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Introduction, Press & Machining

This document provides information about the Manufacturing Technology - I course (MI 104). It includes details about the course content, topics covered, weightage of assessments, list of practical sessions, suggested books and references. The course aims to familiarize students with principles of sheet metal forming, material removal, and finishing operations. Key topics include sheet metal forming processes, machining processes, abrasive finishing and an introduction to manufacturing.

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0% found this document useful (0 votes)
101 views327 pages

Introduction, Press & Machining

This document provides information about the Manufacturing Technology - I course (MI 104). It includes details about the course content, topics covered, weightage of assessments, list of practical sessions, suggested books and references. The course aims to familiarize students with principles of sheet metal forming, material removal, and finishing operations. Key topics include sheet metal forming processes, machining processes, abrasive finishing and an introduction to manufacturing.

Uploaded by

Lucky Daga
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Manufacturing Technology – I

MI1

Instructor – Dr. Rahul S. MULIK

6SULnJ 2013-2014
Manufacturing Technology – I
MI 1
Relative Weightage of Marks
Class Work Sessional (CWS): 00%
Practical Sessional (PRS): 25%
Mid Term Examination (MTE): 25%
End Term Examination (ETE): 50%

Objective: To familiarize students with the principles


of sheet metal forming, material removal, and finishing
operations.
COURSE CONTENT
S. TOPIC ~ No of
No Lectures
1 INTRODUCTION: Classification of different manufacturing 2
processes, application areas and limitations, selection of a
manufacturing process
2 Sheet Metal Forming: Introduction to sheet metal forming 10
operations, Types of presses, drives, Operations: shearing
bending, spinning, embossing, blanking, coining and deep
drawing. Die materials, compound and progressive dies and
punches. Construction details of die set. Auxiliary equipments,
safety devices.
3 Material Removal Processes: Classification of machining 10
processes and machine tools. Tool's materials, different types
of cutting tools, Nomenclature of single point and multi point
cutting tool. Concept of cutting speed, feed and depth of cut.
Coolants. Drilling, Boring and broaching machines. Indexing
head, milling operations using simple, differential and
compound indexing. Introduction to CNC Machines
COURSE CONTENT (Continued)
S. Particulars ~ No of
No Lectures
4 Abrasive Finishing: Operations and applications of surface, 6
cylindrical and centreless grinding processes; dressing, truing
and balancing of grinding wheels; grading and selection of
grinding wheels.
Total 28

Objectives of the Course: To familiarize students with the principles of sheet


metal forming, material removal and finishing operations.
Suggested Books
S. Name of Book, Authors, Year of
No Publisher, ISBN Publication
1 Materials and Processes in Manufacturing, E.Paul 1997
DeGarmo, J.T. Black, R. A. Kohser, Prentice Hall of
India Pvt. Limited- New Delhi
(ISBN 81-203-1243-0)

2 Manufacturing Engineering and Technology, S. 2000


Kalpakjian, S.R. Schmid, Pearson Education, New
Delhi,
(ISBN 81-7808-157-1)
3 Fundamentals of Modern Manufacturing, Mikell 2002
P. Groover, John Wiley and Sons Inc.
(ISBN 0-471-40051-3)
Suggested Books (Continued)

4 Processes and Materials of Manufacture, R.A. 1990


Lindberg, Prentice Hall India Limited,
(ISBN 81-203-0663-5)
5 Manufacturing Technology (Vol 1 and 2), P.N. Rao, 1998
Tata McGraw Hill New Delhi
(ISBN 0074631802)
List of Practicals for MI-104
1 Study of turret lathe
2 Study of grinding machines, attachments and accessories
3 External threading on a given job on lathe machine
4 Internal threading on a given job on lathe machine
5 Taper turning on a given job on lathe machine
6 V -groove cutting on a given job on lathe machine
7 Profile turning on a given job on lathe machine
8 Cutting teeth on a spur gear on milling machine
9 Helical milling on a given circular job
10 Slot cutting on a given job on milling machine
11 Shaping operation on cast iron job
12 Keyway cutting on a given job on slotting machine
Different Components…Different Aspects

Simple
Small

23 feet,
6 tonnes ,
99.72% iron,
No rust since 5th
century AD

Big Complex

Iron pillar
Manufacturing – Need and concept
• Manufacturing - Value addition processes by which raw
materials (low utility and value due to inadequate material
properties and poor or irregular size, shape and finish) are
converted into valued products (high utility due to definite
dimensions and finish)
imparting functional ability.

Value addition by manufacturing.


Manufacturing – Need and concept
Production Engineering covers two domains:
– Production or Manufacturing Processes
– Production Management
• Manufacturing Processes - science and technology of
manufacturing products effectively, efficiently, economically
and environment-friendly through:
– Application of any existing manufacturing process and
system
– Proper selection of input materials, tools, machines and
environments.
– Improvement of the existing materials and processes
– Development of new materials, systems, processes and
techniques
Manufacturing – Need and concept
Production Engineering covers two domains:
– Production or Manufacturing Processes
– Production Management
• Production Management - planning, coordination and control
of the entire manufacturing in most profitable way with
maximum satisfaction to the customers by best utilization of the
man, machine, materials and money. Goal in manufacturing
requires fulfillment of one or more of the following objectives:
– Reduction of manufacturing time
– Increase of productivity
– Reduction of manufacturing cost
– Increase in profit or profit rate
Manufacturing – Need and concept
Manufacturing – Need and concept

Material flow is of three main types:


• Through flow, corresponding to mass-conserving processes
(change in material properties without change in geometry)
• Diverging flow, corresponding to mass-reducing processes
• Converging flow, corresponding to assembly or joining
processes
Manufacturing – Need and concept
A manufacturing process normally consists of a series of basic
processes, which constitute the structure of the material flow.
• Basic processes can be divided into three typical phases:
– Phase 1 (material into a suitable state/geometry like heating, melting,
sawing etc.)
– Phase 2 (desired geometry and/or change in properties)
– Phase 3 (component into the specified end state (solidification, cooling,
deburring etc.)
Engineering Manufacturing Processes
(a) Shaping or forming Manufacturing a solid product of
definite size and shape from a given material taken in
three possible states:
– Solid state – e.g., forging, rolling, extrusion, drawing etc.
– Liquid/semi-liquid state – e.g., casting, injection molding etc.
– Powder form – e.g., powder metallurgical process
(b) Joining process
– Welding, brazing, soldering etc.
(c) Removal process
– Machining (Traditional or Non-traditional), Grinding etc.
Engineering Manufacturing Processes
(d) Regenerative manufacturing
• Production of solid products in layer by layer from raw
materials in different form:
– Liquid – e.g., stereo lithography
– Powder – e.g., selective sintering
– Sheet – e.g., LOM (laminated object manufacturing)
– Wire – e.g., FDM. (Fused Deposition Modeling)
Engineering Manufacturing Processes
Engineering Manufacturing Processes

N
Engineering Manufacturing Processes
Factors affecting the selection of manufacturing processes
• Cost (material, manufacturing, operating and replacement cost)
• Material (specified by design)
• Quantity (determines economics of manufacturing process)
• Machine or equipment availability (Machines and operators)
• Quality Surface finish, Accuracy (geometrical, dimensional)
• Geometry (Cylindrical, conical, threads – Lathe)
(Plane surface, slots – shaping, planning, milling)
(Complex Shapes – Casting, Forging)
Selecting materials for manufacturing

• Mechanical properties of materials


– Strength, toughness, ductility, hardness, elasticity, fatigues,
creep, …
• Physical properties of materials
– density, specific heat, thermal expansion and conductivity,
melting point, and electrical and magnetic properties, ……
• Chemical properties, environmental resistance and wear
– corrosion, toxicity, flammability, ……
• Strength : ability to bear load before fracture
• Toughness: resistance to both elastic and plastic deformation
• Ductility: extent of permanent or plastic deformation that a
material undergoes before fracture (% elongation, % reduction
in area
• Hardness: resistance to plastic deformation which includes
indentation, scratching, or marking
• Elasticity: ability to restore to original shape and size after
removal of external deforming loads
• Fatigue : permanent deformation and/or failure of a component
when subjected to fluctuating (both in magnitude and direction)
loads
• Creep : permanent deformation and/or failure of a component
when subjected to high stresses at high temperature
• Stiffness: resistance to elastic deformation
• Fracture : splitting of a component into atleast two halves
Material-Based Selection of Manufacturing
Processes
Forming Deforming Removing Joining Modifying

Metals XX XX XX XX XX
Materials

Ceramics XX -- X -- --

Polymers XX X X X --

Composites XX -- X X --

XX - Widely Used
X - Seldom Used
-- - Not Used .
• Deformation processes have been designed to exploit the
plasticity of engineering materials
• Plasticity is the ability of a material to flow as a solid without
deterioration of properties
• Deformation processes require a large amount of force
• Processes include bulk flow, simple shearing, or compound
bending
Classification of Deformation Processes

• Bulk (small surface area/volume) deforming processes can


be classified as primary or secondary processes
– Primary processes reduce a cast material into slabs, plates,
and billets
– Secondary processes reduce shapes into finished or semi
finished products
• Bulk deformation processes are those processes where the
thickness or cross sections are reduced
• Sheet-forming operations involve the deformation of materials
whose thickness and cross section remain relatively constant
Classification of States of Stress
Bulk Deformation Processes

• Rolling
• Forging
• Extrusion
• Wire, rod, and tube drawing
• Squeezing processes
Sheet-forming Operations
• High SA/V
• Sheet - thickness < 5 (6) mm, above 6 mm - plate
• Sheet metal processes involve plane stress loadings and lower forces than
bulk forming
• Almost all sheet metal forming is considered to be secondary processing

