Machi

neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Lat
he

1
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

I
ntroducti
on
Amachi ne,whi
chperfor
mst hemateri
alr
emov aloper
ati
onwithtool
s,t
oproduce
desir
edshapeandsi zeoft heworkpiece,i
sknownasamachi netool.The
purposeofthemachinetoolistosaveti
me,costofproduct
ionandtogetbett
er
outputwhichcannotbeobtainedwit
hhandtools.

Lat
he
Thelathei soneoft hemosti mpor
tantmachi nesinanywor kshop.I
tsmain
obj
ecti
vei st oremovematerialbyrotati
ngthewor kagainstacutti
ngtool
.
Thoughal atheisusedtoproducecyl
indri
calwor k,y
etitmayalsobeusedfor
manyot herpur
posessuchasdril
li
ng,
threadi
ng,grindi
ng,
mill
i
nget c.

Workingpr i
ncipl
eofal at
he
I
nal athe,thewor kpieceishel
dinachuckorbet weencent er
sandr otat
ingabout
i
tsaxisatauni form speed.Thecutt
ingtoolheldinthetoolposti sfedintothe
workpi ecef oradesireddepthandinthedesireddirect
ion.Sincethereexist
sa
r
elat
ive mot i
on between the wor
kpi ece and the cut
ting tool
,therefor
et he
materialisremov edi
nt hefor
m ofchi
psandt hedesir
edshapei sobtai
ned.

Typesoflat
he
Thefundamentalpr
incipl
eofoper ati
onofalllathesi
ssameandper f
ormsthe
samef unct
ion,y
ettheyar eclassif
iedaccordingtothedesi
gn,ty
peofdr i
ve,
arr
angementofgear
s, andpur
pose.Thef ol
lowingarei
mport
antty
peoflat
hes.

1.Speedlathe:Itisoneofthesimplestt
y pesofalll
athes.I
tisdri
venbypower
andconsi st
sofabed,aheadst ock,at ai
lst
ockandanadj ust
abl
esl i
def or
support
ingthet ool
.Si
ncethetoolisfedintothewor kbyhandandcut sar e
ver
ysmal l,t
her efor
ethi
stypeoflatheisdr i
venathighspeedsusuallyfr
om
1200to3600r pm.Theworkmaybehel dmainlyf
orwoodwor ki
ng,center
ing,
metalspinni
ng, poli
shi
nget
c.

2.EngineorCent erlathe:Iti
sagener al-purposel atheandiswi delyusedi n
workshops.I tdif
fersfrom aspeedlathet hatithasaddit
ionalmechani sm f or
controll
i
ngt hespi ndl
espeedandf orsuppor tingandcontroll
ingt hefeedof
fi
xedcut ti
ngt ool
.Thecut ti
ngtoolmaybef edbot hincr
ossandl ongitudinal
di
rectionwithr ef
erencetothelatheaxiswi ththehelpofacar ri
age.
Theengi nelathe,dependingupont hedesi gnoft heheadst ockf orreceiv
ing
power ,maybecl assi
fiedasbeltdri
venl athe,mot ordr
ivenlatheandgear ed
headl at
he.

3.Benchlathe:Thebenchl at
heissosmal lthati
tcanbemount edonabench.
Allt
hetypesofoperati
oncanbeper f
ormedont hi
slat
het hatmaybedoneon
an ordi
naryspeed orengi nel at
he.Thisi sused f
orsmal lworkusuall
y
requi
ri
ng consider
able accuracy such as inthe producti
on ofgauges,
punchesandbedsf orpresstools.
2
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

4.Toolr oom lathe:Thet oolroom l atheissi

mil
art oanenginel atheandi s
equippedwi thalltheaccessor i
esneededf oraccurat
etoolwor k.Ithasan
i
ndividual
lydriven-gearedheadst ockwithawi derangeofspi ndlespeeds.
Sincet hi
slathei susedf orprecisionworkont ool
s,gauges,dies,ji
gsand
othersmal l
par t
s,therefor
egreaterskil
li
sneededtooperatethelathe.

5.Capstanandt ur
retlathe:Thecapst anandt urretlathesarethemodi ficat
ion
ofenginelat
heandi spar t
icularl
yusedf ormasspr oducti
onofi denti
calparts
i
nami ni
mum t i
me.Thesel at
hesar esemi automat icandaref i
ttedwithmul t
i
toolholdi
ngdev ices,call
edcapst anandt urretheads.Theadv antageof
capstanandt ur
retlatheist hatsev eraldifferentt ypesofoper at
ioncanbe
perf
ormedonawor kpiecewit houtresett
ingoft hewor kortool
s.

6.Automaticlathe:Theaut omaticlat
hesaresodesi gnedthatthet
oolsare
automatical
l
yf edtot hewor kandwithdr
awnaf terallt
heoperat
ionsare
completedtof ini
sht hewor k.Si
ncetheentir
eoperati
onisautomat
ic,t
hese
l
athesrequirelitt
leattenti
onoftheoperat
or.Theselat
hesareusedf
ormass
product
ionofi denti
cal par
ts.

7.Special pur pose l at

hes: The wor k, whi ch cannot be conv eni entl
y
accommodat edormachi nedonast andardl athe,t
hespecialpur posel athes
areused.
Thegapbedl athewhi chhasar emov ablesect i
onint hebedi nf rontoft he
headstockt om pr ov
ideaspaceorgab, i
susedt oswingext r
al argedi amet er
j
obs.
Thecr ankshaf tlatheisespeci al
lyusedf orturningcrankshafts.
Thewheell athe,whi chi soflargedesi gn,isespeciall
yusedf orfinishingt he
j
ournal andf ortur ni
ngt helocomot i
vedr ivi
ngwheel s.
Theaxl elathei susedf ort ur
ningcaraxl es.
Themanuf act uringlathe,whi chisequi ppedwi t
hfrontandr eartoolbl ocks
andot herfeat ures,i
susedf orturni
ngdupl icati
ngpar t
sr api
dly.

Pri
nci
plepar tsofal at
he
Thevari
ouspar t
sofacent erlat
heareshowni nfig.
Thepri
nciplepar tsareasfollows
1.Bed:Thebedi sthebaseorf oundati
onoft helathe.Itisaheav y
,r i
gid
castingmadei nonepi ece.Ithol
dsorsuppor tsallotherpart
softhelathe.
Thet opoft hebedi spl anedtof or
m gui deway sf orthecarri
ageand
tail
stock.Thegui deway saretwot ypesi .
e.,widef l
atway sareoft wo
typesi .e.
,widef l
atguideway sorinvertedVeegui deway s.General
ly,the
combi nat
ionofbot htheflatandinver
tedVeegui deway sisused.

2.Headstock:Theheadstockpermanentl
yfast
enedontheinnerway satthe
l
eft
-handendoft hebed.I tser
vest osupportthespindl
eanddr i
v i
ng
ar
rangements.Al
llat
hesr ecei
vet
heirpowerthr
oughtheheadstock,which
maybeequi ppedwi t
hast epconepulleyoragear edheaddr i
v e.The
3
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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moder nl athes are pr ovi
ded wit
h all
-gear
ed headstock to getlar
ge
vari
ationofspindlespeeds.
Theheadst ockspi ndl
ei smadehol l
ow,inordertoall
ow thelongbaror
workhol dingdevicestopasst hr
ough.Thef r
ontendoftheholeistaper
ed
forhol di
ngf orholdingcenter
sandot hertoolshavi
ngast andardMorse
taperedshank.Thet hreadednoseenablesthechucks,dri
vingplat
esand
faceplatestobescr ewed.

3.Tailstock:Thet ailst
ocki sthecount erpartoft heheadstockand is
sit
uatedatt heri
ghthandendoft hebed.I
tisusedforsuppor
tingt
hewor k
whent urningoncent ersorwhenal ongcomponenti stobehel di na
chuck.Itisal sousedf orholdi
ngandf eedi
ngt hetoolssuchasdr i
ll
s,
reamers,tapsetc.
Thebodyoft hetail
stockisacast i
ngandpl acedoni tsbase,whichis
shapedt of i
ttheinnerway softhebed.Thet ai
lstockbodyisadjustabl
e
andcanbemov edtowar dsorawayfrom t
heoperator.

Fig:Cent erl
athe
4.Carri
age:Thecar ri
agecont rolsandsuppor tsthecuttingt ool.Thecar ri
age
mov es on t he way s oft he bed,t herefor
ei ts mot i
on par all
elt othe
rot
ational axisofthespi ndle.Thecar ri
agehasf ol
lowi ngmaj orpar ts.
a.Saddl e:Itfi
tsov ert hebedandsl idesalongt heway sbet weent he
headst ockandt ailstock.
b.Cr osssl ide:Itismount edont hesaddle.Itsuppor tst hecompound
rest.Thet r
ansv er semov ementoft hecrosssl i
dei sobt ai
nedby
turningt hecross-sl idehandwheel .
c.Compoundr est:I tismount edont opoft hecr osssl ide.Itcanbe
swi l
ledint oanydesi redangl ei nahor i
zontalplaneandi t
sbasei s
graduat edindegr eest oi ndi
cat eit
sangularset ti
ng.
d.Toolpost :Itismount edabov ethecompoundr est.I tservesto
ri
gidlyclampt hecut ti
ngt ool ortoolhol
deri nadesi redposi ti
on.
e.Apr on:Itisfastedt othesaddl eandhangsov erthef rontoft hebed.
Itcont ai
nsgear s,cl utchesandl eversforoper ati
ngt hecar r
iageby

4
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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handandpowerfeeds.Theapr
onhandwheelcanbetur
nedt
o
movethecar
ri
agel
ongit
udi
nal
l
ybackandf
ort
hbyhand.

5.Feed mechani sm:The f eed mechani sm ofa l athe i

s empl oyed for
i
mpar tedv ar
iousf eedstot hecutti
ngtool .
Thef eedi ssai dt obel ongi t
udi
nalwhent het oolmov espar al
leltothe
wor k.Itisobt ainbythemov ementofthecar r
iage, whichcanbeoper at
ed
byhand, orpower .
Thef eedi ssai dt obecr osswhent het oolmov esperpendiculartothe
wor k.Itisobt ainedwi t
ht hehel pofacr osssl ide,whi chcanbeoper at
ed
byhand, orpower .
Thef eedi ssai dtobeangul arwhent het oolmov esatanangl etot hewor k.
I
ti sobt ainedbyswi vel
ingt hecompoundsl ide,whi chcanbeoper atedby
handonl y.
Thef eedmechani sm consistsoffeedrev erelev er,tumbler
-r
eversinggear ,
feedr od,apronmechani sm andhal fnutmechani sm.

Si
zeandspecif
icati
onofal athe
Thesi
zeofalatheisdeterminedby
1.Thehei ghtofthecentersabovet hetopofthebed.ThisisshownbyH
i
nf i
g.
2.Theswi ngormaxi mum di ameteroft heworkthatcanberotat
edover
theway soft hebed.Thi sisequalt otwi
cet heheightoft
hecenters.
ThisisshownbyDi nfig.
3.Themaxi mum lengthofthewor kthatcanbeaccommodat edbetween

thel
athecent
ers.ThisisshownbyLi nf ig.
Fig:Lathespeci
ficati
ons
4.Themaximum diamet erofthewor kthatcanber ot
atedov
erthel
athe
saddl
e.Thi
sisshownbyD1i nf i
g
5.Themaximum diamet erofthewor kthatcanbeaccommodatedinthe
gabforagabbedl at
he.Thisi sshownbyD2i nfi
g
6.Thenumberandr angeofspindlespeedsandf eedetc….

LatheAccessor ies:
Thelatheaccessor i
esar eusedforhol
dingandsuppor t
ingtheworkandholding
thecut
t i
ngt ools.
1.Cent er s:Therearetwotypecenter
si.e.
,li
vecenteranddeadcenter.A
centerwhi chf i
tsintotheheadst ockspindl
eandr ev
olv
eswi t
ht he
worki scal l
edliv
ecenter,whi
lethecenterswhichisusedi nt
ail
stock

5
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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spindl
eanddoesnotr evol
vei
scalleddeadcent
er.Lat
hecenter
sare
usedf orholdi
nglonglengthj
obs.Thevari
oustypesofcent
ersused
fordif
ferentworksar
eshowninfig.

Fig:Center
s
2.Chucks:I
tisimport
antdevi
ceusedf orholdingandrot
ati
ngt hework
pi
eceinal at
he.Thevar
ioustypesofcentersusedfordi
ff
erentworks
ar
eshowni nfig.
Thecommonl yusedchucksare

Fig:Chucks
Threej aw uni
versalchuck:i t
susedf orholdingr oundandhexagonal
work.
Four-j
awchuck:Ishasf ourjaws,eachofwhichi ndependentl
yadjusted
toaccommodat et hewor ki tsupports.Thi
st ypeofchuckcanhol d
i
rregularshapeofwor k.Theot hertypeofthechuckar ecombination
chucks,magnet i
cchuck,col l
ectchuck,drillchuck,airorhy drauli
c
chuck.
3.Lathedogorcar ri
er:Thewor kplacedonamandr elorheldbetween
centersisrotat
edposi ti
velybycl ampingthedogcar r
iert
ot heendof
thewor k.Thelat
hedogorcar r
iermaybest raighttypeorbendtypeas
shown

i
nfi
g.
a.St
rai
ghtt
ail b.Bentt
ail
Fig:Lathedogorcarr
ier
4.Dri
vepl
ate:Thedri
vepl
ate,asshowni nfi
g.isaci
rcularpl
atewhichis
bor
edoutandt hr
eadedsot hatitcanatt
achedtothespindle.I
talso
car
ri
esaholeforthepi
ninwhi chisusedonl
ywhent heworkisheldin

6
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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al
athedog.
Fig:Driv
eplate Fig:Facepl ate
5.Facepl ate:Thef aceplate,asshowni nf i
g.i ssi mi l
art odriveplate
exceptt hatitisl argerindiameter .Itcont ainsmor eopensl otsorT-
slotsso t hatbol tsmaybeused t o clamp t hewor kpi ecet ot he
faceplate.
6.Anglepl at
e:Anangl eplateissimplyacasti ronwi t
ht wof acepl anedat
ri
ghtangl etoeachot herandhav ingsl ot
si nv ar i
ousposi ti
onsf orthe
clampingbol ts.Ital waysusedwi thf acepl atef orhol dingsuchpar ts,
whichcannotbecl ampedagai nstthev ert
ical surfaceoft hefaceplate.
7.Mandr els:Thel athemandr elisacy lindricalbarwi thcent erhol eat
eachend.I ti susedt o hol dhollow wor kpi ecest o machi net heir
externalsurface.Thewor krevolv
eswi ththemandr elwi t
ht hemandr el,
whichi smount edbet weent hecent ersoft helat he.Thev ari
oust ypes

ofmandr
elsf
ordi
ff
erentcl
assesofwor
kar
eshowni
nfi
g.

Fi
g:Ty
pesofmandr
els

8.Rest s:whenal ongsl enderwor kpiecesar et obet urnedbet weent he

l
at hecent ers,itmustbesuppor t
edatsomei ntermediatepointinor der
topr event
spr i
ngingorbendi ngoft hewor kpiece.
Ther ear etwot ypesofr estsarecommonl yusedi nanengi nelat he.
a.St eadyr est b.Followerrest .
Thest eadyr esti sshowni nf i
g.,itsmai nf unct i
oni stopr ovidea
suppor tf orlongt hinwor kpiecet hatturnedbet weencent ers.When
steadyr estisused, car r
iagecannotbef edt othef ul
llengt
hoft hewor k.
Thef ol
lowerr estisshowni nfig.,i
susedt osuppor tt heworkwhi chis
closet ot hecut ti
ngt ool.Itisboltedt othecr ossslideont hesaddl e
andt ravelswi ththet ool asi
tfeedsal ongt hewor k.

