BESCK204D – Introduction to mechanical Engg Dept. of Mech.

Engg, SSCE, Anekal Module - II

MODULE – 2 - MACHINE TOOLS OPERATION

MACHINING
A product or part can be manufactured by various processes like casting, forging, machining
etc. Machining is an operation that can be carried out manually or by machine, which involves removal of
excess material from the raw material so as to get the required shape and size. So any machine
involved in metal cutting is known as a „Machine tools‟ and the process is called „Machining‟.

MACHINE TOOL
A machine tool may be defined as a power driven machine to produce a product by removing
the excess material using a cutting tool”. The excess material removed is called as chips. Some of
the important machine tools are lathe, drilling machine, milling machine, grinding machine, shaper
etc.

Lathe :-A Lathe is a machine tool employed generally to produce circular object. It is said to the
mother of all machine tools, generally used to perform on other machine tool like grinding shaping
milling can be performed

PRINC IPLE OF WORKING;

A lathe, basically a turning machine works on the principle that a cutting tool can remove
material in the form of chips from the rotating work pieces to produce circular objects. This is
accomplished in a lathe which holds the work pieces rigidly and rotates them at high speeds while a
cutting tool is moved against it.

LATHE SPECIFICATION

1. Maximum diameter of the work piece that can be revolved over the lathe bed. Instead of this
sometimes, the height of the centres above the lathe bed is also specified. One of these
specifications is given by the manufacturers; however both of them are loosely called as "Swing of
the lathe".
2. The Maximum diameter and the width of the workpiece that can swing when the lathe has a gap
bed.
3. The maximum length of the workpiece that can be mounted between the centres.
4. Overall length of the bed. It is the total length of the lathe itself.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 1

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

Major parts of a Lathe

1. Bed
2. Head stock
3. Tail stock
4. Carriage assembly
5. Feed rod
6. Lead screw

BED – the bed is the foundation of the lathe and supports all other parts. The head stock and tail
stock are mounted on the inner guide ways, while the carriage assembly is mounted on the outer
guide ways of the bed.

HEAD STOCK – it is located on the left side over the bed. It comprises of the main drive for different
speeds. The main spindle called the live centre projects out it holds the work piece and rotates the
work piece at various speeds.

TAIL STOCK – it is a movable part mounted on the right side of the lathe bed. It carries the dead
center in it. The main functions are –1.To support the free end of the work piece 2.To hold tools like
drill bit, reamers, taps etc.

CARRIAGE ASSEMBLY – it guides over the outer guide ways of the lathe bed. This assembly holds
the cutting tool and controls the cutting process. It consists of saddle, cross slide, compound rest,
tool post and apron.

SADDLE – It is a H – shaped casting sliding over the guide ways and supports the cross slide,
compound rest and the tool post.

CROSS SLIDE – it is mounted on the saddle. This enables the cutting tool to move perpendicular to
the lathe axis (lateral feed), so as to give the required depth to thework piece.

COMPOUND REST – it is mounted on the cross slide and supports the tool post. It has a circular
base which can be swiveled to any angle in the horizontal plane. It is used in taper turning operation.

TOOL POST – it is mounted on the compound rest and holds the cutting tool firmly during cutting
process.

APRON – this is the area below the saddle, which houses the levers, hand wheels, mechanism for
moment of the carriage assembly.

FEED ROD – it is a long rod in front of the lathe bed and gives longitudinal movement for the carriage
for all its operations expect thread cutting.

LEAD SCREW – it is a long screw with square threads on it mounted front of the lathe bed. It gives the
automatic feed to the carriage during the thread cutting operation.
OPERATION ON LATHE

PLAIN TURNING (TURNING)

The work piece is supported between the two centers which permit the rotation of the work
piece. The cutting tool is fed perpendicular to the axis of the work piece to a given depth of cut, and is
then moved parallel to the axis of the work piece. “This method of machining operation in which the
work piece is reduced to a cylindrical section of required diameter is called ‘turning’”.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 2

