19MEC06 MANUFACTURING

TECHNOLOGY
CENTRE LATHE
 Lathe is one of the oldest important machine tools in
the metal working industry.
 A lathe operates on the principle of a rotating work
piece and a fixed cutting tool.
 Its main function is to remove material from a work
piece to produce the required shape and size.
Major parts of a centre lathe
• This is heavy rugged casting
made to support the working
parts of lathe and also guide
and align major parts of
lathe.
• On top section are machined
ways.
To resist the cutting force and
vibration
• The headstock houses
the main spindle,speed
change mechanism, and
change gears.
• The headstock is
required to be made as
robust as possible due to
the cutting forces
involved,which can distort
a lightly built housing.
• Contains number of different-size gears.
• Provides feed rod and lead-screw with various
speeds for turning and thread-cutting operations

TOP VIEW
 The arrangement which are employed in feed gear
boxes to obtain multispindle speeds and different
rates of feeds are:
I. Sliding Gear Mechanism
II. Sliding Clutch Mechanism
III. Gear Cone And Tumbler Gear Mechanism
IV. Sliding Key Mechanism
V. Combination of any two or more of the above
• Usually two or three levers must be moved to obtain
the desired combination within a given range.
• Used to move cutting tool along lathe bed.
• Consists of three main parts-
i. Saddle
ii. Cross-slide
iii. Apron
• Mounted on top of saddle.
• Provides manual or automatic cross movement for
cutting tool.
 • Fastened to saddle.
• Houses gears and
mechanism required to
move carriage or cross-
slide automatically.
• Locking-off lever inside
apron prevents engaging
split-nut lever and
automatic feed lever at
same time.
• Apron hand wheel
turned manually to move
carriage along lathe bed
• Upper and lower tailstock castings.
• Adjusted for taper or parallel turning by two screws set in base.
• Tailstock clamp locks tailstock in any position along bed of lathe.
• Tailstock spindle has internal taper to receive dead center.
• Provides support for right-hand end of work.
Specification of a lathe
 Length of bed
 Max distance b/w dead and live centres
 Type of bed i.e straight, semi gap, gap type
 Height of centers from the bed
 Swing over the bed
 Swing over the cross slide
 Width of the bed
 Spindle bore
 Spindle speed
Specification of
 H.P of main motor and rpm
 No. of spindle speeds
a lathe
 Spindle nose diameter
 Feeds
 Floor space required
• This term ‘engine’ is associated with the lathe owing to the fact
that early lathes were driven by steam engine. It is also called
Engine lathe or centre lathe
• The most common form of lathe, motor driven and comes in
large variety of sizes and shapes.
• A bench top model usually of low power used to make precision
machine small work pieces.
• It is used for small w/p having a maximum swing of 250 mm at the
face plate. Practically it consists of all the parts of engine lathe or
speed lathe.
 A tool room lathe having features
similar to an engine lathe is much
more accurately built and has a wide
range of spindle speeds ranging
from a very low to a quite high
speed up to 2500 rpm.
 This lathe is mainly used for
precision work on a tools, dies,
gauges, and in machining work
where accuracy is needed.
 This lathe machine is costlier
than an engine lathe of the same
size.
• A lathe in which the work piece is automatically fed
and removed without use of an operator.
It requires very less attention after the setup has
been made and the machine loaded.
 A highly automated lathe, where both cutting, loading, tool changing, and
part unloading are automatically controlled by computer coding.
 E.g. CNC Lathe M/C.(Computer Numerical Control Machine)
Headstock driving
mechanisms
 Back geared headstock.
mechanisms
 All geared headstock.
Feed mechanisms
Tumbler gear reversing mechanism.
Quick-change gearbox.
Tumbler gear quick-change gearbox.
Apron mechanism.
Tumbler gear reversing
mechanism.
Quick-change gearbox.
gearbox.
Apron mechanism.
Work holding devices
 Chucks
 Centres
 Face plate
 Angle plate
 Mandrels
 Steady and follower rest
Magnetic chuck
Three jaw and Four jaw chuck
Types of centres
 Work held between centres
Angle plate and face plate

