Basic Manufacturing Processes

Er. Prashrit Sapkota

Er. Indra Prasad Timilsena
Kathmandu University
 Introduction

The manufactured parts made by bulk deformation and

forming processes, often require further processing or
finishing operations to impart specific characteristics
such as dimensional accuracy and surface finish, before
the product is ready to use.
 Introduction
• Because not all manufacturing operations produce finished
products or products to desired specifications, additional finishing
operations may be necessary.
– a forged part may not have the desired dimensional accuracy; thus
additional operations such as machining may be necessary.
– It may be difficult to produce a product using only one manufacturing
process, a part that, by design, has a number of holes in it, necessitating
additional process such as drilling.
– Also, the holes produced by drilling process may not have the proper
roundness, dimensional accuracy, or surface finish, thus necessitating the
need for additional operations, such as honing.
• These additional operations contribute significantly to the cost of a
product.
 classifications

OR
Machining
Conventional Machining
Material removed from the surface of the work part by means of
sharp cutting tools.
Example: turning, milling, drilling, etc.

Turning Milling Drilling

Abrasive operations
Material removed from the surface of the work part by means
of hard abrasive particles.
e.g. grinding

Grinding
Nontraditional operations
Various energy forms other than sharp cutting tool to remove materi
e.g. electro-discharge machining, water jet cutting etc.

Electro-discharge machining
 Important factors in Machining

1. Workpiece
2. Cutting tool
3. Tool holder
4. Workpiece holding device
5. Machine tool
These operations cannot be carried out efficiently and
economically without a fundamental knowledge of the
often complex interaction among these critical elements.
 Why Machining?

Ability to machine wide range of metals/ materials

– Metals like Al, Cu, Mg, Steel etc.
– Plastic, plastic based composites.

Good dimensional accuracy and surface finish

– For example, in a forged crankshaft, the bearing surfaces and the holes
cannot be produced with good dimensional accuracy and surface finish by
forming and shaping process alone.
Good Control over the dimensions
Parts may possess external and internal geometric features(Variety
of part shapes and special geometry features possible)
– Screw threads, holes, threads, T- slots, Flat, cylindrical shapes.
 Limitations of Machining

Wastage of metal/materials(loss in the form of chips)

Slow process/ Time consuming
Machining parameters
Basic Types of machining processes
 Classification of the cutting tools

• More than one cutting edge

• One cutting edge
• Motion relative to work usually achieved
• Turning uses single point tools
by rotating
• Point is usually rounded to form a
• Drilling and milling use rotating multiple
nose radius
cutting edge tools.

(a) A single-point tool showing rake face, flank, and tool point
(b) a helical milling cutter, representative of tools with multiple
cutting edges
 Machine Tools

Any power-driven machine that performs a machining

operation, like lathe m/c, milling m/c etc.
Functions
1. Holding work piece firmly
2. Positions tool relative to work
3. Machine tool must provide controlled power and controls
speed, feed, and depth of cut.
4. Pumps a Cutting fluid
 Machine Tools
Various types of machine tools used in machine shop are:
– Lathes
– Shapers
– Planers
– Boring Machines
– Drilling Machines
– Milling machines
– Grinding machines
Machine Tools are generally used to
– improve production rates
– reduce cost of production
– reduce fatigue of workers
– achieve better quality
– reduce wastage
 Lathe Machine
Lathe is a machine, which removes the metal from a piece of work to the
required shape & size.
• one of the oldest, most versatile and widely used machine tool
• job is securely and rigidly held in the chuck or in between centres on the
lathe machine and then turn it against a single point cutting tool which
will remove metal from the job in the form of chips
• cutting tool-harder than the material of work piece
Lathe Operations

Knurling
Lathe Machine
Lathe Parts
 Lathe Machine
The major parts of lathe machine
• Bed
• Headstock
• Tailstock
• Carriage
 Lathe Parts
Bed
• base on which all other parts of lathe are mounted
• massive and rigid single piece casting made to support other
active parts of lathe
• Left end of the bed-headstock, right side-tailstock
• carriage of the machine rests over the bed and slides on it
 Lathe Parts
On lathe bed rest two sets of guideways-inner ways
and outerways
– Innerways provide sliding surfaces for the tailstock,
outerways for the carriage
– guideways of the lathe bed may be flat and inverted V-
shape

carriage
 Lathe Parts
Headstock
• Permanently fastened on the inner
ways at the left side of the bed (on
right, tailstock)
• main spindle is adjusted in it,
which possesses live centre to
which the work can be attached
• live centre and sleeve, a face plate,
or chuck can be fitted to the
spindle nose to hold and drive the
work
• Which supports the work and
revolves with the work
 Lathe Parts

Tailstock
• It is situated at opposite side of headstock, mounted on the inner
guide ways of the lathe bed
• Tailstock spindle is hollow tapered shaft, that can be used to hold the
dead centre or other tools
• dead centres have 60°conical points to fit centre holes in the circular
job
• dead centre can be mounted in ball bearing
 Lathe Parts
Carriage
• Mounted on the outer guide
ways, moves parallel to the
spindle axis
• Carriage controls and supports the
cutting tool,
• helps tool moves away or towards
the headstock

The major parts

• Cross slide
• Compound rest
• Tool post
• Apron
 Carriage
Cross Slide: Mounted on the traverse slide of the carriage, and uses a
hand wheel to feed tools into the work piece
Tool Post: To mount tool holders in which the cutting bits are
clamped.
Compound Rest: Compound rest is set up over the cross slide and it
can move in a circular path.
Apron: Attached to the front of the carriage, it has the mechanism
and controls for moving the carriage and cross slide.
 Lathe Cutting Tools