7
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET
Fi
g:Rest
s

LatheTool s
Thet oolusedi nal at
he,forgener al
-pur
posework,i
sasi nglepointcutti
ngt ool
,
butf orspeci aloperati
onsmul t
i-
pointcutt
ingt
oolsar
eused.Thecommonl yused
mat erialarehi ghcarbonst eel,highspeedsteel
,cementedcar bides,diamond
ti
psandcer ami cs.
Thel at hetool s,dependingupont henatureofoperat
iondonebyt hetool,are
cl
assi fiedasf ollows:
1.Tur ningt ool 2.Facingtool 3.Chamferingtool
4.For mt ool 5.Part
ingtool 6.Exter
nalandi nt
ernalthreading
tool
7.Bor ingt ool 8.Knurl
ingtool

Theset
ool
sar
eshowni
nfi
g.

Fi
g:Lat
het
ool
s
Latheoperat
ions
Themostcommonoper ati
onwhi
chcanbecarr
iedoutonalat
hearef
acing,pl
ain
tur
ning,step tur
ning,tapert
urni
ng,dr
il
li
ng,reaming,bori
ng,undercut
ti
ng,
thr
eadingandknurl
ing.

1.Faci
ng:Thisoperationisessenti
alforallworks.I
nt hisoperat
ion,as
showninfig.,t
hewor kpieceishel
dinchuckandt hef aci
ngtoolisfed
fr
om theoutersur
facetothecent
erwitht
hehelpofcrosssli
de.

2.Plai
nt urni
ng:Iti
sanoper at
ionofr emovingexcessamountofmat er
ial
fr
om t hesurf
aceofthecyl
indri
calworkpiece.I
nthisoper
ati
on,asshown
i
nf i
g.Thewor kisheldei
therinthechuckorbet weencent
ersandthe
l
ongitudinalf
eedi
sgiventothetooleit
herbyhandorpower.

8
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET
Fi
g:Faci
ng Fi
g:Pl
aint
urni
ng Fi
g:St
ept
urni
ng

3.St
epturni
ng:Iti
sanoper at
ionofproducingvari
ousstepsofdiff
erent
di
amet
ersintheworkpiece,asshowninfig.Thi
soperat
ioniscar
ri
edout
i
nsimi
larwayasplai
nturni
ng

4.Tapert urni
ng:Taperedsurf
acescanbet urnedbyemployi
ngoneofthe
fol
lowingmet hods.
1.Compoundr estmethod:Thecompoundrestisswiv
eledt
other
equi
red
angle.Figa.Theanglecanbedeter
minedbyt hefor
mula:
Tan=(
D-d)
/2

Where =Hal
f-t
aperangle.
D=lar
gerdi
amet
erofthetaper
.
d=small
erdi
amet
er,
=l
engt
hoft
het
aper
.
Aft
erswiv
eli
ngthecompoundr esttothi
sangl
eaboutt hever
ti
calaxi
s,itis
cl
ampedinposit
ion.Thetaperi
st ur
nedbyhandwheelbyrot
ati
ngthehandle.
Themethodcanbeempl oyedforturni
ngshor
tint
ernalandexter
naltapers
wit
hlar
geangleoftaper
.

2.Wi t
hf ormtool:Shor
texter
naltaper
swi t
hv ari
ousangl
esoftapercanbe
tur
nedwi thaformt ool
,fi
gb,usingcrossf eed.Thewidt
hofthef or
mt ool
sli
ght
lyexceedsthatoft
hetaperbeingtur
ned.

3.Set ti
ng ov
ert he t
ailst
ock:Long workpi
eces wi
th a smallangle of
taper(notexceeding8)areusual
lytur
nedbysetti
ngovert hetailst
ock
center.
(figc)Tailstocksetoveroroffsetcanbedeterminedf r
om the
formula.
H=L(
D-d)
/2
mm
Wher
e L=ful
ll
engt
hoft
hewor
kpi
ece.
=l
engt
htobet
urned.

4.Tapert
urni
ngat
tachment
:Longt
aper
edwor
kisf
requent
lyt
urnedwi
that
aper

9
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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turningattachment .Fi
gd.Br acket1i sat t
achedt ot helathebed.I tcarri
es
gui debar2whi chcanbet urnedt ot her equir
edangl eandcl ampedi npl
ace.
Gui deblockorsl ide3,li
nkedt opt hel athecr ossslide5byt i
emember4, i
s
freet osl
idealongt heguidebar .Thecr osssl idei sdi
sengagedf rom t
hecross
feedscr ew.Upont rav
eloft hesaddl eal ongt hebedway s,t heguideblock
slidesalongthegui debar,andt hrought het i
emember ,
forcest hecrosssl
ide
wi ththecutti
ngt ooltotravelpar al
leltot hegui debaratgi venangleandt he
wor ki
sturnedtot hespecif
iedtaper .
Fig:Tapert urningmet hods
Theangl eoftapercanbef oundoutbyt her elati
on:
Tan=(D-d)
/2
Where =Half-
taperangl
e.
D=lar
gerdi
ameterofthetaper
.
d=small
erdi
ameter
=l
engt
hoft
het
aper
.

5.Dri
l
li
ng:Iti
sanoper ati
onofmaki ngaholeinaworkpiecewit
hthehel
pof
adri
ll
.Inthi
soperation,asshowni nfig.
,theworkpi
eceishel
dinachuck
andthedril
lishel
dint hetail
stock.Thedril
lisf
edmanuall
y,i
ntot
hework
pi
ece,byrotati
ngt
het ailst
ockhandwheel .

Fi
g:Dri
ll
ing Fig:Reami
ng
6.Reaming:Iti
sanoper ati
onoffini
shi
ngt heprevi
ouslydr
il
ledhol
e.I
nthi
s
oper
ation,asshowninf i
g.,ar
eamerishel dinthetai
lst
ockanditisf
ed
i
ntotheholeinthesi
mi l
arwayasfordri
l
ling.

7.Bori
ng:Itisanoper
ati
onofenl ar
gingofahol ealr
eadymadeinawork
pi
ece.Inthi
soper
ati
on,asshowni nfi
g.,abor
ingtoolorbi
tmount
edona
ri
gidbari
sheldi
nthetoolpostandfedint
otheworkbyhandorpower
.

Fi
g:Bor
ing Fi
g:Under
cut
ti
ng

8.Undercutt
ingorgroovi
ng:I
tisanoperati
onofreducingthediamet
erofa
workpieceoverav er
ynarr
owsurf
ace.Inthi
soperat
ion,asshowninfi
g.,
a
toolofappropr
iat
eshapei sfedi
ntotheworkupt ot hedesi
reddept
hat
10
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
r
ightangl
est
othecent
erl
i
neoft
hewor
kpi
ece.

9.ThreadCutti
ng:Theprinci
pleofthreadcutt
ingt
opr oduceahelicalgroove
onacy li
ndri
calorconicalsurf
acebyf eedi
ngthetoollongi
tudi
nallywhen
thejobisrevolv
edbetweencent ersorbyachuck.Thel ongi
tudinalfeed
shouldequaltothepi
tchoft hethreadtobecutperrevol
uti
onoft hewor k
piece.

Calcul
ati
onf
orchange–wheel s:Tocal
cul
atet
hewheel
srequir
edforcut
ti
nga
thr
eadofcer
tai
npitchi
tisnecessaryt
oknowther
ati
ousingfol
lowi
ngrel
ati
on.

Dr
ivi
ngt
eet
h l
eadscr
ewt
urn Pi
tchoft
hescr
ewt
obe
cut
-
--
--
--
--
--
--
---
- = --
--
---
--
--
--
--
--
-= -
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
-
Dri
venteeth spindl
eturn Pit
choftheleadscr
ew

Exampl e:Thepi t
choft hel
eadscr ewis6mm, thepi
tchoft
hethreadt
obecuti
s
1mm.Fi ndchangegear s.
Dr i
vingteeth Pi
tchoft hescrewt obecut 1 1*20
20
-
-----
---
--
--
--
-- = -
--
---
--
--
--
---
--
--
--
--
---
--
--
-- =-
-= - -
--
--= -
--
-
Driventeeth Pi
tchoftheleadscrew 6 6* 20 120
Thedr iverwi l
lhave20Tandt hedr i
vengearont hel
eadscrew120T

Threadcut
ti
ngoper
ation:Changeofgearsofcor
rectsi
zearethenfi
tt
edtothe
endofthebedbet
weent hespindleandthel
eadscrew.Theshapeorfor
m oft
he
thr
eaddependsontheshapeoft hecutt
ingt
oolt
obeused.

Thespeedoft hespi ndleisr educedbyonehal ft

oonef orthofthespeed
requi r
edf ortur ningoper ationandt hehal fnutisthenengaged.Thedept hofcut
usual lyvariesf rom 0. 05to0. 2mm i sgi venbyadv ancingt hetoolper pendicular
totheaxi soft hewor k.Aftert hetool haspr oducedahel i
calgroov eupt ot he
endoft hewor kt hisisquickl ywi t
hdrawnbyt heuseoft hecr osssl i
det hehal f–
nutdi sengaged, andt hetool isbroughtbackt othest art
ingposi t
iont ogivea
freshcut .Bef orer e–engagi ngt hehal fnutitisnecessar ytoensur ethatt hetool
wi l
lfollowt hesamepat hithast raversedi nthepreviouscut ,otherwiset hejob
wi l
lbespoi l
ed, sev eralcutsar enecessar ybeforethef ul
ldepthoft hreadi s
reached.Ar i
singf rom thiscomest henecessi tyto“pick–up”t hethr ead.The
differentmet hodsoft hepi ckingupat hreadar e
1.r eversingthemachi ne
2.mar kingthel athepar t
s
3.Usi ngachasi ngdi alorthreadi ndicator

11
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
Fi
g:Thr
eadi
ng Fi
g:Knur
li
ng

10.
Knur l
i
ng:Iti
sanoper at
ionofprovi
ngknurledsurfaceont
hewor kpiece.I
n
thi
soper ati
on,asshowni nfi
g.,aknur
ledtoolismov edl
ongi
tudinall
ytoa
revolvi
ng work piece surf
ace.The pr oject
ions on t
he knur l
ed tool
reproducedepressi
onont heworksurf
ace.

Thef
oll
owi
ngt
ermsar
ecommonl
yusedwhi
l
emachi
ningawor
kpi
eceonl
athe.

1.Cut
tingspeed(V):I
tisdefi
nedastheperipher
alspeedoftheworkpastt
he
cut
ti
ngt oolorthespeedatwhi chmetalisremovedbyt hetoolf
rom t
he
workpiece.I
tisusuall
ymeasuresinmetersperminute.
Cutti
ngspeed=* d*
n/1000m/ min.
Wheredi sdi
ameterofthewor ki
nmm
Nisr
.p.
m.ofthewor k.

2.Feed:Itisdef
inedasthedistancei
nwhichthetooladvancesf
oreach
revol
uti
onoft
hework.I
tisusuall
ymeasur
einmil
li
meters.

Av
eragecut
ti
ngspeed,
feedanddept
hofcutf
ordi
ff
erentt
ool
mat
eri
als

Mat
eri
al H.S.
S St
ell
i
te Cemented Feed, Depthof
V,
m/ min V,m/min car
bideV, Rev/
mm cut,
m/ mi
n mm
Castir
on 15-19 30 63 0.
2-0.
8 0.5-1for
Mil
dsteel 25-31 55 80 fi
nishi
ng
Brass 60-90 120 180 operati
ons
Aluminu 120 300 360 2-5for
m r
oughi ng
operati
ons

3.Depthofcut:I
tisdef
inedasthedepthofpenet
rat
ionoft hetooli
ntothe
workpieceduri
ngmachini
ng.Inotherwor
ds,i
tisperpendicul
ardist
ance
measuredfr
om themachinedsurf
acet ot
heunmachi nedsurfaceofthe
workpi
ece.Iti
susual
l
ymeasur ei
nmi l
li
met
ers.

4.Sur
facef inish:Typi
calsur
faceroughnesscanobt ai
nedonworkpiece
usi
ngl athemachi nebetween0. 4-
6.3m forav
erageappl
i
cat
ions,6.
3-
25,
0.05-0.4m forl
essfr
equentappl
icati
ons

Powerr
equi
redi
nat
urni
ngpr
ocess.
Powerr
equi
redi
nat
urni
ngpr
ocessi
s( P)
=Fz.v KW
102*60

Fz=Tangent
ial
for
ce, N.
12
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
Fz=wt1scos(-)
[ 1 ]
sincos(+-
)
w-wi dthofcutmm
s-ulti
mateshearst r
essofthewor
kmat
eri
al mm2
N/
t1-Uncutchipthicknessmm
-fri
cti
onangl e(μ=t an)
μ-coeffici
entoffri
cti
on
-shearangl e
-r akeangle
Or
x y
Fz=Czt fFz
Cz=Aconst antdependi
ngontheworkmat er
ialandcutti
ngparamet ers
t=Depthofcut .
f=Feedr ate.
K=Cor r
ect ionfactor
,dependi
ngonactualworki
ngcondi t
ions.
Fordetermi ningthev al
ueofFzthevaluesofthev ari
ouscoeffi
cientsaregiven
i
nthetable.
Wor k Cz X Y Cutt
ingoperati
on
material
Steel 220 0.9 0.775 Turni
ng
270 1.0 0.
9 Facing
C.I 100 1.0 0.
8 Bori
ngTur ni
ng
135 1.0 1.
0 Facing

V=cut
ti
ngspeed,
m/mi
n.

Quest
ions:

1.Whati stheuseofst eadyr est?Whati sdi ff

erencebetweenast eadyr
estand
afoll
owerr est.
2.Whati sdiffer
encebet weenaf aceplateanddr i
v i
ngplate?
3.Whati stheuseofmandr el onlathe?
4.Whatar etheadv antagesofusi ngacol letchuck?
5.Machinet oolbedsar emadeof_ __
__ _
_____________
_mat erial.
6.Halfnutisengagedf orperformingthe_ _ _
_________
___oper at i
on.
7.I
ncapst anl at
he, t
het urr
etismount edon_ _______
_________ __
8.I
naut omat i
cmachi nes,cuttingtoolmov ement sarecont rolled
by______
_ _
_ __
___
9.Whent urningalongshaf tonl atheitsbendi ngcanbepr ev ented

13
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
by
___
___
___
___

14
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

Ex.1:
Exer
ciseonFaci
ng,
Tur
ning,
StepTur
ningandTaperTur
ning

Aim:Toperf
ormfaci
ng,
tur
ning,
stept
urni
ngont
hegi
venmi
l
dst
eelspeci
menby
usi
ngLatheMachi
ne.

Toolsrequir
ed:ChuckKey,3Jaw Chuck,Si
nglepoi
ntcutti
ngt
ool(
H.S.
S),t
ool
postkey,Lat
heMachine,
Verni
erCal
iper
s,Spanner
,Wrench.

Mat
eri
alRequi
red:

Pr
ocedur
e:

Thewor kpi ecei sf i

xedi na3- jawchuckwi t
hsuf ficientov erhang.
Adj ustt hemachi net or unt hej obt oar equi redcut ti
ngspeed.
Fixt hecut ti
ngt ool int het ool postandcent eringoper ationisper for
medsot hat
theaxi soft hej obcoi ncideswi ththel atheaxi s.
Gi vet hef eedanddept hofcutt ot hecut ti
ngt ool
Faci ngoper ati
oni sper for medf r
om t hecent eroft hej obtowar dsoutwardsor
from t heci rcumf er encet owar dst hecent er.
Pl aint urningoper ationi sper formedunt ilt hedi amet eroft hewor kpi ece
reducest o23mm.
Checkt hedi mensi onsbyusi ngv erniercal iper s.
Thenchamf eri
ngi sdoneont he23mm di amet ersur f
ace.
Rev er set hewor kpi ecei nt hechuckandf acingoper at
ioni sper f
ormedt o
reducet hel engt hofwor kpi ecet other equireddi mensi ons.
Agai nPl aint urningoper ationi sperf ormedunt ilt
hedi amet eroft hewor kpiece
reducedt o18mm.
Usi ngV- cuttingt oolgr oov i
ngoper ationi sper formedaccor dingt othegi ven
dimensi onsandf inisht hegr oov eusi ngpar tingt ool .
Swi v elthecompoundsl idet ot her equi redangl eandt apert ur
ningoper ati
onby
rotati
ngt hecompoundsl idewheel .
Theangl ecanbemeasur edbyusi ngt hef ormul abyTanα=D- d/2L
Fi nal lycheckt hedi mensi onsbyusi ngv erniercal ipers.