(a) Angle plate (b) Angle plate used along with face plate
Mandrels
Steady rest and Follower rest
Various Lathe operations
Various Lathe operations
TAPER TURING
Taper turning by a form tool METHODS
Taper turning by swiveling the compound rest
TAPER TURING METHODS
 Taper turning by offsetting the tailstock
TAPER TURING METHODS
 Taper turning by using taper turning attachment
THREAD CUTTING
SPECIAL ATTACHMENTS
 Milling attachment
SPECIAL ATTACHMENTS
 Cylindrical grinding attachment
  CAPSTAN LATHES
SPECIAL PURPOSE LATHES
TURRET LATHES
Photographic view of a
hexagonal turret
Bar feeding mechanisms
Turret indexing mechanism or
Geneva mechanism
Work holding devices used in
capstan and turret lathes
 Air operated chuck
Collet chucks (a) Push out type (b)
draw back type (c) Dead length type
Tool holding devices used in
capstan and turret lathes
 Straight cutter holder
Tool holding devices
 Adjustable angle cutter holder
Tool holding devices
 Multiple cutter holder and Offset cutter holder
Tool holding devices
 Sliding tool holder and Knee tool holder
Automatic lathes
 These are machine tools in which the components are
machined automatically.
 Single spindle automatic lathe
 Swiss type automatic lathe or sliding head automatic
lathe
 Single spindle automatic screw cutting machine
 Multiple spindle automatic lathes
Single spindle automatic lathe

 Arrangement of tool slide

Simple parts produced on cutting off machine

SWISS TYPE AUTOMATIC SCREW MACHINE
SINGLE SPINDLE AUTOMATIC SCREW TYPE MACHINE
MULTI SPINDLE
AUTOMAT
 Parallel Action Multi Spindle Automat
Progressive Action Multi Spindle
Automat
SHAPER
 The main function of the shaper is to produce flat surfaces in
different planes.
ss
Types of quick return mechanisms are used in
the shaper
1) Crank and slotted mechanism
2) Whitworth quick return mechanism
3) Hydraulic shaper mechanism .
DRILLING
 Drilling is a cutting process that uses a drill bit to cut
a hole of circular cross-section in solid materials. The
drill bit is usually a rotary cutting tool, often
multipoint. The bit is pressed against the work piece
and rotated at rates from hundreds to thousands of
revolutions per minute.
Types of drilling machine
 The different types of drilling machine which are most commonly
used are:
 Portable drilling machine.
 Sensitive drilling machine (Bench mounting or table top and Floor
mounting).
 Upright drilling machine (Pillar or Round column section and Box
column section).
 Radial drilling machine (Plain, Semi-universal and Universal).
 Gang drilling machine.
 Multiple spindle drilling machine.
 Deep hole drilling machine.
 Turret type drilling machine
Hand drilling machine
Table top sensitive drilling
machine
Floor mounting sensitive
drilling machine
Box column section upright
drilling machine
Radial drilling machine
Deep hole drill
Gang drilling machine
Twist drill nomenclature
Different operations performed
in a drilling machine
BORING
 Boring is an operation of enlarging and locating
previously drilled holes with a single point cutting tool.
Table type horizontal boring
machine
Planer type horizontal boring
machine
Multiple head type horizontal
boring machine
Vertical boring machines

Double column vertical boring machine Turret boring machine

Jig borers or jig boring
machines
 MILLING MACHINE
 This is a machine tool that removes material as the work is
fed against a rotating cutter.
 The cutter rotates at a high speed and because of the
multiple cutting edges it removes material at a very fast
rate.
TYPES OF MILLING MACHINE
 Column and knee type
 Plain or horizontal milling machine.
 Universal milling machine.
 Omniversal milling machine.
 Vertical milling machine.
 Manufacturing or bed type
 Simplex milling machine.
 Duplex milling machine.
 Triplex milling machine.
 Planer type Special type
 Drum milling machine.
 Rotary table milling machine.
 Profile milling machine.
Plain or horizontal milling
machine
Vertical milling machine
Universal milling machine Omniversal milling machine
Work holding devices used in
a milling machine
Tool holding devices used in a
milling machine
MILLING CUTTERS
1. Slab or plain milling cutters
Side milling cutters
Slitting saws or parting tools

