Machine Tools

&

Operations (2)
Learning objectives

• Explain the basic working principles of

various machine tools

• Describe the structure of various machine

• Describe operations performed on various

machine tools
1. Cont…
1.3.2 Shaping machine

1. Introduction

• Shaping machine is a
reciprocating machine
tool that removes excess
material from the work
piece using a single point
cutting tool.
 1. Cont…
2. Working Principle
• The workpiece is rigidly fixed
on the machine table
• The single point cutting tool
held properly in the tool post
is mounted on a
reciprocating ram
• The reciprocating motion of
the ram is obtained by a
quick return motion
mechanism
• As the ram reciprocates, the
tool cuts the material during
its forward stroke only

• Forward and return strokes constitute one operating cycle of the shaper
1. Cont…
3. Principal Parts
1. Cont…
4. Shaper Operations

• The basic operations done on a shaper can be

classified as:
 Horizontal Cutting: It is the
most common operation on
shaping machine in which the
work is fed in a horizontal
direction under the reciprocating
tool and the surface produced is
horizontal and flat.
 Vertical Cutting: The tool is fed
down wards in vertical cutting o
produce grooves, key-ways,
tongues, parting off and squaring
ends and shoulders
1. Cont…
 Angular Cutting: an operation
employed for machining
inclined surfaces, beveled
surfaces and dove- tails etc.

T
O
O
 Irregular Cutting: shaping L
operation for obtaining
irregular surfaces marked on
the side of the job

WORK
1. Cont…
5. Shaper Machining Time

• Machining time on a shaping machine is calculated

by:
length of the stroke  L 
Average cutting speed V1    m / min 
Time taken in cutting stroke

 L  min  L  min
cutting time    non  cutting time   
V1  V2 
Where V2 = Average return speed (m/min)

L L L L L 1   
Total time per cycle      min
V1 V2 V1 V1 V1
(Where k = Ratio of idle stroke time to cutting stroke time)
1. Cont…

• For shaping a work piece, an allowance of about 5

mm is left on either side of it

shaping width B  width of workpiece  2  allowance

Machining time = no. of cycles x Time required for each cycle

shaping width  B  B
No. of cycles required    
Feed per cycle  f  f

F = feed per cycle in mm

B L 1    L  B 1   
Machining time     min 
f V1 f V 1
1. Cont…
Example

Find the total time required on a shaper to machine

a plate 600 mm × 1,200 mm, if the cutting speed is
15 meters/min. The ratio of return stroke time to
cutting time is 2 : 3. The clearance at each end is
25 mm along the length and 15 mm on width. Two
cuts are required, one roughing cut with cross feed
of 2 mm per stroke and one finishing cut with feed
of 1 mm per stroke.
1.1 Cont…
Solution

Data:
length of the stroke  L 
Average cutting speed V1    15m/ min
Time taken in cutting stroke

length of the stroke  L   length  2  alloance  1200   2  25  1250mm

shaping width B  width of workpiece  2  allowance  600   2 15  630mm

ratio of return stroke to cutting time   2 : 3

cross feed for finish cut f1  2mm / stroke

cross feed for rough cut f2  1mm / stroke

1.1 Cont…
Based on the data given;
L 1    1250mm 1  0.67 
Time per cycle   min  0.14 min
V1 1000  15m

shaping width  B  630

No. of cycles required   roughing    315
Feed per cycle  f1  2

shaping width  B  630

No. of cycles required   finish cut    630
Feed per cycle  f2  1

Total No. of cycles required total   315  630  945

L 1   
Machining time  No. of cyles   945  0.14  132.3min
V1
1. Cont…
1.3.3 Milling Machine Tool

• Milling is the cutting operation that removes metal by

feeding the work against a rotating, cutter having
single or multiple cutting edges.
 1. Cont…
1. Operation Principle of Milling Machine

