UNIT 3MACHINING

OPERATIONS

Machining

It

is a metal removing
operation from the work piece
with the help of machine tools
and cutting tools. Metal is
removed in the form of chip
from the workpiece.

Names of commonly used machine tools:

1. Lathe machines,
2. Drilling machines,
3. Grinders,
4. Shaping machines,
etc.
5. Planning Machines,

6. Milling Machines
7. Boring Machines
8. Metal Cutting Saws
9. Slotting machines

Lathe Machines

Lathe machine

Basic principle of a lathe

machine :
Lathe machines are normally used to produce

cylindrical surfaces. The job is held in the

chuck attached to the head stock or between
the centers provided at the head stock or tail
stock. The tool is held on the compound rest.
Job is rotated at the predetermined speed by
the head stock. The tool is moved relative to
the workpiece with the help of carriage, cross
slide or compound rest. Desired quantity of
metal is removed in the form of chip from the
work piece.

Specification of a lathe machine

A lathe machine is specified by the following
Height of the centers measured from the lathe bed.
Swing diameter over bed. This the largest diameter of
work piece which will revolve without touching the bed.
It is equal twice the height of centers from the bed.
Swing diameter over carriage. It is the largest diameter
that can revolve over the cross-slide. This always less
than the swing diameter over the bed.
Maximum bar diameter. This is the maximum diameter
that will pass through the head stock spindle.
Length of the bed.

Fig.- Specifications of lathe machine

Classification of Lathe machines

Lathes can be classified into following three
types
Engine Lathes
Light weight bench engine lathe
Precision Tool Room lathes
Gap lathes

Turret Lathes
Special Purpose lathes

Basic Operations Performed on a Lathe Machine :

1. Turning Plain turning , Step turning
2. Facing
3. Taper Turning
4. Drilling :
5. Boring :
6. Reaming :
7. Knurling :
8. Forming :
9. Chamfering :
10.Parting Of:
11.Threading or thread cutting

Turning

Plain turning on lathe

machine

Fig.- step turning on lathe machine

Fig.- Facing on lathe

machine

Turning on lathe machine

FIG.- TAPER TURNING BY

COMPOUND REST METHOD

Taper turning by set over method

Taper turning by swiveling the

compound rest

Taper turning by form

tool

Eccentric turning on lathe machine

FIG.- KNURLING

Knurling on lathe
machine

Knurling on lathe using knurling

tool

Knurling tool

FIG.- DRILLING AND

BORING

Drilling on lathe machine

Boring on lathe machine

Drilling on lathe

Boring on lathe

Reaming on lathe
machine

Reaming on lathe using reamer tool

Reamers

FIGURE GROOVING AND PARTING

Parting on lathe machine

Grooving on lathe

Forming on lathe
machine

Chamfering on lathe
machine

Threading on lathe

Threading on lathe
machine

Shaping Machines
A

shaper is used for producing

relatively small flat surfaces. A single
point tool is mounted on a tool box
fitted to a reciprocating ram. The job
is clamped in a vice. There is a
cutting action in the forward motion
of the tool while the return stroke is
idle. Job is given indexed feed.

FIG.- SHAPER

Shaper machine

Shaper operations

Horizontal cutting
Vertical cutting
Inclined cutting
Irregular cutting

HORIZONTAL AND VERTICAL

CUTTING ON SHAPER

INCLINED CUTTING ON
SHAPER

PLANNING MACHINE OR PLANNER

Planning machines are used for generating

large flat surfaces. These flat surfaces may be

horizontal, vertical or inclined. Planing
machines also perform all the functions that a
shaping
machine
does.
The
planning
machines handle larger and heavy jobs.
In planning machines the job is mounted on a
table which moves forward and backward. The
tool is held firmly on the cross rails in the
middle of the machine.

FIGURE- PLANNER

Planer machine

FIG.- MACHINING BED ON PLANNER

Diff. between shaper and planer

Planing Machine Shaping Machine
1. Machine is heavy and is
used for producing large
surfaces
2. Cutting takes place by
reciprocating the work piece
3. Heavier cuts can be given
4. Several tools can be
mounted and employed at a
time
5. Several jobs requiring
similar operations can be
machined at a time
6. Indexed feed is given to the
tool during idle stroke of the
work table.

1. Machine is light and only

small job can be produced.
2. Cutting takes place by
reciprocating the tool.
3. Only light cuts can be given.
4. Only one tool is used at a
time.
5. Only one job can be taken up
at a time.
6. Indexed feed is given to the
job during idle stroke of the
ram.

Milling Machine
In milling machine , milling operation is done.

Milling is a metal removing process by the help of a

multitooth (multi edge) revolving cutting tool. The
cutting tool is held on a spindle called arbour and
the work piece is fixed on a table.
The table reciprocates past the cutting tool and
metal removal takes place. Feed for the next cut
and the depth of the cut are given by the
movement of the table. Each tooth has the same
profile. Each tooth after taking a cut comes in
operation after some interval. This allows the tool to
cool down before the next cut takes place.

FIG.- UP MIILNG AND DOWN

MILLING

FIG.- HORIZONTAL MILLING

MACHINE

FIG.- VERTICAL MILLING MACHINE

Milling machine

Horizontal milling
machine

Vertical milling machine

MILLING OPERATIONS
1.
2.
3.
4.
5.
6.

Plain or Slab Milling

Face Milling
Angular Milling
Form Milling
Straddle Milling
Gang Milling

Drilling Machine

Drilling

is an operation
through which a drilled
hole is produced in a job.
The machine tool used in
this case is called drilling
machine and the cutting
tool used is called a drill bit

FIG.- DRILLING

FIG.- TWIST DRILL

Hand drill, drill bit

Hand drill

Bench drilling machine

Fig.- Radial drilling

machine

FIG.- RADIAL DRILLING MACHINE

Radial drilling machine

Radial milling machine

Operation performed on a drill machine

Drilling : Operation of producing a cylindrical hole in a solid body by

means of a drill.
Reaming : Operation of finishing the drilled hole (that is achieving
the closer tolerances and desired surface finish) by means of a
reamer.
Boring : A drilled hole can be enlarged also by means of boring tool
on the drill machine.
Counter Boring : Enlarging the diameter of the drilled hole only upto
certain depth. For this counter boring tool is used.
Counter Sinking : It is enlarging the top end of a drilled hole and
giving it a conical shape by the help of a counter sinking tool.
Spot Facing : Squaring the surface at the top end of a hole to
provide a true seat for the bolt head or collar.
Tapping : A tap can be rotated inside an already drilled hole to
produce internal threads.

FIG.- DRILLING
OPERATIONS

Grinding
It is the process of removing material by the

abrasive action of a revolving wheel from the

surface of a work piece, in order to achieve
required dimension and surface finish of the
work piece. The wheel used for this purpose is
called grinding wheel. Grinding wheel consists
of sharp crystals called abrasives held
together by a bonding material.

Types of grinding machines

Grinding machines are normally put in two categories :
Roughing Grinders
Bench , pedestral or floor grinders
Swing frame grinders
Portable and flexible shaft grinders
Belt grinder
Precision Grinders
Cylindrical Grinders (three types)
Surface Grinders
Horizontal spindle, reciprocating table surface grinders
Vertical spindle , reciprocating table surface grinders
Internal Grinders

Common Grinding Operations :-

FIG.- INTERNAL GRINDING AND

CENTERLESS GRINDING

FIG.-GRINDING
OPERATIONS

FIG.- SURFACE GRINDING

Hand grinder

Bench grinder

Bench grinder or pedestal grinder

Surface grinder

Cylindrical grinder

Center less grinding

machine