Stress Induced Operations


Shearing Shearing, Blanking, Piercing,
Trimming, Shaving, Notching,
Nibbling
Tension Stretch-Forming
Compression Ironing, Coining, Sizing, Hobbing
Tension and Drawing, Spinning, Bending,
Compression Embossing, Forming
Classification of Presses

• Primary tool for sheet metal working is some form of press


and successful manufacture depends on using right kind of
equipment

– Capacity required
– Type of power (manual, mechanical, or hydraulic) or drive
– Number of slides or drives
– Type of frame
– Speed of operation
Press drive mechanisms
Classification of Presses – Drive Mechanism

• Very light work - manually operated presses (foot operated or


kick presses)
• Heavier work – mechanical drives
• Fast motion and positive control of displacement
• Limited flexibility (length of stroke is set by design of
drive)
• Force varies with position
• Preferred for operations like cutting, up to 10 cm
drawing (maximum pressure near bottom of stroke)
• Capacity – 9000 metric tons
Classification of Presses – Drive Mechanism

• Mechanical drives types:


– Crank-driven
• Simple
• Piercing, blanking, drawing
• Double crank (multiple action dies)
– Eccentric or cam drives
• Used for smaller ram stroke
• Dwell at bottom of stroke
• Deep drawing
– Knuckle-joint drives
• High mechanical advantage alongwith fast action
• Coining
Classification of Presses – Drive Mechanism

• Mechanical drives types:


– Toggle mechnism
• Drawing
– Screw-type drives
• Mechanical action resembling drop hammer
Classification of Presses – Drive Mechanism
• Hydraulic presses
– Motion as a result of piston movement
– Stroke can be programmed (2.5 m)
– Accurate controlled on forces and pressure
– Availability of full pressure throughout the stroke
– Speeds can be programmed to either vary or remain constant
– Slower than mechanical presses in general (exception – 600
strokes per minute for high speed blanking)
Classification of Presses – Drive Mechanism
• Hydraulic presses
– Reproducibility of position will have greater variation than a
mechanical press
– Capacity - exceeding 50,000 metric tons
– Preferred for operations
• requiring a steady pressure throughout a substantial stroke (deep
drawing)
• requiring wide variation in stroke length
• requiring high or widely variable forces.
Classification of Presses – Frame
• Considerations – capacity, accessibility and stiffness
– limitations on size and type of work that can be
accommodated
– Work loading and unloading
– Press setup time e.g., time required for changing dies
• Arch-frame
– Screw-drives for coining
– Seldom used
• Gap-frame (C shaped)
– Versatile
– Good accesability from three directions
– Permit large workpieces
– 1 metric ton to 300 metric tons
Classification of Presses – Frame

• Inclinable press
– Tilted
– Ejection can be assited by gravity or compressed air jet
• Open-back presses
– Opening in back
– Easy ejection of products/scraps
Inclinable gap-frame press
• Turret press
– Multiple holes/slots with varying shaps/size
– Upper and lower turret (muliple punches and dies)
• Horn press
– Cylindrical shaft (horn) in place of bed
– Curved workpieces
– Seaming, punching, riveting

Horn press
Classification of Presses – Frame
• Straight-sided press
– Accesibility from front and rear (from sides as well)

A 200-ton straight-sided press.


Sheet Metalworking

1. Cutting Operations
2. Bending Operations
3. Drawing
4. Other Sheet Metal Forming Operations
Sheet and Plate Metal Products

• Sheet and plate metal parts for consumer and


industrial products such as
– Automobiles and trucks
– Airplanes
– Railway cars and locomotives
– Farm and construction equipment
– Small and large appliances
– Office furniture
– Computers and office equipment
Advantages of Sheet Metal Parts

• High strength
• Good dimensional accuracy
• Good surface finish
• Relatively low cost
• Economical mass production for large
quantities
Sheet Metalworking Terminology

• Punch-and-die - tooling to perform cutting, bending, and


drawing
• Stamping press - machine tool that performs most sheet
metal operations
• Stampings - sheet metal products
Basic Types of Sheet Metal Processes
1. Cutting
– Shearing (simple shearing) to separate large sheets
– Blanking to cut part perimeters out of sheet metal
– Punching/ Piercing to make holes in sheet metal
– Slitting
2. Bending
– Straining sheet around a straight axis
3. Drawing
– Forming of sheet into convex or concave shapes
Shearing, Blanking, and Punching

Principal operations in pressworking that cut sheet metal:


• Shearing
• Blanking
• Punching
• Piercing
Shearing

• Shearing is a process for cutting sheet metal to size out of a


larger stock such as roll stock

• Shears are used as the preliminary step in preparing stock for


stamping processes, or smaller blanks for CNC presses

• The shearing process produces a shear edge burr, which can be


minimized to less than 10% of the material thickness. The burr
is a function of clearance between the punch and the die, and
the sharpness of the punch and the die.
Shearing

• Fracture and tearing begin at the weakest point and proceed


progressively or intermittently to the next-weakest location
– Results in a rough and ragged edge
• Punch and die must have proper alignment and clearance
• Sheared edges can be produced that require no further
finishing
Sheet Metal Cutting - Shearing

Shearing of sheet metal between two cutting edges:


(1) just before the punch contacts work;
(2) punch begins to push into work, causing plastic deformation;
Sheet Metal Cutting - Shearing

Shearing of sheet metal between two cutting edges:


(3) punch compresses and penetrates into work causing a smooth
cut surface;
(4) fracture is initiated at the opposing cutting edges which
separates the sheet.
Conventionally sheared surface

Fineblanked surface
Shearing (Press Operations)
Smooth shearing a rod by putting it into compression during shearing

Slitting - Power shear for 6.5 mm steel


Shearing
Sheet metal cutting operation along a straight line between two
cutting edges
• Typically used to cut large sheets

Shearing operation:
(a) side view of the shearing operation;
(b) front view of power shears equipped with inclined upper
cutting blade.
Shearing
• Shearing (simple/square)
– Both cutting blades are straight
• Curved blades to produce different shapes
– Blanking
– Punching
– Piercing
– Notching
– Trimming
Blanking and Punching

Blanking - sheet metal cutting to separate piece (called a blank)


from surrounding stock
Punching - similar to blanking except cut piece is scrap, called a
slug

Blanking Punching
Blanking and Punching

Blanking - sheet metal cutting to separate piece (called a blank)


from surrounding stock
Punching - similar to blanking except cut piece is scrap, called a
slug
Punching

• Punching is a metal fabricating process that removes a scrap


slug from the metal workpiece each time a punch enters the
punching die. This process leaves a hole in the metal workpiece
Characteristics:
• Ability to produce holes in both strip and sheet metal during
medium or high production processes.
• The ability to produce holes of varying shapes - quickly
Punching

• The punching process forces a steel punch, made of hardened


steel, into and through a workpiece.
• The punch diameter determines the size of the hole created in
the workpiece
• Punching is often the cheapest method for creating holes in
sheet metal in medium to high production.
Punching
Punching and Piercing

• A slug (the material punched out) is produced in punching


operations but not in piercing work
• Piercing is “forming a hole in sheet metal with a pointed punch
with no metal fallout (slug).”
• In this case, a significant burr or deformed sharp edge is created
on the bottom side of the material being pierced.

PIERCE

PUNCHES
Punching & blanking -Tools and Dies

• Basic components of a
piercing and blanking die
set are: punch, die, and
stripper plate
• Punches are normally made
from low-distortion or air-
hardenable tool steel so that
they can be hardened after
machining
Punching & blanking -Tools and Dies

• Theoretically, punch should fit in die with a uniform


clearance approaches zero (practically- 5-7% of stock
thickness)
• Uniform clearance should be maintained around the entire
periphery
• Theoretically, punch should not enter die, but should stop
as its base aligns with top surface of die (practically- punch
enters slightly in die)
Punching & blanking -Tools and Dies

• Punch tilted slightly to


reduce cutting force (shear
angle)
• Shear angle – reduces force
– increases stroke length
Punching & blanking -Tools and Dies

• Subpress dies (modular tooling) – assembled and combined on


bed of press to pierce or blank large parts
Punching & blanking -Tools and Dies

•Dies
– single piece
– component sections (that can be assembled)
•simplifies production
•simplifies replacement
•flexibility of design changes
•standard die components
Punching & blanking -Tools and Dies

Parts requiring multiple cutting type operation


• Progressive die sets- two or more sets of punches and dies
mounted in line (one behind another, all facing in the same
direction)
• Transfer dies move individual parts from operation to
operation within a single press
• Compound dies combine processes sequentially during a
single stroke of the ram
Punching & blanking -Tools and Dies
Progressive die sets
• First operation
– strip stock is fed in first die,
where a hole is pierced and
ram descends
• Second Operation
– ram retracts and strip
advances, the pilot on
blanking punch aligns with
pierced hole
Progressive piercing and blanking die for making a
– further descent of punch square washer
blanks the completed
washer-pieces
– At same time, first punch
pierces the hole for next
washer
Punching & blanking -Tools and Dies
Progressive die sets

Eleven station progressive die stages


Punching & blanking -Tools and Dies
Progressive die sets
• Used for multiple combinations of piercing, blanking,
forming, drawing etc.
• Quick and accurate position of work material
• Simple construction
• Economical to maintain and repair
• Require final cut-off operation
Punching & blanking -Tools and Dies
Transfer die sets
• Part handling must operate in harmony with press motions
to move, orient and position the pieces as they travel
through the die
Punching & blanking -Tools and Dies
Compound die sets
• Piercing and blanking (or other combinations) occur
sequentially during a single stroke of ram