Pr
ecaut
ions:
 Theworkpi
eceshouldbeheldri
gidl
yinthechuckbeforeoper
ati
ngthemachine.
 Toolshoul
dbepr oper
lyground,fi
xedatcorrecthei
ghtandproper
lysecur
ed,andwor
k
al
sobef
ir
mlysecur
ed.
 Bef
oreoper
ati
ngt
hemachi
neseewhet
hert
hej
obandt
ooli
sfi
rml
ysecur
edi
ndev
ices
ornot.
 Opti
mum machi
ningcondi
ti
onsshoul
dbemaint
ained.
 Chipsshoul
dnotbeal l
owedtowoundaroundar evol
vi
ngj
obandcl
ear
edasof
tenas
possi
ble

15
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Resul
t:Hencet
hef
aci
ng,st
ept
urni
ngandt
apert
urni
ngi
sobt
ainedonM.
S.
Speci
men.

Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

Obser
vat
ions(
lef
tsi
de)

S.
No. Gi
ven Obt
ained Er
ror
Di
mensi
ons Dimension

16
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

For
matf
orwr
it
ingt
heRecor
d:

Dat
e:
Ex.2:Exer
ciseonGr
oov
ing,
Thr
eadCut
ti
ngandKnur
li
ng

Ai
m:Toper
for
m gr
oov
ing,
thr
eadcut
ti
ngandknur
li
ngonLat
heMachi
ne.

Toolsrequi
red:Thr
ee Jaw Chuck,Square nose cut
ti
ng t
ool
.Knur
li
ng t
ool
,
thr
eadi
ngtool,Mi
l
dsteelspeci
men,chuckkeyandspanner
.

Pr
ocedur
e:
 Theworkpiecei
sfi
xedina3–j awchuckwi thsuffi
cientover
hang.
 Adjustt
hemachinetorunthej
obtor equi
redcutt
ingspeed.
 Fixthecut
tingt
ooli
nthetoolpostandcenteri
ngoper ati
onisperf
ormedsot
hatt
heaxi
s
ofthej obcoi ncideswi ththel at
heaxi s.
 Faci ngi sperfor medbygi vinglongitudi naldept hofcutandcr ossf eed.
 Perf orm plaint urningoperationuntil thediamet eroft hewor kpi ecer educedt o20mm.
 Chamf er i
ngoper ati
onisdoneaccor dingt othegi vendi mensi ons.
 Thenr everset hewor kpi ecei nt hechuckandpl aint ur
ningoper at
ioni sperformed
accor dingtot hegi vendimensi ons.
 Usingpar ti
ngof ftoolperf
or m groov ingoper at i
ont ot herequireddi mensi ons.
 Reducespeedoft hespindl ebyengagi ngbackgearanduseTumbl erf eedreversing
mechani sm tot ransmitpowert hr
ought hel eadscr ew.
 Andcal culatet hechangegear sfort her equir edpitcht obemadeont hewor kpi
ece.
 Using hal fnutmechani sm per for m t hread cut t
ing operat ion(
righthand t hreading)
accor dingtot hegi vendimensi onsandcont inuesi tunt i
lrequi
r eddept hofcuti sobtained.
 Att hesamespeedknur l
i
ngoper ati
oni sper formedusi ngknur li
ngt ool.
 Forev eryoper ationcheckt hedi mensi onsusi ngv erniercali
per s.

Pr
ecaut
ions:
Beforestart
ingthespindlebypower ,l
athespindleshouldber evol
vedbyoner evolut
ionbyhand
tomakei tsurethatnofouli
ngisthere.
Toolshoul dbepr oper
lyground,fi
xedatcorrectheightandpr oper
lysecured,andworkalsobe
fi
rmlysecured.
Chipsshoul dnotbeallowedtowi ndaroundar evol
vingjobandclearedasof t
enaspossible.
Noat temptshoul dbemadet ocleantherevolvi
ngjobwi thcott
onwast e.
Onhear ingunusualnoise,
machineshouldbest opped.

Resul
t:Hencet
hegr
oov
ing,
thr
eadcut
ti
ngandknur
li
ngi
sdoneont
hegi
venM.
S.

17
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
Speci
men.

Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

Obser
vat
ions(
lef
tsi
de)

S.
No. Gi
ven Obt
ained Er
ror
Di
mensi
ons Dimension

18
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Shaper

19
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
Introducti
on
Theshaperi sarecipr
ocati
ngt ypeofmachi net oolusedf orproducingsmal lfl
at
surfaceswi thhel
pofasi nglepointcutti
ngt oolreciprocatingoverthest at
ionary
wor k piece.The f l
atsurface may be hor izontal,i ncl
ined orv ert
ical
.The
reciprocati
ngmot ionofthetoolisobtainedeitherbyt hecr ankandslottedlever
quickr etur
nmot ionmechani sm,whitwor t
hqui ckr etur nmot i
onmechani sm or
Hy drauli
cmechani sm.
Pr i
nciplepartsofashaper,asshowni nf i
g.,
areasf ollows.
1.Base 2.Column 3. Ram

4.
Tool
head 5.Cr
ossr
ail 6.Tabl
e

Pr
inci
plepar
tsofashaper
.
Wor ki
ngpr i
nciple:
Inashaper ,asingl epointcutti
ngtoolreciprocatesov erthestati
onaryworkpi ece.
Thet ooli sheldi nt het
oolpostoft her eciprocatingr am andper f
or mthecut ti
ng
operationdur ingi t
sf or
war dstroke(wor ki
ngst r
oke) .Itmaybenot edthatdur i
ng
thebackwar dst r
okeoft heram,thetooldoesnotr emov ethemat eri
alfr
om t he
wor kpiece.Bot ht hesestrokesform onewor kingcy cleoft heshaper.
Forshapi ngi
nhor izont
aldirect
ion,t
hecl ampedwor kpi eceisfedagainstthet ool
aftertheev erycy cle.Thedept hofcutisadj ustedbymov i
ngthetooltowar dst he
wor kpiece.
Forshaperi nv erti
caldirecti
on,thetooli sfedv er t
icall
yt owardsthewor kpiece.
Afterev erycut t
ingcy cl
e.Thedept hofcuti sadj ustedbymov i
ngt heworkpi ece
sideway s.

Cl
assi
ficat
ionofshaper
.
1.Accor di
ngtotheram dr
ivemechani
sm:
a.Crankshaper b.Gear edshaper c.Hy
draul
i
cshaper
.

2.Accor
dingtotheposit
ionandt
rav
elofther
am:
a.Hor
izont
alshaperb.Ver
ti
cal
shaper

3.Accordingtothedir
ecti
onoft hecut
tingstroke:
a.Push- cutshaper
:Inapush– cutshaperf orwar
dstrokeisthe
cutt
ingstr
okeandt hebackwardstrokeisanidlestr
oke.
b.Dr aw–cutshaper :Indrawcutshaper ,thebackwardstrokei
sthe
cutt
ingstr
okeandf or
war dst
rokeisani dlest
roke.

20
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
4.Accordi
ngtot
hedesignofthetable:
a.Standar
dshaperb.uni
versalshaper
.

Speci
fi
cat
ionofashaper
1.Maxi mum lengt hofst r
okeinmm.
2.Sizeofshaper .i.e.Length,
widt
handheight
.
3.Maxi mum ver t
ical andhori
zont
alt
ravel
ofthet
abl
e.
4.Maxi mum numberofst r
okesperminut
e.
5.Poweroft hedr ivemot or.
6.Typeofqui ckr eturnmechanism
7.Floorspacer equi r
ed
8.Wei ght
.

ShaperDrive:
1.Mechani caldr
ive
a.Ram drive:
1.Cr ankandsl ot
tedleverqui
ckr eturnmoti
onmechani sm,
2.Whi twor thqui
ckreturnmot i
onmechani sm
Thelengthofram st r
okedependsupont her adiusoft
hecrankpinont hebul
l
gear
,thatis,ABwhi chcanbeadjusted.Thel argert
hecrankradi
us,thelar
ger
ther
am strokewillbeandv i
ceversa.

Cut
ti
ngst oketi
me <B2KB1
-
--
--
--
--
--
--
--
---
--
-- = --
---
--
--
--
-
Ret
urnstroke <B1LB2
Cut
ti
ngti
met oreturnti
merat
iousual
l
yv ari
esbetween2:
1andt
hepr
act
ical
l
imi
tis3:
2.

b.Feed mechani
sm:In a shaperboth downward and cr
oss f
eed
movements maybe obt ai
ned.These movements are pr
ovi
ded
i
nter
mitt
entl
yanddur
ingtheendofreturnst
rokeonly.

21
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
2.Hydraul
i
cdriv
e:I
nahydrauli
c shaperthe ram is moved f
orwar
d and
backwardbyapi
stonmovinginacyli
nderpl
acedundert
heram.

Workhol dingdev i
ces:
Thetopandsi desofashaperhav eT-Sl
otsf orclampingthework.Theworkis
supportedont hetablebyt hef
oll
owingmet hodsdependingont henatur
eofthe
workpiece.
1.clampedinav i
se
2.clampedonthet able
3.clampedtotheangl eplate
4.clampedonaV-bl ock
5.Heldbetweenshaperi ndexcenter.
Shaperoper ati
ons:
Ashaperi samachi netoolpri
maril
ydesignedt ogenerateaf l
atsurf
acebya
si
nglepoi ntcutti
ngtool.Thedif
fer
entoperationswhichashapercanper f
orm ar
e
asfoll
ows:

1.Machi ninghor i
zontalsurfaces:Ashaperi smostlyusedt omachi neaf l
at,
truesur faceonawor kpiecehel di nav iseorotherhol dingdev i
ces.Aft
er
thewor kisproper l
yheldont het able,aplani
ngt oolisseti nthetoolpost
wi t
h mi nimum ov erhang.Thel engt h and positi
on ofst r
okear et hen
adjusted.Thel engthofst rokeshoul dbenear l
y20mm l ongerthanwor k
pieceandt heposi t
ionofst rokei ssoadj ustedt hatt hetoolbegi nsto
mov ef rom adi st
ance12t o15mm bef orethebegi nningoft hecutand
continuest omov e5t o8mm af t
ert hecut.Propercut ti
ngspeedandf eed
i
st henadj usted.Shor tstr
okesshoul dbegivenwi t
hhi ghspeedwhi l
elong
strokeswi t
hsl ow speed.Dept hofcuti sadjustedbyr otati
ngt hedown
war df eedscr ew oft het oolhead.Thedept hofcutf orroughingwor k
rangesf r
om 1.5t o3mm,whi leforf ini
shingworki frangesf r
om 0. 075to

0.2mm.Feedisadjust
edaboutonehal ft
hewi dthofthecutti
ngedgeof
thetoolsothateachcutwillov
erl
apt helastcutt
ingasmoot hsurf
ace
fi
nish.
1.
swivelbase 2.wor k
Fig.Machini
nghori
zont
alsur
face Fi g.Machiningver
ti
calsurf
ace

2.Machi
ningver
ti
calsurf
aces:Aver
ti
calcuti
smadewhilemachi
ningthe
endofaworkpi
ece,squar
ingupabl
ockorcut
ti
ngashoul
der
.Theworkis

22
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
mount edintheviseordir
ectl
yont het abl
eandsur f
acetobemachinedis
carefull
yali
gnedwiththeaxisofther am.Asi de-
cutt
ingt
oolissetonthe
toolpostandt heposit
ionandl engthofst rokeisadjust
ed.Theapronis
swiveledinadirect
ionawayf r
om thesur facebeingcut.Thedownfeedis
givenbyr ot
ati
ngthedownf eedscrewbyhand.Thef eedi
sabout0.25mm
givenattheendofeachr et
urnstroke.

3.Machi ni
ngangularsur
faces:Thewor kissetont hetabl
eandt hev
erti
cal
sli
deoft hetoolheadisswivel
edtot her equiredangl
eeit
hertowar
dsleft
ort owardr i
ghtf r
om the ver
ti
calposi tion.The apron i
sthen fur
ther
swiveledawayf rom t
hewor ksot hatthet oolwil
lcl
eartheworkduring
ret
ur nstr
oke.Thedownfeedisgivenbyr ot ati
ngdownfeedscr
ew.Angular
surfacecanalsobemachi nedi
nauni versal shaper
.

1.wor
k 2.work
Fi
g.Machi
ningangul
arsur
face Fi
g.Machi
ningi
rr
egul
arsur
face

4.Machini
ngi rr
egularsur
faces:A shapercanal sopr oduceacont our
ed
surf
ace,i.e.aconv exorconcav esurf
aceorcombi nati
onofanyoft he
abovesur faces.Toproduceasmal lcontouredsurf
aceaf or
mingtooli
s
used.Ifthecur veissuffi
cient
lylar
ge,power -cr
oss–f eedinconj
uncti
on
wit
hmanualdownf eedi
ssoadj ust
edt hatthetoolwil
ltracether
equir
ed
contour
.

5.Machini
ngsplinesorcutti
nggear s:Theworkismount edbetweentwo
center
sandaspl ineiscutsimi
lartothecutt
ingakey way.Af
terthefi
rst
spl
ineiscut
,thewor ki
srotat
edthroughapredeter
minedamountbyusing
theindexpl
ateandi ndexpin.Whilecut
ti
nggearaf ormedtoolisused.

6.Cutti
ngslots,grooves,andkeyways:Wi t
ht hesui
tabletool
sashapercan
veryconv enient
lymachi neslotorgr oovesonawor korcutext er
nal
keywaysont heshaf tandint
ernalkey
way sonpull
ey sorgears.Forcutt
ing
slotsorkey waysasquar enosetoolsimilartoapar t
ingtoolisselect
ed.
Thespeedi s
reducedwhilecut t
ingakey way.
1.Vise 2.Tool 3.Wor k
Fig.Cutt
ingexter
nalkeyway

23
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Cutt
ingSpeed:Inashaper ,thecut t
ingspeedi sther at
eatwhi chthemet ali
s
removedbycutti
ngtool.Thisisexpr essedinmet er
spermi nut
e.
Lengt hoft hecutt
ingst r
oke
Cutt
ingspeed = - -
--
--
----
--
--
----
--
--
--
--
--
---
---
-
Timer equi r
edbyt hecuttingstroke
V = nL(1+m) /1000
WhereL=lengthofthecutti
ngst r
okei nmm.
m=t herat
iobetweenr eturntimet ocut t
ingtime.
n=thenumberofdoubl est r
okesoft her am permi nuteorr.
p.m oft
hebull
wheel
v=thecutti
ngspeedexpr essedi nm/mi n.

Feed:Feed i sthe relati

ve movementoft he toolorwor kin a dir
ecti
on
perpendicul
artot he axis ofreci
procati
on ofram perdouble st
roke and
expressedinmm.Thef eedisalway
sgi v
enattheendofretur
nstr
okewhent he
toolisnotcutti
ngthemet al
.Theselect
ionofthefeeddependsuponthekind
met al
,typeofj
ob,etc.

Av
eragecut
ti
ngspeedandf
eedofdi
ff
erentmat
eri
als

Wor
k
mat
eri
al Highcarbonst
eel H.S.
S Cementedcar
bide
Cutti
ng Feed Cutt
ing Feed Cutt
ing Feed
speed mm/ mi
n speed mm/ mi
n speed mm/mi
m/ min m/mi n m/mi n n

Casti
ron 9 1.5 18 2 30 0.
125-
Mil
dspeed 12 1.
25 24 1.
5 0.
5
45 0.
125-
0.
5

Depthofcut :Depthofcuti sthet

hicknessofmet alt
hatisremovedinonecut
.It
i
st heper pendiculardistancemeasuredbet weenmachi nedsurfaceandnon
machinedsur face.Theselecti
onofthedepthofcutdependsuponthekindmetal
,
t
y peofjob,etc.Thedept hofcutfordeepcutsoftheorderof10mm.Forshall
ow
roughi
ngcutoft heorderof2.5mm andforfi
nishi
ngcutoft heor
derof0.
4mm.

