DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING (IPE)

DHAKA UNIVERSITY OF ENGINEERING & TECHNOLOGY, GAZIPUR

Course No: IPE 1730 (1.50 Credit Hour)

Course Title: Machine Shop Practice II Sessional
Experiment 1: Study of engine lathe machine and cutting external and internal thread using
an engine lathe.

Engine lathes are the most versatile machines of the lathe group. They serve for machining work pieces
bounded by surfaces of revolution and for machining work pieces bounded by surfaces of revolution and
for cutting threads the chief application is in piece and small -lot production and for repair work.

CONSTRUCTION ARRANGEMENT AND PRINCIPAL UNITS OF ENGINE LATHES

All engine lathes have practically the same arrangement of the principal units. In a typical Engine Lathe the
principal units are:

1. Headstock. 2.Tailstock 3.Spindle 4.Slide Ways 5.Saddle 6.Tool post 7.Compound Rest 8.Power Feed
Clutch 9.Feed Rood 10.Bed 1l.Lead Screw l1.Break Clutch Control 13.Half Nut l4.Apron 15.Rack
16.Motor Drive 17.Gear Box

LATHE ACCESSORIES
l. Lathe Centers 2.Lathe Dogs. 3. Toolholder 4.Cutting Tools 5.Steady Rest 6.Follow Rest 7. Knurling
Tools 8.Chucks. 9. Faceplates. l0.Mandrels ll. Taper Attachments

MODERN LATHE OPERATION

A11 Lathes have same basic basis design. Their components serve one of three primary Functions:
a) Driving the lathe-line of power.
b) Holding and rotating work
c) Holding and moving tool.
Various operations are performed in a lathe other than plain turning. They are
 Facing
 Turning
 Straight turning
 Step turning
 Chamfering
 Grooving

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 Forming
 Knurling
 Undercutting
 Eccentric turning
 Taper turning
 Thread cutting
 Drilling
 Reaming
 Boring
 Tapping

1. Facing
Facing is the operation of machining the ends of a piece of work to produce flat surface square with the
axis. The operation involves feeding the tool perpendicular to the axis of rotation of the work. Facing
operation is illustrated in Fig. below.

Fig. Facing

2. Turning
Turning in a lathe is to remove excess material from the workpiece to produce a cylindrical surface of
required shape and size.
 Straight turning
The work is turned straight when it is made to rotate about the lathe axis and the tool is fed parallel
to the lathe axis. The straight turning produces a cylindrical surface by removing excess metal from
the workpieces.

Fig. Turning
 Step turning
Step turning is the process of turning different surfaces having different diameters. The work is held
between centers and the tool is moved parallel to the axis of the lathe. It is also called shoulder
turning.
3. Chamfering
Chamfering is the operation of bevelling the extreme end of the workpiece. The form tool used for taper
turning may be used for this purpose. Chamfering is an essential operation after thread cutting so that the
nut may pass freely on the threaded workpiece.

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 Fig. Chamfering

4. Knurling
Knurling is the process of embossing a diamond shaped pattern on the surface of the workpiece. The
knurling tool holder has one or two hardened steel rollers with edges of required pattern. The tool holder is
pressed against the rotating work. The rollers emboss the required pattern. The tool holder is fed
automatically to the required length. Knurls are available in coarse, medium and fine pitches. The patterns
may be straight, inclined or diamond shaped.

Fig. Knurling

5. Taper turning
A taper may be defined as a uniform increase or decrease in diameter of a piece of work measured along
its length. Taper turning methods are
I. Form tool method
II. Compound rest method
III. Tailstock set over method
IV. Taper turning attachment method
V. Combined feed method
5.1 Form tool method
A broad nose tool is ground to the required length and angle. It is set on the work by providing feed to the
cross slide. When the tool is fed into the work at right angles to the lathe axis, a tapered surface is generated.
This method is limited to turn short lengths of taper only. The length of the taper is shorter than the length
of the cutting edge. Less feed is given as the entire cutting edge will be in contact with the work.

Fig. Form Tool Method

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5.2 Compound rest method
The compound rest of the lathe is attached to a circular base graduated in degrees, which may be swiveled
and clamped at any desired angle. The compound rest is swiveled to the angle calculated as above and
clamped. Feed is given to the compound slide to generate the required taper.