Part is blanked and subsequently pierced in the same stroke


The blanking punch contains the die for piercing.
Punching & blanking -Tools and Dies
Compound die sets

• More complex
• More breakage
• More expensive
• Precise alignment
Nibbling
• Contour is progressively cut by producing a series of
overlapping notches (removing the material in small
increments)
• Simple tools for complex shapes
• Nibbling is used when the contour is long and a separate
punch is impractical and
uneconomical
• Edge smoothness – determined by
shape of tooling and degree of
overlap in successive cuts
Lancing

• Metal cutting operation in which the metal is sliced or slit to


free up metal without separating it from the original sheet.
• Does not create a slug
• Save material and eliminate the need for scrap removal
• Done in progressive dies
Trimming

• Removal or Trimming of the Flash


Shaving

• Finishing operation
• Removal of the burrs left on product during the blanking or
punching/piercing operation
• Greater dimensional accuracy
• Close tolerance work
Notching

• Cutting a specified small portion of material towards the edge


of the material stock
Cutoff

• Separate a stamping or other product from a


strip or stock
• Produces the periphery counter to the
workpiece
Dinking

• Used to blank shapes from low strength


materials (rubber, fiber, cloth etc.)
(Hammer or mechanical press
acts on shank)
Design for punching & blanking

• Design rules
– Diameters of pierced holes should not be less than the
thickness of the metal (minimum 0.3 mm)
– Minimum distance between holes or the edge of the stock
should be at least equal to the metal thickness
– The width of any projection or slot should be at least 1
times the metal thickness (never less than 2.5 mm)
– Keep tolerances as large as possible
Bending

• Bending is the plastic deformation


of metals about a linear axis with
little or no change in the surface
area
• Forming- multiple bends are made
with a single die
• Spring-back is the “unbending” that
occurs after a metal has been
deformed
Bending

Bend Allowance is length of neutral axis in bend area and is used


for determination of blank length for a bend part
Lb = α (R + kT)
Where,
α is bend angle (rad),
T is sheet thickness,
R is bend radius,
k is constant (from (0.33 for R<2T) to 0.5 (for R>2T))
Ideal case k = 0.5
Bending

A 10 mm wide and 4 mm thick steel sheet is required to be bent at 3.14


radians at bend radius 10 mm. Determine the bend allowance?
Bend radius R = 10 mm
Sheet thickness t = 4 mm
Since R > 2t, k = 0.5
α = 3.14 rad
Bend allowance = (3.14)(10 + 0.5*4) = 14.74 mm
Bending

(a) bending (b) rolling (c) Bending 90o


Bending
Bending
Minimum Bend Radius - the ratio at which a crack appears on outer
surface of bend
Expressed in terms of thickness (2T, 3T, 4T etc.)
R/Tmin = (50/(r-1)) ; Best Fit ----- R/T = (60/(r-1))
Where,
R is bend radius (Min Bend Radius ‘R’- at which crack occurs)
, T is sheet thickness, r is tensile reduction of area of sheet metal

50% tensile reduction of area can be


bent over itself

R/T Ratio versus % Area Reduction


Bending
Bending Force
• Simple bending of a rectangular beam
• Bending force is function of :
– strength of material
– length of bend (L)
– thickness of sheet (T)
– size of die opening (W)
• Maximum bending force is
P = kYLT2 / W
Where, T is sheet thickness, R is bend radius,
k is 0.3 – 1.3, Y is yield stress
Bending
Bending Force
A 600 mm * 2.5 mm steel sheet is required to be bent at 900 using a V
– die. Yield stress of the material is 500 MPa and the die opening as
10 times the material thickness. Estimate the force required for the
operation.
• Solution : Here, Y = 500 MPa
L = 600 mm, t = 2.5 mm
k = 1.3 (for V – die)
• W = 25 mm
• Bending force P = k.Y.L.t2 / W
• = 1.3 x 500 x 600 x (2.5)2 / 25
• = 97.5 KN
Bending
Bending Force
A 600 mm * 2.5 mm steel sheet is required to be bent at 900 using a
wiping die with radius = 3.75 mm. Yield stress of the material is 500
MPa and the die opening as 10 times the material thickness.
Estimate the force required for the operation.
Y = 500 MPa
L = 600 mm, t = 2.5 mm
k = 0.3 (for Wiping die)
W = 2.5+3.75.3.75 mm = 10 mm
Bending force P = k.Y.L.t2 / W
W
= 0.3 x 500 x 600 x (2.5)2 / 10
= 56.2 KN
Angle Bending (Bar Folder and Press Brake)

• Bar folders make angle bends up to 150 degrees under 1.5 mm


sheet metal
• Press brakes make bends in heavier sheets or more complex
bends in thin material
Press Brake
• Heavier sheet and/or complex bends
• Mechanical/Hydraulic with narrow/long bed and short strokes
• Optional operations - Seaming, embossing, punching etc.
• 7 m long sheets
• Die material
– hardwood (low strength materials)
– Carbon steels, gray-iron
Press Brake

Roll Bead Formed

(a) Bead forming with a single die (b) Bead forming with two dies, in a press brake
Bending

Springback
Ri/ Rf = 4(RiY/ET)3 - 3(RiY/ET) + 1
Where, Y is yield stress, E is elastic modulus
• Spring back increases with decrease of E and increase of R/T
and Y
• Springback
Q. A 5 mm sheet is bent to a radius of 10 mm. Calculate the
radius of part after it is bent
(Yield stress = 205 MPa, E = 190 Gpa)
Ri / Rf = 4(RiY/ET)3 - 3(RiY/ET) + 1 (overbend or springback allowance)
RiY / Et = (10 x 205 * 106) / (190 x 109 x 5) = 0.00216
Ri / Rf = 4 (0.00216)3 – 3 (0.00216) +1
= .993
Bending
Springback

• Remove the bent piece at stage (b) – positive spring back


• Upon unloading at stage (d) – negative spring back (inwardly)
because it is being unbent from stage c
• The amount of this inward (negative) spring back can be
greater than the amount of positive spring back
Bending

Springback
Bending

Springback

• High Temprature
Considerations for Bending
• If the punch radius is large and the bend angle is shallow,
large amounts of spring back are often encountered
• The sharper the bend, the more likely the surfaces will be
stressed beyond the yield point
• Parts with multiple bends should be designed with most of
them at same bend radius (less setup time and tooling cost)
• Bends should be made with the bend axis perpendicular to
the rolling direction (fracture in hard material)
Considerations for Bending

• The minimum inner radius should be at least 1 X material thickness


• Minimum flange width should be at least 4 times the stock thickness
plus the bending radius (damage to tooling or operator)

• Tolerance should not be less than 0.8mm


Considerations for Bending

• Forming Near Holes – When a bend is made too close to a


hole, the hole may become deformed (teardrop)
– For a hole < 1" in diameter the minimum distance "D" = 2T + R
– For a slot or hole > 1" diameter then the minimum distance "D" =
2.5T + R

A. Teardrop B. hole < 1” C. hole > 1”


Air-Bend, Bottoming, and Coining Dies

• Bottoming dies contact and


compress the full area
within the tooling
– Angle of the bend is set by
the geometry of the tooling
+ springback
• Air bend dies produce the
desired geometry by simple
three-point bending
Air-bend (left) and bottoming (right)
• If bottoming dies go beyond press brake dies
the full-contact position, the
operation is similar to
coining
Roll Forming

• Roll forming is a process


by which a metal strip is
progressively bent as it
passes through a series of
forming rolls
• Only bending takes place
during this process, and
all bends are parallel to
one another
• A wide variety of shapes
can be produced, but
changeover, setup, and
adjustment may take
several hours
Roll Forming
• Progressive bending
of metal strips as it
passes through series
of forming rolls
(80 m/min)
• Any material that can
be bent can be rolled

Eight-roll sequence for the roll forming of a box channel


Roll Bending
• Roll bending is a continuous form of three-point bending
– Plates, sheets, beams, pipes
– Lower rolls – driven
– Upper roll – controls degree of curvature
Forming Rolls
Tube Bending
• Wet Sand
• Flexible mandrels
• Pressure bulging
• Key parameters: outer diameter of the tube, wall thickness, and
radius of the bend
Tube Bending
Draw Bending, Compression Bending, and Press Bending

(a) Draw bending, in which the form block rotates


(b) moving tool compresses the workpiece against a stationary form
(c) press bending, where the press ram moves the bending form.
Tube Bending

Production of fittings for plumbing


(expanding tubular blanks)
Seaming and Flanging

• Seaming is a bending operation that can be used to join the


ends of sheet metal in some form of mechanical interlock
• Common products include cans, drums, and containers
• Flanges can be rolled on sheet metal in a similar manner as
seams

Various types of seams used on sheet metal.


Straightening
• Opposite of bending
• Done before subsequent forming to ensure the use of flat or
straight material
• Various methods to straighten material
– Roll straightening (Roller levering)
– Stretcher leveling- material is mechanically gripped and stretch
until it reaches the desired flatness

Method of straightening rod or sheet by passing it through a set of straightening rolls


Drawing and Stretching Processes

• Drawing refers to the family of operations


where plastic flow occurs over a curved axis
and the flat sheet is formed into a three-
dimensional part
Deep Drawing and Shallow Drawing
• Deep drawing is typically
used to form solid-bottom
cylindrical or rectangular
containers from sheet metal
• Shallow drawing - depth is
less than diameter
Deep Drawing and Shallow Drawing
• Key variables:
– Blank and punch diameter
– Punch and die radius
– Clearance
– Thickness of the blank
– Lubrication
– Hold-down pressure
Limitations of Deep Drawing

• Typical limits to drawing operations


– Wrinkling (movement of blank into die cavity induce
compressive stresses in flange)
– Tearing (walls elongates and tend to thin)
– Earing (Edges of cups may become wavy)?

