MODULE-II

Introduction Machine Tool Operations

Introduction to Advanced Manufacturing Systems

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Dr. Bharath V
 INTRODOCTION TO SYLLABUS

MODULE-2- II (8 hours)

 Machine Tool Operations : Working Principle of lathe, Lathe operations: Turning,

facing, knurling. Working principles of Drilling Machine, drilling operations: drilling,

boring, reaming. Working of Milling Machine, Milling operations: plane milling and

slot milling. (No sketches of machine tools, sketches to be used only for

explaining the operations).

 Introduction to Advanced Manufacturing Systems: Introduction, components of

CNC, advantages and applications of CNC, 3D printing.

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 MACHINE TOOLS
MACHINE TOOL AND MACHINING
 Machining is the process of removing the excess material from the work piece in the form of

chips, by forcing a cutting tool with one or more cutting edges to arrive the required shape

and size.

 Machine tool is a power driven machine to perform machining. Generally, a machine tools shall

produce either cylindrical or flat surfaces on majority.

A machine tool performs three major functions

 It rigidly supports the work piece and the cutting tool.

 It provides relative motion between the work piece and the cutting tool

 It provides a range of speeds & feeds.

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 MACHINE TOOLS
Machine Tools:

The most commonly used machine tools are;

 Lathe

 Grinding machine

 Drilling Machine

 Shaping Machine

 Planning Machine

 Milling Machine

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 MACHINE TOOLS
LATHE MACHINE

Working Principle:

 Lathe is a machine tool which holds the work in a holding device and rotating it against a

suitable cutting tool to remove the excess metal from the work.

 If the tool is moved parallel to the axis of rotation of the work, a cylindrical surface is

produced.

 If the tool is moved perpendicular to the axis of rotation of the work, a flat surface is

produced.

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 MACHINE TOOLS
Lathe machine classifications:

Lathes are classified as;

(i) Bench Lathe

(ii) Speed lathe

(iii) Engine Lathe

(iv) Tool room lathe

(v) Capstan & Turret lathe

(vi) Automatic lathe

(vii) Special purpose lathe

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 MACHINE TOOLS
BENCH LATHE SPEED LATHE

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P R Venkatesh, Mech Dept, RVCE, B'lore Dr. Bharath V
 MACHINE TOOLS
ENGINE LATHE (OR) CENTER LATHE

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 MACHINE TOOLS
TOOL ROOM LATHE

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 MACHINE TOOLS
CAPSTAN AND TURRET LATHE

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 MACHINE TOOLS
AUTOMATIC LATHE

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 MACHINE TOOLS
SPECIAL PURPOSE LATHE

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 MACHINE TOOLS
PARTS OF LATHE

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 MACHINE TOOLS
Major parts included in lathe construction :

The major parts included in lathe construction :

1. Bed

2. Headstock

3. Tailstock

4. Carriage

5. Feed rod

6. Lead screw

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 MACHINE TOOLS
Major parts included in lathe construction :
1. Bed:
• The lathe bed forms the support for all other parts.
• At the top of the bed, precision machined guide ways (inner & outer)
are present.
• The headstock & tailstock are mounted on the inner ways which keep
them perfectly aligned with each other.
• The outer ways guide the movement of carriage assembly.
• Bed is usually made of grey cast iron because of its good damping
property and low frictional resistance.

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 MACHINE TOOLS
Major parts included in lathe construction :

2. Headstock :

•Headstock is a box like casting mounted at the left end

of the machine.

•It consists of a spindle and gear box to rotates the

spindle at different speeds.

•The spindle has external threads to receive a work

holding device such as a chuck or face plate.

•The gear box distributes power to the feed rod and

leads screw for turning or thread cutting operation.

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 MACHINE TOOLS
Major parts included in lathe construction :
3. Tailstock :
•Tailstock is mounted at the right end of the
machine.

•It may be slides on the guide ways to

support different lengths of work pieces
between centers and clamped to bed at any
desired location.

•It carries a dead center or revolving

center.

•Tailstock can be offset for taper turning.

