ME G532: MTE

Lecture 1: Machine Tool

 Machine Tool
Machine Tool - Definition
• 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.

Basic functions of Machine Tools

• Machine Tools basically produce geometrical surfaces like flat, cylindrical
or any contour on the preformed blanks by machining work with the help of
cutting tools and motions.

The 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 (speed, feed and depth of cut).
Manf. Processes
Classification:
 Manufacturing Concepts
• ‘Manufacturing’ derived from Latin Word ‘Manufactus’.
• Manus=Hand and Factus=made, that literally means ‘Made by Hand.’
• In broader sense it means that making the products from raw materials
by using various processes and using various tools and machines.
• In modern context it also even also includes use of computers for
manufacturing.
• Manufacturing can be defined two ways, one technologic (Fig a) and
the other economic (Fig b).
 Manufacturing Industries
Industry consists of enterprises and organizations that produce goods and/or
provide services. Industries can be classified as primary, secondary, or tertiary.
Primary industries cultivate and exploit natural resources, such as agriculture
and mining.
Secondary industries take the outputs of the primary industries and convert
them into consumer & capital goods. Manufacturing is the principal activity in
this category, but construction and power utilities are also included.
Tertiary industries constitute the service sector of the economy.
 Essential Requirements

The blank and the cutting tool are properly mounted (in fixtures) and moved in a
powerful device called machine tool enabling gradual removal of layer of material
from the work surface resulting in its desired dimensions and surface finish.
Additionally some environment called cutting fluid is generally used to ease
machining by cooling and lubrication.
 Classification of Machine Tool
❑ By the degree of automation
➢ Machine tools with manual control.
➢ Semi-automatic machine tools.
➢ Automatic machine tools.

❑ By weight
➢ Light-duty machine tools weighing up to 1 t.
➢ Medium-duty machine tools weighing up to 10 t.
➢ Heavy-duty machine tools weighing greater than 10 t.
 Classification of Machine Tool
❑ By the degree of specialization
➢ General-purpose machine tools — which can perform
various operations on workpieces of different shapes and
sizes.

➢ Single-purpose machine tools — which can perform a

single operation on workpieces of a particular shape and
different sizes.

➢ Special machine tools — which can perform a single

operation on workpieces of a particular shape and size.
Lathe
Other machining operations on
centre lathe
(a) Facing.
(b) Taper turning.
(c) Contour turning / profiling
(d) Chamfering.
(e) Parting or cutting off.
(f) Threading.
(g) Boring.
Schematic illustration of a computer numerical-controlled turning center. The
two spindle heads and three turret heads make the machine very flexible in its
machining capabilities. Source: Courtesy of Hitachi Seiki Co., Ltd.
 Horizontal Boring Process
Vertical Boring
Process
Horizontal boring machine (Courtesy: Bravo Industries)
Horizontal boring operations (a) rotating workpiece and (b) rotating boring bar
Vertical boring machine (Courtesy: Weaver Mabbs Engineering)
Shaping Process Planing Process
Horizontal shaping machine (Courtesy:
Jiwan Singh & Sons)
Vertical shaping machine (Courtesy: Ajax
Machine Tools International, Ltd.)
Planing machine (Courtesy: XingTai
XinRong Machinery Co., Ltd.)
Drilling Process
Bench drill (Courtesy: Ozito Industries)
Radial drill press (Courtesy: Knuth
Machine Tools USA, Inc.)
Machining operations related to drilling
(a) Reaming.
(b) Counterboring.
(c) Countersinking.
(d) Center drilling.
(e) Spot facing.
(a) Reaming. The cutting tool, the reamer, is similar to a drill but has several
cutting edges with straight or helical flutes. It is intended to remove a
small amount of workpiece material, but it improves the accuracy and
surface finish of a previously drilled hole.
(b) Counterboring. Counterboring provides a stepped hole, in which a larger
diameter hole concentrically follows a smaller diameter one. A
counterbored hole is used to seat bolt heads into a hole so that the heads
do not protrude above the surface.
(c) Countersinking. This process is similar to counterboring, but a
countersunk hole is cone shaped to seat flat head screws and bolts.
(d) Center drilling. This process is also called centering, which is to produce a
shallow, conical hole with clearance at the bottom. This center hole can
guide the subsequent drilling to prevent the drill tip point from wandering
as the hole is started.
(e) Spot facing. It is intended to provide a flat surface around the end of a
hole, which is perpendicular to its axis. This flat surface is used to seat a
washer or nut.
Taps: Internal screw threads on an existing hole are produced by tapping. A tap
is a threading tool with multiple cutting teeth. The fully shaped thread on the tap
serves to clear away the chips. Similar to drilling process, tapping operation is
performed by providing rotating primary and linear feed motions either on the
cutting tool or workpiece. Thus, this operation can be done on drilling machine
or lathe, respectively. However, since most tapping operations require low
rotational speed, they are often performed manually, in which the tap is attached
to a T-handle tap wrench, either via a chuck or a gripper.
Dies: It has the same cutting action as a tap but is designed to produce external
threads on a cylindrical surface. Most of these operations are also performed
manually using die wrench. Nonetheless, external threading using a die can be
carried out on a lathe, in which the tailstock is replaced with a turret that holds
the cutting tool (i.e., the die).
Tap Wrench
Taps Dies