 The work is rigidly clamped on

the table of the machine and the
revolving multi teeth cutter
mounted on a spindle or an
arbor.
 The cutter revolves at a high
speed and the work fed slowly
past the cutter.
 The workpiece mounted on the
table can be fed either in the
direction opposite to that of
rotating cutter or in the same
direction of the cutter
 As the work advances, the cutter
teeth remove the metal from the
work surface to produce the
desired shape.
1. Cont…
1.1 Conventional/up Milling Vs Climb/Down Milling

Up milling Down milling

1. Cont…
2. Classification of milling machines

• Milling machines are broadly classified into:

 Column and knee type milling machines
 Fixed bed type or manufacturing type milling machines
 Planer type milling machines
 Production milling machines
 Special purpose machines
1. Cont…

1. Column and knee type Milling Machines

 These machines are all general purpose machine
tools and have a single spindle only.
 depending on the spindle position and table
movements, they are further classified as follows:
 Hand Milling Machine
 Plain or Horizontal Milling Machine.
 Vertical Milling Machine
 Universal milling machine
1. Cont…

1.1 Principle Parts of Column and knee type Milling Machine

Horizontal Knee milling machine

Vertical Knee milling machine
cutters are mounted in the spindle cutters are mounted on a
perpendicular to the work table horizontal arbor across the table
1. Cont…

2. Fixed bed type or manufacturing type Milling Machines

 Sturdy and rigid, heavier in weight and larger in size machine tool
 Operations performed on these machines includes slot cutting,
grooving, gang milling and facing

Fixed bed type or manufacturing

type Milling Machines classified as:

a) Plain type (having single horizontal

spindle)
b) Duplex head (having double
horizontal spindles)
c) Triplex head (having two horizontal
and one vertical spindle)
d) Rise and fall type (for profile milling)

Duplex milling machine

1. Cont…

3. Planer type Milling Machines

 These machines are
used for heavy works
 Up to a maximum of four
tool heads can be
mounted over it, which
can be adjusted vertically
and transverse directions
1. Cont…

4. Production Milling Machines

 These are also manufacturing

machines that do not have fixed
bed

 They include the following

machines.
a) Rotary table or Continuous type
b) Drum type.
c) Tracer controlled.
1. Cont…

5. Special purpose machines

 These machines are designed to

perform specific type of operation only

a) Thread Milling Machine

b) Profile Milling Machine
c) Gear Milling or Gear hobbling
Machine
d) Cam Milling Machine
e) Planetary type Milling Machine
f) Double end Milling Machine
g) Skin Milling Machine and
h) Spar Milling Machine.
1. Cont…
3. Operations Performed on a Milling Machine

• The basic operations performed on a milling machine

includes:

 Plain or slab  Form milling

milling  Straddle milling
 Face milling  Gang milling
 End milling  Slitting or saw
 Slot milling milling
 Angular milling  Gear cutting
1. Cont…
Plain or slab milling

 Machining of a flat surface

which is parallel to the axis
of the rotating cutter

• Cutter: Plain/ Slab milling

cutter.

• Machine: Horizontal
Milling machine.
1. Cont…
Face milling:

 Operation carried out for surface

producing a flat surface,

which is perpendicular to
the axis of rotating cutter.

• Cutter: Face milling

cutter.

• Machine: Vertical Milling

Machine
1. Cont…
End milling:
 Operation performed for
producing flat surfaces, slots,
grooves or finishing the edges of
the work piece.

• Cutter: End milling cutter

• Machine: Vertical Milling

Machine
1. Cont…
Slot milling:
 Operation of
producing slots like
T-slots, plain slots, Plain Slotting
Dovetail Slotting
dovetail slots etc.,

• Cutter: End milling

cutter, T-slot cutter,
dovetail cutter or side
milling cutter

• Machine: Vertical
Milling Machine
1. Cont…
Angular milling:
 Operation of producing all
types of angular cuts like
V-notches and grooves,
serrations and angular
surfaces.

• Cutter: Double angle cutter.

• Machine: Horizontal Milling

Machine
1. Cont…
Straddle Milling:
 Operation of machining
two parallel surfaces
simultaneously on a work
piece.
Straddle Milling
• Cutter: 2 or more side &
face milling cutters

• Machine: Horizontal Milling

Machine
1. Cont…
Gang Milling:
 Process of machining a
number of flat horizontal
and vertical surfaces of a
work piece by using a
combination of more than
two cutters mounted on a
common arbor.

