BASICS OF

MECHANICAL
ENGINEERING
machining process
 MACHINING PROCESSES
Machining is a process by which jobs are produced to the desired
dimensions and surface finish by gradually removing the excess
material from it in the form of chips with the help of cutting tool(s)
moved past the work surface(s).
List of different Machining processes:
1. Turning – Face turning, taper turning, contour, form
2. Drilling
3. Milling
4. Grinding
5. Knurling
6. Boring
7. Reaming
8. chamfering
 MACHINE
Machine tool is a TOOLS
machine that imparts required size and shape to
a workpiece with desired accuracy by removing metal from the
workpiece in the form of chips.

List of different Machine tools:

1. Lathe – mother of machine tools

2. Shaping machine
3. Slotting machine
4. Milling machine
5. Drilling machine
6. Grinding machine
7. Broaching machine
 LATH
E

 General purpose machine tool

 Work piece is held and rotated against a suitable cutting tool ( single
point)
 Mainly used for producing surfaces of revolution
 If tool moves parallel to workpiece cylindrical surface is produced
 If tool moves perpendicular to workpiece flat surface is produced
a) Bed :
Parts of Lathe
 Main body structure maintained at convenient height.
 Provides the strength and stability to the machine
b) Head  Permanently fixed on the bed
stock:  Has gears to adjust speed, chuck to hold the workpiece
c) Tail  Free to move over the top of bed through guide ways
 Supports other end of workpiece
stock:  Also used to fix tools during drilling & reaming
d)Carriag  Moves over the bed, also with lead screw if engaged
e:  Houses saddle, compound rest etc. to control the tool
e)Lathe  Tapered components at head & tail stock
 At head stock  live centre, At tailstock  dead centre
centres:  Live centre rotates with tool, dead centre just supports
f) toolpost  Holds tool, adjusting too to convenient working position
g) Lead  Long threaded shaft used only for screw thread cutting
screw:
• Removal
TURNIN
material from periphery of workpiece to
of
cylindrical surface. G obtain

• Uses a single point cutting tool.

• Done in Lathe
Procedure for turning
 Workpiece is firmly held &rotated using chuck ( work holding device).

 Face the end of workpiece & drill hole to support side with
dead
centre

 Fix tool in tool post such that tip is in level with workpiece.

 Tool moved perpendicular to axis of workpiece  depth of cut

 Tool moved parallel to axis of workpiece  remove material along

length
engineering-resource.com
Application:
 Brake drums and brake disks,
 valve parts, nozzles,
 pipe and tube fittings including tees and elbows,
 rollers,
 pistons,
 turbine rotors,
 hubs,
 pins and axles,
 gun barrels and handles.
 MILLING
 Work piece is held firmly and
MACHINE
fed against a tool rotating at high
speed.
 A multi point cutter is used.
 Each cutting edge removes
small amount of metal as
workpiece advances
 Horizontal &vertical
arrangements

Up milling Down milling

 TWO WAYS OF
Up Milling FEED Down milling
Also called conventional milling Also called climb milling
Work piece fed in opposite direction Work piece fed in same direction as
of cutter rotation that of cutter rotation
Chip thickness varies from min. Chip thickness varies from max. at
at starting to max. towards end beginning to min. towards end
Load on cutting tool Load on cutting tool
increases gradually decreases gradually
Since cutter is moving opposite, it cutter rotates in same direction it
tends to lift the work piece form tends to support the work piece
the vice. in the vice
Rough finish Smooth finish
HORIZONTAL MILLING
MACHINE
a) Base
Parts of Milling machine
 Main body structure maintained at convenient height.
 Provides the strength and stability to the machine
b) Column  Main supporting frame mounted vertically on base.
c) Knee  Rigid cast, slides up and down the column
d)Saddle  Rigid component slides horizontally over knee
e)Table  The workpiece is firmly held in the table
 It slides on guide ways , move horizontally over saddle
f) Elevating  Supports the knee & adjust the height of knee
screw  Moves workpiece towards or away from tool
g) Spindle  Placed in the column.
 Receives power from motor in the column and rotates
h)Arbor  Rod on which cutter is mounted
i) overarm  Mounted on top of column, supports other end of arbor.
Vertical milling machine
 Over arm and arbor
replaced by spindle
head
 Spindle head houses
motor rotating
spindle.
 Cutter is fixed in
the spindle and
rotates with the
spindle
 The spindle head can
be rotated along
vertical plane to mill
inlcined surfaces
DIFFERENT MILLING
OPERATIONS-I
1) Plain milling
 Also called slab milling
 Flat surface parallel to axis of cutter
 Uses plain milling cutter