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

FACING

This operation on lathe is used to produce either flat surface or shoulders at the end of the
work piece and used to reduce the Length of the work piece. The work piece is held rigidly in the
chuck. The cutting tool is fed perpendicular to the axis of the lathe from the outer edge of the work
piece towards the center.
KNURLING

It is an operation used to emboss serrated surface on work piece using a knurling tool. It is
used to produce straight, angled or diamond pattern on the work piece mainly for gripping purpose.
The knurling tool is set in the tool post such that upper and lower rollers of the knurl head touches the
surface of the work piece. The spindle speed is kept 60 to 80 rpm. The feed of the knurl tool is 0.38 to
0.76 mm/rev.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 3

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

MILLING

Milling is a metal removal process in which the work piece is fed into a revolving cutting tool,
thereby removing excess material. The cutting tool is known as milling cutter which is a multipoint
cutting tool. Milling Machine – It is a power operated machine tool in which the work piece mounted
on the table is fed against the milling cutter to get the required shape.

PRINC IPLE OF MILLING –

In milling, the work piece is rigidly held on table and is slowly fed into the uniformly rotating cutter
to get the required shape.
The work piece can be fed in either direction of the rotating cutter.
(a) Up milling (conventional)
(b) Down milling (climb)

UP MILLING (CONVENTIONAL)

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 (CLIMB)

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.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 4

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

UP MILLING DOWN MILLING

Work piece fed opp. to the cutter rotation Work piece fed in same direction to the cutter
rotation
Chip Thickness – Min at cut beginning & Max at Chip Thickness – Max at cut beginning & Min at
cut end. cut end.
Cutting force directed upwards tends to lift the Cutting force directed downward tends to keep
work piece. Hence greater clamping force is the work piece firmly. Hence lesser clamping
required force is required
No good surface finish Good surface finish

CLASSIFICATION OF MILTING MACHINE

The milling machines are broadly classified into:

1. Plain or Horizontal Type of Milling Machine
2. Vertical Milling Machine
3. Universal Milling Machine
4. Planer Type Milling Machine
5. Profile Cutting Milling Machine

HORIZONTAL SPINDLE COLUMN & KNEE MILLING MACHINE

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 5

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

It is one of the most popular type of milling machine, and is commonly called horizontal milling
machine, because of the horizontal position of the spindle. This type of machine is used to cut
grooves, slots, keyways, gear teeth etc. The machine consists of the following parts:
a) Base is usually a strong and a hollow part, which forms the foundation of the machine and
upon which all the other parts are mounted. The base also serves as a sump for the cutting fluid. A
pump and filtration system can be installed in the base. The hole provided in the center of the base,
houses the support for the elevating screw that raises and lowers the knee.
b) Column is a vertical hollow casting and is usually combined with the base to form a single
casting. The column houses the spindle and bearings as well as the drive units (gears, clutches,
shafts, and shifting mechanisms) for transmitting power from the electric motor to the spindle at
desired speeds. The front face of the vertical column is provided with a square or dovetail type
guideways on which the knee slides up and down.
c) Spindle is a hollow shaft supported by the column with suitable bearings that absorb both
radial and thrust loads. The spindle is made hollow and tapered inside to accept standard arbors. The
spindle obtains power from the mot or and transmits it to the arbor. The arbor carrying the cutter
rotates about a horizontal axis.
d) Overarm mounted on the vertical column supports the yoke, which in turn supports the free
end of the arbor.
e) Knee is a casting that slides up and down on the vertical guideways provided on the column
by means of an elevating screw. The knee supports the saddle.
f) Saddle mounted on the knee is provided with two slides (guideways) on its top and bottom
surfaces. The slides are machined at right angles to each other. The lower slide fits the slide
provided on top of the knee and facilitates horizontal movement of the saddle. The upper slide
provided on the saddle accepts the slide provided on the bottom surface of the worktable.
g) Worktable is larger in size and rests on the saddle. The bottom surface of the table has a
dovetail slide that fits in the slide on the top surface of the saddle. This arrangement facilitates the
work table to be moved longitudinally or at right angles to the movement of the saddle. The
worktable is provided with T -slots all along its length for mounting vice or other work holding
devices. This enables the workpiece to be clamped rigidly on the table. The worktable may be
manually controlled or power fed. A dial graduated in thousandths of an inch (not shown in figure) is
provided to allow for accurate table movement and placement.