It can also carry tools like drill bit, reamer,
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tap, etc. Dr. Bharath V
 MACHINE TOOLS
Major parts included in lathe construction :

4. Carriage Assembly
• it supports and feeds the cutting tool against the work during operation of the
lathe.

• The carriage slides along the outer guide ways and consists of the following parts :

1. Saddle (Part no. 03A)

2. Cross slide (Part no. 03)

3. Compound slide (Part no. 02,02B)

4. Tool post (Part no. 01)

5. Apron (Part no. 05)

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 MACHINE TOOLS

Major parts included in lathe construction :

Saddle :
It is a H-shaped casting that slides over the outer guide ways and serves as a base for the cross slide.

Cross slide:
It is mounted on the saddle and enables the movement of the cutting tool laterally across the lathe
bed by means of a cross feed hand wheel.

Compound rest:
It is mounted on the top of the cross slide and supports the tool post. It can be swiveled to any angle
to facilitate taper turning & threading operations.

Tool post:
It is mounted on the top of the compound rest and carries the cutting tool

Apron:
The portion of the carriage that extends in front of the lathe is called an apron. It houses feed
mechanisms. It contains pinion which engages with the rack for longitudinal feed.

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 MACHINE TOOLS
Major parts included in lathe construction :

5. Feed Rod:
• The feed rod is a long shaft used to drive the apron mechanism for cross & longitudinal
power feed during turning, boring & facing operations. The feed rod is powered by a set
of gears from the headstock.

6. Lead Screw:

• It is a long threaded shaft geared to the

headstock. Closing a split nut around the
lead screw engages it with the carriage. It
used only for thread cutting operations.

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 MACHINE TOOLS
OPERATIONS OF LATHE
The most common operations performed on a lathe are:

 Turning
 Facing
 Parting
 Grooving
 Knurling
 Drilling
 Boring
 Taper turning
 Thread cutting

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 MACHINE TOOLS
TURNING OR PLAIN TURNING:
Chuck
Spindle
 Plain turning is a lathe operation to remove Work piece
Depth of cut
excess material from the work piece & to

produce cylindrical surface.

 Using the cross slide the cutting tool is

first adjusted for desired depth of cut.

Dead center
 As the work piece revolves, the tool is fed

against the work-piece in a direction

Feed Cutting Tool
parallel to the axis of the spindle.
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 MACHINE TOOLS
FACING:
 Facing is a lathe operation to produce a

flat surface normal to the axis of

rotation of the spindle.

 During facing, the carriage is locked to

the lathe bed to prevent its movement.

 Using cross slide the cutting tool is fed

at right angle to the axis of the work

piece.

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 MACHINE TOOLS
KNURLING :
 Knurling is the process of embossing a diamond shaped pattern on the surface of the

work piece by the use of revolving hardened steel wheels pressed against the work.

 Knurling is done to provide grip on handles, screw heads and other cylindrical parts to

be gripped by hand.

Knurling Tool Knurled surface 24

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 MACHINE TOOLS

THREAD CUTTING :
 The principle of thread cutting on a lathe is to
produce a helical groove on a revolving cylindrical
surface by feeding the tool longitudinally as shown
in fig.
 The change gear calculations are made for the
desired pitch of the screw and the split nut is
closed.
 This engages the carriage with the lead screw and
the threading tool is fed into the work using both
cross feed & longitudinal feed.

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 MACHINE TOOLS

DRILLING :

 Drilling is an operation of producing cylindrical hole

by means of a cutting tool called drill.

Drilling
 A drill it is placed in the tapered hole of a tailstock
sleeve and is fed into the work by rotating the hand
TWIST DRILL

wheel of the tailstock

Chuck

Work piece Tailstock

Spindle Drill bit

Sleeve
Feed
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 MACHINE TOOLS

TAPER TURNING :
 Taper turning is an operation on a lathe to produce conical surface
on work pieces.
 Taper on a lathe is the difference between the diameters over a length.
 If ‘D’ is the larger diameter & ‘d’ the smaller diameter, l is the length between
the two diameters, then

Taper (or) Conicity = (D-d)/ l


(D-d)/2
Half angle of taper α = tan-1  D - d 

 2l 
d
D  

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 MACHINE TOOLS

Taper Turning Methods

A taper may be turned by any one of the following methods :