?
Limitations of Deep Drawing
• Shallow Drawing – little change in circumference and small
area is confined by blankholder
• Deep Drawing – more change in circumference
• More wrinkle and tear -Thin material
Deep Drawing

• Deep Drawability (LDR)


– LDR = Do/Dp
– Where, Do – max. blank diameter, Dp – is punch diameter
• Ability of a sheet metal for successful drawing
operation is defined by normal anisotropy (R)
R = Width strain / Thickness strain
Cold rolled sheets have anisotropy
in planer direction
Rave = (R0+ 2R45+ R90)/4
Where angles are relative to
rolling direction
Deep Drawing

• Earing is caused by planer anisotropy of sheet (ΔR)


• ΔR = (R0 -2R45+R90)/2
• at ΔR = 0, no ears are formed
Limitations of Deep Drawing

• Different techniques can be used to overcome these limitations


– Simple shapes – Multiple operations
– Complex shapes - Draw beads
– Vertical projections and matching grooves in the die and
blankholder
• Trimming may be used to reach final dimensions
Limitations of Deep Drawing

• Reverse redrawing – starting cup is placed over a tubular die


and punch acts to turn it inside out
• Forward redraw - material undergoes reverse bending as it
flows into the die
Draw beads

• Control flow of blank in die cavity


Ironing
• Process that thins the walls of a drawn cylinder by passing it
between a punch and a die
• Die and Punch Set Used is Similar to that of Drawing
Operation Except that the Clearance Between the Die and
Punch is Smaller than that Used in the Drawing Operation.
• The Material Gets Compressed Between Punch and Die which
Reduces the Thickness and Increases the Height.
• The Wall Thicknesses can be Reduced to as Much as 50% in a
Single Ironing Operation.
Embossing
• Press working process in which raised lettering or other
designs are impressed in sheet material
• Drawing and bending of the material
• Die set consists of a die and punch with the desired contours,
so that when the punch and die meet, the clearance between
them is same as that of the sheet thickness
• Providing dimples on sheets to increase their rigidity
• Decorative sheet work used for panels
Embossing
Bending and Embossing
COINING
• Closed–die forging
operation (the flow of the
material occurs only at the
top layers and not in the
entire volume)
• Coining die consists of the
punch and die which are
engraved with the
necessary details required
on both sides of the final
object.
• The blank is compressed
by the die with a very high
pressure (5 to 6 times
strength of material) is
applied due to which very
fine details are obtained
on the surface.
Spinning
• Produces rotationally symmetrical shapes
– Spheres, hemispheres, cylinders, bells, and parabolas
• Sheet metal is rotated and shaped over a male form and
gradually moving force is applied (blank takes shape of form)
• Setup – Centre lathe
– Head stock – hard wood form block (desired shape)
– Tail stock – Blank ( freely rotating, hard wood or metal)
Spinning

• After Proper Clamping, the Blank is Rotated to its Operating


Speed.
• Spinning Speed Depends on the Blank Material, Thickness
and Complexity of the Desired Cup.
• Then the Hard Wood or Roller Type Metallic Tool is Pressed
and Moved Gradually on the Blank so that it Conforms to the
Shape of the Form Block.
• Spinning is Comparable to Drawing for Making Cylindrical
Parts.
Spinning
• Spinnability –
– as the ability of a metal to undergo shear spinning
deformation without exceeding its tensile strength and
tearing
– Related to tensile reduction of area
Spinning Types

1. Conventional spinning
– Conical and curvilinear shapes
– Normally at room temperature
Spinning Types
2. Shear Spinning
• Part diameter is maintained where as thickness is reduced
• Considerable forces
• Considerable heat
• Requires cooling
• Tooling – tool steels
• No wastage of material
• Balancing required
Spinning Types
3. Tube Spinning
• Thickness is reduced by spinning them on cylindrical mandrel
using rollers
• Reduction depends on tensile reduction of area of the material
• Both external or internal
• Both forward or backward
Tool and Die Materials

• High strength, impact toughness, wear resistance at room and


elevated temperatures
Tool and Die Materials

• Shearing
– Cold D2, A2, A9, S2, S5, S7
– Hot H11, H12, H13
• Press Working Zn alloys, 4140 steel, CI, Comp., A2, D2, O1
• Deep Drawing W1, O1, Ci, A2, D2
• Coining W1, O1, A2, D2, D3, D4, H11, H12, H13
Safety devices
• Barrier guards
– Prevent operators exposure to nip points and pinch points
– Fixed, adjustable or self-adjusting
– Mechanical, electric, hydraulic, and optical interlocks are
provided untill barrier guards are in place

1. Spring-type interlock
shuts off power to machine
when guard door is opened
2. Guard can only be
removed by removing the
Plug
Source : Triodyne , Inc.
Safety devices

• Dead-man Control: power is automatically


shut off in the event of operator passes out or
dies – e.g. belt strap in elevated cranes
• Presence setting devices
Safety devices

• Maintenance – Zero mechanical state


• Locking out
• Personal protective equipment ( goggles, face shields, ear
plugs, helmets, gloves, aprons etc.)
Machining
Machining
• Machining
– A subtractive process used to get desired shape, size, and
finish by removing surplus material in the form of chips
by a cutting tool and by providing suitable relative motion
between the workpiece and cutting tool
– Process of finishing by which jobs are produced to the
desired dimensions and surface finish by gradually
removing the excess material from the preformed blank in
the form of chips with the help of cutting tool (s) moved
past the work surface (s).
• Machining requirements
Machining Processes

Using SINGLE-Point Using MULTI-Point Using ABRASIVES


Cutting Tools Cutting Tools as Cutting Tools

 Turning  Milling  Grinding


 Step Turning  Drilling  Honing
 Taper Turning  Reaming  Lapping
 Form Turning  Knurling  Polishing
 Contour Turing  Sawing  Buffing
 Facing
 Necking
 Parting-Off
Unconventional Machining
 Boring
Processes
 Counter-Boring
 Counter-Sinking AJM, USM, WJM
 Shaping ECM, ECG
 Planing CHM
IBM, PAM, EDM, LBM, PAM
Machine tool
• A machine tool is a non-portable power operated and
reasonably valued device or system of devices in which energy
is expended to produce jobs of desired size, shape and surface
finish by removing excess material from the preformed blanks
in the form of chips with the help of cutting tools moved past
the work surface (s)
• Physical functions of a Machine Tool in machining are:
– firmly holding the blank and the tool
– transmit motions to the tool and the blank
– provide power to the tool-work pair for the machining
action
– control of the machining parameters, i.e., speed, feed and
depth of cut
Basic Machine Tools
Centre lathes
– Cylindrical shapes
– Manual lathes or CNC
Basic Machine Tools
Centre lathes

External

Internal
Basic Machine Tools
Shaping machine
• Ram: it holds and imparts cutting motion to the tool through
reciprocation
• Bed: it holds and imparts feed motions to the job (blank)
• Housing with base: the basic structure and also accommodate the
drive mechanisms
Basic Machine Tools
Shaping machine
• Power drive with speed and feed change mechanisms
• Shaping machines are generally used for producing flat surfaces,
grooving, splitting etc.
Basic Machine Tools

Planing machine
• In planing the job reciprocates for cutting motion and the tool
moves slowly for the feed motions unlike in shaping machine.
• Planing machines are usually very large in size and used for
large jobs and heavy duty work.
Basic Machine Tools
Drilling machine
• Drilling (originating or enlarging cylindrical holes)
• Boring, counter boring, counter sinking etc.
• Cutting internal threads in parts like nuts using suitable
attachment
Basic Machine Tools

Drilling machine
• Column with base: it is the basic structure to hold the other
parts
• Drilling head: this box type structure accommodates the power
drive and the speed and feed gear boxes
• Spindle: holds the drill and transmits rotation and axial
translation to the tool for providing cutting motion and feed
motion – both to the drillD
• Pillar drill, column drill, radial drill, micro-drill etc.
Basic Machine Tools
Milling machine
• Flat surfaces
• Slotting
• Slitting
• Grooving
• Parting
• Forming
Classification of Machine Tools

1. Direction of major axis


– horizontal center lathe, horizontal boring machine etc.
– vertical – vertical lathe, vertical axis milling machine etc.
– inclined – special
2. Purpose of use
– general purpose – e.g. lathes, milling, drilling machines etc.
– single purpose – e.g. facing lathe, roll turning lathe etc.
– special purpose – for mass production
3. Number of spindles
– single spindle – center lathes, milling machines etc.
– multi-spindle – gang drilling machines etc.
Classification of Machine Tools

4. Degree of automation
– Manual – e.g. lathes, drilling machines etc.
– Semi-automatic – e.g. turret lathe
– Automatic – e.g., CNC Drill, CNC Mill, CNC lathe etc.
5. Type of automation
– fixed automation – e.g., single spindle and multispindle
lathes
– flexible automation – e.g., Machining Centers
6. Precision
– Ordinary
– High precision
Classification of Machine Tools

7. Size
– Heavy duty – e.g., heavy duty lathes (e.g. ≥ 55 kW), boring
mills, etc.
– Medium duty – e.g., lathes (e.g. – 3.7 ~ 11 kW), column
drilling machines etc.
– Small duty – e.g., table top lathes, drilling machines,
milling machines.
– Micro duty – e.g., micro-drilling machine etc.