Sur
facef
ini
sh:Ty
picalsur
facer
oughnesscanobt
ainedonwor
kpi
eceusi
ng
24
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
shapi
ngmachinebetween1.6–12. 5m f
orav
erageappl
i
cat
ions,12.
5-25,
0.4-
1.6m f
orl
essfr
equentappl
i
cat
ions

Powerr
equi
redi
nashapi
ngpr
ocess
Powerr
equi
redi
nashapi
ngpr
ocessi
s(P)
=Fz.v KW
60

Fz=Tangent i
alfor
ce, N.
Fz=wt1scos(-)
[ 1 ]
sincos(+-
)
w-wi dthofcutmm
s-ulti
mateshearst r
essofthewor
kmat
eri
al mm2
N/
t1-Uncutchipthicknessmm
-fri
cti
onangl e(μ=t an)
μ-coeffici
entoffri
cti
on
-shearangl e
-r akeangle

Or
x y
Fz=Czt fFz
Cz=Aconst antdependingontheworkmat er
ialandcutti
ngparamet ers
t=Depthofcut .
f=Feedr ate.
K=Cor r
ect i
onfact or
,dependi
ngonactualworki
ngcondi t
ions.
Fordetermi ni
ngt hevalueofFzthevaluesofthev ari
ouscoeffi
cientsaregiven
i
nthetable.
Wor k Cz X Y Cutt
ingoperati
on
material
Steel 220 0.9 0.775 Turni
ng
270 1.0 0.
9 Facing
C.I 100 1.0 0.
8 Bori
ngTur ni
ng
135 1.0 1.
0 Facing

V=cut
ti
ngspeed,
m/mi
n.

Quest
ions:
1.Howdoy ouspeci f
yashaper?
2.Inashaper ,t
hemet ali
sremov edduring_______
___mot i
on.
3.Inshaper, reci
procati
ngmot i
oncanbeobt ainedby____
_______
4.Inashaper ,t
helengthofthestrokeisincreasedby______
______
5.Whatar et heusesofshaper ?
6.Howt hej obsar eheldonthetableofhor i
zontalshaper
?
7.Whati sthedi ff
erencebetweenapushcutshaperandpul lcutshaper
?
8.Whati sthedi ff
erencebetweent hepl
ainshaperanduni versalshaper
?
25
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
9.Whatar
etheappl
icat
ionsofshaper
.
10.
Whatar
eadvant
agesofhydraul
icdri
veov
ert
hemechani
cal
dri
ve.

26
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Ex.3:Exer
ciseonShapi
ngt
opr
epar
epl
ainsur
faces

Aim:Tomakeasquar
eshapeofagi
venAl
umi
nium r
ect
angul
arbl
ockusi
ng
shapi
ngMachi
ne.

Tool
srequi
red:
ShaperMachi
ne,
Singl
epoi
ntcut
ti
ngt
ool
.

Mat
eri
alRequi
red:
Alumi
nium Bl
ockSpeci
men

Pr
ocedur e:
 Fi xt heblockont hevicesucht hattheflatsurfaceofthesquarebl ockisat
ri
ghtangl e.
 Fi xt hesinglepointcuttingtooltot hetoolhol derwhichislocatedatt he
clapperbox.
 Adj ustthelengt
hoft hest r
okeandt het oolpointer
.
 Nowmov et hebedinsuchawayt hatthesi nglepoi
ntcutti
ngtoolt ouches
theedgeoft heblock.
 St ar tt
hemachi newi t
ht hegivenmi nimum dept h.
 Adj ustthelengthoft hestrokeanddept hofcutsucht hatthemat eri
alis
remov edal ongtheedgeoft hebl ock.
 Thi sprocessiscontinuedunt i
lthewor kpieceismachinedcompl etely.

Pr
ecaut
ions:

 Markingshoul dbedoneaccur at
ely.
 Thewor kpi eceshoul dbesetsecurelyandr i
gidl
yinthev ice.
 Beforest artingashapermakesur ethatthewor kv ise,tool,andr am ar
e
securel
yf ast ened.
 Checkt hatt het oolandt ool
holderwil
lclearthewor kandal sot hecolumn
onther eturnst roke.
 Alway sst andpar all
eltothecutti
ngstrokeandnoti nf r
ontofi t.
 Nev erattemptt oremov echipsorreachacr ossthet ablewhi l
et heram i
s
i
nmot i
on.
 Neverat t
emptt oadjustamachi newhi l
eitisinrotati
on.
 Suitablefeedsanddept hofcutshouldbemai nt
aineduniforml y
.

Resul
t:Theshapi
ngoper
ati
oni
sobt
ainedf
ort
hegi
venspeci
men.

27
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

28
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

29
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Sl
otti
ng
Machi
ne

Intr
oduct i
on
Thesl otti
ngmachi nef allsundert hecategor yofr eciprocat i
ngt ypeofmachi ne
toolsimilartoashaper .I toper atesalmostont hesamepr incipl
east hatofa
shaper.Themaj ordi f
ferencebet weenasl otterandashaperi sthatinasl otteris
thatinasl otterther am hol di
ngt oolreciprocat esinahor izontalaxis.Av erti
cal
shaperand a sl otterar e almostsi mi l
art o each ot heras r egards t heir
constructi
on,oper ation,anduse.Theonl ydi fferencebei ng,incaseofav erti
cal
shaper,ther am hol dingt oolmayal soreciprocat eatanangl et othehor izontal
tableinaddi t
iontot hev erti
calst r
oke.Ther am canbeswi v el
edni tmor et han5˚
tot hev erti
cal.Thesl otteri susedf orcut ti
nggr oov es,key way sandsl otsof
vari
ousshapes, f ormaki ngr egularandi rregularsur facesbot hinternaland
external
,f orhandl i
ngl argeandawkwar dwor kpi eces,f orcut ti
ngi nt
er nalor
30
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
ext
ernalgear
s and many otheroper
ati
ons whi
ch cannotbe conv
eni
ent
ly
machinedi
nanyothermachi
netool
.

Typesofsl
ott
ingmachi
ne
Therearemai
nlyt
woclassesofslot
ter:
1.punchsl
ott
er 2.Preci
sionslot
ter

Punchslot
ter
:Thepunchslott
erisaheavy,ri
gidmachinedesignedforr
emoval
ofl
argeamountofmetalf
rom lar
gefor
gingsorcast
ings.Thelengthofst
rokeof
apuncheri
ssuff
ici
ent
lyl
arge.I
tmaybeasl ongas1800–2000mm.

Preci
sionslot
ter
:Thepreci
sionsl
ott
erisal i
ghtermachineandi soperat
edat
hi
ghspeeds.Themachi neisdesi
gnedtotakelightcut
sgivingaccurat
efini
sh.
Theprecisi
onmachinesar
eusedforgener
al-
purposework.Andproducti
onbasis
work.

Slott
ersize:
Thesi zeofasl ot
terisspecifi
edbymaxi mum l engt
hofst r
okeoft heram,
expressedinmm.Thesi zeofagener alpurposeorpr eci
sionsl ot
terusuall
y
rangesfrom 80-
900mm.Tospeci f
yasl ott
ercorr
ectl
ythediameteroft hetabl
ein
mm,amountofcr ossandl ongi
tudinaltr
aveloftabl
eexpressedinmm.Number
ofspeedsandf eedsavai
lable,
h.p.ofthemot or
,fl
oorspacerequiredetc.

Slot
ti
ngmachi neparts
Figuresi
llustr
ateasl ot
ti
ngmachi
ne.Thediff
erentpart
sofasl ot
ti
ngmachine
are
1.Base 2.Column 3.Saddl
e 4.Cr osssli
de 5.
Rotat
ingtable
6.Ram andt oolheadassembl
y 7.Ram dr
ivemechanism 8.Feedmechani
sm

Feedmechani sm:Inaslot
ter,thefeedi sgi v
entobythetabl
e.Aslot
ti
ngmachi ne
tablemayhav ethr
eetypesoff eedmov ement
1.Longi tudinal 2.Cross 3.Ci rcular
I
ft het ableisf edper
pendiculartot hecol umntowardorawayf r
om it
sf ace,the
feedmov ementister
medasl ongitudinal.
I
ft hetabl eisfedparal
lelt
ot hef aceoft hecolumnthefeedmov ementistermed
ascr oss.
I
ft hetabl eisrotat
edonav erticalaxis,thefeedmovementister
medasci rcular

31
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Fi
g:Slott
ingmachine
1.Base2.Feedgear3.Cr osssli
de4.Table5.Cr ossfeedhandl e6.
Longit
udinalf
eedhandle7.Cir
cularf
eedhandl e8.Tool 9.Ram 10.Crank
di
ck
11.Leverforcount
erbal
anceweight12.Bullgear13.Conepul ley14.Col
umn
15.Feedshaft16.Pawlactuati
ngcr ank

Sl
ott
ingoper
ati
ons:
Theoper
ati
onsperformedi nasl ot
terare
1.Machini
ngfl
atsur faces.
2.Machini
ngcyli
ndr i
calsurface
3.Machini
ngir
regularsur f
aceandcam machi
ning.
4.Machini
ngslot
s, keywayandgr ooves.

Slot
tertools
ASlottermachi netooldif
ferswidelyfrom ashaperorapl anertoolast hetool
i
nasl ott
err emov esmet alduri
ngi tsv erti
calstroke.Thischangedcut ti
ng
condit
ionpresent salotofdiff
erencei nthet oolshape.Inal at
he,shaperora
pl
anert oolthecut ti
ngpressureact sper pendicul
art othetoollength,wher e
asinasl ott
erthepr essureactsalongt helengt hofthetool.Theslottertools
areroustarei ncrosssect i
onandar eusual l
yoff orgedtype.Fig.Showst he

32
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
di
ff
erentsl
ott
ert
ool
susedi
ndi
ff
erentoper
ati
ons.

Fi
g:Sl
ott
ert
ool
s

Cutt
ingspeed:Cut
ti
ngspeedofasl
ott
erisdef
inedbyt
heratewi t
hwhicht
he
metalisremov
edduringdownwar
dcutt
ingstr
okeandisexpressedi
nmetersper
minute.

Cut
ti
ngspeedsf
orsl
otti
ngi nm/ min.
Workpiec e(M.
S.) Sl
ott
ing,m/
min
Tool
Hi
ghcar bonsteel 1
5
Hi
ghspeedst eel 30
Carbides 60
Cerami cs 1
20

Feed:Feedi
sthemov ementoftheworkperdoublest
rokeex
pressedinmm.
Longi
tudi
nal
andt
ransv
ersepowerfeedr
angesf
rom 0.
05-2.
5mm /str
oke.

Dept
hofcut
:Dept
hofcuti
stheper
pendi
cul
ardi
stancemeasur
edbet
weent
he

33
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
machi
nesur
faceandunmachi
nedsur
faceex
pressedi
nmm.

Quest
ion:
1. Whati st hediffer
encebet weenav er
ti
calshaperandaslot
ter
?
2. Whatar et heusesofasl otter?
3. Cl assi
fythesl ott
ermachi ne?
4. Whatar et hevari
ousr am drivemechanismsofasl ot
ter
?
5. Howdoy ouspecifytheslottermachine?
6. Howt her am holdingtool r
eciprocat
esinslott
ermachine?

34
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Ex:
4:Exer
ciseonKeyWayCut
ti
ngonaSl
ott
er

Ai
m:Toper
for
m key
waycut
ti
ngonasl
ott
ingmachi
neonagi
venny
lonspeci
men

Tool
srequi
red:Sl
ott
ingMachi
ne,Si
ngl
epoi
ntcut
ti
ngt
ool
,chuckkey
,Thr
eeJaw
Chuck.

Mat
eri
alr
equi
red:
Nyl
onSpeci
men

Pr
ocedur
e:

 Ini
tiallyf i
xt hespeci meni nt he3j aw chuckoft heslot
ti
ngmachi neby
usingt hechuckkey .
 Fixthesi nglepointcuttingtoolint
het ool post.
 Adjustt hespeedt ot hemi ni
mum v alueof28r pm
 Adjustt hest r
okelengt hwiththehelpoft helev erandthehandl
eatthetop
toal engthof100mm
 Swi tchont heslott
ingmachi ne.
 Nowt hecut ti
ngtool mov esintheverticaldir
ect i
on.
 Bringt hetool i
ncont actwiththegi
v enny l
onspeci men.
 Nowbyi ncreasi
ngt hedept hofcutsl owlyby1mm akey wayiscutonthe
speci men.

Pr
ecautions:
 Thewor kpieceshoul dbesetsecur
elyandr igi
dlyi
nthev i
ce.
 Bef orestartingt hemachinemakesur ethatthewor k,vi
ce,tool
,andram
aresecurelyf astened.
 Checkt hatt het oolandtoolhol
derwi l
lclearthewor kandalsoclearthe
columnont her eturnst
roke.
 Makesur ethatt heaxisoftheworkpieceispar al
l
eltotheli
neofactionof
tool.
 Nev erat
temptt oadjustamachinewhileitisinmoti
on.
 Sui t
ablefeedsanddept hofcutshoul
dbemai ntai
nedunifor
ml y.

Resul
t:Thesl
ott
ingoper
ati
oni
sdonef
ort
hegi
venspeci
men.

35
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

Obser
vat
ions(
lef
tsi
de)

36
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Dr
il
li
ng
37
Machi
neTool
sLab Dept
.OfMechani
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Engg.
:VNR
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Int
roducti
on
TheBasi cpurposeofadr i
ll
i
ngmachi nei
st odr
il
lcylindr
icalhol
einworkpieces.
Theholesare cutoutoft hemateri
alwit
hacuttingtool,whichisknownasdr i
ll
.
Thedr i
llisfi
xedi narotati
ngspindl
eandcanbef edtowar dstheworkpiece,
whichmaybef ixedt
ot hetabl
eort othebaseoft hespi ndl
e.Thespeedofthe
spi
ndleandt hefeedcanbeadjustedaccordi
ngtothewor kpiece.

Typesofdril
li
ngMachi ne
Thedif
fer
entt ypesofdr i
ll
ingmachi nesare:
1.Portabledr il
lingmachi ne
2.Sensiti
v edr i
lli
ngmachi ne
a.Benchmount i
ng b.Fl
oormount
ing
3.Uprightdr il
lingmachi ne
a.Roundcol umnsect ion b.Boxcolumnsecti
on
4.Radialdr i
ll
ingmachi ne
a.Plain b.Semi uni
ver
sal c.Univ
ersal
5.Gangdr i
ll
ingmachi ne
6.Multipl
espi ndledri
ll
ingmachi ne
7.Automat icdr i
ll
i
ngmachi ne
8.Deephol edr il
li
ngmachi ne
a.Ver t
ical b.Hor izontal
.

Pri
ncipl
epartsofdr
il
li
ngmachine:
Thediff
erentpar
tsofaradi
aldri
l
li
ngmachi
neareasfol
l
ows:
1.Base 2.Col
umn 3.Radialarm4.Dri
l
lHead
5.Spi
ndlespeedandFeedmechanism

Radi
alDr
il
li
ngMachi
ne

38
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Wor ki
ngprincipl
eofadri
lli
ngmachi ne:
Met alcut
ti
ngoper at
ionthatproducescy li
ndr
icalhol
esorenl argesexi
stsholes
withanendcut t
ingt
ooli
scal l
edasdr il
l
ing.Theend-cutt
ingtoolusedfordri
l
li
ng
holesinthewor kpi
eceiscalledast wistdri
l
landi sprovidedwi t
htwocutti
ng
edges.Inordertocutoffchips,twomot ionsi
.e.rot
arymotionandl i
nearmoti
on
towardsthefixedworkpiece(feed)aregivent
ot hedri
ll
simultaneousl
y.