 By form tool

 By swiveling the compound rest

 By Tailstock off set method

 By using Taper turning attachment

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 MACHINE TOOLS

Taper Turning using form tool :

 Here a form tool which has a straight edge set at
the desired angle is used.
 The angle between the cutting edge and the axis of
the spindle equals half taper angle.
 This method is limited to short tapers & is
mainly used for chamfering. Work piece
Taper








 Feed
Form tool
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 MACHINE TOOLS

Taper Turning by swiveling compound rest :

 The compound rest may be swiveled & clamped at
any desired half angle of taper on a circular base
graduated in degrees.
 The tool is fed by rotating the compound slide
screw.
 This is also limited to short tapers as the
movement of the compound slide screw is limited.

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 MACHINE TOOLS

Taper Turning by Tailstock set over (offset) :

• In this method, the center line of the work piece may be offset from the axis of the
lathe and the tool is fed parallel to the axis of the lathe.
• This is achieved by moving the tailstock either towards or away from the operator by
means of a set over screw. Used for small tapers on long jobs.

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 MACHINE TOOLS
LATHE SPECIFICATIONS :

Overall length of bed

Distance between centers

Swing diameter
over gap in the bed
Swing diameter
Lathe Bed
over lathe bed

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 MACHINE TOOLS
LATHE SPECIFICATIONS :
The size of a lathe is specified by the following:

1. Maximum diameter of the work piece that can be revolved over the lathe bed.

It is also called as height of centers above the lathe bed Or Swing diameter over lathe bed.

2. Maximum diameter and width of the work piece, that can swing when the lathe has a gap

bed.

3. Maximum length of work piece ,that can be mounted between centers.

4. Overall length of bed: It is the total length of the lathe itself.

5. Maximum number of speeds & feeds available.

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 Milling: The milling is a type of machining process which removes the material from the
work piece by feeding the work past a rotating multipoint cutter. The metal removal rate is
higher very high as the cutter has a high speed and many cutting edges.
Up Milling:
The work piece is fed opposite to the direction of
the rotating cutter.
Chips are progressively thicker.
Since the cutting forces are directed upwards it
tends to lift the work piece.
Gives poor surface finish. Used for hard
materials.

Down Milling:
The work piece in the direction of the rotating cutter.
Chips are progressively thinner.
Cutting forces are directed downwards, which keep the
work piece pressed to the table.
 Gives good surface finish. Used for soft materials and
finishing operations. 34
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 Difference between Up Milling & Down Milling
Sl Up-Milling Down-Milling
1 Cutter rotates against direction of Cutter rotates with direction of feed.
feed.
2 Tool wear is more because the tool Tool wear is less compare to the up
runs against the feed. milling, due to the cutter rotate with
the feed.
3 The cutting chips are carried The chips are carried downward by the
upward by the tool so known as up tool so known as down milling.
milling.
4 It requires high cutting force It requires low cutting force.
compare to down milling.
5 High quality cutting fluid is In this process heat does not diffuse in
required because heat diffuse in the work piece, so simple cutting fluid is
the work piece. required.
6 Tool life is low Tool life is good.
7 This gives less surface finish This gives better surface finish.
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 Types of Milling Machine
 Column Knee type milling machine

 Fixed Bed type Milling Machine

 Planar type Milling machine

 Production Milling Machine

 Special Purpose Milling Machine.

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 Applications of Milling Machine

 The milling machine is used for making various types of gears.

 It is generally used to produce slot or groove in work pieces.

 It can able to machine flat surface and irregular surfaces too.

 It is used in industries to produce complex shapes.

 It is used in Institutions or colleges to conduct lab tests on milling machine.

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Milling Machine
• Base

• Column

• Knee

• Saddle

• Table

• Over-arm

• Arbor/Spindle

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 Milling Machine Working Principle:
• Milling machine employed in the metal removing operation in which
the work is rigidly clamped on the table of the machine and the
revolving cutter which has multiple teeth is mounted on the
arbor.

• The cutter revolves at high speed and the work is fed slowly past
the cutter.

