Material Removal Processes

MACHINES USED FOR MACHINING

Lathe Reducing Length/DiameterMilling Reducing Thickness/SlottingDrilling Making HoleShaper Reducing Thickness/SlottingPlanner Reducing Thickness/Slotting

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

LATHE

“The Mother of Machines”

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

It can make Cylindrical and Flat Surface

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

TYPES

o Engine Latheo Speed Latheo Bench Latheo Tool Room Latheo Special Purpose Latheo Gap Bed Lathe

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

BASICS

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Headstock

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Bedways

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Carriage/Apron

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Tailstock

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Lathe Drive Mechanism

Belts are moved from pulley to pulley to change speeds (rpm)

Pulley System without back gear: 4 High range speeds

Pulley System with back gear: 4 Low range speeds

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Carriage Feed

A. Longitudinal Feed or “Turning” - The tool is fed along the work.

C. Cross Feed or “Facing” – The tool is fed across the work.

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Carriage Feed

Power Feed for:

Turning

Facing

Used for greater control and accuracy.

Speed controlled by the “Quick Change Gear Box”

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Carriage and Apron

The controls on the carriage and apron control all the tool and carriage movement.

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Lathe Carriage and Apron

Compound Rest Knob

Half Nut Lever

Carriage Lock Screw

Apron Hand

WheelApron Feed Change Lever

Compound Rest

Power Feed

Clutch

Cross Slide

Cross Feed Knob

Tool Post

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

CHUCK

Three Jaw Chuck

- For holding cylindrical stock centered.

- For facing/center drilling the end of your aluminum stock

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

CUTTING TOOL

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

BASICS MACHING (TURNING)

Excess Material is removed to reduce DiameterCutting Tool: Turning Tool

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

MACHINING IN LATHE

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

TURNING BETWEEN CENTERS

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

FACING

machine end of job Flat surface or to Reduce Length of JobTurning ToolFeed: in direction perpendicular to workpiece axis

Length of Tool Travel = radius of workpieceDepth of Cut: in direction parallel to workpiece axis

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

FACING

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

KNURLING

A Forming Process: Produce rough textured surfaceFor Decorative and/or Functional PurposeKnurling Tool

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

GROOVING

Produces a Groove on workpieceShape of tool shape of grooveCarried out using Grooving Tool A form toolAlso called Form Turning

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

PARTING OFF

Cutting workpiece into Two Similar to groovingParting ToolHogging – tool rides over – at slow feedCoolant use

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

CHAMFERING

Beveling sharp machined edgesSimilar to form turningChamfering tool – 45° To

• Avoid Sharp Edges• Make Assembly Easier• Improve Aesthetics

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

TAPER TURNING

BY FORM TOOL

BY COMPOUND REST

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

DRILLING/REAMING/BORING

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

LATHE TOOLS

lathe tools are usually shapedby the machinist using a

grinding wheel

a “boring bar” lets you get deepinside a part for making an innerdiameter (for holes larger thanavailable drill bits & reamers)

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

DRILLING

Basic hole making processes account for approximately 50-70% of all the metal removal processes utilized today

o Drillingo Reamingo Tappingo Boring

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

Drills and Reamers

standard “jobber” drill: will flex/walk, follow pilot

stub drill for less walk/greater rigidity

reamers (straight or spiral)finish off hole (last several thousandths)precise hole diameterfor insertion of dowel pins, bearings, etc.plunge while spinning, extract stillcountersink: for screw heads & deburring hole

center drill establishes hole position with no walk

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

PORTABLE DRILLING MACHINE

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

SENSITIVE DRILLING MACHINE

Sensitive• Light weight-light duty• Feed of the drill is “sensitive” to the

touch of the operator• Used primarily for low production

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

PILLAR / UPRIGHT DRILL PRESS

Upright Drill Press• Larger than the sensitive• Can be equipped with a gearbox and

variable speed head• Hand and automatic feed mechanism• Automatic coolant system• Table can move on a rack and pinion

system

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

RADIAL DRILL PRESS

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

GANG DRILLING MACHINE

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

MULTI SPINDLE DRILLING MACHINE

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

MILLING

Milling is one of the basic machining processes. Milling is a very versatile process capable of producing simple two dimensional flat shapes to complex three dimensional interlaced surface configurations.

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

MILLING PROCESS

The milling process:– Typically uses a multi-tooth cutter– Work is fed into the rotating cutter– Capable of high MRR– Well suited for mass production

applications– Cutting tools for this process are called

milling cutters

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

CONVENTIONAL UP/DOWN MILLING

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

BASIC MILLING OPERATIONS

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Department of Mechanical Engineering

I. SIVA, SL/Mech.

SOME OTHER MILLING OPERATIONS

Saddle Milling Form Milling Slotting Slitting

THANKS

I. SivaSenior LecturerDepartment of Mechanical EngineeringFaculty ID: 01019Office: Fitting Carpentry Shop/Workshop ComplexeMail: siva@akce.ac.in