Specif
icati
onofdr i
lli
ngmachi ne:
Adr i
l
li
ngmachi nei
sspeci f
iedbyf oll
owi ngparameter
s
1.Dr il
l
ingcapacity
2.Taperi nspindle
3.Di stancebetweenspi ndl
ecol umni ncaseofradialdr
il
li
ngmachi
ne
4.Tr ansverseofspindle
5.Mi nimum distancebet weenspi ndleandtabl
e
6.Mi nimum distancebet weenspi ndleandbaseplate
7.Wor ki
ngsurfaceoftabl e
8.Rangeofspi ndlespeed,
9.Rangeofpowerf eedperr evoluti
on
10.Mot orspeedandmot orpower .

Workhol di
ngDevi
ces:
Thedev i
cescommonlyusedforholdi
ngthewor
kindri
ll
ingmachi
near
e:
1.T-boltandcl
amp 2.Dri
ll
pressvi
se 3.Stepblock
4.V-Block 5.Anglepl
ate 6.Dri
l
lji
gs.

ToolHoldi
ngDev i
ces:
Therevolvi
ngspi ndleof dri
l
lingmachi
necanhol ddiff
erentcutt
ingt
ool
sfor
di
ffer
entoper ati
ons.Thedifferentmet
hodsused forholdingtoolsi
nadril
l
spi
ndleare:
1.Bydirectlyfi
tt
ingi
nthespindle
2.Byasl eeve
3.Byasocket
4.Bychucks
5.Byspeci alatt
achment
s
a.Tappingat t
achments b.Fl
oat
ingholder

TwistDr i
ll
s:
Themostcommont ypeofdr i
l
li nuset odayistwistdri
ll
.Themat er
ialf
or
manuf acturi
ngof
twistdril
lareH.S.S.
,carbonst
eel,cementedcarbi
deti
ppedbits.Twi
stdri
l
lisan
end-cutt
ing
tool.Thef ol
lowi
ngfigur
eshowsdi ff
erentpar
tsofadri
l
l bi
t.

39
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

Twi
stdr
il
lnomencl
atur
e

Recommendedv al
uesofpointangl
e,hel
i
xangl
esandr el
i
efangl
esar egiv
eni n
fol
l
owingtable.
Materi
altobe Poi
ntangle Heli
xangle Li
preli
efangle
dri
ll
ed
Steel 116-118 30 12-15
Castir
on 118-125 18-30 8-
12

40
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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Copper 125 35-45 12-
15
Bronze 118-125 8-
12 12-
15
Al
uminum al
loy
s 130-140 35-45 12-
15

Dril
lSi
zes:
Standarddril
lsareavial
ableinf oursizeseries,thesizeindicati
ngt hedi
amet erof
thedri
llbody.
1.Fracti
onalsize:Si
zer angeis1/ 64’’t
o1/4’ ’withincrement sof1/64’
’
2.Mill
imetersize:Si
zer angeis0. 5to10mm wi thincrement sof0.1mm
3.Number ed Size:{
80-10)Si ze range i s 0.0135’’to 0.228’’wi thvery sli
ght
i
ncrement s
4.Letter
ed size (At o Z) .Size r ange is 0.234’’to 0.413’’wi thvery sli
ght
i
ncrement s.
Thediamet erofthedr i
l
lshoul dalway sbesl i
ght l
ysmal l
erthant hatoftheholeit
i
st odril
l
.Sincedril
lsalway scutov ersize

Dri
ll
ingoper at
ions:
Themostcommonoper ati
onswhichcanbecar
ri
edonadr i
l
li
ngmachi
neareas
fol
l
ows
1.Dr i
l
li
ng:I ti
sanoperat
ionofpr
oduci
ngaci
rcul
arhol
eonaworkpi
eceby
f
orcingadr i
ll
agai
nstit
.

Dri
ll
i
ng
2.Reaming:I
tisanoperati
onofsli
ghtl
yenlar
gingamachinedholetoproper
si
zewithasmoothfinish.Ther
eamerisanaccuratet
oolandisnot
desi
gnedtonremovemuchmet al
.Thereamingal
lowanceisusuall
y

0.
2mm onl
y.
Reaming
3.Bor
ing:I
tisanoperat
ionofenl
argi
ngaholethathasal
readybeendr
il
led
byasingl
epointt
ool,soastomakeitt
ruetorequir
edsize.

41
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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Bori
ng
4.Counterbori
ng.Iti
sanoperat
ionofenl
argingt
hemout hofadril
l
edhole
tosetboltheadsandnutsbel
owthesurfacesothatt
heymaynotproject
outfr
om thesurfacel
evel
. Counterbor
ing

5.Tappi
ng:I
tisanoperat
ionofpr
oduci
ngi
nter
nal
thr
eadsi
nahol
eby
meansofatoolcal
ledtap.

Tappi
n
g

1 2 3
HandTaps
Thehandt apsi l
lustratedi nfi
g.areusuall
ymadei nset softhree.According
totheISspeci f
icationt heyare1.Rougher2.Inter
medi ate3.Fini
sher.
Theendoft herougherhasaboutsi xt
hreadstapered.Thisisusedt ostar tt
he
thr
eadsot hatthet hreadsar eformedgraduall
yast hetapisturnedintot he
hole.
Theintermediatei staper edbackf r
om theedgeaboutt hreeorf ourt
hreads.
Thisisusedaf terther oughert aphasbeenusedt ocutt hethreadsasf aras
possibl
e.
Thefini
sherhasf ullthreadsf ort
hewhol eofit
slength.Thisisusedt ofinish
thewor kpreparedbyt heot hertwotaps.

6.Countersi
nki
ng.I
tisanoperati
ontolevel
thet
opofadr
il
ledhol
efor
makingaconical
seatforf
latheadscrew.

Count
ersi
nki
ng

42
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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7.Spotfaci
ng:I
tisanoper
ati
ont
ofi
nishof
fasmallport
ionofr
oughsur
face
aroundadri
ll
edholet
ohavesmoot
hseatforbol
thead.

Spotfaci
ng
Dri
llspeed:
Thecut t
ingspeedindri
l
li
ngistheper i
pheralspeedofthedri
llr
elat
ivet
ot hewor
k
Cutti
ngspeed=( π*D*N) /1000 m/ min
D=Di ameterofdr i
l
l i
nmm
N=Wor kspeedi nr.
p.m.
Thecut t
ingspeeddependsupont hemat eri
altobecut,t
hetoolmateri
al,
capacit
yofmachi ne,
quali
tyofsurfacefini
shandt hecool
antused.

Cutt
ingSpeedsf ordril
l
ingi
nm/min
Mat er
ial H.
S.S.dri
l
ls,m/
min Car
bonSteel
,m/mi
n
Softcastir
on 30-45 12-23
Mi l
dsteel 24-45 9-17
St
ainl
essst eel 18-21 7.
5-10.5
Al
umi num andal l
oys 60-90 24-45

Feed
Feedofadr i
l
listhedist
anceitmov esintothewor kwit
heachr ev ol
uti
onofthe
spindl
e.I tisgeneral
lymeasur edinmm/r evol
utionofthespindle.Thet ypi
cal
feedinmm/ revol
uti
onforv ar
iousdr i
l
ldiametersforhard( Carbonsteelsand
all
oyst eels)andsoft(C. I
,Brass,Aluminum al
loys) mater
ialsrespecti
vel
yar e
3mm:0. 05,0.07;6mm:0. 07,
0.10;9mm:0. 1,
0.15;12mm:0. 12,0.
20;25mm:
0.22,
0.35.

Dept
hofcut
Dept
hofcuti
ndr
il
li
ngi
sequal
toonehal
foft
hedr
il
ldi
amet
er.

Surfacef
ini
sh:Typicalsur
facer
oughnesscanbeobtainedusingdri
l
li
ngmachine
between 1.
6-6.3 μm f oraver
age appl
icat
ions,6.
3-12.
5,0.
8-1.
6 μm f
orl ess
fr
equentappli
cati
ons.

TorqueandPoweri ndr
ill
i
ng
Thet orqueTindr il
li
ngequal stheproductofthecir
cumf er ent
ialf
orceQandthe
arm coupleis(T)=Q*( d/2)Kg–mm
Thetor queisalsodeterminedf r
om theformul
a:T=cd1.9s0.8
Thethr usti
ndrill
i
ngi sdeter
mi nedfr
om theformula:B=kds0.78
Wher ed=di amet erofthedril
linmm, n-r.
p.m.,ands=f eedi nmm, andc=34and
k=85f orsteel
oful ti
matestrengthof75kg/ mm2

43
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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Thetot
alnethorsepowerdevel
opedatthedri
llpointequal
sthehor
sepowerdue
tot
hetorquepl
ust hehor
sepowerduetothethrustasfoll
ows:
P= 2πTN____
___ +_ __
___
_ _
Bsn__ _
____ KW
1000*60* 102 1000*60*102

Do’
sanddon’tsfordr i
l
li
ng
1.Whil
edr i
ll
ing,dril
lbi
tmustbef i
ttedfirmlyinthedri
llchuck.
2.Workmustbef i
rmlytightenedi nt hev i
ce.
3.Centerpuncht heinit
ial posit
ionoft hedr il
lhole.
4.Usethecor r
ectr .
p.m.
5.Usecoolants(Wat er,emul sionset c.)whiledril
li
ng.
6.Useslowf eedr at
es
7.Usenonmet all
icendpi ece(Pr eferablywood)wi thj
ob.
8.Dri
ll
bitmustber emov edf rom thewor kpiecewhi l
eitisrot
ati
ng.

Quest
ions
1.Def inedrill
ingoperation.
2.Howdoy ouspecifyt hedril
l
ingmachi ne?
3.Whatar et hevari
ousmat eri
alst hatareusedf ordril
l
ingtools?
4.Whatf actorsaffectthecut ti
ngspeedi ndri
ll
ing?
5.Howdr i
l
lsar eheldinadr il
li
ngmachi ne?
6.Di ffer
entiatebetweendr il
li
ng, bori
ngandr eami ng.
7.Whi chtype-dri
ll
i
ngmachi neisusedf ordri
ll
ingriff
lebarrel
s?
8.Whi chtypeofdr i
ll
ingmachi nei susedf ordr il
li
ngnumberofhol
esi
na
pieceofwor ksi
mul taneously?
9.Whatar et hevari
ousmot ionsi nuniversal
dril
li
ngmachi ne?
10.Differ
entiatebetweenCount erbor i
ngandcount ersi
nking.

44
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

Ex5:
Exer
ciseonDr
il
li
ngandTappi
ng

Aim:Tomakeahol eandi
nternalt
hreadonagiv
enwor
kpi
eceast
hepert
he
requi
reddi
mensi
onsusi
ngr
adialdri
l
li
ngmachi
ne.

Tool
srequi
red:
Dri
l
lbi
tsofr
equi
redsi
zes,
tappi
ngt
ool
s,Radi
aldr
il
li
ngmachi
ne

Mat
eri
alRequi
red:
Mil
dst
eel
plat
e.

Pr
ocedure:
 Taket hespecimenofr equir
eddi mensi onsandmar kthepointswherethe
holesar etobedr i
ll
ed.
 Pl acethespecimeni nt hev i
ce.
 Byoper at
ingthel ockingmechani sm,t her adialarmi srotatedandis
pl
acedatt hepointwher etheholeist obedr i
l
led.
 Inser tthepil
otdril
l i
nt hechuckusi ngt hechuckkey .
 Swi tchont hemot orbyr otat
ingt hespi ndlef eedhandwheelandst ar
t
dril
l
ingbyf orci
ngt hewheel againstthewor kpiece.
 Nexthandt apsar epl acedi nthet opwr enchandi nt
ernalthreadsi
nthe
holearemade.

Pr
ecaut
ions:

 Ensurethatthel
ocki
ngisproper
lydonebeforedr
il
li
ng
 Makesur ethatt
heproperl
ubri
cati
onispr
ov i
ded
 Chipsshouldbebrushedawaybeforel
ubri
cati
on.

Resul
t:Thedr
il
li
ng&t
appi
ngoper
ati
oni
sdonef
ort
hegi
venspeci
men.

45
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

46
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Mi
l
li
ng

47
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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Intr
oducti
on
Mill
ingisdefi
nedasamachi ni
ngpr ocessf
orr emovingexcessmat er
ialf
rom a
wor kpi
ecewithar otat
ingcutti
ngtool.Therot
atingcutt
ingtoolcall
edt
hemi l
l
ing
cutteri
samul tipointtoolhavi
ngt heshapeofasol idofrevol
utionwi
thcutt
ing
teethar
rangedeitherontheperipheryoronendf aceorontheboth.

I
ngeneral
,allmi
ll
i
ngoper ationscanbegroupedi
ntothefoll
owingtwotypes:
1.Peri
pheralmi
ll
ing:Thef i
nishedsurf
aceispar
all
eltotheaxi
soft hecutt
erand
i
smachi nedbycutterteethlocat
edontheperi
pheryofthecutt
er.

2.Facemi
ll
i
ng:Inf
acemi l
l
ing,t
hefini
shedsur
faceisatri
ghtangl
etothecutt
er
axi
sandi
tisobt
ainedbytheteet
honperi
pheryandthefl
atendoft
hecutter
.

Sur
facegenerat
ionmet hods:Therear et womet hodsofmi ll
i
ngf l
atsurf
acewi t
h
pl
ainmil
li
ngcutter
sdependi ngont her elat
ivedi
rectionoffeedofthewor ktabl
e
andther
otati
onofthecut ter
.
1.Conventi
onal(Up)Mi ll
i
ng:Thedi rectionoffeedoft hewor kt
ableisopposit
e
t
othedir
ecti
onofrot at
ionofthecut ter.
2.Climb(down)Mi l
l
ing:Thedirectionoft hewor ktabl
efeedandt herotat
ionof
t
hecutt
erissame.

Fi
g:A:Downmil
li
ngB: Upmill
ing
1. Di
recti
onofworkfeed2.Chip3.Machi
nedsurface4.
Di
recti
onofr
otati
onofcutter
5.St
artofcut 6.Wor
ksur f
ace 7.Depthofcut 8.Feedper
t
ooth

Mill
i
ngmachi nes:Mill
ingmachineswer ebasi cal
lydev el
opedf l
atsur faces.But,
thepresentmi ll
ingmachinescanmachi neflat,cont ouredandhel icalsur f
aces,
cutgearsanddov ar
iousotherj
obs.Duet oal lthis,ami l
l
ingmachi neisoneof
mostusef ulandnecessarymachi netoolsfoundi nt heshopandi tranksnextt o
thelat
heini mpor t
ance.
Mill
i
ng machi nes are desi
gned t o hol
d and r otate mi l
li
ng cutters,hel dthe
workpieceandf eedtheworkpiecetot hemill
inginoneofsev er
aldirections.

Cl
assi
fi
cat
ionofmi
l
li
ngmachi
nes:
48
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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a.Accordi
ngt otheaxi soft hespi
ndleoft hemachine:
1.Hor i
zontalmi ll
ingmachi ne
2.Ver t
icalmilli
ngmachi ne
b.Accordi
ngt othepur poseofthemachi ne
1.Gener alpurposemi ll
ingmachines:
i
. Plai
nmi lli
ngmachi ne(Horizontal
spindl
e)
i
i. Universalmi ll
i
ngmachine( Hori
zontalspi
ndlewithswi
vel
table)
i
ii
. Omni versalmi ll
i
ngmachi ne( Hori
zontalspindl
ewithswiveltabl
e
andswi vel knee)
i
v. Ver t
ical milli
ngmachine

2.Pr
oducti
onMi l
l
ingMachines:
i
. Pl
anert ypemil
li
ngmachi nes
i
i. Bedt ypemil
li
ngmachi nes
i
ii
. Dr um typemill
i
ngmachi nes
i
v. Handoper at
edmi l
lers
v. Continuousorrot
arymi ll
er s
vi
. Tr acercontr
oll
edpr oduction-mi
l
li
ngmachi
nes.

