)
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Tool wear
Flank wear
Crater wear
Diffusion wear
pa
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Tool life
Taylors tool life equation
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Surface finish
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o Cooling action
o Lubricating action
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UNIT II : CENTRE LATHE AND SPECIAL PURPOSE LATHES
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Tail stock
Bed
Carriage
Feed rod
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Lead screw
Feed change gear box
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Lathe specifications
Distance between centers
Swing over the bed
pa
Swing over the cross slide
Horse power of the motor
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Number of speeds
Number of feeds
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Cutting tools
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o Nose radius
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Types of tools
Parting tool
Turning tool
Right hand turning tool
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Left hand turning tool
Radius turning tool
Thread cutting tool
Chamfering tool
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Internal turning tool
Inter facing tool
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Recess or groove making tool
Internal threading tool
Lathe operations
Turning
pa
Facing
in
Knurling
Parting
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Drilling
Boring
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Special attachments
Copy turning attachment
Radius turning attachment
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Machining time and power estimation
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Capstan And Turret Lathe
The principle parts are
Bed
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Head stock
Cross slide and saddle
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The turret saddle and auxiliary slide
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Comparison of capstan and turret lathe
S.No. Capstan lathe Turret lathe
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1. Short slide since the saddle is Saddle moves along the bed, thus
clamped on the bed in position. allowing the turret to be of large
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size.
2. Light duty machine, generally for Heavy duty machine, generally for
components whose diameter is less components with large diameters
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3. Too much overhang of the turret Since the turret slides on the bed,
when it is nearing cut. there is no such difference.
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Automatic lathes
Classification
Automatic lathes may be classified based on their
Size
Type of blank machined
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Processing capacity
Machining accuracy obtained
Principle of operation design features
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Number of spindles and work positions
Type
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Single spindle automates
Cutting off
pa
Swiss type
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Automatic screw machine
Special type
ej
Special type
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UNIT-III : RECIPROCATING AND MILLING MACHINES
Shaper
The main parts of shaper are
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Base
Column
Table
Ram
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Tool head assembly- tool feed handle, tool slide, apron, clapper box, tool
holder
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Specifications
Stroke length
Length and width of table
pa
Number of ram double strokes per minute
Motor horse power
Range of ram speeds
in
Planer
ej
Table
Columns or housing
Cross rail
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Tool head
Specifications
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Types Of Milling Machine
Column and knee type
o Horizontal
o Vertical
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o Universal
o Turret type
Production type
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o Simplex
o Duplex
o Triplex
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Planomillers
Special type
pa
o Rotary table
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o Drum type
o Copy milling
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o Keyway milling
o Spline shaft milling machine
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Base
Column
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Knee
Saddle
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Table
Arbor
Over-arm
Spindle
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Specifications
The maximum length of longitudinal, cross and vertical travels of the table
and its dimensions
Main drive motor power
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Number of spindle speeds
Distance from spindle nose to table surface
Milling cutters
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Based on construction
Solid
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Inserted tooth type
Based on mounting
Arbor mounted
Shank mounted
pa
Nose mounted
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Based on rotation
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Based on helix
Right hand helix
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Slitting saw
Special form cutters
End mills
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Methods of milling
Upmilling (conventional milling)
Down milling (climb milling)
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Hole making operations
The types of hole making operations performed on these holes are
Drilling
Boring
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Reaming
Counter sinking
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Counter boring
Tapping
pa
Universal Drilling Machine(Radial Drilling Machine)
The main parts are
Base
in
Column
Radial arm
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Drill head
Salient features
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UNIT-IV : ABRASIVE PROCESS, SAWING, BROACHING AND GEAR
CUTTING
Grinding wheel specification and selection
Abrasive types
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Aluminium oxide
Silicon carbide
Cubic boron carbide
Diamond
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Grain size
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Fine
Medium
Coarse
Bond
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Vitrified
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Silicate
Synthetic resin
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Rubber
Shellac
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Metal
Grade
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Soft
Medium
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Hard
Structure
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Open
Medium
Dense
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Grinding wheel types
Wheel balancing
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Types of grinding machines
Cylindrical grinding
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Surface grinding
Centreless grinding
ul
Cylindrical Grinding Machine
The main parts are
Base
pa
Tables lower and upper table
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Head stock
Tail stock
ej
Wheel head
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Types of feed in centreless grinding
Infeed
Through feed
End feed
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Honing
Honing is a low abrading process which uses bonded abrasive sticks for
removing stock from metallic and non-metallic surfaces.
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The advantages of honing are
Correction of geometrical accuracy
Out of roundness
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Taper
Axial distortion
Dimensional accuracy
pa
Lapping
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Lapping is generally the final finishing operation done with loose abrasive grains.
The process is employed to get
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Super finishing
Super finishing is another abrasive process which utilizes either a bonded
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abrasive like honing for cylindrical surfaces or a cup wheel for flat surfaces. It is
generally used for
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Polishing and Buffing
Polishing is done with a very fine abrasive in loose form smeared on the
polishing wheel with the work rubbing against the flexible wheel. A very small
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amount of material is removed in polishing. In buffing the abrasive grains in a
suitable carrying medium such as grease are applied at suitable intervals to the
buffing wheel. Negligible amount of material is removed in buffing while a very
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high luster is generated on the buffed surface. The dimensional accuracy of the
parts is not affected by polishing and buffing operations.
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Abrasive belt grinding
In this process a continuous moving belt with an abrasive is used for grinding the
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surfaces. The abrasive belt is normally passed between two wheels with one
being driven while the other remains idle. The workpiece is oscillated across the
face of the abrasive belt to obtain a uniform belt wear and surface finish.
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Sawing machines
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Manual
Power
Band saw
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Vertical
Horizontal
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Contour
Circular saw
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Broaching
Broaching is a multiple tooth cutting operation with the tool reciprocating similar
to the sawing operations. The similarities end there, since in broaching the
machining operation is completed in a single stroke as the teeth on the cutting
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tool called broach, are at a gradually increasing height corresponding to the feed
per tooth of a milling cutter.
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Broaching machines
Push broaching machines
Pull broaching machines
ul
Surface broaching machines
Continuous surface broaching machines
Gear cutting
pa
Gear forming Vs Gear generation
in
Gear shaping
ej
Gear hobbing
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UNIT-V : CNC MACHINE TOOLS AND PART PROGRAMMING
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Components of N.C
o Program of instructions
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o Machine control unit
o Machine tool
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N.C. Procedure
o Process planning
o Part programming
o Tape preparation
pa
o Tape verification
in
o Production
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Components Of CNC
A tape reader
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Advantages
Greater flexibility
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High productivity
Good reliability
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Metric conversions
Memory functions
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Manual part programming
Coordinate function
Feed function
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Speed function
Tool function
Preparatory functions
Miscellaneous functions
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Program number
Tool length compensation
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Cutter radius compensation
Canned cycles
APT language
The complete APT part program consists of the following four types of
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statements
Geometry
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Motion
Post processor
auxiliary
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