• Cutter: Different cutters

as required.

• Machine: Horizontal
Milling Machine
1. Cont…
4. Cutting Tools
1. Cutting tools for horizontal milling

a. Slab Mills b. Side and Face c. Slitting Saws

For heavy cutting of Cutters For cutting deep
large and flat surfaces. This type of cutter has slots or for parting
cutting edges on the off.
periphery and sides of
the teeth for cutting
shoulders and slots.
1. Cont…

2. Cutting tools for vertical milling:

a. End Mills
Commonly used for facing, slotting and profile
milling.
b. Rough Cut End Mills
For rapid metal removal.

c. Slot Drills
For producing pockets without drilling a hole
before hand.

d. Face Milling Cutters

For heavy cutting.
1. Cont…
5. Cutting Parameters in Milling

• The desired cutting speed in milling operation is

determined from the rotational speed of the spindle by;
v
N
D

Where N = spindle rotational speed in rev/min; v = cutting speed in

m/min (in/min); D is the original diameter of milling cutter in m (ft)

34
1. Cont…

• The feed f also called the chip load, in milling is

calculated from the feed rate equation

fr  Nnt f

Where fr = feed rate in mm/min (in/mm); N = spindle rotational speed

in rev/min; nt is the number of teeth on the cutter; f is the chip load in
mm/tooth (in/tooth)

35
1. Cont…

• Material removal rate in milling is determined using

the product of the cross sectional area of the cut and
the feed rate.

RMR  wdfr

Where w = width of the workpiece in mm (in); d = depth of material in

mm (in); fr = feed rate in mm/min (in/mm)

36
1. Cont…

• The time required to mill a workpiece of length L is

given by;
L A
Tm 
fr
Where A = approach distance required to fully engage the cutter in mm
(in); L = length of work piece in mm (in); fr = feed rate in mm/min
(in/mm);

• For slab milling the approach distance is given by;

A  d D  d 
Where d = depth of cut in mm (in); D = diameter of cutter in mm (in)
37
1. Cont…

• For face milling, the approach distance is given by;


A  0.5 D  D2  w2 
Where A = approach distance required to fully engage the cutter in mm
(in); w = width of the work piece, mm(in);

38
1. Cont…

• If D = w, the approach distance A = 0.5D;

• When the cutter is offset to one side of the work, the
approach distance is given by;

A  w  D  w
Where A = approach distance required to fully engage the cutter in mm
(in); w = width of the cut, mm(in);

39
1. Cont…
Example

A peripheral milling operation is performed on the top

surface of a rectangular workpart which is 300 mm
long by 100 mm wide. The milling cutter, which is 75
mm in diameter and has four teeth, overhangs the
width of the part on both sides. Cutting conditions
are: v = 80 m/min, f = 0.2 mm/tooth, and d = 7.0 mm.
Determine:
a) the time to make one pass across the surface,
b) the material removal rate during the cut.

40
1. Cont…
Solution

a) the time to make one pass across the surface,

L A
Tm 
fr

v 80000mm
N  N  339.5rev / min
D   75mm

fr  Nnt f  fr  339.5  4  0.2  271.6 mm / min

A  d D  d   A  7  75  7   21.8mm
L  A  Tm  1.18min
Hence Tm 
fr
41
1. Cont…
Solution

b) the material removal rate during the cut

RMR  wdfr

RMR  100  7  271.6  190,120mm3 / min

42
1. Cont…
1.3.4 Drilling Machine Tool

• Drilling is a machining operation used to create a

circular cross section hole in a work part

• A drilling machine tool

makes holes in the job
by removing excess
material from it with the
help of a cutting tool
called drill bit.
1. Principle of Drilling Operation

• Drilling is done by forcing a rotating drill into

stationary job as on a drilling machine or by
forcing stationary drill in a rotating
workpeiece as on a lathe or milling machine.
1. Cont…
2. Basic Parts of a Drilling Machine

