Machine Tools

Dr. N.K. Singh

Associate Professor (Workshop)
Indian School of Mines
Dhanbad

Manufacturing Processes
Material Removal Processes (Machining)
Joining Processes (Welding, Brazing, Soldering)
Casting Processes
Forming Processes

Material Removal Processes (Machining)

Cutting tools
Machine Tools
Lathe turning
Drilling
Milling
Grinding
Broaching, sawing, filing
Nontraditional machining process (EDM)
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Cutting Tool

In the context of metalworking, a cutting tool, is any

tool that is used to remove metal from the workpiece
in form of chips. It frequently refers to a tool bit.
Tool material should be harder than the material
which is to be cut
They must be able to withstand the heat generated
in the metal cutting process.
They also must have a specific geometry, designed
so that the cutting edge can contact the workpiece
without the rest of the tool dragging on its surface.
The angle of the cutting face is also important.
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Classification of Cutting tools

single point cutting tool

multiple point cutting tool.

A single-point cutting tool

has only one cutting edge

used for increasing the size of holes, or
boring, thread making, turning etc.

A single-point cutting tool

Nomenclature of cutting tool

Multiple-point cutting tools

have two or more cutting edges.

Example:- milling cutters, drills, and
broaches.

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Milling cutters

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Cutting Tool Materials

Tool Steels
High Speed Steel (HSS)
Carbides
Coated Carbide
Ceramics and cermet
TiN Coated High-Speed Steel
CBN
Diamond tool

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Machine Tool

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Machine tools

Lathe turning
Drilling
Milling
Shaper
Planer
Grinding
Broaching, sawing, filing
Nontraditional machining process (ex EDM)

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Lathe Turning

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Lathe Turning

Turning
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Lathe

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Gear System

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Tailstock

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Long Job is supported by

tailstock

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Drilling in lathe machine

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Cutting parameters

Speed
Cutting speed is defined as the speed at which
the work moves with respect to the tool (usually
measured in feet per minute).

Feed
Feed rate is defined as the distance the tool
travels during one revolution of the part.

Depth of Cut
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Cutting speed and feed determines the

surface finish, power requirements, and
material removal rate.
The primary factor in choosing feed and
speed is the material to be cut.
However, one should also consider material
of the tool, rigidity of the workpiece, size and
condition of the lathe, and depth of cut.

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Lathe Turning
Facing

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Lathe Turning

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Lathe Turning

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Specification of Lathe
Machine
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Swing over bed

Swing over carriage
Distance between centers
Hole through spindle
Travel of cross-slide
Taper of tailstock spindle
Length overall
Width overall
Height overall
Shipping weight
Motor/Speed Control
Spindle speed range

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Milling Machine tool

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Milling Machine Tool

Milling is one of the basic machining

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

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Process

The milling process:

Typically uses a multi-tooth cutter

Work is fed into the rotating cutter
Capable of high MRR
Well suited for mass production applications
Cutting tools for this process are called milling
cutters

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Vertical Mill

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Horizontal Mill

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Classification of Milling

Peripheral Milling (SLAB Milling)

Face Milling
End Milling

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Peripheral Milling (SLAB

Milling)

The milled surface is

generated by teeth
located
on
the
periphery of the cutter
body.
The axis of cutter
rotation is generally in a
plane parallel to the
workpiece surface to be
machined.
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Face Milling

The cutter is mounted

on a spindle having an
axis
of
rotation
perpendicular to the
workpiece surface.
The milled
surface
results from the action
of cutting edges located
on the periphery and
face of the cutter
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End Milling

The cutter in end milling

generally rotates on an axis
vertical to the workpiece.
It can be tilted to machine
tapered surfaces.
Cutting teeth are located on
both the end face of the
cutter and the periphery of
the cutter body.

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METHODS OF MILLING

Up Milling
Down Milling

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UP MILLING
(conventional milling)

The direction of the

cutter
rotation
opposes the feed
motion.
For example, if the
cutter
rotates
clockwise
,
the
workpiece is fed to
the right in up milling.

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DOWN MILLING (climb

milling)

The direction of cutter

rotation is same as the
feed motion.
For example, if the
cutter
rotates
counterclockwise , the
workpiece is fed to the
right in down milling.

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Other Milling Operations

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Grinding Machine

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Grinding Machine

The primary purpose of a grinding wheel is to

sharpen tools (eg. drill bits).
The hard abrasive of the wheel is made for
removing very hard materials like high speed steel.

Never grind on the side of the wheel.

Never grind a soft material such as Aluminum. The material
will coat the wheel and prevent the abrasive from working
properly. (SHOW)

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Cavity

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Grinding Wheel Specification

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Safety Measures

Safety Glasses
EVERYONE MUST WEAR SAFETY GLASSES IN THE SHOP.

Clothes and Hair

Check your clothes and hair before you walk into the shop. In
particular:
IF YOU HAVE LONG HAIR OR A LONG BEARD, TIE IT UP.
If your hair is caght in spinning machinery, it will be pulled out if
you're lucky. If you're unlucky, you will be pulled into the
machine.
NO LOOSE CLOTHING.
Ties, scarves, loose sleves, etc. are prohibited

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Safety Measures (Cont..)

NO GLOVES
REMOVE JEWELERY
WEAR APPROPRIATE SHOES
No open toed sandals. Wear shoes that give a sure
footing.
Safe Conduct in the Shop
Be aware of what's going on around you. For
example, be careful not to bump into someone while
they're cutting with the bandsaw (they could lose a
finger!).

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Safety Measures (Cont..)

Machining
IF YOU DON'T KNOW HOW TO DO SOMETHING, ASK!
BEFORE YOU START THE MACHINE:
Study the machine. Know which parts move, which are
stationary, and which are sharp.
Double check that your workpiece is securely held.
Remove chuck keys and wrenches.
DO NOT LEAVE MACHINES RUNNING UNATTENDED!
CLEAN UP MACHINES AFTER YOU USE THEM!
A dirty machine is unsafe and uncomfortable to work on.
Do not use compressed air to blow machines clean. This
endangers people's eyes and can force dirt into machine
bearings

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