VERTICAL SPINDLE COLUMN & KNEE MILLING MACHINE:

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 6

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

Vertical spindle milling machines are similar in construction to the horizontal milling machines,
except that the spindle is held in a vertical position. This type of machine is generally used to perform
end milling and face milling operations.
a) Base is usually a strong and a hollow part, which forms the foundation of the machine and
upon which all the other parts are mounted. The base also serves as a sump for the cutting fluid. A
pump and filtration system can be installed in the base. The hole provided in the center of the base,
houses the support for the elevating screw that raises and lowers the knee.
b) Column is a vertical hollow casting and is usually combined with the base to form a single
casting. The column houses the spindle and bearings as well as the drive units (gears, clutches,
shafts, and shifting mechanisms) for transmitting power from the electric motor to the spindle at
desired speeds. The front face of the vertical column is provided with a square or dovetail type
guideways on which the knee slides up and down.
c) Overarm mounted on the vertical column supports the yoke, which in turn supports the free
end of the arbor.
d) Knee is a casting that slides up and down on the vertical guideways provided on the column
by means of an elevating screw. The knee supports the saddle.
e) Saddle mounted on the knee is provided with two slides (guideways) on its top and bottom
surfaces. The slides are machined at right angles to each other. The lower slide fits the slide
provided on top of the knee and facilitates horizontal movement of the saddle. The upper slide
provided on the saddle accepts t he slide provided on the bottom surface of the worktable.
f) Worktable is larger in size and rests on the saddle. The bottom surface of the table has a
dovetail slide that fits in the slide on the top surface of the saddle. This arrangement facilitates the
work table to be moved longitudinally or at right angles to the movement of the saddle. The
worktable is provided with T -slots all along its length for mounting vice or other work holding
devices. This enables the workpiece to be clamped rigidly on the ta ble. The worktable may be
manually controlled or power fed. A dial graduated in thousandths of an inch (not shown in figure) is
provided to allow for accurate table movement and placement.
g) Spindle is located vertically, parallel to the face of the column, and perpendicular to the top
of the worktable. The spindle is mounted in the spindle head and carries the cutter at its end. The
spindle head houses the motor & feed controls, & can be either fixed type or swiveling type

In fixed type, the spindle head is fixed, and hence the spindle remains vertical. The spindle can
be adjusted up and down to perform operations like grooving, slotting, facing, drilling and boring.
While, in swiveling type, the spindle head can be swiveled to any angle to the surface of the worktable.
This permits working on angular surfaces of workpieces.

Milling Process
Plain Milling or slab Milling
Plain milling, also called surface milling, peripheral milling or slab milling is a machining process
for producing a plain horizontal surface with a milling cutter whose axis is parallel to the surface of the
work piece being machined. The process is carried out on a horizontal milling machine with a cutter
having straight or helical teeth formed on the periphery of a cylindrical surface . The cutter is mounted
on the arbor, rotating at a suitable speed, while the work piece is fed against the cutter causing
material to be removed from the work piece. A plain smooth surface can be produced with this
process. Helical tooth cutter removes greater amount of material and produces a smooth surface finish
when compared to the straight tooth cutters.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 7

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

SLOT MILLING
Slot milling is a machining process for producing slots like T -slots, plain slots, dovetail slots etc.,
in worktable fixtures and other work holding devices. The operation may be performed using either end
milling cutter, T-slot cutter, dovetail cutter, or side milling cutter. The type of cutter selected depends
on the shape of the slot to be produced.

