Unit-3

Machine tools: Lathe, Drilling and Grinding M/c

Manufacturing processes
What is a machine tool?
Generating Shape in Machining

(b) Taper Turning (c) Contour Turning

(a) Straight Turning

(d) Plain Milling (e) Profile Turning

Lathe machine
3-D view
Lathe Machine Parts – Functions
Lathe Machine Parts – Functions
• Lathe Bed
• Base of Lathe Machine
• Supports all other parts
• Usually made up of CI (Cast Iron)
• Absorbs shocks/vibrations (if any)
• Two guide ways
• Headstock
• Also called as Live Center of Lathe
• Permanently fixed to left hand side of lathe
• Supports spindle which holds chuck
• Houses main drive (gear box)
• Provides multiple speeds to work-piece (or job)
• All Geared headstock, Back Geared Headstock
• Headstock with Cone Pulley Arrangement
Lathe Machine Parts – Functions
• Tailstock
• Also called as Dead Center of Lathe
• Located on right hand side Lathe Machine
• Movable along guide ways (removable as well)
• Holds Dead Center which supports long work pieces / shafts
• Useful for drilling, reaming or tapping operations
• Carriage
• Located between Headstock and Tailstock of Lathe
• Slides along guide ways on lathe bed
• Holds cutting tool
• Provides longitudinal and cross feed to cutting tool
• Carriage consists of Saddle, Apron, Cross Slide, Compound Rest and Tool Post
Lathe Machine Parts – Functions
• Lead Screw
• Very Important part of Lathe
• Long threaded shaft driven by feed drive
• Provides mechanized/automatic motion to carriage for screw threads on the
job
• Lead Screw is MUST for Threading Operations on Lathe
• Split Nut or Half Nut Mechanism converts rotary motion of lead screw to
linear motion of carriage

• Feed Drive
• Unit to transmit power and motion from main drive to lead screw
• Useful to get the desired reduction ratio
Lathe Machine Operations – Turning
• Turning

• Most basic operation done on lathe

machine
• Job or work piece is turned (rotated)
using rotary motion of spindle, hence
lathe is also called Turning Machine!
• Lathe operator is called “Turner”!
• Removal of material from a
cylindrical work-piece or job
• To reduce diameter of cylindrical job
• Tool motion parallel to the axis of
lathe
• Tool used is called “Turning Tool” and
it is “Single Point Cutting Tool”
• Rough turning, using roughing tool or
knife tool
• Finish turning using finishing tool
 Lathe Machine Operations – Taper Turning

• Taper Turning

• To reduce diameter of
work piece uniformly
along the length of work
piece
• Taper turning using “form
tool”
• Taper turning by “tailstock
set over” method
• Taper turning using “taper
turning attachment”
• Taper turning by
“swiveling the compound
rest”
Lathe Machine Operations – Taper Turning
 Lathe Machine Operations – Facing

• Facing
• Removal of material from end
surface of the work piece or
job
• To have a reference plane to
mark and measure the step
lengths of work
• To have a face at right angle
to the axis of the work
• To reduce length of job
• To maintain the total length
of the work
• Facing Tool is used
• Tool motion is perpendicular
to axis of lathe
• To produce flat surface
(especially after parting off
operations)
Lathe Machine Operations – Facing
 Lathe Machine Operations – Chamfering
• Chamfering
• Process of beveling the sharp
edges of work piece
• Chamfered jobs avoids
injuries to hands of persons
handling the job
• Provides aesthetic look to
the work piece
• Chamfering tool is used
• To permit easy assembly of
mating parts (shaft & hole)
• Chamfer specified as CH 2 x
45 (2 mm deep at an angle of
45 degrees
• Form Tool Method
• Filling Method
• Compound Slide Method
Lathe Machine Operations – Grooving

• Grooving or Groove
Cutting

• To create narrow groove

on cylindrical work
piece
• Shape of tool is
replicated as shape of
groove
• Operation also known
as Form Turning!
• Square Groove, Round
Groove and ‘V’ Type
Grooves
Lathe Machine Operations – Parting

• Parting

• Process of cutting work

piece into 2 parts
• Parting tool is used
• Extension of grooving
operation where feed is
provided till axis of work
piece
• Care needs to be taken
when work piece splits
into two parts
 Lathe Machine Operations – Knurling

• Knurling

• Process of embossing a
diamond shaped regular
pattern on the surface of job
• Tool used is called “Knurling
Tool”
• Parallel or Straight Knurling
• Diamond or Criss-Cross
Knurling
• Concave or Convex Knurling
• Squeezing metal into peaks
and valleys using plastic
deformation
• Provides non-slip grip to the
job
• Aesthetic or Decorative look
 Lathe Machine Operations – Drilling