• The work can be fed in a vertical, longitudinal, or cross direction

depending upon the type of milling machine being used.

• As the work proceeds, the cutter-teeth removes the metal from

the surface of the job(workpiece) to produce the desired shape.
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• Base :
• The base is the part upon which the whole machine parts
are being mounted.

• It is a type of foundation for the machine.

The base is mostly made up of cast iron, so it has
good strength and rigidity.
• Cutting fluid can also be stored in the base.

• Column: The main supporting frame which consists of

all the driving mechanisms and the motor is called the
column.
• The driving mechanism usually consists of a cone
pulley mechanism in which the v-belt is being used
to connect it to the motor.
• Further by using this driving mechanism the speed
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of the machine can control as per our requirement. Dr. Bharath V
• Knee :
• The knee shape is quite similar to that of the
human body knee. This is an important part of
this machine that supports the other parts
like the saddle and table.

• It is attached to the column and has

guideways by which it can move up and down
with the help of the elevating screw for
adjusting its height.

• Saddle: The saddle is present on the top of the

knee which further carries the table. Its basic
function is to support the table.
• A saddle can slide on the guideways which are
exactly at 90 degrees to the column
face. Saddle moves crosswise(in or out) on
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 • Table: The table is present on the top of the saddle.
• The table consists of T-slots or sometimes fixtures are used
for holding up the workpiece on the table.
• A table can travel longitudinally in a horizontal plane.

• Over-arm:
• It is also called the over-hanging arm.
• Overarm is present at the top of the column.
• The basic function of the over-arm is to support the
arbor and spindle.

• Spindle or Arbor: The top portion of the column contains

the spindle. The spindle is also an important part of the
machine as it is the part where the multipoint cutter is
attached.
• Power required for the rotation of the spindle is
obtained from the motor through the belt, gear,
and clutch assembly.
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 Difference between Horizontal & Vertical Milling M/C
Sl Horizontal Milling M/C Vertical Milling M/C
1 A cutter is mounted on the arbor Here instead of an arbor, the cutter is mounted
directly on the spindle.
2 In the Horizontal Milling machine, a cutter the cutter moves up and down.
is fixed not moving up and down.
3 The spindle is horizontal and parallel to the The spindle is vertical and is perpendicular to the
work table. worktable.
4 The spindle can not be tilted in this machine Here spindle can be tilted so angular cutting
so angular cutting operation is not possible. operation is possible.
5 The operation like The operation like
Plain, Gear, Straddle, Gang Milling T slot, angular, Flat, Slot Milling operations are
operations are performed. performed
6 The price of the machine is high. The price of this machine is low.
7 Chances of getting a poor surface finish are we can get a poor surface finish here.
not possible
8 Heavier in weight. & Tool life is longer. less heavy in weight & Tool life is no longer.
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 Advantages of Milling Machine:
• High speed: In Milling, the rate of metal removal is very high as the cutter rotates at a high
speed and has multiple cutting edges.

• Better surface finish: The surface finish of the materials machined on the milling machine is
better because of the multi-cutting edges.

• Increased Productivity: CNC Milling Machines are the machines in which the milling operation
is being controlled by software. It has increased the overall production with better finish and
accuracy.
• High Accuracy: In the milling machine, the products machined are of high accuracy, especially
in the case of the most advanced form of milling machine which is the CNC Machine.
• Huge Application: The indexing head makes it suitable for so many applications as the exact
rotation of the job is possible by the use of it. Milling can be used for machining flat surfaces,
irregular surfaces, contoured surfaces, slotting, gear cutting, and many more.
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 Disadvantages of Milling Machine:
• High crater wear: High crater wear is found which can be tackled by reducing speed and
using harder carbide.

• High Flank wear: It has a high flank wear rate which can be prevented by reducing speed
and increasing the feed rate. Further to avoid it one should use harder carbide with proper
geometry and sharpened cutting edges.

• High Chatter: This happens due to poor rigidity of cutter, machine, loose arbor, and
improper geometry. This situation can be improved by increasing feed, reducing speed, and
using unequal pitch cutters.