Die Wrench
Horizontal milling Process Vertical milling Process

Peripheral (or Slab) milling Face milling

Horizontal milling machine (Courtesy:
CNC Establishment)
Vertical milling machine (Courtesy:
Harbor Freight Tools)
Schematic illustration of the principle of a five-axis machining center. The
pallet, which supports the workpiece, can be swiveled around two axes (hence a
total of five axes), Courtesy of Toyoda Machinery.
Schematic illustration of a five-axis profile milling machine. Note that there
are three principal linear and two angular movements of machine components.
 Shapes of Mill:
Various operations of Peripheral Milling: Cylindrical, angular, convex, concave

(a) Slab milling. This is the simplest form of peripheral milling, on which the
width of the tool extends beyond both sides of the workpiece.
(b) Side milling. The mill, which can either be wider or narrower than the
workpiece, is used to machine the side of the workpiece.
(c) Slot milling. The mill, which is narrower than the workpiece, is used to create
a slot in the workpiece. If a thin mill is used to cut the workpiece in two, the
process is called saw milling.
(d) Straddle milling. This process is the same as side milling, but two mills are
used at the same time to cut both sides of the workpiece.
 Slot cutting
Form cutting

Straddle milling
Angular milling
Various operations of Face Milling:

Face Mill:

Long edge Mill:

(a) Conventional face milling.

(b) Shoulder milling.
(c) End milling.
(d) Profile milling.
(e) Pocket milling.
(f) Surface contouring.
(a) Conventional face milling. In this process, the diameter of the mill is
longer than the width of the workpiece.
(b) Shoulder milling. The mill overhangs at the side of the workpiece on
which the machining takes place. Hence, this process creates a shoulder
feature.
(c) End milling. The diameter of the mill is less than the width of the
workpiece, creating a slot in the workpiece.
(d) Profile milling. The periphery of the mill is used to machine the outside
periphery of the workpiece. In contrast to the previous three milling
process, the end of the mill does not touch the workpiece.
(e) Pocket milling. This is a derivative of end milling, in which the end mill is
used to mill shallow pockets.
(f) Surface contouring. This process uses a ball-end or ball-nose mill to
machine three-dimensional surfaces. To do so, this end mill is fed with
respect to the workpiece across a curvilinear path at close intervals.
Two basic milling operations: (a) up milling and (b) down milling

Based on the direction of the feed motion with respect to the rotation of the
cutting tool, milling operations can be categorized as up and down millings. In
up milling, also known as conventional milling, when cutting the workpiece, the
teeth motion is in the opposite direction to the feed motion. In down milling,
also known as climb milling, the teeth motion is in the same direction as the
feed motion during cutting. Consequently, the chip formed in up milling
increases in thickness, while the one in down milling reduces throughout the cut.
Two basic milling operations: (a) up milling and (b) down milling

Face milling
Cutters

Peripheral
Cutters
Thank you