Manufacturing Techniques

Resource 2

Machining Operations & Techniques

Edexcel Principles of Learning in Engineering Resource 2

Aims

Set up a Centre Lathe for a manufacturing process Set up a Milling Machine for a manufacturing process Use conventional manufacturing techniques to produce components

Edexcel Principles of Learning in Engineering Resource 2

Objectives

Set cutting tool to perform manufacturing operations Perform basic machining techniques using a Centre Lathe Perform basic machining techniques using a Milling Machine Various work holding devices used to support components Drilling using a tailstock Produce internal & external threads using hand tools

Edexcel Principles of Learning in Engineering Resource 2

Turning Operations

Edexcel Principles of Learning in Engineering Resource 2

Types of machining process using Centre Lathe

Facing Turning a diameter to length Knurling Centre drilling/drilling/reaming/internal & external threads Boring Chamfering

Edexcel Principles of Learning in Engineering Resource 2

Work holding devices

3 jaw chuck
The 3 jaw chuck is the most commonly used work holding device on a lathe. Holds round & hexagonal shaped work pieces.

4 jaw chuck

The 4 jaw chuck can be used to hold a variety of components. Each jaw must be individually tightened and centred using a DTI clock

Face plate
The face plate is attached to the lathe spindle. Work pieces are clamped to the face plate using t-nuts in the slots

Revolving centre
The revolving centre is used to machine components between centres using the tailstock.

Edexcel Principles of Learning in Engineering Resource 2

Setting tool to centre

The tool is positioned in the tool post & adjusted to centre height using packing strips. The packing strips are placed underneath the tool as shown in fig. 1. The centre is obtained by positioning a dead centre in the tailstock.

Fig 1

Fig 2

Edexcel Principles of Learning in Engineering Resource 2

Types of machining process using Centre Lathe

A knurling tool moves across the side of the component producing a hatch pattern with a required force applied onto the work piece.

A single point knife tool moves along the side of the material removing a depth of material & producing various features like tapers & steps.

A single point knife tool moves across the face of the component removing a small amount of material to produce a smooth flat surface.

Edexcel Principles of Learning in Engineering Resource 2

Types of machining process using Centre Lathe

The face plate is attached to the lathe spindle. Work pieces are clamped to the face plate using t-nuts in the slots

Drilling on a Lathe can be performed using the tailstock. The Jacob's chuck is locked in the tailstock with the drill pieces secured in the chuck using a chuck key.

A chamfer tool moves into the work piece, to a required depth, producing a chamfered edge

Edexcel Principles of Learning in Engineering Resource 2

Milling Operations

Edexcel Principles of Learning in Engineering Resource 2

Work holding devices

Machine Vice

Swivel Base Vice

V block

Clamping directly to the table

Edexcel Principles of Learning in Engineering Resource 2

How to Set a cutting tool

The cutting tool is positioned in the appropriate tool holding device and locked in the spindle using a draw bar.

Edexcel Principles of Learning in Engineering Resource 2

Types of machining process using a milling machine

Blocking out Facing Slot cutting Drilling T-slot cutting

Edexcel Principles of Learning in Engineering Resource 2

Blocking out procedure This process involves machining all 6 faces on a block of material.

Edexcel Principles of Learning in Engineering Resource 2

Milling processes

Edexcel Principles of Learning in Engineering Resource 2

Taps & Dies

Edexcel Principles of Learning in Engineering Resource 2

Taps & Dies

Cutting internal threads Internal threads are produced using the correct size tapping drill and tapping sequence. The tap wrench is rotated clockwise to feed the tap into the hole & should be relieved by half a turn every full thread.

Cutting external threads External threads are produced using a die & die stock. The external diameter of the material must equal the external thread required. The die stock is rotated clockwise & should be relieved by half a turn every full thread.