3.Speci
alpurposemilli
ngmachines:
i
. Diesinki
ngmachi nes
i
i. Cam mi l
l
ers
i
ii
. Thr eadmi l
l
er s
i
v. Keywaymi l
lers

Hori
zontalmi l
li
ngmachi nes:Hor izontalkneet y
pemi ll
ingmachi near eclassif i
ed
asplainoruniversaldependi ngonwheat herornott het ablecanbeswi veledi na
hori
zontalplane.Thet ableont heuni versalmill
i
ngmachi necanbeswi veledup
to45o tot her i
ghtorl ef t
,maki ngpossi bleangul arandhel i
calmi ll
i
ng.Most
hori
zontalmi l
l
ingmachi neswhi chhav eav er
ti
calspi ndleheadcanbeconv erted
o
i
ntoav ert
icalspindlemachi ne.Someoft heseheadscanbeswi v el
edby180 .
Vert
icalmi l
li
ngmachi nes:Ver ti
calkneet ypemi lli
ngmachi nehav eav ertical
spi
ndle.Theymaybeei theroft hef i
xedhead, sli
dinghead, swivelheadt ypeori t
maybeacombi nationoft helastt wo.Ver ti
calmill
ingmachi nehav eneit
herov er
arm norbr ace.Al ltheot herf eatur
esar esubst antiall
yt hesameasi nt he
hori
zontalmachi nes.A v ert
icalmi l
li
ng machi ne i s especial l
y sui
tablef or
operati
onswi t
hendandf acemi ll
s.

Pri
ncipal
par
tsofmi
l
li
ngmachi
ne:
1.Base 2.Col
umn 3.Knee 4.Saddl
e 5.Tabl
e.

49
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET
6.Ov
erhangar
m 7.Fr
ontbr
ace 8.Spi
ndl
e 9.Ar
bor

Fi
g1.Pl
aincol
umnandkneet
ypemi
l
li
ngmachi
ne

Mill
ingmachi nemechani sm:
Themi l
l
ingmachi nemechani sm i
scomposedofspi ndledriv
eandt hetablef eed
dri
v e.Allt
hemoder nmachi nesaredrivenbyindiv
idualmot orshousedwi thi
nt he
column,andt hespindl
er eceivespowerf rom acombi nati
onofgear sandcl utch
assembl y.Mul t
ipl
espeedoft hespindlemaybeobt ainedbyal ter
ingt hegear
rat
io.Thepowerf eedmechani sm containwithi
nt hekneeoft hemachi net o
enablet hetabletohavet hreedi f
fer
entf eedmov ement si.
e.,l
ongit
udinal,cross
andv ert
ical.

Si
zeofthemi l
l
ingmachi ne:
1.Dimensionsofthewor ksurfacetabl
e
2.Maximum lengthofthel ongi
tudi
nal,
crossandv
ert
ical
trav
eloft
het
abl
e.
3.Numberofspi ndlespeeds
4.Spindl
enoset aper
5.Powerav ai
labl
e
6.Netweight
7.Fl
oorspacer equir
ed,etc.

Typesofmi
l
li
ngcutter
s:
1.Plai
nmil
li
ngcutter
s:Thesecutter
sarecyl
indr
icali
nshapeandhav ecutti
ng
t
eet
hontheper
ipheryonl
y.Theyareusedf
ormi l
l
ingpl
ainorf
latsur
faces.

50
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET
Fi
g2.Plai
nmill
ingcut
ters
a.St
rai
ghtpl
ainmi
l
li
ngcutt
erb.Hel
ical
plai
nmill
ingcut
terc.sl
abcut
ter

2.Facemi l
lingcut ters:Facemi l
li
ngcut t
er,wit
ht eethont heendf acei susedf or
machi ningl arge,flatsur faces.Thecut terismount edonanar bororr i
gidly
clampedont henoseoft hemachi nespindle.(See3.a)
3.Profil
emi l
li
ngcut t
er:Cut ter
swi thacur v
edt oothoutlineoft hesameshapeas
thepr ofil
eoft hewor kpi ecear ecalledprof i
leorfor m milli
ngcut t
ers.Gear
mi l
l
ingcut t
ersar eaki ndoff orm mill
ingcuttertomachi neanyst andardgear
tooth.(See3. b)
4.Endmi l
ls:Endmi l
l
shav ecuttingteethont heendaswel lasont heper i
phery.
They ar e empl oy ed f ormaki ng deep gr ooves,pr ofil
er ecesses,st eps,
perpendi cularpl aneset c.End mi ll
scan beused on a hor izontalmi ll
i
ng
machi ne, butitisbet tertouset hem onav er t
icalmil
lingmachi ne.( See3.c)
5.Sidemi ll
ingcut t
er:Thesecut ter
shav eteethar oundtheper ipher yandalsoon
oneorbot hsi des.Pl ainsidemi l
li
ngcut t
ershav est rai
ghtt eetht heout si
de
andsi det eethonbot hsi des.(See3.d).Halfsidemi l
li
ngcut ters( See3.e)
6.Angularmi lli
ngcut ter:Thesecut t
ersar emadeassi ngleordoubl eangl e
cutter
sandar eusedt omachi neanglesothert han90 .Someoft hecommon
cutter
sar et he45and60si ngl
eangl ecut terandt he45 ,60and90

doubleangl
ecut
ter
s.Theyfindthemostwideappl
i
cati
onintooli
ntool
product
ionf
ormi
l
li
ngchi
pflut
esonvari
ouscut
ti
ngt
ool
s.(
See3.
f,
g)
Fig3:Mil
li
ngcut
ter
s

7.Accor
dingt
othepurposeoruse,wehaveT-sl
otmil
li
ngcut
ter
s,wooddruf
f
keysl
otmil
li
ngcut
tersanddovetai
lcut
ter
sformi
ll
i
ngdovetai
lgui
des.(
See

51
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
3.h)
8.Metalsli
tt
ingsaws:Forcutti
ngspli
nesandnarrowgr oov
esonworkpieceand
alsoforcuttingmater
ial
s,metalsli
tt
ingsawsareused.Topr omot
euniform
work,theendf acesofthesemill
sarealter
nat
ivel
ychamf er
edatanangleof
45.Thisallowsthechipstofreelymoveinthet oothspaceandfaci
li
tat
es
thei
rremov al.(
See3.i
)

Cutt
ermateri
als:Generalpurposesoli
dmi l
li
ngcutter
sarecommonlymadeof
H.S.
S.someofcut tersaretungstencar
bideteet
hwhi chmaybebrazedont
he
ti
psofteet
horinsertedandheldinthebodyofcutt
erbymechani
cal
means.

Wor khol dingdev ices:

Thewor ki ssuppor t
edont het ablebyt hef ol
lowi ngmet hodsdependi ngont he
natureoft hewor kpiece.
6.Cl ampedi napl ai
nv ise
7.Cl ampedi nauni versalv i
se
8.Cl ampedi naswi vel vi
se
9.Cl ampedont hetable
10.Clampedwi thdi v
idinghead.
Mil
lingoper ations:
1.Mi lli
ngf latsur faces:
Hor i
zont al f
latsur facesar emi l
l
edon
i
.Pl ainhor izontal,uni versalhori
zont almachineswi t
hpl ai
ncutter
sasshown
infig.2. c
Vertical flatsur facear emi l
ledon
i.Pl ainhor izontal,uni versalhori
zont almachinesbysi demi l
l
ingcutters.
ii
.Ver t
ical –spi ndle-mi l
li
ngmachi neusingendmi l
ls.
iii
.Ver t
icalf latsur facear ealsomi lledonpl anert ypemachi neswi thface
milli
ng cut ters.(Fig4. a)
I
nclinedf latsur facemi ll
edon
i
.Pl ainmi ll
ingmachi newi t
hsingleanglecut ter(seef i
g.3.
f)
ii
.On v er ti
calspi ndle machi ne wi tht he spi ndle swiveled t
or equir
ed
angl e.(seef i
g4.b)

52
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

Fi
g4.Mi
l
li
ngoper
ati
ons

2.Mi
l
li
ngsl
ots,
groovesandspl
i
nes:
Rectangular,T-anddov etail
slotsaremilledonv erti
cal spi
ndlemachi neby
meansofsui tablemi lli
ngcut t
er,r
ectangularslotscanal somachi nedon
plai
nhor i
zont alspindlemi ll
ingmachineswi t
hsidemi l
li
ngcutters(see.3.
h)
Keyway sofr ectangul arcrosssectionarev ert
icalspindlemachinesoron
keywaymi lli
ngmachi nesbyusi ngendmi l
lsandspeci alcut
ters.Key ways
canbemi lledonhor i
zontalspindlemachi nesbyusi ngside-mil
li
ngcut ter
s.
Spli
nesmaybemi lledonhor i
zontalspindlemachi nesbyusi ngsi ngleand
doubleangl ecut t
ers.

3.Mil
li
ngcontouredsurf
aces:Contouredsurf
acesofsmal lwidt
har emi l
l
ed
onplainmill
i
ngmachi nes,usi
ngf orm-mi
ll
ingcutt
ers.Thepr ofi
leofthe
cutt
erwit
hthatofworkpiece.Sur
faceofmor ecomplexshapear emil
leda
gangofsi mplecutt
er,
(fi
g4.c)iscal l
edgangmi lli
ng.Compl exshaped
surf
acescanalsomil
ledusingtemplateonatracer
-cont
rol
ledmachine.

4.Cutti
ngt oothedgear sandheli
calgears:Spurandhel icalgear
sarecutby
for
m mi ll
ingcut t
ersonplainmilli
ngmachi nesorbyendmi l
ltypecutt
ers
onv ert
icalspindlemachi nes(Fig4.d).Thecut t
erpr ofi
lemustexact l
y
coinci
dewi t
hthet oothspaceoft hegear.Divi
dingheadi susedt oindex
thegearbl ankthroughtherequi
redanglefrom onet oothspacetothenext.

5.Gangmi ll
i
ng,St raddlemill
i
ng,St r
ingmi l
li
ng:Whent woormor emil
l
ing
cuttersaremount edonar borsot hateachcutterwi l
lpr
oduceit
sown
disti
ncti
vesur faceast hewor kpieceisfed toit,theoperat
ioni
scall
ed
Gangmi l
li
ng.(f
ig3c)
Straddlemi l
l
ingi saspeci alfor
m ofgangmi ll
ingi nwhichsidemil
l
ing
cuttersaresidemi l
li
ngareusedt omachinebot hsidesofawor kpi
ece
si
mul taneously(Fig3.e)
Inst r
ingmi ll
ingt wo ormor ewor kpiecearemount edont hemil
l
ing
machi netablei naline,sothattheyaresuccessivelyfedtooneormore
mi l
li
ngcutters.

Div i
ding heads:Dividing head isused t oindextheWor kpiecethr
ough t he
requiredanglef r
om onespacet othenext.
Ty pesofdi vi
dingheads.
1.Pl ai
n:Apl ai
ndividingheadhasaf ixedspindl
eaxisandthespi
ndlerotates
onlyaboutahor i
zont alaxi
s.
2.Uni ver
sal:Thespindl ecanber ot
atedatdi f
fer
entangl
einthevert
icalplane
fr
om hor i
zontal
tov erti
cal.(
SeeFig.5)

53
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET
3.Opt i
cal
:Thesemodelsareusedforhi
ghpreci
sionangul
arset
ti
ngofthework
piecewi t
hrespecttot
hecutter
.Forreadi
ngtheangles,anopti
calsy
stem i
s
builti
ntothedi
vidi
nghead.

Fig5: Universal di
vi
dinghead
1.Swi vel
li
ngblock2.Li vecent er3.Indexcrank4.Indexplate
Met
hodsofi ndexi
ng
1.Directi ndexing:I
ndi rectindexing,t heindexplatei
sdi rect
lymountedon
thedi v i
dingheadspi ndle.Withast andardindexi
ngplatehav i
ng24holes,
allf actorsof24canbei ndexed,t hatist heworkcanbedi vi
dedint
o
2,3,4,6,8,
12,24part
s, butfracti
onofangl esarecannotbedi v
ided.

2.Simplei
ndexing:I
nsimpleorplainindexi
ng,ani ndexingpl
ateselectedfor
thepart
icul
arappl
icat
ion,i
sfit
tedont hewor m shaftandlockedthrougha
l
ockingpin.
I
ft henumberofdi vi
sionsont hejobcircumf erenceneededz,t henthe
numberoft ur
nsthatthecrankmustber otatedf oreachindexi
ngcanbe
foundfr
om theformul
a, n=40/ z

3.Compoundi ndexing:whennoneoft hei ndexingplatehasahol ecircl

e
whichwouldenabl et hewor ktobedi videdbysi mpleindexi
ngmet hod,
compoundindexingmet hodcanbeused.
Ifthenumberofdi visionsont hejobcircumf erenceneededz,t henthe
numberofturnst hatthecr ankmustber otat
edf oreachindexingcanbe
foundfr
om theformul a, 40 n1 n2
-
--
- = --
- - -
-
z N1 N2
wheren1bet henumberofhol estobei ndexedi nN1holecircleandn2
thenumberofholest obei ndexedi
nN2hol ecircle.

4.Dif
fer
ent
ial
indexi
ng:Di
ff
erent
ial
indexi
ngi
sanaut
omat
icmet
hodofdoi
ng
compoundindexi
ng.

Cutti
ngSpeed:Thecutti
ngspeedofami l
l
ingcutt
erisit
speripherall
i
nearspeed
resul
ti
ngfrom rot
ati
on.I
tisexpr
essedi
nmetersperminute.
V=dn/1000 ( m/ min.
)
V=cutt
ingspeed d-thediamet
erofthecut
termm n-t hecutt
erspeed
i
nr .
p.m.

54
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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Feed:
Therat
ewi thwhi cht hewor kpieceadvanceundert hecut ter
1.Feedpert ooth(Sz)(mm/ t
ooth)ist hedi stancet hewor kadv ancesi
n
ti
mebet weenengagementbyt hetwosuccessi v
et eeth
2.Feed percut terr evoluti
on (Sr)(
mm/ r
ev )i sthe di st
ance the wor
k
advancesi ntimewhent hecutterturnsthroughoner evoluti
on.
3.Feedpermi nut e(Sm) (
mm/ min)ist hedi stancet hewor kadvancei
n
onemi nute.
Sm =Sz*Z*n
Wher e,Z=numberoft eethinthecutter
n-t
hecut terspeedinr .
p.m.

Av
eragecut ti
ngspeedandfeedofdif
ferentmat er
ial
s
Wor k Facemill
ing Per i
pher
almilli
ng
materi
al Toolst
eel H.S.
S Toolst
eel H.S.
S
Cutti
ng Feed, Cut ting Feed, Cut ti
ng Feed, Cutting Feed,
speed, mm/ mi speed, mm/ speed, mm/ speed, mm/
m/ min n m/ mi n mi n m/ min mi n m/ mi n mi n
Mildsteel 7.2-18 24- 42 6-15 18- 36 7.2 18- 6- 15 15- 30
–18 36
Greycast 150- 15 300- 30 250- 15 250- 60-20 100-
i
ron 25 50- 10 80- 30
15
Bronzeor 18- 36 200- 20 42- 72 30-60
Brass 300- 18-36 180-
30 100- 30
20

Av
eragecut
ti
ngspeedofdi f
ferentmat
eri
als
Wor kmat eri
al Cutti
ngspeedm/ min
(CarbideTool
)
Machinest eel 45-75
Toolsteel 40-60
Castiron 40-60
Bronze 60-120
Al
umi num 300-600

Depthofcut
:Thedept
hofcuti
nmil
li
ngisthethicknessoft
hemateri
alremoved
i
nonepassoft hewor
kundert
hecut
ter
.Itisexpressedinmil
l
imet
er.Thedepth
ofcuti
susuall
y1mm –8mm.