6. Configuration
– Stand alone type – most of the conventional machine tools.
– Machining system – e.g., machining center, FMS etc.
Cutting Tool
• Removes excess material through direct mechanical contact
• Tool moves along the workpiece at a certain velocity (cutting speed – V)
and a depth of cut (to) to produce a chip just ahead of tool by shearing the
material continuously along the shear plane
Tool material Selection depends on:
• Work material (hardness, chemical and metallurgical state)
• Part features (geometry, accuracy, finish, surface-integrity)
• Machine tool characteristics (rigidity, horsepower, speed, feed , precision)
• Support system (Operator, sensors, controls, method of chip removal,
lubrication, maintenance)
Cutting Tool

Tool Selection (material, geometry, cutting conditions)


Cutting Tool
• Tool Material Characteristics
– Hardness
– Toughness
– Wear Resistance
– Chemical Inertness
– Resistance to bulk deformation
– Thermal Properties
– High Stiffness
– Geometry
– Finish
Cutting Tool

Hardness of cutting materials


Hardness—resistance to deforming and flattening
Toughness—resistance to breakage and chipping
Cutting Tool

Wear resistance—resistance to abrasion and erosion


Cutting Tool
Cutting Tool

Cast-cobalt alloys (1915)


Cutting Tool
Cutting Tool

• Tool steels
• HSS
• Coated HSS
• Cast Cobalt Alloys
• Carbides / Sintered Carbides
• Coated Carbides
• Ceramics
• Cermets
• Diamonds
• Polycrystalline CBN’s
– and many more…………..
Cutting Tool
Tool steels
• Carbon and low-/medium-alloy steels
• Steel is considered to be carbon steel:
– when no minimum content is specified or required for Cr,
Co, molybdenum, Ni, Ti, W, V or zirconium etc.
– when the specified minimum for copper does not exceed
0.40 percent;
– when the maximum content specified is less than Mn - 1.65,
Si - 0.60, Copper - 0.60.
– steel which is not stainless steel
• 0.9 to 1.3% carbon
• With increase in carbon content, steel become harder and
stronger
Cutting Tool
Tool steels
• With increase in carbon content, steel become lesser ductile
and melting point decrease
• Hardness loss at 200 0C
• Mo and Cr increases hardenability
• Mo and W improves wear resistance
• Applications
– Drills, Taps, Dies etc.
– Low speeds
Cutting Tool
HSS
• Good wear resistance, hardenability and hot hardness
• Good toughness and resistance to fracture
• Good cutting at 400 0C
• Easy fabrication
• Types
– Molybdenum (M series)
• 10% Mo with Cr, V, W, Cr and Co
• High abrasion resistance than t series
• Less Distortion than T series
• Cheaper than T series
– Tungsten (T series)
• 12-18% W, Cr, V and Co (18-4-1 W-Cr-V)
• Used for complex tool geometries
Cutting Tool
TiN coated HSS
• Film thickness 0.00254 - 0.00508 mm
• 10-20% higher cutting speeds than HSS
• Gear cutters, drills, bandsaw, circular saw blades, form tools,
inserts etc.
• Reduced tool wear
• High hardness
• PVD
Cutting Tool
Cast Cobalt Alloys
• Cobalt rich, chromium-tungsten-carbon cast alloys
• Stellite tools (Deloro Stellite Company)
• Non-magnetic and corrosion-resistant cobalt alloy
• W or Mo and a small amount of carbon
• Retain hardness to much greater temperatures
• 25 % higher cutting speeds than HSS
• Cast to shape
• Used only for single point tools or saw blades
Cutting Tool
Carbide or Sintered Carbides
• Types:
– Tungsten carbide (WC bonded together in a cobalt matrix)
• 1-5 µm WC particles are combined with cobalt in a mixer, then presses and
sintered into the desired insert shapes.
• Cemented carbides \ Sintered Carbides
• With increase of Co – toughness increases but there is decrease in strength,
hardness and wear resistance
• Machining steels, CI, nonferrous and nonmetals
– Titanium Carbide (TiC in Ni-Mo alloy matrix)
• Higher wear resistance than WC
• Lesser toughness than WC
• Machining hard materials like steels, CI
• Higher speeds than WC
• Finishing and semifinishing ferrous alloys
• Auto industry using Ni-Mo binder
Cutting Tool
Inserts
• Individual cutting tools with several cutting points
• Sq inserts (8 cutting edges), triangular insert (6 cutting edges)
Cutting Tool
Inserts are clamped on tool shank with various locking
mechanisms
• (a) Clamping
• (b) Wing lock pins
• (c) Thread-less lock pins - secured with side
• (d) Brazed on a tool shank
Cutting Tool

Chip Breaker
• Continuous chips are undesirable as they are a potential safety hazard
• Cutting at low speed may lead to welding of chips to tool face
• Ideal chip – Shape of letter “C” or number “9” and fits within 25 mm
square block
• Procedure used for breaking chips intermittently is with use of chip breaker
Cutting Tool

Chip Breaker
(a) tightly curled chip
(b) chip hits workpiece and breaks
(c) continuous chip moving away from workpiece
(d) chip hits tool shank and breaks off
Cutting Tool

Chip Breaker
• Controlling chip flow
• Eliminating long chips
• Reducing vibration and heat
Cutting Tool

Chip Breaker
• Chip breaking in softer materials like Al include machining at
small increments and then pausing.
• In shaping, milling or other such intermittent operations chip
breakers are not required
Cutting Tool

• American National Standards Institute (ANSI) – C-1 to C-8


• ISO Standards – P, M and K

Classification of Tungsten Carbides


Cutting Tool

ISO Classification of Carbide Cutting Tools


According to Use
Cutting Tool

Coated Carbide tools


• Coating increase tool life by 200-300 times
• Coating increase 50-100% in speed of the same tool life
• 80-90 % of carbide tools are coated
• Bulk tool material can be tough, shock resistant carbide that can withstand
high temperature plastic deformation and resist breakage
• Thin chemically stable, hard refractory coating of TiC, TiN, TiCN or
Al2O3, Diamond, TiAlN, CrC, ZrN etc.
• Fine grained coatings
• Free form binders and porosity
• Low coeff. of friction for coating – non adherence of chips on rake face
Cutting Tool

Coated Carbide tools


• Single or multiple
• Multiple coating provide stronger metallurgical bond between
coating and substrate
• For multiple coating:
– Innermost layer should bond
with substrate
– Outermost layer should resist
wear
– Intermediate layer should
bond well and be compatible
with both layers
Cutting Tool
Cutting Tool

Ceramics (White or cold-presses ceramics)


• 1950
• Pure Aluminium oxide, Al2O3, or SiC
• Pressed into insert shapes
under high pressure
• TiC and ZrO may be
added to improve
toughness and
resistance to thermal
shock
Cutting Tool

Ceramics
• Particulates or whiskers
• 2 to 3 times cutting speed than WC
• High hardness and chemical inertness
• Hard and brittle – require rigid tool holders and machine tools
• Less tendency to adhere to metals during machining – good SF
• Used for high speed cutting/finishing of super-alloys and high
strength steels
• Not suitable for Al, Ti as they react with alumina based
ceramics
Cutting Tool

Cermets (Ceramics + Metal)


• Black or hot-pressed ceramics
• Mix of 70% aluminium oxide and 30% TiC
• Intermediate performance between ceramics and carbides
Cutting Tool

Polycrystalline CBN
• High hardness (Knoop 4700 at 20 oC 4000 at 1000 oC)
• Low chemical reactivity
• 0.5-1 mm layer of PCBN is bonded to a carbide substrate by
sintering under pressure.
• Carbide provides toughness – CBN provides high wear
resistance and cutting edge strength
• Used for automotive industry
Difficult-to-machine materials
• Used for aerospace materials
• Higher cost than ceramics tools or cemented carbides but tool
life is 5-7 times that of a ceramic tool
Cutting Tool

Polycrystalline CBN

PCBN Tips

Solid PCBN
Cutting Tool

Diamond
• High Wear resistance, low tool-chip friction, sharp cutting edges
• Used for fine surface finish and dimensional accuracy
• Brittle - Light and uninterrupted finishing cuts
• High speed machining and fine feeds
• Single-crystal diamond tool – machining optical mirrors
• Polishing is not required after machining
• Polycrystalline diamond tools (compacts or industrial diamonds) – small
synthetic crystals, fused by high pressure and temperature to a thickness of
.5-1 mm and bonded to a carbide substrate
Tool Geometry
Tool Geometry

• One or more sharp cutting edges


• Connected to cutting edge – two surfaces
– Rake face – directs the flow of newly formed chip and is
oriented at an angle α (rake angle – measured relative to
plane perpendicular to work surface)
• Positive rake angle – reduces cutting force
– Flank – provides a clearence between tool and newly
generated work surface, thus protecting the surface from
abrasion (relief angle)
Tool Geometry

• Tool point (nose radius) – The point (rounded to a certain


radius) on tool penetrates below the original work surface
Cutting Condition

• Cutting speed ‘v’


• Tool movement (lateral across the work) – feed ‘f’
• Penetration of cutting tool below the original work surface –
‘DOC’
RMR = vfd
where, RMR = material removal rate (mm3/min), v = cutting
speed (mm/s), d = DOC (mm)
Types of Chips
• Chip has two surfaces
Shiny – in contact with rake face (rubbing of chip as it moves
up the tool face)
Rough or jagged – no contact with any solid body
• Primary shear Zone – along the shear plane
• Secondary Zone – shearing action after chip has been formed
(results from friction between chip and tool along the rake
face)
• Continuous
• Continuous with BUE
• Serrated
• Discontinuous
Types of Chips