Slitting saw End milling cutters Face milling cutter

T-slot milling cutter Involute gear milling cutter
Convex milling cutter Concave milling cutter Corner rounding milling cutter
Single angle milling cutter and Double angle milling cutter
MILLING OPERATIONS

Schematic view of the face milling operation

End milling
Parting by slitting saw Straddle milling
Form milling operations
Gear Generating Processes
1.Gear Shaping
2.Gear Planning
3.Gear Hobbing
Gear Shaping
ABRASIVE PROCESSES: GRINDING
The cutting action of abrasive grits of disc type grinding
wheel similar to cutting action of teeth of the cutter
in slab milling.
Applications of grinding
To remove small amount of metal from work pieces and finish
then to close tolerances.
To obtain a better surface finish.
To machine hard surfaces that cannot be machined by high-
speed steels.
Grinding of tools and cutters and resharpening of the same.
Grinding of threads.
Stock removal (abrasive milling) finishing of flat as well as
cylindrical surface.
GRINDING WHEELS
 Grinding wheel consists of hard abrasive grains called
grits, which perform the cutting or material removal, held
in the weak bonding matrix.
Types of abrasives
1.Natural abrasives - Emery (50 - 60 % crystalline Al2O3 + Iron
Oxide), Sandstone or Solid Quartz, Corundum (75 -
90 % crystalline Al2O3 + Iron Oxide) and Diamond.

2.Artificial abrasives - Aluminium Oxide (Al2O3), Silicon

Carbide (SiC), Artificial diamond, Boron Carbide
and Cubic Boron Nitride (CBN).
Bond
 It is an adhesive substance which holds the abrasive grains
together to form the grinding wheel.
 Types of bonds - Bonds are classified into two types
1.Organic (Resinoid, Rubber, Shellac & Oxychloride )
2.Non – Organic (Metallic, Vitrified & Silicate)
TYPES OF GRINDING PROCESS
1. Cylindrical grinding process.
2. Surface grinding process.
3. Centreless grinding process.
Rough Grinding Machine
1.Bench Grinder
2.Portable Grinder
3.Abrasive Belt Grinding
Precision Grinding Machine
1.Cylindrical Grinder
Surface Grinders
1. Horizontal Spindle Reciprocating Table surface
grinding machines
2. Horizontal Spindle Rotary Table surface
grinding machines
Vertical Spindle Rotary Table
surface grinding machines
Centreless Grinder
Internal Grinding
 Internal grinding is used to grind the internal diameter of the
work piece.
 Tapered holes can be ground with the use of internal grinders
that can swivel on the horizontal.
 Center less grinding is when the work piece is supported by a
blade instead of by centers or chucks.
BROACHING
 Broaching is a machining process for removal of a layer
of material of desired width and depth usually in one stroke
by a slender rod or bar type cutter having a series of cutting
edges with gradually increased protrusion.
Basic principle of broaching
Schematic views of finishing hole by broaching
Typical examples of shapes produced by internal broaching
Different types of broaches
Internal broaching or external broaching.
Pull type or Push type.
Ordinary cut or Progressive type.
Solid, Sectional or Modular type.
Profile sharpened or form relieved type.
Internal broaching – tools
External broaching – making slot
PUSH BROACHING MACHINES

Push down type vertical surface broaching machine

Pull type horizontal internal broaching machine
Horizontal surface broaching machine
Vertical surface broaching machine
CONTINUOUS BROACHING MACHINES
NUMERICAL CONTROL
MACHINE
 Numerical control of machine tools may be defined as a
method of automation in which various functions of machine
tools are controlled by letters, numbers, symbols and
alphanumeric instructions.
Types of NC systems
Machine controls are divided into three groups:

Traditional numerical control (NC).

Computer numerical control (CNC).
Distributed numerical control (DNC).
Controlled axes
 NC system can be classified on the number of directions
of motion they are capable to control simultaneously on a
machine tool.

Identification of controlled axes for (a) lathe, (b) vertical spindle

milling machine and (c) horizontal spindle milling machine
Components of NC Machines
Classification of NC Machines Based on NC System
 The Three major types of NC systems are:
Point-to-point (PTP) system.
Contouring system.
Straight