Carbide tip tools

Grooving tool
Cut-Off blade
Parting blades
Boring bar
Side tool
 Specification of Lathe Machines
Size of a lathe is generally specified by the following means
• maximum diameter that can be rotated over the bed ways
• Maximum length of the job that can be held between head stock and tail stock centres
• Bed length, which may include head stock length also
• Maximum diameter of the bar that can pass through spindle or collect chuck of capstan lathe
Others:
Maximum swing over bed
Maximum swing over carriage
Height of centers over bed
Maximum distance between centers
Length of bed
Width of bed
Morse taper of center
Diameter of hole through spindle
Face plate diameter
Size of tool post
Number of spindle speeds
 Types of Lathe Machine
Engine Lathe
The most common form of lathe, motor driven so spindle speed can be
varied by engine and comes in large variety of sizes and shapes.
Carriage will be available so cutting tool can travel in longitudinal and
transverse directions.

Bench Lathe
A bench top model usually of low power used to make precision
machine small work pieces and where accuracy of work is primary.

Tracer Lathe
a lathe that has the ability to follow a template to copy a shape or
contour.
 Types of Lathe Machine
Automatic Lathe
A lathe in which the work piece is automatically fed and removed
without use of an operator. Cutting operations are automatically controlled
by a sequencer of some form
Turret Lathe
Lathe which have multiple tools mounted on turret either attached to
the tailstock or the cross-slide, which allows for quick changes in tooling and
cutting operations.
Usually used in mass production lines.
Computer Controlled Lathe
A highly automated lathe, where both cutting, loading, tool changing,
and part unloading are automatically controlled by computer coding.
 Lathe accessories/attachments
• devices used for holding and supporting the work and the tool
on the lathe-lathe operations
• additional equipment's provided by the lathe manufacturer or
bought separately, used for special purpose
• lathe attachment include milling attachment, grinding
attachment, gear cutting attachment, turret attachment and
crank pin turning attachments and taper turning attachment
– Chucks
– Centres(live/dead)
– Drive plates
– Face plate
– Lathe Dogs
– Mandrel
– Rests
 Chucks
• Most important devices for holding and rotating a job in a
lathe
• attached to the headstock spindle by bolts
• Jobs of short length and large diameter or of irregular shape,
which cannot be conveniently mounted between centres, are
held quickly and rigidly in a chuck
• Several types of lathe chucks available in market are,
– Three Jaw universal Chuck: Self centering chuck
– Four Jaw Independent Chuck: Adjustable Centre
– Combination Chuck
– Magnetic Chuck
– Collet chuck
– Air or Hydraulic Chuck
– Drill Chuck
Shaper

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 Shaper- Introduction
• It is a reciprocating type of machine tool
• Ram moves the cutting tool forward/backward in a
straight line
• Intended, primarily, to produce flat surface by the
successive movement of the tool
• Such as horizontal, vertical or inclined- any surface of
straight-line elements
• With special tools and attachments, external and internal
key ways, grooves, dovetails and T-slots can be obtained.
• A shaper is used to generate flat (plane) surfaces by
means of a single point cutting tool
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 Shaper contd…
• Ram pushes the cutting tool through work piece to
remove the material
• When ram returns, no cutting takes place
• In between cutting and return stroke, tool moves in
horizontal direction perpendicular to cutting direction/
feed direction
• Generally used for machining flat surfaces in horizontal,
vertical or angular direction

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Principal components
of a Shaper

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 How does a Shaper work?
• A single point cutting tool is held in the tool holder, which is
mounted on the ram
• The work piece is rigidly held in a vice or clamped directly on the
table
• cutting tool held in tool holder, ram reciprocates
• moves forward and backward over the work piece.
• cutting of material takes place during the forward stroke of the ram
• Return stroke remains idle and no cutting takes place during this
stroke
• The time taken during the idle stroke is less as compared to forward
cutting stroke and this is obtained by quick return mechanism.

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 Working principal- shaper
• Shaper are driven mechanically or hydraulically
• Stroke length can be varied by changing length of crank

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 Working contd...
• Single point cutting tool
Reciprocates.
• Cutting takes over the
stationary work in single stroke.
• Vice and Tool holder can be
swiveled at desired angle to
produce grooves, slots and
Angular cuts
• Shaper can be horizontal or
vertical based on the plane of
movement of ram/tool

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42
 Planer- Introduction
• Unlike Shaper, in planer the work piece reciprocates while the cutting tool
remains rigid
• Like a shaper, planer is used primarily to produce horizontal, vertical or inclined
flat surfaces by a single point cutting tool
• used for machining large and heavy work pieces that cannot be accommodated
on the table of a shaper
• Planner tool remains stationery and work piece reciprocates.
• Cutting can be horizontal, vertical and angular
• Two or more tools can be operated simultaneously
• Planer is mainly of two kinds;
– open housing planer and double housing planer

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Planer contd…

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 How does it work?
• tool is clamped in the tool holder and work on the table
• work reciprocates past the stationary cutting tool
• feed is imparted by the lateral movement of the work piece
• like shaper, the planner is equipped with clapper box to raise the tool in
idle stroke

The different mechanisms used to give the reciprocating motions are;

– Reversible motor drive
– Open and Cross belt drive
– Hydraulic Drive 45
Precision Planer Miller

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Shaper Vs Planer