• Continuous
– Good surface
– Steady cutting force
– Undesirable in automated machining)
– Formed in ductile materials at high cutting speeds and high rake angles
Tool Geometry
Continuous with BUE
• Ductile materials at low-to-medium cutting speeds, friction
between tool and chip tends to cause portions of work material
to adhere to rake face of tool near the cutting edge
• BUE forms and grow, then becomes unstable and breaks off
• Detached BUE sometimes takes away portions of tool rake
face (may lower tool life)
• Detached BUE that are not carried off may imbed in newly
created work surface causing roughness
• Thin stable edge protects tools
Types of Chips

Serrated (segmented, non-homogeneous)


• Difficult-to machine- materials like Ti, Ni-base super alloys at
higher cutting speeds.
• Saw-tooth appearance (semi-continuous)
• Produced by cyclical chip formation of alternating high shear
strain followed by low shear strain
Types of Chips

Discontinuous
• Brittle materials (like CI) at low cutting speeds
• Chips forms as separate segments
• Fluctuating cutting forces
• Irregular texture to machined surface
• Desirable for ease of chip disposal
Types of Chips

Type of Chip ?
Orthogonal Cutting

• Cutting edge is perpendicular to direction of cutting speed


• Force by tool forms chip in material by shear deformation
along shear plane (angle Ø with work plane)
• Cutting edge is positioned at a certain distance below original
work piece (to - chip thickness prior to chip formation
• When chip forms along shear plane its thickness increases (tc)
• Chip thickness ratio ‘r’
– r = to/tc
Lathe
Lathe
• Oldest Machine Tool invented
• Principal form of surface produces – cylindrical
• Turning - Workpiece is rotated, while single-point cutting tool
removes material by traversing in direction parallel
(cylindrical jobs) to the axis of rotation
Lathe
Types:
– Engine lathe
– Tool room lathe
– Speed lathe
– Turret lathe
– Automatic lathe
– Numerical control lathe
Centre Lathe
• Generally workpiece is clamped by centres in lathe
• Also called as Engine lathe (driven by steam engines)
• Heavy duty machine tools with all the components have power
drive for all tool movements except on compound rest
• Most engine lathes are equipped with chip pans and a built-in
coolant circulating system
Lathe
Tool room lathe
• Tool making / smaller parts
• Greater accuracy and usually a wider range of speeds and
feeds than engine lathes.
• Designed to have greater versatility to meet the requirements
of tool and die work
• Generally used for machining smaller parts
• High range of sizes
Lathe
Speed Lathe
• Speed lathes usually have only a headstock, a tailstock, and a
simple tool post
• Usually three or four speeds
• Mainly used for wood turning, polishing, or metal spinning
• Spindle speeds up to 4000 rpm.
Lathe
Turret Lathe
• Hexagon turret replaces the tailstock
• Turret used for mounting tools and feed into the work piece
• Turret lathes Use the 11 station tooling and so as to increase
production rate by reducing tool changing time .
• Six tools can be mounted on the hexagon turret
• Turret can be rotated about the vertical axis to bring each tool
into the operating position
Lathe
Lathe

• Headstock
• Spindle
• Live centre
• Gear box
• Feed Gear box
• Tailstock
• Carriage
• Cross slide
• Tool post
Lathe

Lathe Specifications
Lathe
Work Holding Devices
• Suitable locations
• Effective clamping
• Support
• Face plate: for holding irregular shape w/p
• Lathe centers: for holding long jobs
• Chuck:
– 3 jaw chuck for circular or hexagonal section
– 4 jaw chuck for irregular shapes
– Magnetic chuck for holding soft metal
Lathe

Work Holding Devices


Lathe
Lathe

Mandrel
– for holding hollow disc shape w/p for machining
of side faces
Lathe
Collet
– for holing small diameter tool and work pieces
Lathe Tool Geometry

• Tool cross-section – square or rectangular


• Shank (supported in tool post of lathe) – part of tool, on one
end of which cutting point is formed

α=0 -α

Positive Rake Zero Rake Negative Rake


Positive rake – helps reduce cutting force and thus cutting power requirement
Negative rake – to increase edge-strength and life of the tool
Zero rake – to simplify design and manufacture of the form tools.
Clearance angle must be positive (3o ~ 15o)
Lathe Tool Geometry

• Zero or negative rake are used for better heat conductivity on


carbide, ceramic PCD and PCBN tools
• Negative rake angle increase tool forces, it keeps tool in
compression and provides added support to cutting edge. This
help in making intermittent cuts and in absorbing impact
during initial engagement of tool
Lathe Tool Geometry

Systems of description of tool geometry


• Tool-in-Hand System
– where only the salient features of the cutting tool point are identified or
visualized (no quantitative information)
• Machine Reference System – ASA system
Lathe Tool Geometry

Machine Reference System


• American Standards Association (ASA) system
• Geometry of a cutting tool refers mainly to its several angles
or slope of its salient working surfaces and cutting edges.
Those angles are expressed w.r.t. some planes of reference.
• Machine Reference System (ASA) is based on three planes of
reference and three coordinates of reference. These references
are chosen based on the configuration and axes of the machine
tool concerned.
Lathe Tool Geometry
Lathe

a. 3D views of tool
b. Oblique view of tool from cutting edge
Lathe Tool Geometry

• Back-rake angle: Angle b/w face of tool and base of shank (measured in a
plane through the side cutting edge, and at right angle to base)
• Side-rake angle: Angle b/w face of the tool and the base of shank
(measured in a plane perpendicular to the base, to the side cutting edge)
The side rake and back rake angle combines to form effective rake
angle (true rake or resultant rake)
• End-relief angle: Angle between the portion of the end flank immediately
below the end cutting edge, and a line drawn through this cutting edge
perpendicular to the base (measured in plane perpendicular to the end
flank)
• Side-relief angle: Angle between portions of the end flank immediately
below the side-cutting edge and a line drawn through this cutting edge
perpendicular to the side flank
Relief angles affects tool life and surface quality of workpiece
Lathe Tool Geometry

• Side and end cutting-edge angles defines nose angle. Side


cutting Edge angle controls the width and thickness of chips
• Nose radius has a major influence on surface finish. High nose
radius decrease tool wear and improves surface finish.
Lathe Tool Geometry
Machine Reference System
• American Standards Association (ASA) system
• Geometry of a cutting tool refers mainly to its several angles
or slope of its salient working surfaces and cutting edges.
Those angles are expressed w.r.t. some planes of reference.
• In Machine Reference System (ASA), the three planes of
reference and the coordinates are chosen based on the
configuration and axes of the machine tool concerned.
Lathe Tool Geometry
Kinds of tools and surface
Lathe

• Right/Left tool
– Tools have primary cutting edge by means of which the
direction of the movement of tool for removing of metal is
indicated
– Tool is termed as right, right palm is placed on tool, the
direction of thumb indicates the direction of tool motion
(tool towards the headstock)
Lathe
Turning is the process of machining external cylindrical and
conical surfaces.
– Straight turning: for producing cylindrical shapes
– Taper turning: for producing conical shapes
– Facing: making edges square and clear
– Chamfering: slightly tapering and rounding off of edges
– Threading: for producing threads
– Drilling: for creating /producing hole
– Boring: for enlarging hope and correcting shape
– Parting off or necking: separating or making square groove
– Knurling: making impression for firm gripping
– Reaming: finishing purpose
Lathe
Lathe - Turning

Turning Cuts
Roughing
– As heavy as proper chip thickness, tool life, machine power
and work material properties permit
– Slow speeds for hard workpieces
Finishing
– Light, usually less than (0.015 in or 0.38)
– Usually same tool is used for roughing and finishing
Lathe - Turning
Cutting speed – V (fps)
DOC d = (D1-D2)/2
Length of Cut = Distance travelled ‘L’ + Allowance ‘A’
Feed - f
Rpm value of machine tool - N = 12V/πD1
Cutting Time – T = (L+A)/fN
MRR = L(πD12- πD22)/4
(L+A)/fN
Neglecting A and substituting N

MRR = 12Vfd (d is very small as compared to D1(d = 1))


Lathe – Taper Turning
• Cutting tool is fed at an angle to the axis of rotation producing
an external/internal conical surface.
• Tapers generally specified in degrees of included angle between
the sides (or rate of change in diameter along the length
mm/mm)
Taper tuning can be performed by using:
• Swiveling of compound rest (short and steep tapers)
• Form tools
• Offsetting tail stock
• Taper turning attachment (fine taper-ness)
• NC lathe with programmed movement of tool
Lathe – Taper Turning
Swiveling of compound rest (short and steep
tapers)
Tool is set
at half of taper angle w.r.t. lathe
axis and moved with compound rest
only

Manual Feed (non-uniform)