• A drilling machine consists of the following parts:-

V Belt
Pulley

Drill head

Arm Electric Motor

Spindle

Colum/pillar
Chuck Chuck key

Work table

Base Rack and Pinion

Mechanism
1. Cont…
3. Classification of Drilling Machines

a) Based on construction or structure, drilling

machines can be classified as;

 Portable, Sensitive, Radial, Up right,

Gang, Multiple spindle, Automatic and
Deep hole

b) Based on feed type drilling machines can be

classified as;

 Hand/manual driven
 Power/automatic driven
1. Cont…
3.1 Portable drilling machine
• small and compact machine tools
• drills small holes up to 12 mm diameter in
large work piece.
• feed is applied manually by hand
1. Cont…
3.2 Sensitive Drilling Machine
• These are small
machines designed for
drilling holes at high
speed in light work
pieces.
• Equipped with a hand
feed mechanism, which
enables the operator to
“feel” how the drill is
cutting and to control the
down feed.
• Categories:-
• Bench mounted
• Floor mounted Holes of diameter 1 mm to 15 mm
5
1. Cont…
3.3 Upright Drilling Machine

• These are similar to

sensitive drilling machines
except that they are
equipped with gearbox for
speed control.
• Spindle may be advanced
to the work piece by:
• hand lever
• hand wheel, and or
• automatically fed
• Categories:-
• Round column or
Pillar drilling machine
• Floor mounted 5
1. Cont…
3.4 Radial Drilling Machine

 Radial drilling machines allows

distance between the drill chuck
and the pedestal / vertical
column to easily be adjusted.
 Depending on the different
movements of horizontal arm,
table and drill head, this
machine can be classified as;
 Plain radial drilling machine
 Semi universal drilling
machine, and
 Universal drilling machine

5
Holes up to 7.5 cm
1. Cont…
Advantages of Radial Drilling Machine
 Larger and heavier work may be machined
 The drilling head may be easily raised or lowered to
accommodate various heights of work.
 The drilling head may be moved rapidly to any desired location
while the workpiece remains clamped in one position
 The machine has more power; thus, larger cutting tools can be
used.
 On universal models, the head may be swiveled so that holes can
be drilled on an angle.
5
1. Cont…
3.5 Gang Drilling Machine

 Gang drilling machine involves a

number of single spindle drilling
machine columns placed side by
side on a common base and have a
common worktable.
 Each drill head has its own power
unit and carries a tool to perform an
operation on a job in sequence.
 The job is moved from one spindle
to the other spindle for performing
various operations.

5
1. Cont…
3.6 Multiple-Spindle Drilling Machine

 Multi-spindle drilling machines are

equipped with two or more spindles
driven by a common head.
 This machine is used for drilling a
number of holes simultaneously in
a work piece.
 Feeding motion is usually obtained
by raising the worktable.

5
1. Cont…
3.7 Automatic Drilling Machine

• These are high performance/precision

automatic machine designed for
variety of operations being done on
the work piece.
• They can automatically change tooling
with a turret or automatic tool changer.
• Speeds, feeds, and table position is
controlled using a computer program.

5
Drill Bit
1. Cont…
4. Drilling Operations
 Drilling operations refer to those operations that can
be performed on a drilling machine which includes:
1) Drilling
2) Reaming
3) Boring
4) Counter boring
5) Counter sinking
6) Spot facing
7) Tapping
1. Cont…
4.1 Drilling
 An operation in which circular cross section holes are
produced in solid metal by rotating the drill and feeding it
through the work piece.
1. Cont…
4.2 Reaming
 Reaming is an operation of
sizing and shaping an already
drilled hole using a cutting
tool called reamer.
 A reamer is multi-toothed
tool designed for removal of
relatively small amount of
material from a previously
drilled hole.
1. Cont…
4.3 Boring

 It is a process of enlarging
already existing hole to meet
desired size
 Radial increment is large as
compared to reaming
operation

