0% found this document useful (0 votes)
58 views17 pages

Me 2252 - Manufacturing Technology - Ii II Year Mechanical Engg. B-Sec Notes On Lesson Unit - I: Theory of Metal Cutting

This document provides an overview of topics related to manufacturing technology and machine tools. It discusses various types of machine tools like turning machines, drilling machines, boring machines, and milling machines. It also covers topics like chip formation, orthogonal cutting, cutting tool materials, tool wear, surface finish, and cutting fluids. The document then describes the construction and operations of center lathes and special purpose lathes. It concludes with sections on reciprocating machines, milling machines, and milling cutters.

Uploaded by

Lenin Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
58 views17 pages

Me 2252 - Manufacturing Technology - Ii II Year Mechanical Engg. B-Sec Notes On Lesson Unit - I: Theory of Metal Cutting

This document provides an overview of topics related to manufacturing technology and machine tools. It discusses various types of machine tools like turning machines, drilling machines, boring machines, and milling machines. It also covers topics like chip formation, orthogonal cutting, cutting tool materials, tool wear, surface finish, and cutting fluids. The document then describes the construction and operations of center lathes and special purpose lathes. It concludes with sections on reciprocating machines, milling machines, and milling cutters.

Uploaded by

Lenin Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 17

ME 2252 MANUFACTURING TECHNOLOGY II

II year Mechanical Engg. B-Sec

Notes on Lesson

UNIT I : THEORY OF METAL CUTTING

om
Material removal process

Types of machine tools

.c
Turning machines
Drilling machines

ul
Boring machines
Milling machines
Grinding machines pa
Shaping and planing machines
Gear cutting machines

in
Unconventional machining machines
Special machines like automats, copy turning machines, reaming ,
copy milling machines, centreless grinding machine, broaching
ej

machine etc.
.R

Chip formation
Discontinuous chip
Continuous chip
w

Continuous chip with built-up edge


w

Orthogonal cutting
Mechanics of orthogonal cutting
w

Merchants cutting force circle


Orthogonal cutting with shear plane
Strain and strain rate in orthogonal cutting

1
Requirement of a cutting tool material
Cutting tool materials
Carbon tool steels
High speed steel

om
Cast cobalt alloys
Cemented carbides
Coated carbides
Ceramics

.c
Diamond
Cubic boron nitride(CBN)

ul
Tool wear
Flank wear


Crater wear
Diffusion wear
pa
in
Tool life
Taylors tool life equation
ej

Surface finish
.R

Ideal surface finish in turning


Cutting fluids
Function of a cutting fluid
w

o Cooling action
o Lubricating action
w

Types of cutting fluid


Water based emulsions
w

Straight mineral oils


Mineral oils with additives

2
UNIT II : CENTRE LATHE AND SPECIAL PURPOSE LATHES

Centre lathe constructional features


Head stock

om
Tail stock
Bed
Carriage
Feed rod

.c
Lead screw
Feed change gear box

ul
Lathe specifications
Distance between centers


Swing over the bed
pa
Swing over the cross slide
Horse power of the motor
in
Number of speeds
Number of feeds
ej

Cutting tools
.R

Cutting tool geometry


o Back rake angle
o Side rake angle
w

o End relief angle


o Side relief angle
w

o End cutting edge angle


o Side cutting edge angle
w

o Nose radius

3
Types of tools
Parting tool
Turning tool
Right hand turning tool

om
Left hand turning tool
Radius turning tool
Thread cutting tool
Chamfering tool

.c
Internal turning tool
Inter facing tool

ul
Recess or groove making tool
Internal threading tool

Lathe operations
Turning
pa
Facing
in
Knurling
Parting
ej

Drilling
Boring
.R

Taper turning methods


Form tool method
w

Compound rest method


Tailstock set over method
w

Using taper turning attachment


w

Thread cutting method

4
Special attachments
Copy turning attachment
Radius turning attachment

om
Machining time and power estimation

.c
Capstan And Turret Lathe
The principle parts are
Bed

ul
Head stock
Cross slide and saddle


pa
The turret saddle and auxiliary slide
in
Comparison of capstan and turret lathe
S.No. Capstan lathe Turret lathe
ej

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
.R

size.
2. Light duty machine, generally for Heavy duty machine, generally for
components whose diameter is less components with large diameters
w

than 50mm. as 200mm.


w

3. Too much overhang of the turret Since the turret slides on the bed,
when it is nearing cut. there is no such difference.
w

5
Automatic lathes
Classification
Automatic lathes may be classified based on their
Size
Type of blank machined

om
Processing capacity
Machining accuracy obtained
Principle of operation design features

.c
Number of spindles and work positions
Type

ul
Single spindle automates
Cutting off
pa
Swiss type
in
Automatic screw machine
Special type
ej