Two separate milling cutters are required for milling T -slots. Initially, a plain cutter, side cutter
or an end milling cutter is used to cut the throat (open slot) starting from one end of the workpiece to
its other end. A T -slot milling cutter is then used to cut the headspace to the desired dimensions.
Similar procedure is followed for cutting a dovetail slot, but a dovetail slot cutter is used in place o f T-
slot cutter.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 8

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

DRILLING MACHINE:
It is a machine which is used to drill the holes on the components or workpiece with the help of
drill bits. The drill bits are also called as Multi-point cutting tools which can have their rapid impact on
the Material Removal Rate (MRR) i.e. a single-point cutting tool (like the one used in a lathe machine)
can remove the material slowly whereas, a multi-point cutting tool removes the material at a faster
rate and thereby increases MRR.

PARTS OF DRILLING MACHINE:

The parts of Drilling Machine are as follows.
 Base
 Vertical Column
 Swivel Table
 Power Transmission system (Stepped Cone Pulley)
 Drill Feed Handle (Hand Wheel)
 Chuck
 Table Clamp
 Drill bit
 Spindle

EXPLANATION FOR THE PARTS OF DRILLING MACHINE:

BASE:
The base is made up of Cast Iron which has the capability of high compressive strength,
good wear resistance, and good absorbing capability (i.e. absorb the vibrations induced during working
condition) and for these reasons, it acts as a base to the drilling machine.

VERTICAL COLUMN:
It is exactly placed at the center of the base which can act as a support for rotating the Swivel
table and holding the power transmission system.

SWIVEL TABLE:
It is attached to the column which can hold the machine vice in the grips and thereby, the
workpiece is fixed in the machine vice to carry out the drilling operation.
The Swivel table can move up and down by means of rotational motion and c an be locked to the
column by means of locking nut.
POWER TRANSMISSION SYSTEM:
It consists of motor, stepped pulley, V-belt, and the Spindle. The power transmission is
explained in the working of the drilling machine.

DRILL FEED HANDLE:

By the rotation of hand-wheel, the spindle moves up and down in the vertical direction in order
to give the necessary amount of feed to the work. Here, the rotational motion is converted into linear
motion by means of a Rack and Pinion mechanism which was explained below.

CHUCK:
It is used to hold the workpiece. Generally, 3 jaw chuck is used for holding circular components
and 4 jaw chuck is used for holding rectangular components.

TABLE CLAMP:
It is used to lock the swivel table at the desired location.

SPINDLE:
It is used to hold the drillbit along with jaws.

DRILL BIT:
It is the major part of this machine and is used to remove the material in the form of holes from
the surface of the workpiece.

WORKING PRINC IPLE OF DRILLING MACHINE:

When the power is given to the motor, the spindle rotates, and thereby the stepped pulley
attached to it also rotates. On the other end, one more stepped pulley is attached and that is inverted
to increase or decrease the speed of the rotational motion.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 9

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

Now, a V-belt is placed in between the stepped pulleys so as to drive the power transmission.
Here a V-belt is used instead of a flat belt, in order to increase the power efficiency.

Now the drill bit also rotates which was placed in the chuck and which was in connection with
the spindle. As the Pulleys rotates, the spindle also rotates which can rotate the drill bit.

Now, by the rotation of hand-wheel, the spindle moves up and down in the vertical direction in
order to give the necessary amount of feed to the work and this drill bit is used to make the holes on
the component placed in the machine vice.

TYPES OF DRILLING MACHINES:

Below is the list of drilling machines which are used in the industries for the production of the
materials.
 Radial drilling machine
 Upright drilling machine
 Multiple Spindle drilling machine
 Deep hole drilling machine
 Sensitive drilling machine
 Portable drilling machine
 Gang drilling machine

DRILLING:
 Drilling is the most important and common drilling machine operation. In the drilling, we
usually, produce a cylindrical hole inside the work piece and remove the material inside it. Here,
the material is removed by the rotating edge of the cutting tool . And that rotating edge is called
a drill.
 Drilling does not produce a fine hole. The internal surface of the hole is usually rough, and the
hole is always bigger than the drill size.
 Suppose if we have a drill of 12mm diameter then, the size of the hole produced by it may be
12.125 mm or greater than that.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 10

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

REAMING:
 The size of the hole after the drilling process may not be
perfect. Most of the time, its internal surface may not be finished properly.
 Reaming is done to obtain the desired size of the hole. Also, the internal surface of the hole
gets appropriately finished with this process. Reamer is used for reaming. Reamer is a multi-
point cutting tool.
 The important benefit of the reaming is that it can remove an extremely small amount of metal
approximately 0.375 mm
 The spindle speed in reaming is half of that of the drilling process.