• Chip clogging: The milling machine also suffers from the problem of chip clogging which can
be reduced by using reducing the number of teeth on the cutter and increasing speed and
chip pockets. 45
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 The following Operations are performed by the Milling Machine:

• Plain or Slab Milling Operation

• Straddle Milling Operation
• UP and DOWN Milling Operation
• Groove Milling Operation
• Face Milling Operation
• Gear Milling Operation
• End Milling Operation
• Side Milling Operation and
• Gang Milling Operation
• T-Slot Milling Operation

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 Plain/Slab Milling Operation:

 Plain or slab milling is a process in which the

plain, horizontal or flat surfaces are produced,
which are parallel to the axis of the rotation
of the cutter. A peripheral mill cuter is used
for performing the slab milling operation.

 Face milling is a type of milling operation in which the

layer of material is removed from the face of the
Face Milling Operation: material.

 The end milling cutter is preferred for performing

face milling operations.
 In Face Milling operation the teeth for cutting are
present on both the periphery and the face of the
cutter.

 The axis of rotation of the cutter is perpendicular

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 End Milling Operation:

 This type of operation is the combination of the

slab milling and face-milling operation used for
creating slots in the work piece and is mostly used
for handling the complicated profile.

Gang Milling Operation:

 This is a type of milling operation in which

multiple cutters are being mounted on the
same arbor to produce the desired shape on
the work piece.

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 Straddle Milling Operation:

The straddle is the type of milling

process in which milling is performed
on two surfaces simultaneously. T-slot
milling is a unique example of straddle
Milling.

Angular Milling Operation:

It involves removing portions of material from a
work piece to form the desired product.
However, unlike conventional milling, angular
milling creates flat surfaces that aren't parallel
(or perpendicular) to the axis of the cutting tool.

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Bed: The bed is the main part of the machine on which the whole machine is being mounted. The
bed is made up of cast iron, so it has high compressive strength and good wear resistance.

Pillar : The pillar is a type of vertical column that rests on the bed. A pillar is present at the
center of the bed. The pillar helps the motor and the spindle head.

Swivel Table:
The table is the place where the workpiece is being mounted. The table is attached to the
column and it can be rotated around the column and can have an upward and downward moment. A
table can be adjusted at any angle as per the requirement.

Motor:
The motor is present at the top of the column. The inside motor shaft is there which is
connected to a stepped pulley so that we can increase or decrease the speed of the rotation of
the motor.

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Stepped pulley: Two steeped pulleys are present on either side of the column at the top. Out
of these two, one pulley will be in an upward direction while the other pulley is inverted. Always
both the pulleys will be there in the opposite direction.

The basic function of the stepped pulley is to control the speed of the rotation of the
motor.
Spindle: Spindle arrangement is present at top of the column opposite to the arrangement of
the motor.
The top of the spindle is attached to one of the stepped pulleys. The bottom of the spindle is
connected to the chuck.

Chuck: Chuck is present at the bottom of the spindle. The basic function of the chuck is to
hold the cutting tool firmly.

Drill bit:A drill bit is an actual cutting tool that is used to create a hole in the workpiece.

Hand Wheel: The basic function of the hand wheel is to adjust the spindle position as per the
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 The following Operations are performed by the Drilling Machine:

• Drilling Operation
• Tapping Operation
• Reaming Operation
• Spot Facing Operation
• Boring Operation
• Grinding Operation
• Counter Boring Operation

• Counter sinking Operation

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Drilling operation: Drilling is the process of creating circular holes on the job(workpiece) using
a drill.

Boring operation: Boring is the process of enlarging a hole by means of an adjustable cutting
tool with only one cutting edge.

Reaming Operation: It is basically a type of finishing operation. It is a process of sizing and

finishing a hole by means of a reamer having several cutting edges.

Counter Boring Operation: Counter boring is a type of operation in which it is used to enlarge
a particular portion of the hole.

Counter Sinking Operation: Countersinking can be defined as the process of enlarging the end
of the hole to give it a conical shape for a short distance.

Taping Operation: Tapping is the process of creating internal threads by means of a tool
called the tap.

Spot Facing Operation: Operation of removing the chip present on the surface of the hole for
proper seating of head nuts etc. This can be done by an end mill cutter with drill machines.
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