• Drilling

• Process of making a
circular hole in cylindrical
job
• Tailstock is used to hold
cutting tool which is called
as “Drill”
• Drill is feed against
rotating job by rotating
hand wheel of tailstock in
clockwise direction
• After making hole, the
drill is withdrawn by
rotating the tailstock
handle in anti-clockwise
direction
Lathe Machine Operations – Boring

• Boring

• Process of enlarging
already existing hole
in the job
• Tailstock is used to
hold the tool
• Skill of operator plays
imp role
• Tool used is called as
“Boring Tool”!
 Drilling machine-Working principle
 Drilling is an operation through which
holes are produced in a solid material
using a rotating tool.
 The machine tool used for this purpose is
called as drilling machine.
 In drilling operation, the workpiece is
clamped firmly on the worktable by using
nuts and bolts.
 The drill is press fitted in a drill chuck.

 The rotating drill is made of harder material than that of workpiece and it is fed
against the stationary workpiece by either hand or power feed.
 During this process, the material is removed in the form of chips.
 It is important to note that, during the process, high amount of heat is generated
hence continuous supply of coolant is required.
 In a drilling machine, holes are produced quickly and at low cost.
Basic elements of drilling
machine
 Basic elements of drilling
machine
Base
 It is part of machine which supports the entire structure.
 Generally, base it made from the casting.

Column
 It is the vertical member of machine which supports the table
and head containing all the driving mechanisms.
 It may be made of round section or box section.

Work table
 It is mounted on the column. It is may be round or rectangular in
shape.
 It is used for clamping the workpiece directly over its face and
provided with T-slots.
 It has vertical as well as swing or circular motion.
 Basic elements of drilling
machine
Drill head
 Drill head carries driving and feeding mechanism from the
spindle.
 The driving mechanism is used for driving the drill spindle which
consists of an electric motor, gear box, etc. whereas, feeding
mechanism is used for feeding the drill into the workpiece.
 The drill head is mounted on the top of the column.

Spindle drive
 Spindle is hollow part, in which drill (tool) is inserted.
 During the operation, spindle rotates as well as moves up and
down, hence the drill also rotates as well as moves up and down.
 Drilling machine operations
Boring
 Boring is the process of enlarging already drilled
hole by using an adjustable cutting tool which is
called as boring tool.
 This operation is used for finishing a drilled hole
accurately and bring it to the required size as well
as to correct the roundness of a hole.
 Boring tool has only one cutting edge.
Counter-boring

 This operation is used for enlarging

only limited portion of a hole and
called as counter-boring.
 The tool used for this purpose is called
as counterbore.
 Drilling machine operations
Counter-sinking
 It is used for enlarging the end of a
hole and to give it a conical shape
for a short distance.
 The tool used in this operation is
called as countersunk.
 These tools have included angles of
600 , 820 ,900
Spot facing

 It is the operation of smoothing and

squaring the surface around a hole
for the seat of a nut or head of the
screw.
 The hole may be spot faced below
or above the rough surface.
 Drilling machine operations
Tapping
 Tapping is an operation of cutting internal
threads by using a cutting tool called as tap.
 For tapping purpose, the machine should be
equipped with a reversible motor or some other
reversing mechanism.
 A tap in fed to a already drilled hole along the
axial direction to produce internal threads.
Trepanning
 When large diameter holes are required in
sheet metal, then trepanning operation is
carried out.
 It is carried out by using trepanning tool.
 A small hole, to suit the pilot is drilled at the
centre of the required position.
 The adjustable arm is extended so that the
edge of the high speed-steel cutting tool
produces the required hole size.
 Grinding machine-Working principle

 Grinding is the process of removing the material by the abrasive action of a

revolving wheel on the surface of a workpiece.
 Grinding wheel consists of a sharp crystals which are called as abrasives, held
together with the bonding materials.
 During the process, a high speed revolving grinding wheel is brought in contact
with the workpiece and material from it is removed by using abrasive action.
Cylindrical grinding machine
Centreless grinding machine
 Surface grinding machine
1. Reciprocating table
i. Horizontal spindle
ii. Vertical spindle
2. Rotary table
i. Horizontal spindle
ii. Rotary spindle
Reciprocating table type surface grinders
Rotary table type surface
grinders
Internal grinding machine
Manufacturing processes
 Casting
Casting is the process in which the parts of desired shape are
produced by pouring the molten metal or alloy into a cavity and then
allowing the metal or alloy to cool and solidify.
This solidified piece of metal or alloy is called as casting.
Casting or founding is the most popular method of producing metal
or alloy parts of nearnet shape.
Types of Casting:
1. Sand Casting.
2. Investment Casting.
3. Die Casting.
4. Centrifugal Casting

Features of casting process:

• Cast Components are brittle.
• Close dimensional controls are not expected .
• No restriction on the size of the component
• No restriction on the type of metal or alloy used.
• Surface finish is un satisfactory, Machining is required.
• Extremely thin sections can not be cast.
• Large variations in section thickness of components are not allowed.
• Economically suitable for both job and mass production.
 Steps involved in casting process
1. Pattern making
2. Sand preparation
3. Core making
4. Melting
5. Pouring
6. Finishing
7. Testing
8. Heat treatment
9. Re-testing
Advantages and disadvantages of casting
• Advantages:
Complex shapes can be easily produced by casting process.
Provides better vibration damping capacity to components.
Flexibility of design in terms of shape, size and quality of
product.
Very heavy and bulky parts can be manufactured.
It produces machinable parts.
Used for small as well as mass production.
Advantages and disadvantages of casting
• Disadvantages:
Cast components are generally brittle i. e. weak in tension.
Defects like cracks, blow holes, etc. make casting weak and
unsuitable for use.
Cast components require more machining.
Welding of cast components is difficult.
Accuracy of cast components is less.
During heating of metal, pollution of atmosphere takes place.
 Applications of casting process
Automobile parts (pistons, cylinders, clutch and gear
housings, gear blanks, etc.)
Machine parts (pulleys, gear blanks, beds, frames, etc.)
Aircraft parts (Engine blades, motor housings, etc.)
Turbine vanes, power generators, pump parts, filters,
valves, etc.
Agricultural parts, railway crossings, sanitary fittings, etc.
Construction, communication and atomic energy
applications.
 Forging process
Forging is the process in which the desired shape and size is obtained through
plastic deformation of metal under the action of externally applied force at
high temperature.
It is the metal forming process which is done by either hand or by machine.

 The metals which are used in forging

process must possess the required ductility
 The commonly used forging materials are:
Aluminium alloys, copper alloys, low
carbon steels, alloy steels, nickel alloys,
tungsten alloys, magnesium alloys,
titanium alloys, etc.
 Types of forging
1. Hand forging
Fig. Hand forging

 It is the process of deforming the hot material into the required

shape by the application of repeated blows of hammer held in hand.
 This process is only used for making simple components of small size.
 Types of forging
2. Drop forging

 This process utilizes closed impression die

to obtain required shape of the
components.
 The forging is produced by the impact or
pressure which forces the hot metal
(billet) to form the shape of the dies.
 The equipment used for applying the
blows is called as drop hammer.
 During the process, the ram is raised to a
definite height and then it is allowed to
drop or fall freely under its own weight.
 Applications of forging
Manufacturing of car axles
Connecting rods
Crankshafts
Leaf springs
Crane hooks
Jet engine blades
Rail-road equipments
Agricultural machinery etc.
Sheet metal working
Sheet metal working or press working is a chipless manufacturing
process by which various components are produced from sheet metal.
Thickness of metal sheet varies from 0.1-10 mm.
Sheet metal working operations
Sheet metal working

Metal cutting operations Metal forming operations

1. Bending
1. Blanking 2. Drawing
2. Punching 3. Embossing
3. Notching 4. Forming
4. Perforating 5. Coining
5. Slitting
6. Lancing
7. shaving
 Sheet metal working operations
Blanking Punching (piercing)

Fig. Blanking and

punching
 Sheet metal working operations
Notching Perforating

Slitting Lancing
 Sheet metal working operations
Shaving  Shearing
 Sheet metal working operations
Bending
 Sheet metal working operations
Bending
 Sheet metal working operations
Drawing

Embossing Forming
 Sheet metal working operations
Coining

Wire drawing
Deep drawing
 Metal joining processes
These processes are used to join two or more metal parts.
These processes are applied in general fabrication work for
steam or water-tight joints.
Temporary or permanent type of fastening is also enabled
by these processes.
The commonly used joining processes are
 Welding
 Soldering
 Brazing
 Adhesive bonding
 Welding process
It is joining process used for various metals and their
alloys.
In these processes, two or more pieces of metals are
joined by application of either heat or pressure or both.
In plastic/pressure welding, the metal pieces to be joined
are heated to a plastic state and then forced together by
external pressure.
In fusion/non-pressure welding, the metal pieces to be
joined are heated to molten state and allowed to solidify.
Advantages and disadvantages of welding
Advantages
A large number of metals or alloys, both similar and dissimilar
can be joined by welding.
It can be mechanized.
Strength of welded joint is more.
It provides leak-proof joint.
Welding equipments are not very costly.
Disadvantages
It gives harmful radiations, fumes and spatter.
Welding results in residual stresses and distortion of the
workpiece.
Heat generated in welding process produces metallurgical
changes hence, the structure of welded joint is different than
that of parent metal.
 Applications of welding process
Aircraft construction (welding of engine parts, turbine
frames, ducts, etc.)
Rail-road equipments (Air receiver, engine, front and rear
hoods, etc.)
Pipings and pipelines (open pipe joints, oil and gas
pipelines, etc.)
Pressure vessels and tanks
Buildings and bridges (column base plates, erection of
structures, etc.)
Automobile parts (trucks, buses, cars, bike parts, etc.)
Machine parts (frames, beds, tools, dies, etc.)
 Arc welding process
It is a fusion welding process in which welding heat is obtained from
an electric arc between an electrode and the workpiece.
 The temperature produced
at the centre of an arc is
6000 to 70000C.
 In this, the base metal is
melted by the temperature
of the arc, forming a pool of
molten metal.
 Either A. C. or D. C. supply is
used.
 The electrodes used in the
process are of two types i.e.
bare and coated electrodes.
 The length of electrodes varies from 250 mm to 450 mm whereas,
diameter varies from 1.6-9 mm.
Shielded metal arc welding (SMAW)
Tungsten Inert Gas (TIG) Welding
 Soldering
It is a process in which two or more metal items are joined together
by melting and flowing a filler metal into the joint.
The filler metal used in the process is called as solder which have
relatively low melting point.
In this process, the parts to be joined are heated which causes solder
to melt and drawn into the joint by capillary action.
In this process, base metals are not melted like welding.