BORING:
 Boring is a type of drilling operation in which we increase the diameter of the hole which was
previously produced. Boring is done due to the following reasons:
 It is implemented for machining the internal surface of the hole which was produced by the
casting process.
 For correcting the roundness of the hole.
 For finishing the hole correctly and for making it of the required size.
 The boring tool is used for this process. The boring tool has only one cutting edge. The boring
tool is placed in a boring bar which has a tapered shank. The speed of the spindle in the boring
is usually very less than the reaming.

TAPPING
 In tapping, a tap is used for making internal threads. That means tap works as a cutting tool
inside the tapping.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 11

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

 Tapping in a drilling machine can be performed by hand. Or you can also use any external
power for doing this.
 The metal is removed, when the tap is inserted into the hole. Tap also produces internal t hreads
which can be fit into the external threads of the identical size.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 12

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

ADVANCED MANUFACTURING SYSTEM

INTRODUC TION TO ADVANCED MANUFACTURING

Advanced manufacturing refers to the use of new innovative technologies, processes, and
methods for producing the desired products. While Traditional manufacturing is based on the use of
dedicated plant and production lines with little or no flexibility, Advanced manufacturing involves
versatile production methods that fully utilize capital plant and are more efficient, effective and
responsive. Although there are circumstances where traditional, dedicated methods are still
appropriate, advanced manufacturing has the capacity to accommodate the varying production
requirements and mass customization commonly encountered by industries, without the need for
excessive capital investment. A few manufacturing systems or technologies defined under advanced
manufacturing include:
1) CAD/CAM/CAE
2) Rapid prototyping (Additive manufacturing)
3) Industrial Robotics etc.

CNC MACHINES
CNC is a short name for Computer Numerical Control. It refers to a computer controller that
accepts a program or a set of instructions and stores it in the memory of the computer, which in turn
controls the working of the machine tool. The program can be modified or edited while it is in the
computer memory as and whenever required thereby offering a great degree of flexibility in
manufacturing

COMPONENTS OF CNC MACHINE

The external appearance of a CNC machine is very similar to that of a NC machine, however the
limitations of a NC machine is successfully overcome with the various components incorporated in a
CNC machine. CNC machine basically consists of three components.
These include:
 Part program and program input device
 Controller unit, also called machine control unit (MCU), and
 Machine tool.

PART PROGRAM & PROGRAM INPUT DEVICE

In a CNC machine, the part program is done either manually on punched tapes and then fed
into the memory of the computer, or with the aid of various computer softwares that automatically
generates the program required to produce the desired part. In today's industrial practice, manual
method of programming is obsolete.

MACHINE CONTROL UNIT (MCU)

In modern CNC technology, the machine control unit (MCU) consists of a microcomputer and
related control hardware that stores the program of instructions and executes it by converting each
command into mechanical actions of machine tool, one command at a time. The MCU includes system
software, calculation algorithm, and transition software to convert the part program into a usable
format for the MCU. It also acts as a feedback controller for precise positioning of machine table or
spindle.

Program FeedBac k

Input Device Controller Tool

Unit
(Computer) Work Piece

Machine Tool

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 13

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

MACHINE TOOL
The machine tool performs the actual machining operation, and can be of any type like lathe,
drilling machine, milling machine, etc. The machine tool consists of work table and tool spindles whose
motion can be controlled accurately by the driving system that receives commands from the MCU. A
part with the desired features is produced by the machine tool.