Multiple spindles automates


.R

Cutting off bar


Drilling, forming, cutting off bar
Bar
w

Special type
w
w

6
UNIT-III : RECIPROCATING AND MILLING MACHINES

Shaper
The main parts of shaper are

om
Base
Column
Table
Ram

.c
Tool head assembly- tool feed handle, tool slide, apron, clapper box, tool
holder

ul
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

The main parts of planer are


Bed
.R

Table
Columns or housing
Cross rail
w

Tool head
Specifications
w

Dimensions of the table


Horizontal distance between the two vertical housings
w

Length that the table can travel


Height from top of the table to the top of cross rail
Type of drive

7
Types Of Milling Machine
Column and knee type
o Horizontal
o Vertical

om
o Universal
o Turret type

Production type

.c
o Simplex
o Duplex
o Triplex

ul
Planomillers

Special type
pa
o Rotary table
in
o Drum type
o Copy milling
ej

o Keyway milling
o Spline shaft milling machine
.R

Horizontal Milling Machine


The basic parts of the horizontal milling machine are
w

Base
Column
w

Knee
Saddle
w

Table
Arbor
Over-arm
Spindle

8
Specifications
The maximum length of longitudinal, cross and vertical travels of the table
and its dimensions
Main drive motor power

om
Number of spindle speeds
Distance from spindle nose to table surface

Milling cutters

.c
Based on construction
Solid

ul
Inserted tooth type

Based on mounting


Arbor mounted
Shank mounted
pa
Nose mounted
in
Based on rotation
ej

Right hand rotation


Left hand rotation
.R

Based on helix
Right hand helix
w

Left hand helix


w

Plain milling cutters


Side and face milling cutters
w

Slitting saw
Special form cutters
End mills

9
Methods of milling
Upmilling (conventional milling)
Down milling (climb milling)

om
Hole making operations
The types of hole making operations performed on these holes are
Drilling
Boring

.c
Reaming
Counter sinking

ul
Counter boring
Tapping

pa
Universal Drilling Machine(Radial Drilling Machine)
The main parts are
Base
in
Column
Radial arm
ej

Drill head
Salient features
.R

Provides movement of the spindle in three directions


Several holes can be drilled on a work piece without moving the same.
w
w
w

10
UNIT-IV : ABRASIVE PROCESS, SAWING, BROACHING AND GEAR
CUTTING
Grinding wheel specification and selection
Abrasive types

om
Aluminium oxide
Silicon carbide
Cubic boron carbide
Diamond

.c
Grain size

ul
Fine
Medium
Coarse

Bond
pa
Vitrified
in
Silicate
Synthetic resin
ej

Rubber
Shellac
.R

Metal

Grade
w

Soft
Medium
w

Hard
Structure
w

Open
Medium
Dense

11
Grinding wheel types

Wheel balancing

Dressing and truing

om
Types of grinding machines
Cylindrical grinding

.c
Surface grinding
Centreless grinding

ul
Cylindrical Grinding Machine
The main parts are
Base
pa
Tables lower and upper table
in
Head stock
Tail stock
ej

Wheel head
.R

Surface grinding machine


Horizontal spindle and reciprocating table
Vertical spindle and reciprocating table
w

Horizontal spindle and rotating table


Vertical spindle and rotating table
w

Centreless grinding machine


w

The main parts are


Grinding wheel
Regulating wheel

12
Types of feed in centreless grinding
Infeed
Through feed
End feed

om
Honing
Honing is a low abrading process which uses bonded abrasive sticks for
removing stock from metallic and non-metallic surfaces.

.c
The advantages of honing are
Correction of geometrical accuracy
Out of roundness

ul
Taper
Axial distortion
Dimensional accuracy
pa
Lapping
in
Lapping is generally the final finishing operation done with loose abrasive grains.
The process is employed to get
ej

Extreme accuracy of dimension


Correction of minor imperfection of shape
.R

Refinement of the surface finish


Close fit between mating surfaces
w

Super finishing
Super finishing is another abrasive process which utilizes either a bonded
w

abrasive like honing for cylindrical surfaces or a cup wheel for flat surfaces. It is
generally used for
w

Removing surface fragmentation


Reducing surface stresses and burns and thus restoring surface
integrity
Correcting inequalities in geometry

13
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

om
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

.c
high luster is generated on the buffed surface. The dimensional accuracy of the
parts is not affected by polishing and buffing operations.

ul
Abrasive belt grinding
In this process a continuous moving belt with an abrasive is used for grinding the
pa
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.
in
Sawing machines
ej

The various types of sawing machines used are


Hack saw

.R

Manual
Power
Band saw
w

Vertical
Horizontal
w

Contour
Circular saw
w

14
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

om
tool called broach, are at a gradually increasing height corresponding to the feed
per tooth of a milling cutter.

.c
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
.R
w
w
w

15
UNIT-V : CNC MACHINE TOOLS AND PART PROGRAMMING

Numerical Control (N.C)


It can be defined as a programmable automation in which the process is
controlled by numbers, letters and symbols.

om
Components of N.C
o Program of instructions

.c
o Machine control unit
o Machine tool

ul
N.C. Procedure
o Process planning
o Part programming
o Tape preparation
pa
o Tape verification
in
o Production
ej

Components Of CNC
A tape reader

.R

Micro or mini computer


Computer hardware interface and servo mechanism
Machine tool
w

Advantages
Greater flexibility
w

High productivity
Good reliability
w

Metric conversions
Memory functions

16
Manual part programming
Coordinate function
Feed function

om
Speed function
Tool function
Preparatory functions
Miscellaneous functions

.c
Program number
Tool length compensation

ul
Cutter radius compensation
Canned cycles

Computer assisted part programming


pa
Preparing the part programs for CNC machine tools manually is a viable system
for any kind of job. But the assistance of a computer is desirable for part
in
programming because of a variety of reasons. The first and foremost in this
respect is the complexity of the work piece which makes manufal part
ej

programming a very difficult exercise. Close tolerance contouring to some


mathematically defined, or through a set of points other than a circular arc, is an
.R

example requiring too many coordinate calculations making manual part


programming too tedious to be practicable.
w

APT language
The complete APT part program consists of the following four types of
w

statements
Geometry
w

Motion
Post processor
auxiliary

17

You might also like