Short and steep tapers
Limited movement of comp. rest
Low productivity
Poor surface roughness
Lathe – Taper Turning
Form Tools
Feed is given by plunging the tool directly into the work
Short tapers like chamfering
Tool may vibrate excessively on long tapers
Poor surface quality in long tapers
Lathe – Taper Turning
Offsetting tail stock
Offsetting results in inclination in job’s axis of rotation
by half angle of taper
The feed is given parallel to guide ways
Lathe – Taper Turning
Taper turning arrangement
Separate slide way is arrange at rear of cross-slide. This slide can
be rotated at angle
The cross-slide is made free by disconnecting it from lead screw
Taper turning
attachment
• Cross
slide is
made free
and tool
is moved
with help
of
attachme
nt at an
angle
Lathe-Boring
Boring
Enlarging of an existing hole
Correction of eccentricity
Holes may be bored straight, tapered or irregular threads
Similar to internal turning while feeding tool parallel to rotation
axis of workpiece
Higher clearance angle and lower length to diameter
Boring bar is used
Lathe-Boring
Boring
Cutting Time – T = (L+A)/fN
Rpm value of machine tool - N = 12V/πD1
MRR = L(πD12- πD22)/4
(L+A)/fN
MRR = 12Vfd
Lathe-Facing
Facing
Producing flat surface
Tool is fed across the end of rotating workpiece
Tool feeds perpendicular to axis of rotating workpiece
Cutting speed is determined from largest diameter on workpiece
Tool point must be set exactly at height of center on workpiece
Length of cut - L = D1/2 (rod)
- L = (D1-D2)/2 (tube)
Lathe-Facing
Cutting Time – T = (L+A)/fN = (D1/2 + A)/fN
Rpm value of machine tool - N = 12V/πD1
MRR = π D12dfN
substituting N, L=D1/2 MRR = 6Vfd
Lathe-Facing

End facing: facing by tool moving radially


outward from the center

Shoulder facing: facing the stepped


cylindrical work piece
Lathe - Parting

Necking is a making partial cut-off


Lathe - Parting
Cut-off tool is used
One section of workpiece is severed from remaining
Tool should be set exactly at height of axis of rotation
Tool is fed perpendicular to rotational axis
Length of cut - L = D1/2 (rod)
- L = (D1-D2)/2 (tube)
Cutting Time – T = (L+A)/fN = (D1/2 + A)/fN
Rpm value of machine tool - N = 12V/πD1
MRR = π D12dfN
substituting N, L=D1/2 MRR = 6Vfd
Lathe - Drilling
Drilling
Tool (Drill) can be mounted on the tailstock of engine lathes or
turrets of turret lathes
Fed by hand against a rotating work piece along the axis of lathe
Coolant can be used
Occasional withdrawal to clear chips and delivery of coolant to
cutting edge
Lathe - Reaming
Similar to drilling on lathe
It is semi-finishing operation that
enlarges an existing hole
Tool is rotated and fed along
rotational axis.
Lathe - Knurling
Knurling
Roughening the surface of work
piece for better gripping.
Generally a cold-forming process
Process involves pressing of two
hardened rolls against the rotating
work piece with sufficient force to
form impression (the knurl) like
raised diamond pattern.
Contour turning

The tool follows a contour creating a


contoured form on the turned part
instead of parallel to the axis.
Cross slide is made free to follow
the path of contour.
Form Turning
Cutting edge of Tool has a Specific Form or Shape and is
fed radially inward towards the axis of rotating work
piece.
Chamfering
 The tool is fed radially inward
used to cut an angle on the
corner of the cylinder,
forming a chamfer to avoid
sharp edges.
Drilling

• Drilling is most common single machining


operation
• Drilling makes up 25% of machining
• Drilling occurs at the end of a tool
Drilling
1. A small hole is formed by the web—chips are not cut here in
the normal sense.
2. Chips are formed by the rotating lips.
3. Chips are removed from the hole by the screw action of the
helical flutes.
4. The drill is guided by lands or margins that rub against the
walls of the hole.

Twist Drill
Drilling

Twist Drill
Drilling
Drilling

• Rake angle of a drill varies along the cutting edges (lips)


– Negative close to point
– Equal to helix angle out at lip
• Generally rake angle is 24o
• High speed drilling - rake angle is 30o
• Soft materials (plastics) – rake angle is 0o to 20o
• Cone angle – affects direction of flow of chip across the tool
face and into the flute
– Generally cone angle of 118°
– Brittle materials (gray CI, Mg alloys) 90° to 118°
– Ductile materials (Al alloys) 118° - 135°
Drilling

• The most common drills are twist drills


• Twist drills have three parts
– Body: consisting of spiral grooves called flutes, separated
by lands
– Point: a wide variety of geometry are used
– Shank: a straight or tapered section where the drill is
clamped.
Drilling

(a) straight shank with tang,


(b) tapered shank with tang,
(c) straight shank with whistle notch,
(d) straight shank with flat notch.
Drilling

Cutting Speed at drill center is low (approaching zero)


Cutting speed at outer tips is highest

Intersection of web and


cone produces a
straight line chisel end
Drilling
• Straight line chisel point causes drills to “walk” along the
surface
• This effect is counter by using centering techniques
– Center punches
– Pre-drilled guide holes for large holes
• Specialized tips are used to produce self centering holes where
hole position is critical.
– Helical tips
– Four-facet tips
– Racon
– Bickford
– Center core, or slot drills
Drilling
Drilling
Drilling

Center Core Drill


Twin carbide tips brazed
on steel shank and a
slot in center
Drilling
Drilling

• Specialty Drills
– Hole cutters: used for holes in sheet stock
– Step drill – used for two or more diameters
– Subland drills: used for multi diameter holes
– Indexable drills: used for high speed shallow holes in solid
stock
– Centre drill bit with internal coolant
– Micro drills (pivot drills): used for holes 0.02 to 0.0001
inch diameter where grain boundaries and inclusion
produce non-uniform material properties
Drilling

Hole Cutters
• When cutting large
holes in sheet stock, a
hole cutter is used
• Hole cutters have a pilot
drill in the center used
to accurately locate the
center
• Also called a hole saw
Step Drill
Drilling
Single set of flutes and is ground to two or more diameters
Subland Drill
Separate set of flutes on a single body for each diameter.
Drilling
Indexable Drills
Drilling

• Microdrills
0.0001 in – 0.125 in
Drilling

Drill Chucks
• Small Drill Press – Chuck is permanantly
attached
• Large Drill Press – Chuck has tapered shank
that fits into the taper on machine spindle
• Chucks use chuck keys/collet-type holders
Drilling

Drill Chucks
Machine Tools for Drilling

• Drilling can be performed on:


– Lathes
– Vertical mills
– Horizontal mills
– Boring machines
– Machine centers
• Specialized machines designed specifically for
drilling called “drill presses”
DRILLING MACHINE
 Drilling is Most Commonly Performed on a Drill Press.

DRILL PRESS Consists


of Following Parts
1. Base,
2. Column
3. Power-Head
4. Spindle
5. Worktable
These may be bench
or floor mounted
depending on the
size
 Drill can be fed
manually or Upright Drill Press.
automatically
TYPES of DRILLING MACHINES

MAIN TYPE Applications

1. BENCH Holes up to 0.5 in. Diameter can


be Drilled. Very High Speed up to
30,000 rpm

2. UPRIGHT Speeds Ranges from 60 to 3500


RPM

3. RADIAL For Large Workpieces that


Cannot Easily be Handled
Manually.
TYPES of DRILLING MACHINES

MAIN Applications
TYPE
4. GANG Mass Production variety of
purposes such as Holes of
Different Sizes, Reaming,
Counterboring, on a Single Part.
TYPES of DRILLING MACHINES
MAIN Applications, Designation
TYPE
5. MULTI- Mass Production Machines with as many
SPINDLE as 50 Spindles Driven by a Single
Power head and Fed Simultaneously
into Work.
6. DEEP- For Drilling Long (Deep) Holes in
HOLE Rifle Barrels, Connecting Rods, and
Long Spindles.
Reaming
• Used to accurately size and finish hole previously
formed by drilling
• Improve hole surface finish
• Rotary cutting tool with several straight or helical
cutting edges along body
• Two classifications
• Hand
• Machine
Reaming
• Hand Reamers
– few thousandths of an inch
– Straight or tapered shank
– Square tang
– Straight or spiral flutes
• Machine Reamers (Chucking)
– Chamfers on front end – seat firmly and
concentrically
– Straight or tapered shank
– Straight or spiral flutes
Reamer Parts and Body
• Shank
– Straight or tapered and used to drive reamer
– Hand reamers have square on end to accommodate tap
wrench
• Angle of Chamfer
– Part of reamer that actually does cutting
– Ground on end of each tooth
– Clearance behind each chamfered cutting edge
• Rake angle: angle formed by face of tooth when
line drawn from point on front marginal edge
through center of reamer
Ream Geometry

Tapered – first 1/3rd of length


Hand Reamers

• Finishing tools
• Holes drilled to .003-.005 inch undersize
• Square on shank for wrench
• Teeth on end tapered so can enter hole easily
Roughing

Taper hand reamers Finishing


Machine Reamers
• Used in any machine tool for both roughing and
finishing hole
• Types
• Rose reamers
• Fluted reamers
• Carbide-tipped reamers
Rose Reamer

• A rose reamer has no relief on the periphery and is offset by a


back taper to prevent binding.
• Straight or tapered shanks with straight or helical flutes
• Teeth on end have 45º chamfer backed off to produce cutting
edge
• Cut on end angle only
• Usually made .003 to .005 in under normal size
• They are primarily used as roughing reamers
Fluted Reamers

• Have more teeth than rose reamers for


comparable diameter
• Lands relieved for entire length
• Fluted reamers cut along side as well as at
chamfer on end
• Considered finishing tools and used to bring hole
to size
Carbide-tipped Reamers

• Similar to rose or fluted reamers, except carbide tips


been brazed to cutting edges
• Can run at higher speeds and still maintain their size
Shell Reamers
• Reamer heads mounted on driving arbor
• Shank of driving arbor may be straight or tapered
• Two slots in end of reamer fit into lugs on driving arbor
• Various head sizes can be easily interchanged on one
arbor
• When reamer becomes worn, it may be replaced and
driving arbor used with other reamers
• Shell – tool steel (smaller sizes), carbide (larger sizes)
• Economical for larger holes
Expansion Hand Reamer