2) Face milling
 Flat surface perpendicular to axis of cutter
 Uses face milling cutter

3) Side milling
 Flat vertical face along side of workpiece.
 Uses side milling cutter
 DIFFERENT MILLING
OPERATIONS-II
4) End milling
 Produces flat surfaces – vertical or horizontal.
 Cutting edges on periphery & at one end.
 Uses end milling cutter

5) Angular milling
 Angular surfaces produced on workpiece
 Uses angle milling cutter

6) T – slot milling
 First end milling.
 Uses T - slot milling cutter
 DIFFERENT MILLING
OPERATIONS-III
7) Form Milling
 For producing specific profiles on work pieces
 Uses form milling cutter.
 The cutter has shape corresponding to profile required

 Gear cutting is done to produces gears

 The form cutter will have profile of the space between gear teeth.
 MILLING – MACHINING
 Work piece is held firmly and fed against a multi point cutter.
OPERATION
Each cutting edge removes small amount of metal as workpiece
advances.
 Interrupted cutting, small chip size, varying chip size in single
cut
 Plain surfaces– horizontal, vertical, angular, slot cutting, gear cutting
etc.
 Different milling operations are plain milling, side milling, end
milling, form milling, face milling etc.
 With respect to workpiece and tool rotation classified in to up milling
and down milling
 Done in machine tool called milling machine.

Up milling Down milling

Application:
 Gear manufacturing,

 keyway slotting,

 guide ways,

 brackets,

 ribs,

 flanges
 DRILLING
•
MACHINE
Workpiece is held firmly and
a rotating tool is forced into
it.

• The tool is a multi point (

Twisted)cutting tool.

• Common tool is called the

drill bit.

• Used for creating circular

holes and related variants.

• Radial drilling
machine,
vertical drilling machine.
 Parts of Drilling machine

a) Base  Foundation over which entire arrangement is placed.

b) Column  Main supporting frame mounted vertically on base.
c) Table  The workpiece is firmly held in the table
 It can move up and down over the column.
 Can be set at various positions in horizontal plane.
d)Drill  Mounted on top of column.
head  Supports spindle head and motor
 Spindle head houses drill holding and rotating devices
 A drill chuck is mounted on spindle to hold drill.
DIFFERENT OPERATIONS DONE IN DRILLING
MACHINE-I
1) Drilling
 For creating holes in work piece
 Rotating multi point ( twisted) cutting toll is used
 Work piece is held firmly in the table.
 Drill bit corresponding to required hole dimensions is selected
 Drill bit is fixed into the drill chuck.
 Table is adjusted to required height.
 The rotating drill bit is lowered into the workpiece using speed
spindle.
DIFFERENT OPERATIONS DONE IN DRILLING
MACHINE-I
2) Boring
 For enlarging already created hole
 Cutting point is on the circumference
 Adjustable single point tool used.

3) Reaming
 For sizing and finishing a hole
 Tool used is called reamer (reaming tool)
 Reamer has several cutting edges
 Removes small amount of material for
already existing hole.

4) Counter boring
 For increasing size of hole to restricted
depth.
 Special cutter is used
 VARIOUS DRILLING
OPERATIONS
5) Counter sinking
 Creating cone shaped enlargement at
end of hole.
 Special cutter used

6) Tapping
 For cutting thread inside a hole.
 Tool used is called a tap.

7) Spot facing
 Smoothing and squaring surface around a hole.
 For providing proper seating for nut and washer
Application:

For making Dies,

Oil holes in engine parts,

holes for fastening etc…….

 GRINDING - MACHINING
• OPERATION
Uses abrasive tool called grinding wheel.

• Abrasive tool is made to rub against the work piece.

• Done in grinding machine

• Abrasive material :
Natural : sandstone, emery, diamond
artificial: silicon carbide, boron carbide, aluminum oxide

• Mainly used :-
a. To remove small amount of metal to get dimensional accuracy.
b. To obtain better finish
c. To machine hard surfaces
d. To sharpen tools
 GRINDING MACHINE-
SCHEMATIC
a) Base  Foundation over
which
entire arrangement is placed.
b)  Main supporting frame
Column mounted vertically on
base.
c) Table  The workpiece is firmly held
in the table
 It can move up and down
over the column.
 Can be set at various
positions in horizontal
plane.
d)Wheel  Mounted on top of column.
head  Supports spindle head and
motor.
GRINDINGMACHINE- ACTUAL
MACHINERY
 GRINDING
OPERATIONS
Cylindrical grinding:

 Produces cylindrical surface on

workpiece.