ADVANTAGES & DISADVANTAGES OF CNC MACHINES

ADVANTAGES

 HIGHER PRODUCTIVITY. The machine can run for 24-hours, in all the 365 days with little or
no interruption.
 HIGHER PRECISION, with better quality control of products.
 Multi operational facilities (or tasks).
 Does not require a skilled operator.
 IMPROVED AUTOMATION - The operator intervention during manufacturing can be reduced,
and in some cases eliminated. Many CNC machines can run unattended during their entire
machining cycle, thereby freeing the operator to do other tasks.
 REPEATABILITY & RELIABILITY-Once the program is verified and executed for one
production run, the same program can be recalled for subsequent productions thereby
maintaining uniformity in the dimensions and tolerances of the parts. Hence CNC machines can
be consistently relied upon.
 FLEXIBILITY-CNC machines can run a variety of programs and have workpieces leading to
fast changeovers and set -ups. Further, programs can be modified as and when required before
starting the operation.
 MOTION CONTROL-CNC machines allow motion of the cutting tool in two or more directions
(x, y & z-axis), or move the machine slide, spindle, or other parts precisely by means of
servomotors instead of the usual cams, levers, etc., as in the case of conventional machines
 INCREASED MACHINE UTILIZATION- if properly used, CNC machines can run continuously
for 24 hours and 365 days

DISADVANTAGES
 High initial cost of the machine
 High maintenance cost
 Requires skilled programmer.

CNC MACHINING CENTERS

A machining center can be defined as a CNC machine tool, controlled by a computer program
that can perform multiple machining operations like milling, drilling, tapping and boring operations by
variety of tools with Automatic Tool Changer ATC) unit. In short, Machining centers refer to CNC milling
machines CNC machining centers can be broadly categorized into t wo varieties: Vertical machining
centers (VMC) and Horizontal machining centers (HMC),

VERTICAL MACHINING CENTERS (VMC)

Vertical Machining centers with vertical spindles are mainly used for flat type of work, such as
plates, where the machining is done on only one face of the workpiece in a single set -up. With the use
of rotary tables, more than one side of a workpiece, or several work pieces, can be machined without
operator intervention. Vertical machining centres using a rotary table have four axes of motion: three
are linear motions of the table while the fourth is the table's rotary axis that can be used either for
indexing or a pull rotary motion.

HORIZONTAL MACHINING CENTERS (HMC)

Horizontal machining centers with horizontal spindles are used for heavy rectangular parts,
where the machining has to be done on more than one face in a single setup. Since the machines
involve bulk metal removal rates, the cutting tools used are normally large in size. The maintenance
and cost of the machine is comparat ively higher. Like vertical machining centers, horizontal centers
have multiple-axis table movements. T ypically, the horizontal centers table ic capable of rotating to all
four sides of a workpiece to the tooling.

CNC TURNING CENTERS

A turning centre can be defined as a CNC machine tool controlled by a computer program that
can perform multiple machining operations like cylindrical turning, taper turning, thread cutting, facing,

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 14

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

parting-off, and other operations by a variety of tools mounted on a turret with Automatic Tool
Changer (ATC) unit. In short, Turning centres refer to CNC lathes. All the operations are similar in
principle to that performed on a traditional lathe, except the operations with relevant tools and process
parameters like speed, feed, and depth of cut are all controlled by the computer program.

DEFINE 3D PRINTING or ADDITIVE MANUFACTURING:

Additive manufacturing is the formalized term for what used to be called rapid prototyping and
what is popularly called 3D Printing. The term rapid prototyping (RP) is used in a variety of industries
to describe a process for rapidly creating a system or part representation before final release or
commercialization.
It can be defined as the layer by layer fabrication of three dimensional models directly from a
computer aided design data.

ADDITIVE MANUFACTURING CONVENTIONAL MANUFACTURING

Produces a model by adding layer Produces a model by removing bit by bit

Material Addition process Subtraction process

(Material Removal Process)
Complex geometry unlimited Complex geometry limited

Reduced lead time & cost Increased lead time & cost.