• Designed to permit adjustment of approximately


.006 in. above nominal diameter
• Hollow and has slots along length of cutting
section
• Tapered threaded plug fitted into end of reamer
provides for limited expansion
• Cutting end of reamer ground to slight taper
Adjustable reamers

• Have inserted blades that can be adjusted approximately


at .015 in over or under nominal reamer size
– Adjusting nuts on either end
Reaming Speeds
• Reaming speed depend on:
– Type of material being reamed
– Rigidity of setup
– Tolerance and finish required for hole
• Generally reaming speed 1/2 to 2/3 speed used for
drilling same material
• High speed – used when setup rigid
• Lower speed – used when setup less rigid
• Coolants improve surface finish and allows higher speed
Reaming Feeds

• Feed used for reaming usually two to three times greater than
drilling
• Rate varies with material reamed
• Generally .001 to .004 in. per flute per revolution
• Feed too low: excessive reamer wear, chatter
• Feed too fast: reduce hole accuracy, poor surface finish
Tapping
• Tap is a chip producing threading tool with multiple cutting
teeth
• Carbon steels for light duty operations
• HSS for production work (M1, M2, M7 and M10)
• Tapered – reduce torque required
• Bottoming – blind holes
• Collapsible – taps are collapsed
after tapping operation
Tapping

Essential requirements:
• Cutting Fluid
• Periodic reversal and removal (intermittent cutting)
Tapping

• Hand Operation
• Machines
– Drilling
– Lathes
– Vertical Milling Machines
– Special Tapping Maachines
Broaching

• Machining process that uses a toothed tool (broach)


• Types of broaching
– Linear (broach is run linearly against a surface of the
workpiece to effect the cut. Linear broaches are used in a
broaching machine
– Rotary (In rotary broaching, the broach is rotated and
pressed into the workpiece to cut an axis symmetric shape.
A rotary broach is used in a lathe
• In both processes the cut is performed in one pass of
the broach, which makes it very efficient.
Broaching

• DOC = sum of depth of cut of each tooth


Broaching

0O to 20O
1O to 4O

Pitch = k(l)1/2 ,
where k is constant (1.76), l is length of cut surface
Broaching
• Shape - similar to a saw, except the teeth height increases over
the length of the tool
• Broach contains three distinct sections:
– Roughing
– Semi-finishing
– Finishing
Broaching

Broaching machines move the broach in a linear motion at a


predetermined speed and provide a means for handling the
broach automatically.
• Hydraulic / Mechanical
• Horizontal or vertical (stroke required)
• Vertical broaching machines
– Strokes less than 1.5 m
– Push broaching or pull broaching
– Less space
• Horizontal broaching
– Much more common than vertical machines
– Longer strokes
Milling

• Basic process of progressive chip removal to produce a surface


• Milling can produce the desired surface with a single or
multiple passes
• Milling lends itself easily to mass production
• In milling axis of rotation of the cutting tool is perpendicular
to the direction of feed
• Geometric form created by milling is a plane surface and other
geometries are created either by controlled cutter path or the
cutter shape
• it is an interrupted cutting operation where the teeth of the
milling cutter enter and exit the work during each revolution.
Conventional face milling
Milling

Two categories:
– Peripheral milling: the surface is generated by teeth
located on the periphery of the cutter body. The
surface is parallel with the axis of rotation of the
cutter.
– End milling: also called facing milling, the surface
is generated is at a right angle to the cutter axis.
Material is removed by the peripheral teeth and the
face portion providing finishing action.
Peripheral Mills
Face Mills
Vertical and Horizontal Cutters

Face milling viewed from above Slab or side milling being done
with vertical spindle-machine as a down milling process with
horizontal spindle-machine
Up Versus Down Milling

• Conventional milling is called up milling


– The cutter rotates against the direction of feed of the
workpeice.
– The Chip is very thin at the beginning and increased along
its length.
– The cutter tends to push the work along and lift it upwards
from the table.
• Down milling the cutter rotation is the same as the direction of
feed
– The maximum chip thickness is at the point of tooth contact
with the work piece. Dulling the teeth more quickly
– The work piece is pulled into the cutter, eliminating any
effects from looseness of the work table feed screw.
Climbing versus Conventional Mills
UP Milling DOWN Milling
The direction of The direction of
motion of the cutter cutter motion is in
is opposite to the the feed direction
feed direction.
Milling – Milling –
“against the feed." “with the feed."
Cutting force Cutting force
direction is direction is
tangential to the downward,
periphery of the tending to hold the
cutter which tends work against the
to lift the work milling machine
piece as the cutter table.
exits the material.
Milling cutter
• Milling cutters are classified on the basis of methods of
mounting and direction of rotation.
• Method of mounting
• arbor cutters have a center hole for mounting on an arbor.
• shank cutters have either a tapered or a straight shank.
•tapered shanks cutters can be mounted directly in the
milling machine spindle.
•straight shank cutters are held in a chuck.
Arbor for a Horizontal Spindle Milling
BASED ON DIRECTION OF ROTATION (Applies only to Face
and End Milling Cutters)
• Right-hand cutter must rotate counterclockwise (viewed from the
front end of the machine spindle).
• Left-hand cutter must rotate clockwise.
Typical geometry of milling cutter
Pitch. The pitch refers to the angular distance between like parts
on the adjacent teeth. The pitch is determined by the number
of teeth.
Face of Tooth. The tooth face is the forward facing surface of the
tooth which forms the cutting edge
Cutting Edge. The cutting edge is the angle on each tooth which
performs the cutting.
Land. The land is the narrow surface behind the cutting edge of
each tooth.
Rake Angle. The rake angle is the angle formed between the face
of the tooth and the centerline of the cutter. The rake angle
defines the cutting edge and provides a path for chips that are
cut from the workpiece.
Primary Clearance Angle. The primary clearance angle is the
angle of the land of each tooth, measured from a line tangent
to the centerline of the cutter at the cutting edge. This angle
prevents each tooth from rubbing against the workpiece after it
makes its cut.
Secondary Clearance Angle. The secondary clearance angle
defines the land of each tooth and provides additional
clearance for the passage of cutting oil and the chips.
Milling Cutters

• There are a variety of mills used, the most common being face
mills and end mills
• Face mills have indexable inserts along the periphery
• Face Mills come in a variety of geometry
– Center hole for arbor mounting
– Side mill
– Staggered-tooth
– Straddle milling
– Slitting cutters
• End mills are either HSS or have indexable inserts
• End Mills come in a variety of geometries
Staggered Tooth
TYPES of PERIPHERAL or TYPES of FACE MILLING
PLAIN MILLING
(a) slab milling: basic form of (a) conventional face milling:
peripheral milling in which the cutter the diameter of the cutter is
width extends beyond the work- greater than the work-part
piece on both sides. width, so that the cutter
overhangs the work on both
sides.

(b) slot milling (slotting): the (b) partial face milling: the
width of the cutter is less than the cutter overhangs the work on
work-piece width. very thin cutter only one side.
can be used to mill narrow slots or to
cut a work-part in two, called saw
milling.
TYPES of PERIPHERAL MILLING TYPES of FACE MILLING

(c) side milling: cutter machines (c) end milling: the cutter
the side of the workpiece. diameter is less than the work
width, so a slot is cut into the
part.

(d) straddle milling: the same as (d) profile milling: this is a form
side milling, only cutting takes of end milling in which the outside
place on both sides of the work. periphery of a flat part is cut.
Machines for Milling

• The four most common types of manually controlled


milling machines are listed below in order of
increasing power (and therefore metal removal
capability):
– 1. Column-and-knee-type milling machines
• a. Horizontal spindle
• b. Vertical spindle
– 2. Ram-type milling machines (head with motor, belt drive
and spindle)
– 3. Bed-type milling machines
– 4. Planer-type milling machines
Basic Mill Construction

• Most mills consist of column-and-knee designs


– The column is mounted on a base and the spindle mounted
on a knee extending from the column.
– The knee has vertical movement
– The material in mounted on a table with longitudinal
movement, and the table is mounted on a saddle with
transverse movement
• Most common of this type mill is the Ram mill which
has a motor and pulley system mounted on the top of
the column.
The ram-type knee-and-column
milling machine is one of the most
versatile and popular milling machine
tools ever designed.
Plain Column and Knee type milling machines
Plain Column and Knee type milling machines
Turret Milling
Bed Type Milling Machine

• Made for deep cuts and heavy material


removal, the bed only had horizontal
movement (longitudinal motion)
• Spindle head can be moved vertically
in order to setup machine
• Once the bed is set up, the spindle
height is not changed during
operation.
• These machines are very common due
to their ease of use.
Planer-type milling

• Very heavy parts


• Single pass milling
• Several milling heads
• Large amount of metal removal
while permitting the table and
workpiece to feed very slowly
Machines for Milling

• Milling machines whose motions are electronically


controlled are listed in order of increasing production
capacity and decreasing flexibility:
– 1. Manual data input milling machines
– 2. Programmable CNC milling machines
– 3. Machining centers (tool changer and pallet exchange
capability)
– 4. Flexible Manufacturing Cell and Flexible Manufacturing
System
– 5. Transfer lines
Milling Acessories

• Vertical Milling Attachment

• Universal Milling Attachment


Milling Acessories

• Universal Dividing Head


Dividing Head
Dividing Head

• Number of Turns of crank = 40/cuts per revolution


• THANKYOU

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