Sur
facefinish:Ty pi
calsurf
acer oughnesscanobtai
nedonwor kpieceusing
mil
li
ngmachi neBetween0. 8– 6. 3m forav
erageappl
i
cat
ions,6.
3-25,0.
05-
0.
4m forlessfrequentappl
icat
ions

Tor
queandpowerinmi
ll
ing
Thetor
quei
nmill
i
ngisdeter
minedf
rom t
hef
ormul
a

55
Machi
neTool
sLab Dept
.OfMechani
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Engg.
:VNR
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ET
T=FzD Kgf-mm
2
Fz=t *d*b*f
1000*V
t-Chipthi
cknessi
nmm
d-Depthofcut,mm
b-Wi dt
hofcut,mm
f-feedrat
e,mm/mi n.

t
=(f
/n)*
[√(
d/D)
]

N-R. P.M oft hemi ll

ingcut ter
n-Numberoft eethi ncut ter.
D-Di amet eroft hecut ter.
t
f=f*n*N
t
f –f eedpert eeth
Wher eD=di amet eroft hecut terinmm.
PowerP= 2πTn KW
1000* 60* 102
Quest ions:
1.Def inemi lli
ngpr ocess.
2.Def inemi lli
ngcut ter
3.Whatar et het hreemot ionsonapl ai
nmi ll
ingmachi ne?
4.Whati sthedi ffer encebet weenf acemi ll
i
ngandendmi l
l
ing?
5.Whati sdiv i
dinghead?
6.Whati stheadv ant ageofhel i
calt oothcut t
erov erastraighttoot
hcutt
erfor
slabmi l
li
ng?
7.Howdoy ouspeci f
ythemi lli
ngmachi ne?
8.Tocutt hespi nesi nashaf t
,whi chmustbeaccur atel
yspaced,t heworkis
mount edi n____ _
_ ______
9.Whatar et hev ariousmat erial
st hatar eusedf ormill
ingcutter
s?
10.Whatar ev ariousmot ionsi nuni versalmilli
ngmachi ne?
11.Whati smeantbyConv ent ional/Upmi l
li
ng?
12.Whati smeantbycl imb/ downmi l
ling?
13.Whi choft hepr ocessi .
e.conv entional/cl
imbmi l
l
ingsurfacefini
shisbet
ter
?
Why ?

Ex:
6.Exer
ciseonMi
l
li
ngMachi
net
oPer
for
m GearCut
ti
ng

Ai
m:Toper
for
m gearcut
ti
ngoper
ati
ononmi
l
li
ngmachi
net
oobt
ainagear
.

56
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET
Tool
srequi
red:
Indexi
nghead,
Flycut
ter
,Ver
nierCal
i
per
s,Mi
l
li
ngMachi
ne

Mat
eri
alr
equi
red:
Nyl
onSpeci
men

Pr
ocedur
e:

 Fixthet ooli nthear borandf ixthejobbet weent ailstockdeadcenterand

theindexi nghead.
 Sett hespeedt o100r pm byadjustingt hel
ever.
 Adjustt hecut tertot oucht hewor kpieceandmaket hedepthofcuttobe
zero.
 Sett hespi ndlepinont he27pi nhol eandmov et hesect orsuchthatthere
arehol esbet weent het wosect ors.
 Swi t
chont hemachi neandgi vet hedept hofcut.
 Now t aket hehandwheelsucht hatt hewor kpiecemov estowardst he
rotatingcut t
ingtool andmakeasl otont heworkpi ece.
 Byr otatingthespi ndleont heindexingpl at
ethespi ndlepincutsthework
piecei nto12sl ots.

Pr
ecaut
ions:

 Donotatt
empttochangethespeedwhi
lethemachineisinmoti
on.
 Donotchanget
heindexi
ngspindl
ewhil
eoperat
ingorcutt
ing.

Resul
t:Ther
equi
redgearpr
ofi
l
eisobt
ainedbyusi
ngmi
l
li
ngmachi
ne.

Wor
kpi
ecedi
agr
am (
lef
tsi
de)

57
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

58
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

Gri
ndi
ng
Machi
nes

59
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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Intr
oduct i
on
Grindingisamet alcut
ti
ngoper ati
onperfor
medbymeansofar otat
ingabr
asive
wheelt hatactsasacut t
ingt ool.Thi
sisusedtofi
nishwor kpi
eces,whichmust
showahi ghsurfacequal
ity,accuracyofshapeanddimensions.Most l
ygri
nding
operationisthefini
shi
ngoper at
ion,i
tremovescomparat
ivelyl
it
tlemetalusuall
y
0.25-0.50mm inmostoper ati
ons.

Gr
indi
ngmachines,
accor
dingtothequal
i
tyofsur
facemaycl
assi
fi
edas
1.
Roughgr
inders 2.Pr
ecisi
ongr
inder
s

Roughgrindersar et hosegr i
ndi
ngmachineswhosechi
efworkistheremovalof
stockwithoutanyr eferencetotheaccuracyoft
heresul
ts.Theyaremainl
yof
foll
owi
ngt ypes:
1.Floorst andandbenchgr i
nder
s
2.Por tabl
eandf lexi
bleshaf
tgri
nder
s
3.Swi ngframegr inders
4.Abr asiv
ebel tgr i
nders

Pr
eci
siongrindersar
ethoset
hatf
ini
shpar
tst
over
yaccur
atedi
mensi
ons.They
maybeclassif
iedasfol
l
ows:

1.Cyli
ndr i
cal grinder s
a.Cent erty pe( plain) b.Centert ype(uni
ver
sal
) c.
Cent
erl
ess
2.Int
ernal grinder s
a.Chucki ng
i.Pl ain ii
.Uni
ver sal
b.Pl anet ary
c.Cent erless
3.Surfacegr inder s
a.Reci pr ocat ing
i.Hor i
zont alspi
ndl
eii
.Vert
ical spindl
e
b.Rot ar yt able
i.Hor i
zont alspi
ndl
eii
.Vert
ical spindl
e
4.Tool andcut tergr i
nder
s
a.Univer sal b.Special
5.Special gri
ndi ngmachi nes

Cy l
i
ndr i
cal centertypegr i
nders:
Cent ertypecy l
indri
cal gri
ndersarei
ntendedpr i
mar i
lyforgri
ndingplai
ncy li
ndrical
parts,althought heycanal sobeusedf orgr
indingcont our
edcy l
i
ndrical,tapers,
faces and shoul der s,fi
ll
ets,and even cams and cr ank shaft
s.Pl aint ype
cyli
ndr i
calgrindingmachi neshowninf ig.
Itconsistsoff oll
owi ngparts:
1.Base 2.Tabl e 3.Headst ock 4.Tail
stock 5.Wheel head 6.
Cross-feed

60
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
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ET

Fi
g:Blockdi
agram ofaplancent
er–typegri
nder
1.Headst
ock 2.Gri
ndi
ngwheel 3.Wheelhead4.Tai
lst
ock5.Uppert
abl
e
6.Lowert abl
e7.Base

Themai ndif
ferencebet
weenplai
nanduniver
sal
cyl
i
ndri
calgr
indi
ngmachineare,
i
nuni v
ersalgrindi
ngmachinetheheadstockcanbeswivel
edatanangl ei
na
hori
zontalpl
ain,Thewheelheadandsl
idecanbeswiv
eledandtrav
ersedatany
angl
e.

Inter
nalgrinders:
Inter
nalgrindersar eusedtofini
shstr
aight
,taper
edorformedholestocor
rect
size,shape,andf ini
sh.Thedepthofcutdependsuponthediamet
erofthehole
beinggr oundandmayv aryfrom 0.
5– 0.02mm i nr
oughingandfrom 0.
002-
0.1mm inf i
nishingoperat
ions.

Tool andcut tergr inder s

Toolandcut tergr i
nder smai nl yusedf ort osharpenandr econdit
ionmulti
ple
toothcut tersl i
ker eamer s,mi ll
ingcut t
ers,dril
l
s,taps,hobs,andot herty
pesof
tool
s used i nt he shop.Wi thv ar
ious at t
achment stheycan al so do l
i
ght ,
cyli
ndrical,andi nter nalgri
ndingt ofi
nishsuchasj i
g,fixt
ure,dieandgaugedet ail
s
andshar pensi ngl epoi ntcut tingtools.t heyarecl assif
ied,accor di
ngtot he
purposeofgr inding, i
ntotwogr oups:
1.Uni versalt oolandcut tergr i
ndersar eparti
cularl
yintendedf orshar
pening
ofmi scellaneouscut t
er s.

61
Machi
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sLab Dept
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:VNR
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2.Si
ngl
epurposegr
inder
sar
eusedf orgri
ndi
ngt
oolssuchasdri
ll
s,t
oolbi
ts,
et
c.Aty
picalt
ool
andcutt
ergr
inderisshowni
nfoll
owingf
igur
e.

Fi
g:Toolandcutt
ergri
nder
1&3Wheel
2.Wheelhead4.Base5.Saddl
e6.t
abl
e7Col
umn

Sizeandcapaci tiesofgr inder s

Grindingmachi nesi zeisspeci fiedaccor dingtot hesi zeoft helargestwor kpiece
thatcanbemount edont hemachi ne.
Thesi zeofacy l
indricalgr inderi sdesi gnatedbyt hedi amet erandl engthbot h
expressed in mm oft he l argestwor k piece t he machi ne can nomi nall
y
accommodat edbet weencent ers.Thedi amet eroft hewor kpi eceshoul dnot
exceedonehal foft henomi nalcapacityoft hemachi ne.
Thesi zeofani nternalgr inderi sspeci fi
edbydi amet erofwor kpiecethatcanbe
swungandt hemaxi mum l engt hofst r
okeofwheel ,all expressedinmm.
Foral lt
ypesofsur facegr i
nder s,par
ticularl
yf orar eciprocati
nggr inder,thesize
i
sgener all
yexpr essedi nt er msoft ablear eaandmaxi mum hei ghtfrom thetable
towheel .Thedi amet eroft hechuckort ableusuallyspeci fi
est hesizeofar otary
surfacegrinder.
Thesi zeofat oolandcut t ergr inderisspeci f
iedbyt hemaxi mum si zeoft hetool
thatcanbeshar penedordr essed.

WorkHol
dingdev i
cesandat t
achment s:
1.Steadyrestsforcyli
ndri
calgri
nder s
2.Chucksandf ixtur
esforothergrinders
3.Magnet i
cchucksusedpar ti
cularlyonsur
facegr
inder
s.
4.Wheel Dressi
ng
5.Ultr
awheel cleani
ngdev i
ces

Princi
palGrindi
ngoperati
ons
1.Externalcyli
ndri
calgri
ndingproducesastrai
ghtortaper
edsurfaceonawork
pieceisshownf i
g.Thewor kpiecemustber ot
atedaboutit
sownaxi sbet
ween
centersasitpasseslengthwiseacrosst
hefacearevol
v i
nggri
ndi
ngwheel

62
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Fi
g:Ext
ernal
gri
ndi
ng Fi
g:I
nter
nal
gri
ndi
ng

2.Inter
nalcyli
ndri
calgr i
ndi
ngproducesinter
nalcyli
ndri
calholesandtaper
sis
shownf i
g.Thewor kpiecearechuckedandpreci
selyrot
atedaboutt
hei
rownaxis.
Thegr i
ndingwheelor ,inthecaseofsmal lboreholes,thecyli
ndr
icalwheel
rot
atesagainstthesenseofrotat
ionoftheworkpiece.

3.Taper
edsurfacesaregroundedoncyl
indri
calgri
ndi
ngmachinebyswi
vel
ing1.
Thetabl
etot het aperangl
eoft hewor
kpi ece2.thewheelheadtothesame
angl
e.Or3.Theheadst ockwit
htheworkpiececlampedi
nachuck.

Fi
gTapergr
indi
ng

4.Formed surface:They aref i

nished on cy
li
ndri
caland surf
ace gr
indi
ng
machi
nes.Atypicalformedsur
facegr i
ndi
ngisthegri
ndingofbedwaysmaybe
doneonwaygrinders.Thefr
om gri
ndersareshowninfi
g

Fi
g:For
m gr
indi
ng

63
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5.Geart eet
h:Thegearteetharegroundedongeargr
indi
ngmachi
nesei
therby
thegenerati
ngprocessorfor
mi ngpr
ocessinwhi
chfor
medwheelsar
eused.The
generat
ingprocessisshownfig.

Fi
gGeargr
indi
ng

6.Threads:Thethr
eadgri
ndi
ngisdoneonthreadedmachi
neswit
heithersi
ngl
e
ormul t
ipl
eribwheel
s.Int
hegri
ndingofext
ernalt
hreadwi
thmult
ipl
eribwheel
s
thewor kismountedbetweencenter
sandisr ot
atedatadef
ini
tespeed.The
thr
eadedgr i
nder
sareshowninf
ig.

Si
ngl
ethr
eadgr
indi
ng Pl
ungecutgr
indi
ng

ThegrindingWheel
Agr i
ndingwheeli samul t
ipointcutt
ermadeofmanyhar dparticl
esknownas
abrasi
ves,whi chhavebeencr ushedtoleavesharpedgeswhi chdot hecutt
ing.
Theabr asiv
egr ai
nsar emi xedwi thasuitablebond,whichactsasamat ri
xor
hol
derwhent hewheeli sinuse.Thegr indingwheelisdesignatedwiththeir
var
iouschar acter
isti
cs,togiveageneralindicat
ionofthehardnessandgritsize
ofanywheel ascompar edwithanother.

Grindingwheel designat ion:w–A–46–K–5–V–17

Wher ew-manuf act urer’
sabr asi
vesymbol
A-Abr asivet ype
46–Gr i
tsize
K–Gr ade
5–St ructure
V–Bondt ype
17–Manuf act ur
er ’
stypesymbol
Abr asi
vet ype:Thegr i
ndingwheeli smadeupofpar t
icl
esofhar dsubstance
calledt heabr asiveembeddedi namat r
ixcal l
edt hebond.Theseabr asives
knownasgr i
tspr ov idet hesharpedges,whi chdot hecutt
ing.Typi
calabr
asives
are:
a.Al umi num oxi dedenotedbythel etter---A
b.Si l
iconcar bidedenotedbytheletter- -
-S
c.Di amonddenot edbyt hel
ett
er- --D
Gritsize:Gritsizei susedt odescr i
bethefinenessoft hemeshusedi ngrading
theabr asi
v egrits,thel argerthesize,t
hefinert hegr i
t.Therangeofgri
tsizesis

64
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asf
oll
ows
Coar se 6-24
Medi um 30-60
Fine 70- 600
Grade:Thegr i
tsar ehel dbyasui tablebondingmat eri
al,theamountofwhi ch
decidest hegr adeorhar dnessoft hewheeli ndi
cati
ngther elati
vestrengthofthe
holdingmat rix.Incr easingt heamountofbondi ngmat erialthusincreasingthe
rat
iooft hebondmat erialtogr i
tmat er
ialmakesawheel appearharder .
Thewheel gradesar e:
Ver ysof t- -
--
- Ct oG
Sof t ----
- Ht oK
Medi um - ---
- Lt oO
Har d -
---
- Pt oS
Ver yhar d- --
-- Tt oZ
Str
uct ure:Thet erm st ructur erefer stot hegritspaci
ngandi sindicatedbya
numberv ar
yingf rom 0- 12wi thlowernumber ssigni
fyi
ngcl oserpackedgr it
s.
BondTy pe:Thef ol lowi ngbondmat eri
alaregeneral
lyused
Vitri
fiedbond --
-V
Sili
cat e --
-S
Resi noi d --
-B
Shel l
ac --
-E
Oxy chl oride --
-O
Rubber --
-R
Selectionofgr indingwheel dependsonmat eri
altobegrounded, amountofst ock
tober emov ed, areaofcont act ,ty
peofgr i
ndingmachineet c..