 The work piece is held and rotated

about its axis & traversed across
the face of a rotating wheel.

 After each traverse, wheel is moved

towards the workpiece for further
removal to get desired tolerance
Surface grinding:
 Produces flat surface on workpiece.
 The grinding wheel is rotated on a vertical axis.
 Work piece is traversed under revolving grinding wheel.

Form grinding
 Creates profile shapes on the workpiece

 Uses form grinding wheel.

Application:

Guide wires,

spool

valves, bar

stock, pins,

bushings,

engine parts
etc.
 CNC
MACHINES

CNC =MCU + MACHINE

 MCU – MACHINE CONTROL
CPU (central processing unit) – manages the other MCU components based
UNIT
on software in main memory

Memory – 2 types
1.Main/Primary Memory : RAM (Part programs being executed stored
temporarily) & ROM (Operating system and machine interface programs
stored here)
2. Secondary Memory : Program storage

I/O Interface – For communication b/w various components; E.g. Keyboard,

screen.

Controls for machine tool axis and spindle speed:

Hardware components that control position and speed of machine axis.

Sequence controls for machine tool function:

Features like coolant control, tool changer, clamping device actuation etc.

To avoid overloading the CPU, a programmable logic controller (PLC) is sometimes

used to manage the I/O interface for these auxiliary functions.
MCU, is the brain of a CNC machine tool.

It reads the part programs and controls the machine tools operations.

It decodes the part program to provide commands and instructions to the

various control loops of the machine axes of motion.

Advantages of CNC Disadvantages of CNC

•High accuracy in manufacturing
•Storage of more than one  High cost
part program More maintenance
•Program editing at the
machine tool.
•Short production time
•Greater
manufacturing flexibility
•Reduced human error.
 CAD/
 CAD/CAM – use ofCAM computers (software + hardware) in
designing process and planning & manufacturing stages.

 Computer-Aided Design (CAD) is the use of computers to

assist in the creation, modification, analysis, or optimization
of a design.
 CAD is most commonly associated with the use of an
interactive computer graphics system, referred to as a CAD
system.
 Computer assists the designer to convert his ideas and
knowledge into mathematical/graphical model
 E.g. Software - AutoCAD
• Computer aided manufacturing (CAM) is the use of
computer systems to plan, manage, and control the
operations of a manufacturing plant through direct or
indirect computer interface with plant’s resources.

• Use of computers for 2 purposes:

– Monitoring & control of manufacturing processes (CNC)
– Manufacturing support – applications than help
with process planning, scheduling, quality control
etc.
E.g. Software’s like MasterCam, CAMworks etc.

Some software’s help in both CAD & CAM- E.g. CATIA,

FUSION 360 etc.
 RAPID
PROTOTYPING
 Rapid prototyping is a group of techniques used to
quickly fabricate a prototype of an object using three
dimensional Computer aided design (CAD)data
 Primarily uses method of layer by layer or additive
means of construction – “Additive layer Manufacturing”
 Also known as 3D printing
 Mainly has three techniques:
 Stereolithography.

 Fused Deposition Modeling.

 Selective Laser Sintering.

METHODOLOGY OF RAPID PROTOTYPING
 RAPID/ ADDITIVE
• MANUFACTURING
Additive manufacturing technique involves 3 fundamental steps:
1. GENERATION OF MATHEMATICAL
LAYER INFORMATION
• Process starts with 3D modeling of the product and
it is then
exported as an STL (Standard Tessellation Language) file
• These STL files are used as an input to various slicing software's,
which generates layer data
2. GENERATION OF PHYSICAL LAYER MODEL
• The above file is then used to control the material deposition
path and produce the 3D part
• The method of layer by layer material addition varies from one
technique to other.
3. POST PROCESSING
* The final step in the process chain is the post-processing task.
*At this stage, generally some manual operations are necessary
therefore skilled operator is required.
* In cleaning, excess elements adhered with the part or support
structures are removed. Sometimes the surface of the model
finished by sanding, polishing or painting for better is
surface aesthetic appearance. finish or
ADVANTAGES AND DISADVANTAGES

Advantages
Almost any shape or geometric feature can be produced
Material wastage is minimal to nil
.

Reduction in time and cost for making prototype

Errors can be detected at early stage
No tooling, jigs and fixtures are required
Disadvantages
The price machinery is high
The surface is usually rougher than machines surface