59
1. Cont…
4.4.1 Counter boring
 It is a process of enlarging
the opening of already
existing hole by making a
cylindrical step within the
hole
 The cylindrical step is
produced so that it can
accommodate bolt head
within it
1. Cont…
4.5 Counter Sinking

 Countersinking is an
operation that produces a
tapered angular hole to fit
a flat-head conical
machine screw.
1. Cont…
4.6 Spot Facing
 Spot facing is similar to
counter boring except the
depth of step produced is spot face
relatively shallow
 The shallow step is
produced so that it can
accommodate washer

62
1. Cont…
4.7 Tapping

• It is a process of producing
internal threads within
already existing hole
• Tapping in a drill press may
be performed either by
hand or under power with
the use of a tapping
attachment.
63
1. Cont…
4.7.1 Types of thread tap

64
1. Cont…

Drilling Reaming Counter Boring Spot Counter

Tapping
Facing Sinking
1. Cont…
5. Cutting Parameters in Drilling

• The desired cutting speed in drilling determined

from the rotational speed of the spindle by;
v
N
D

Where N = spindle rotational speed in rev/min; v = cutting speed in

mm/min (in/min); D is the drill diameter, mm (in)

66
1. Cont…

• Feed f in drilling is specified in mm/rev (in/rev) and

can be calculated by;

fr  Nf

Where fr = feed rate mm/min (in/mm); N = rotation speed in rev/min;

f = feed mm/rev (in/rev)
67
1. Cont…

• Drilled holes are either through holes or blind holes

• The machining time required to drill a through hole
can be determined by;
tA
Tm 
fr
Where fr = feed rate in mm/min (in/mm); Tm =
machining time in min; A = an approach
allowance in mm (in) that accounts for the drill
point angle, representing the distance the drill
must feed into the work before reaching full
diameter and t = thickness of the work piece in
mm (in)
  Where θ is the drill point angle,
A  0.5D tan  90  
 2 D = diameter of the drill in mm
68
1. Cont…

• The machining time required to drill a blind hole

can be determined by;

dA
Tm 
fr

Where fr = feed rate in mm/min (in/mm); Tm =

machining time in min; A = an approach
allowance in mm (in) that accounts for the drill
point angle, representing the distance the drill
must feed into the work before reaching full
diameter and d = hole depth in mm (in)

  Where θ is the drill point angle,

A  0.5D tan  90  
 2 D = diameter of the drill in mm
69
1. Cont…

• The rate of metal removal in drilling is determined

as the product of the drill cross sectional area and
the feed rate;
 D2 fr
RMR 
4
Note: Equation is valid only after the drill reaches full diameter and
excludes the initial approach of the drill into the work

70
1. Cont…
Example

A drilling operation is to be performed with a 12.7

mm diameter twist drill in a steel workpart. The
hole is a blind hole at a depth of 60 mm and the
point angle is 118̊ . The cutting speed is 25 m/min
and the feed is 0.30 mm/rev. Determine
a) the cutting time to complete the drilling
operation, and
b) metal removal rate during the operation, after
the drill bit reaches full diameter.

71
1. Cont…
Solution

a) the cutting time to complete the blind hole

drilling operation
dA  
Tm  where fr  Nf and A  0.5D tan  90  
fr  2
v 25000mm / min
N  N  626.59rev / min
D  12.7mm
rev mm
fr  Nf  r
f  626.59  0.3  187.98mm / min
min rev

   118 
A  0.5D tan  90    A  0.5 12.7 tan  90    3.8mm
 2  2 

dA 60  3.8
Tm   Tm   0.34 min
fr 187.98
72
1. Cont…
Solution

b) material removal rate during the operation,

after the drill bit reaches full diameter.

 D2 fr
RMR 
4

mm
  12.7mm  187.98
2

RMR  min  23812.72mm3 / min

4

73
Acknowledgements

1. Kesavan. R. Machine Tools, Laxmi Publications,

2010

2. Sharma. P.C. Testbook of Machine Tools and Tool

Design, Chand & Co 2005, ISBN 13: 9788121923620)

3. Machine Tools – C Elanchezhian and M. Vijayan,

Anuradha Publications
THE
END