Glazing:Glazingmeanst hewheelbecomesdul lorgl azed.Thati sthecut t

ing
pointsoft heabr asiveshav ebecomedul landwor ndownt ot hebond.Gl azing
takesplacewhenawheeli stoohar dorr evolvesatt oof astaspeed.Ther emedy
forglazi
ngi stodecr easet hespeedoruseasof terwheel .
Loading:Loadi ngmeanst hecut ti
ngf aceoft hewheelhaspar ticlesoft hemet al
being ground adher ing toi t,t huspr event i
ng t he wheelf rom cut ti
ng f reely.
Loadingmaybecausedbyt akingcut sthatar et oodeepandbynotusi ngt he
ri
ghtcut t
ingfluid.Ther emedyf orloadingist oincr easet hespeedoft hewheel or
useasof t
erwheel .
Dressing:dr essingremov est heloadingandbr eaksawayt hegl azedsur f
aceso
thatsharpabr asivepar ti
clesar eagainpr esentedt ot hewor k.Acommont ypeof
wheeldr esserknownasst ardresser.Abr asivewheeldr essersoper ati
ngathi gh
speeds ar ef requentlyused t o dress ot herwheel s.Forpr ecision and hi gh
fi
nishinggradingdi amondpoi ntsar eusedf ordr essing.
Truing:Truingi sthepr ocessofchangi ngt heshapeoft hegr i
ndi ngwheelasi t
becomeswor nanor igi
nalshape, owingt ot hebr eakingawayoft heabr asiveand
bond.Tr uinganddr essingar edonewi t
hsamet ools,butnotf orthesame
purpose.

Cut
ti
ngspeedandWor
kspeed:
Thecut
ti
ng(v)i
sther
elat
ivespeedoft
hewheel(
Vw)
(per
ipher
alspeed)andt
he
65
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workspeed.I
texpressedinm/sec.
v=( *Dw*Nw) /
1000m/ sec.
WhereDw isthedi ameterofthegri
ndinginmm,andNw ist
hespeedoft
he
wheeli
nr.p.
s.
Thewor kspeedwi threl
ati
ontowheelspeeddet
erminest
hehar
dnessoft
he
wheel

Wheel
speedf ordiffer
entty
pesofgr
inding
Typeofgr i
nding Sur
facespeed( m/mi
n)
a.Vitr
if
iedbond
wh 1500-2000
eel 1200-1500
s 600-1800
Cy l
indrical 1500-2000
Sur face 1500-1800
Internal
Tool andcut ter 2000-3000
Cent erl
ess

b.Resinoi
dbonded
wheels(
snaggi
ng)

Wor kspeedf ordi

ff
erentmater
ial
s
Wor kmat er
ial Surf
acespeedi
nm/
min
Roughi
ngcut Fi
nishi
ngcut
Castiron 60 120
Aluminum 30 60
HardSt eel 20 30
Softsteel 9 15

Coolantsappli
cati
ons
Gri
ndingmachi neusesacoolantbox,whichspreadsalargeamountofcool ant
overthewor k,wheelfaceandsides.Sodawat erismostlyusedasacool ant.
Thisdissi
patestheheatnormall
ygenerat
eddur i
nggri
nding.Thet emper
atur
ei s
o
about2000C.Cool ant
simprovethewheelli
feandsurf
acef i
nish.

Feed
Thefeed(s)i
ncyli
ndr
icalgri
ndingisthelongi
tudi
nalmovementoft heworkpiece
perrevol
uti
on.I
tisexpressedinmm/ r
ev.oftheworkpiece.Longi
tudi
nalfeedis
usuall
yfr
om 0.6-
0.9oft hefacewidthoft hewheelforroughgri
ndingandf r
om
0.4–0.6ofthefacewidthforfi
nishgri
nding.

Dept
hofcut
Thedepthofcuti
sthet
hicknessoft
helayerofmetalr
emovedinonepass.I
tis
expr
essedi
nmm.Thedept hofcuti
stakeninarangefr
om 0.
005–0.04mm

66
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Surfacef
ini
sh:Typicalsur
facer
oughnesscanobtai
nedusinggri
ndi
ngmachine
between0.1–1. 6m f oraver
ageappli
cat
ions,1.
6-6.
3,0.
025-
0.8m f
orless
fr
equentappl
icat
ions.

Powerr equir
edingr indingmachi
ne
Powerr equir
edingr indingmachi
neis(
P)= Fz*v
wh KW
6120
0.7 0.
7 0.6
WhereFz=Cp.Vw . Vs . t
1
Fz=Tangent i
alf
or ce,Kgf.
Vw =Wor kspeed, m/ min.
Vs=Tr ansversefeedr ate,mm/min.
t1 =Depthofcut, mm
vwh=Wh eelspeed, m/ min.

Precaut
ionswhi leusi ngthegr indingwheel
1.Donotst andinf rontofgr indingwheel .
2.Usegr indinggoggl eswhilegr i
ndi ng.
3.Usehandgl ov es.
4.Wor ksuppor tmustbev eryst rong.
5.Gr i
ndingwheel shoul dr
ot atetowar dstheoperat
or.
6.Usepr opercool antwhi l
egr i
ndi ng.
7.Gr i
ndingwheel mustbef irmlyf ixedtothespindl
e
8.Gr i
ndingwheel guar dmustbei nitsplace.
9.Checkf orbr eakdownofgr i
ndingwheel ,l
i
kecracks,
anyl
oosepar
ti
cles,
etc.
10.Peri
odicall
ydr esst hegrindingwheel

Quest
ions:
1.Def i
negrindingpr ocess.
2.Whati sthedi ff
erencebet weenr oughandpr ecisi
ongrindi
ng?
3.Def i
negrindingwheel
4.Whati sthedi ff
erencebet weenpl ainanduni versalcyl
i
ndrical
gri
nder
s?
5.Whatar et headv ant agesanddi sadv ant
agesofcent er
lessgri
ndi
ng?
6.Whatar ef actor
sef f
ect stheselectionofgrindingwheel ?
7.Whati sthedesi gnat ionofgrindingwheel ?
8.Whati smeantbygl azi ng?
9.Whati smeantbyl oadi ng?
10.Whatismeantbydr essi ng?
11.Whatismeantbyt ruing?
12.Whataret heappl i
cat ionsoftool andcuttergrinder?

67
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Ex.7.Exer
ciseonGr
indi
ngofTool
Angl
es(
Tool
&Cut
terGr
inder
)

Ai
m:Topr
epar
easi
ngl
epoi
ntcut
ti
ngt
ool
aspert
hegi
vent
ool
nomencl
atur
e.

Tool
srequi
red:
Uni
ver
sal
tool
&cut
tergr
inder
,spanner
,gr
indi
ngwheel

Mat
eri
alr
equi
red:
H.S.
S(Hi
ghSpeedSt
eel
)

Pr
ocedur
e:

 Fixthewor kpi
eceint heworkholdi
ngdev i
ce.
 Adjusttheswivelvicetorequi
redanglesforbackr
akeangl
eandsiderake
anglerespecti
vel
y.
 Rotatethehandwheel t
ogetsidecutti
ngedgeandthecl
earanceangl
e.
 Adjusttheswiveltotherequir
edangles.
 Rotatethehandwheel t
ogetsidecutti
ngedgeandthecl
earanceangl
e.
 Indexthejobagain.
 Mov ethejobt owardsthegr i
ndi
ngwheelt ogetthecut
ti
ngedgeandt he
endclearanceangle.

Pr
ecaut
ions:

 Takeappropri
ateangl
ewhileadjust
ingtheangleonthefi
xtur
e.
 Propercareshoul
dbetakenwhilegrindi
ngthetool
.
 Ensurethatt
hecolumnislockedbeforestar
ti
ngthegri
ndingoper
ati
on.

Resul
t:Hencet
hesi
ngl
epoi
ntcut
ti
ngt
ool
ismadebyt
hegi
venspeci
men.

68
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Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

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Ex.
8:Exer
ciseonGr
indi
ngt
otheRequir
edAccur
acybySur
faceGr
indi
ng
Machine

Ai
m:Toper
for
m asur
facegr
indi
ngoper
ati
ononasur
facegr
indi
ngmachi
ne.

Toolsrequi
red:Sur
face gr
indi
ng machi
ne,t
risquar
e,st
eelr
ule and Ver
nier
cal
iper
s.

Mat
eri
alRequi
red:
M.S.
Blockof120×40×40mm

Pr
ocedur
e:

 Thegivenwor kpieceistakenandcheckedf oritsdi

mensions.
 Thejobisplacedont hegrindi
ngmagnetatopenedposi t
ion.
 Theneachf aceisgrindedtotherequi
redaccur acybyconstantspeed.
 Thejobisremov edfrom therequir
edaccuracy.
 Fi
nall
ythejobi scheckedbyusi ngver
niercali
persandthetrisquare.

Pr
ecaut
ions:

 Duri
ngtheoperati
ondonotst andinf r
ontofthegri
ndi
ngwheel
,orthe
gri
ndi
ngwheelagainstt
heworkpiece.
 Donotusethesideofthewheelunlessthewheeli
sspeci
fi
cal
l
ydesi
gned
fort
hatpur
pose.
 Donotexceedthemaximum operat
ingspeed.

Resul
t:Thesur
facegr
indi
ngoper
ati
oni
sdonef
ort
hegi
venspeci
men.

70
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Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

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Ex.
9:Exer
ciseongr
indi
ngt
heCy
li
ndr
ical
Jobusi
ngCy
li
ndr
ical
Gri
ndi
ngMachi
ne

Ai
m:Toper
for
m acy
li
ndr
ical
jobusi
ngcy
li
ndr
ical
gri
ndi
ngmachi
ne.

Toolsr
equi
red:Cy
li
ndr
icalgr
indi
ngmachi
ne,
steelr
ule,
ver
niercal
i
per
s&sur
face
pl
ate.

Pr
ocedur
e:

 Thewor kpieceistakenandcheckedf
orit
sdimensi ons.
 Thewor kpi eceisfixedinbet
weentheliveandt hedeadcent
erandi
s
rotat
ed.
 Machiningisdonebyt hemomentoft hegrindingwheelontothewor
k
piece.
 Remov ethej obandcheckit
sdimensi
onalaccuracy.

Pr
ecautions:
 Dur i
ngtheoperati
ondonotst andinf r
ontofthegri
ndi
ngwheel
,orthe
grindi
ngwheelagainstt
heworkpiece.
 Donotuset hesideofthewheelunlessthewheeli
sspeci
fi
cal
l
ydesi
gned
forthatpur
pose.
 Donotexceedt hemaximum operat
ingspeed.

Resul
t:Thust
hecyli
ndr
icalj
obwasdonet
other
equi
redaccur
acyonacy
li
ndr
ical
gri
ndi
ngmachine.

72
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Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

ALLDI
MENSI
ONSAREI
NMM

73
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PLANAR
MACHI
NE
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I
NTRODUCTI
ON

Pl ani
ngi soneoft hebasicoper ati
onsper formedi nmachi ningwor kandi s
primaril
yint endedf ormachi ninglargef latsur faces.Thesesur facesmaybe
hor i
zontal
,v ert
icalorincl
ined.Inthisway ,thef unctionofapl anni ngmachi neis
quitesimilartot hatofashaperexceptt hatthef or
meri sbasi call
ydesignedt o
under t
akemachi ningofsuchl argeandheav yj obswhi char ealmosti mpr acti
cal
tobemachi nedonashaperormi ll
ing,etc.I tisanest abli
shedf actthatt he
planningmachi nepr ovestobemosteconomi calsof arast hemachi ni
ngofl arge
fl
atsur f
acesi sconcer ned.Howev er,aplanningmachi nedi f
fersfrom ashaperi n
thatformachi ning, t
hewor k,l
oadedont hetable, r
eciprocatespastt hestationary
toolinapl aner,wher easinashapert het oolr eciprocatespastt hestationary
wor k.

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MAI NPARTSOFAPLANER
Apl anerconsi stsoft hefoll
owi ngmai npar t
s.
Bed
Tabl e
Housi ngsorcol umns
Cr oss–r ail
Tool head
Cont rol
sThesemachi nesareheav ydut ytypeandcar r
yav eryr i
gid
const ruction.
Theyempl oyhi ghspeedsf orcut tingbutt hesi zeofwor ktheycanhandl ei s
l
imitedt othewi dthoftheirtabl ei
.e.t hehor izont aldistancebet weent he
columns.
Extremel yl ar geandheav ycast ings,l ikemachi nebeds,t ables,plates,sl i
des,
columns,et c.,whi chnor mallycar rysl i
di ngsur facesl i
kegui deway sordov etail
s
on t heirl ongi tudinalf aces,ar e usual lymachi ned on t hese machi nes.Al so
becauseofl ongt ableandl argert ablet rav el,onei t
hersi deoft hecol umns,i tis
possi blet ohol danumberofwor kpi ecesi naser iesov erthebedl engthand
machi net hem t ogether.Thiswi l
lef fectasubst antialsav i
ngi nmachi ningt i
me.
Further because of no. of t ool heads t he sur faces can be machi ned
simul taneousl y.Thi seffectsf urt
herr educt ioni nmachi ni
ngt ime.Al sobecause
ofhi ghr igidityofhi ghr i
gidit
yoft hemachi neandr obustdesi gnoft hecut ting
toolsheav iercut scanbeeasi lyempl oy ed,whi chl eadst oqui ckermet alremov al

76
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and reduced machining time.Thus an ov eral
lpicture emerges thatthe
employmentoft hi
stypeofmachi neapartfr
om i
tscapacit
ytohandlesuchheav y
andlargej obswhicharedi ff
icul
ttobehandl edonot hermachines,leadsto
fast
ermachi ni
ng and reduced machi ni
ng t
ime and hence to economi cal
machining.Howeverconsider
ableti
mei susedi
nsetti
ngupapl aner.

OPERATIONDONEONAPLANER:
Thecommonoper ati
onsper f
ormedonapl anerincl
udet
hef
oll
owi
ng:
Machininghorizont
alflatsurf
aces.
Machiningverti
calfl
atsurfaces.
Machiningangularsurfaces,i
ncl
udingdovetai
ls.
Machiningdiff
erenttypesofslotsandgrooves.
Machiningcurvedsurfaces.
Machiningalongpremar kedcontours.

Ex.10:Exer
ciseonPl
ani
ngt
omakea‘
V’Bl
ock

Ai
m:Tomakea‘
V’bl
ockofagi
venM.
S.bl
ockusi
ngpl
ani
ngMachi
ne.

Tool
srequi
red:
Plani
ngMachi
ne,
Singl
epoi
ntcut
ti
ngt
ool
.

Mat
eri
alRequi
red:
M.Sbl
ockof100×100×20mm

77
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Pr
ocedure:
 Fixt heblockont hev iceandf i
xt hejobusi ngT-Bol
ts.
 Fixt hesinglepointcut t
ingtooltot hetoolholder.
 Adj ustthelengthoft hestrokeandt hetool poi
nter
.
 Star tt
hemachi newitht hegivenmi nimum dept h.
 Adj ustthelengt hoft hestrokeanddept hofcutsucht hatthemater
iali
s
r
emov edont hesurfaceoft hebl ock.
 Thi sprocessi sconti
nuedunt i
lthewor kpieceismachinedcompl
etel
y.

Pr
ecaut
ions:

 Al
way sstandparal
leltothecut
ti
ngstrokeandnotinfrontofi
t.
 Neverat temptt
oremov echipsorreachacrossthetablewhi
lether
am i
s
i
nmot ion.
 Neverattempttoadjustamachinewhilei
tisinrot
ati
on.

Resul
t:Thust
heV-Bl
ocki
smadeon t
hegi
ven speci
men byusi
ng Pl
anar
Machi
ne.

Wor
kpi
ecedi
agr
am (
lef
tsi
de)

Exer
cise

78
Machi
neTool
sLab Dept
.OfMechani
cal
Engg.
:VNR
VJI
ET

ALLDI
MENSI
ONSAREI
NMM

79