 Solder material
is mixture of
lead and tin.
Advantages and disadvantages- soldering
Advantages
 Variety of dissimilar metals can be joined.
 It is simple and low cost method.
 Workpieces of different thickness can also be joined.
 It is low temperature process hence, there is no change in properties of
metals.
Disadvantages
 Soldered joints are not stronger.
 Soldered joint has limited service at elevated temperatures.
 Corrosion resistance of soldered joint is less.
Applications
 In assembly of electronic components
 Joints in sheet metal objects like food cans, roof flashing, iron, etc.
 Joints in wires
 Assembly of jewellery components
 Brazing
It is the metal joining process in which a filler metal is heated and
distributed between two or more close fitting parts by capillary
action.
In brazing, metallic parts are joined by a non-ferrous filler metal or
alloy.
It is similar to soldering, except the temperature used to melt the
filler metal is above 4500C.
The filler metals used in the process are copper and silver based
alloys.
 Advantages, disadvantages of Brazing
Advantages
Dissimilar metals and non-metals can be brazed.
Due to uniform heating of parts, it produces less thermal
distortion than the welding process.
Complicated components can be brazed at low cost.
It produces clean joint.
Disadvantages
Strength of brazed joints is less as compared to welded joints.
It can be damaged under high service temperatures.
Filler metals used in the process are costly.
Applications
Brazing can join non-metals to metals, porous metal components,
dissimilar metals
Joining of electrical equipments, pipes, heat exchangers, etc.
Joining of carbide tool tips, steam turbine blades, etc.
Soldering and brazing-comparison
Sr. Parameter Soldering Brazing
No.
1. Filler metal Lead and tin Alloys of copper, silver and
nickel.

2. Temperature Filler material has MP below Filler material has MP above

4270C. 4270C.
3. Strength of Weak Strong
joint

4. Application Used for carbon, low alloy Used for cast iron, steels, Cu
steel, cast iron, stainless steel, and alloys, Al and alloys, Mg
Cu and alloys, Al and alloys. and alloys, etc.
5. Corrosion Less More
resistance
6. Joint profile Small gap between the joints Smooth joint
Advanced manufacturing trends
Industry 4.0
Industry 4.0 comprises many things, but is generally considered to involve the use of big data and automation to
create efficiencies in processes. A full implementation of Industry 4.0 equipment and practices is a huge capital
commitment, but these technologies will slowly make their way into more and more facilities, forcing others to
follow in order to remain competitive.

More helping hands from robots

Robots in the manufacturing setting are nothing new – but as they become smarter, safer and more mobile, the
industry will see their use grow. Inventory, assembly and machining become increasingly efficient as robots are
able to do more and provide greater benefit to their human co-workers.

Wearable tech
Following the shift to handhelds, the next step in on-demand data and information will be wearable devices.
Smart watches, headsets with heads-up displays and other wearables will provide critical data more quickly and
unobtrusively than ever.
• VR and AR
Virtual reality and augmented reality are finally beginning to realize the promise they have
advertised for years. These technologies will impact areas like training and maintenance in
various ways, including:
• “Hands-on” training  — Training and testing can be carried out in a VR environment,
creating a much safer and lower-risk process.
• Remote maintenance — Much like arthroscopic surgery done remotely via camera,
augmented reality will allow for maintenance technicians to carry out procedures from a
remote location, making great strides toward closing the skills gap and improving efficiency.
• Greater control over processes — Both VR and AR can yield greater efficiency, improved
accuracy and more targeted, predictive maintenance by providing more visibility and
insight into processes as they occur.