GENERIC PROCESS OF AM:

AM involves a number of steps that move from the virtual CAD description to the physical
resultant part. Different products will involve AM in different ways and to different degrees. Small,
relatively simple products may only make use of AM for visualization models, while larger, more
complex products with greater engineering content may involve AM during numerous stages and
iterations throughout the development process. Furthermore, early stages of the product
development process may only require rough parts, with AM being used because of the speed at
which they can be fabricated. At later stages of the process, parts may require careful clea ning and
post-processing (including sanding, surface preparation, and painting) before they are used, with AM
being useful here because of the complexity of form that can be created without having to consider
tooling. Later on, we will investigate thoroughly the different stages of the AM process, but to
summarize, most AM processes involve, to some degree at least, the following eight steps

Step 1: CAD
All AM parts must start from a software model that fully describes the external geometry. This
can involve the use of almost any professional CAD solid modelling software, but the output must be a
3D solid or surface representation. Reverse engineering equipment (e.g., laser and optical scanning)
can also be used to create this representation.

Step 2: Conversion to STL

Nearly every AM machine accepts the STL file format, which has become a de facto standard,
and nowadays nearly every CAD system can output such a file format. This file describes the external
closed surfaces of the original CAD model and forms the basis for calculation of the slices.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 15

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

Step 3: Transfer to AM Machine and STL File Manipulation

The STL file describing the part must be transferred to the AM machine. Here, there may be
some general manipulation of the file so that it is the correct size, position, and orientation for
building.

Step 4: Machine Setup

The AM machine must be properly set up prior to the build process. Such settings would relate
to the build parameters like the material constraints, energy source, layer thickness , timings, etc.

Step 5: Build
Building the part is mainly an automated process and the machine can largely carry on without
supervision. Only superficial monitoring of the machine needs to take place at this time to ensure no
errors have taken place like running out of material, power or software glitches, etc.

Step 6: Removal
Once the AM machine has completed the build, the parts must be removed. This may require
interaction with the machine, which may have safety interlocks to ensure for example that th e
operating temperatures are sufficiently low or that there are no actively moving parts.

Step 7: Post-processing
Once removed from the machine, parts may require an amount of additional cleaning up before
they are ready for use. Parts may be weak at this stage or they may have supporting features that
must be removed. This therefore often requires time and careful, experienced manual manipulation.

Step 8: Application
Parts may now be ready to be used. However, they may also require additional treatment
before they are acceptable for use. For example, they may require priming and painting to give an
acceptable surface texture and finish. Treatments may be laborious and lengthy if the finishing
requirements are very demanding. They may also be required to be assembled together with other
mechanical or electronic components to form a final model or product.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 16

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

AM PROCESS

Photo Polymerization Process Printing Process

Stereolithography (SLA), 3D Printing, Ballistic
Solid Ground Curing (SGC) Particle Manufacturing
(BPM)

Extrusion Process
Fused Deposition Modeling Powder Bed Sintering
(FDM) SLS, DMLS. SLM, EBM

Sheet Lamination Process

Laminated Object Modeling Metal Deposition Process
(LOM) LENS, DMD

Photo Polymerization Process Stereo lithography (SLA), Solid Ground Curing(SGC)

Extrusion Process Fused Deposition Modelling (FDM)

Sheet Lamination Process Laminated Object Modelling (LOM)

Printing Process 3D printing, BPM (Ballistic Particle Manufacturing)

Selective Laser Sintering (SLS), Direct Metal Laser Sintering

Powder Bed Sintering (DMLS), Selective Laser Melting (SLM), Electron Beam Melting
(EBM)

Laser Engineered Net Shaping (Lens), Direct metal Deposition

Metal Deposition Process
(DMD)

ADVANTAGES:
• No fixtures is required
• No material wastage
• Complex parts can be manufactured.
• Excellent surface finished parts – hence less or no finishing operation.
• High Production rate.
• Less Defects.
• No limitation of Material
• Process speed is very high.

DISADVANTAGES:
• Not suitable for large components.
• Parts inside are difficult to manufacture.
• Post processing is necessary for the parts.
• Needs supports structures for overhanging features.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 17

BESCK204D – Introduction to mechanical Engg Dept. of Mech. Engg, SSCE, Anekal Module - II

• Post curing operation are time consuming

• Few process leaves fumes and odours.
• Machines set up is time consuming process.
• Few processes need continuous supervision.

Prof. Rajesh, / Asst. Prof – Mech. Engg. SSRCE – Anekal Page | 18