Fig. Compound Rest

Method Method
5.3 Tailstock set over method
Turning taper by the set over method is done by shifting the axis of rotation of the workpiece at an angle to
the lathe axis and feeding the tool parallel to the lathe axis. The construction of tailstock is designed to have
two parts namely the base and the body. The base is fitted on the bed guideways and the body having the
dead centre can be moved at cross to shift the lathe axis.

Fig. Setting over the tailstock

Method Method
The dead centre is suitably shifted from its original position to the calculated distance. The work is held
between centres and longitudinal feed is given by the carriage to generate the taper. The advantage of this
method is that the taper can be turned to the entire length of the work. Taper threads can also be cut by this
method. The amount of set over being limited, this method is suitable for turning small tapers
(approx. upto 8°). Internal tapers cannot be done by this method.

5.4 Taper attachment method

The taper attachment consists of a bracket which is attached to the rear end of the lathe bed. It supports a
guide bar pivoted at the centre. The bar having graduation in degrees may be swiveled on either side of
the zero graduation and set at the desired angle to the lathe axis. A guide block is mounted on the guide bar
and slides on it. The cross slide is made free from its screw by removing the binder screw. The rear end of
the cross slide is tightened with the guide block by means of a bolt. When the longitudinal feed is
engaged, the tool mounted on the cross slide will follow the angular path as the guide block will slide
on the guide bar set at an angle of the lathe axis. The depth of cut is provided by the compound slide which
is set parallel to the cross slide.

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 Fig. Taper Turning Attachment

6. Thread cutting
Thread cutting is one of the most important operations performed in a lathe. The process of thread cutting
is to produce a helical groove on a cylindrical surface by feeding the tool longitudinally.
1. The job is revolved between centres or by a chuck. The longitudinal feed should be equal to the pitch
of the thread to be cut per revolution of the work piece. The advantage of this method is that long
tapers can be machined. As power feed can be employed, the work is completed at a shorter time. The
disadvantage of this method is that internal tapers cannot be machined.
2. The carriage should be moved longitudinally obtaining feed through the lead screw of the lathe.
3. A definite ratio between the longitudinal feed and rotation of the headstock spindle should be found
out. Suitable gears with required number of teeth should be mounted on the spindle and the lead screw.
4. A proper thread cutting tool is selected according to the shape of the thread. It is mounted on the tool
post with its cutting edge at the lathe axis and perpendicular to the axis of the work.
5. The position of the tumbler gears are adjusted according to the type of the thread (right hand or left
hand).
6. Suitable spindle speed is selected and it is obtained through back gears.
7. Half nut lever is engaged at the right point as indicated by the thread chasing dial.
8. Depth of cut is set suitably to allow the tool to make a light cut on the work.
9. When the cut is made for the required length, the half nut lever is disengaged. The carriage is brought
back to its original position and the above procedure is repeated until the required depth of the thread
is achieved.
10. After the process of thread cutting is over, the thread is checked by suitable Gauges

Fig. Thread Cutting

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7. Grooving
Grooving is the process of cutting a narrow groove on the cylindrical surface of the workpiece. It is often
done at end of a thread or adjacent to a shoulder to leave a small margin. The groove may be square, radial
or bevelled in shape

Fig. Grooving
8. Forming
Forming is a process of turning a convex, concave or any irregular shape. For turning a small length formed
surface, a forming tool having cutting edges conforming to the shape required is fed straight into the work.

REFERENCES
1. Machine tool Technology by Repp/McCarthy
2. Machine Tool by N. Chernov
3. Machine Tool by N. Acherkan

Experiment 2: Study of knee type milling machine and cutting gear tooth using simple
indexing.

2.1 Introduction

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Milling machine is a machine tool that removes material from a work piece by rotating a cutter and moving
it into the material. Milling machines are a very versatile machine tool. Milling machines are capable of
machining one or two pieces as well as large volume production runs. The milling machine can produce a
variety of surfaces by using a circular cutter with multiple teeth that progressively produce chips as the
cutter rotates. Compare this to an engine lathe that removes material from a work piece by rotating the work
piece and not the tool.

2.2 Types of Milling Machine

There are two major types of milling machines, the vertical milling machine and the horizontal milling
machine. As their names imply, a vertical milling machine spindle axis is vertical and the horizontal milling
machine spindle axis is horizontal. In addition the vertical milling machine has a machine table that moves
perpendicular to the spindle axis of rotation and the horizontal milling machine has a work table that moves
parallel to the spindle axis of rotation.
The vertical milling machine is the most common type found in the machine shop today (figure 2.1).
However, during the first half of the 20th century the horizontal milling machine was the primary machine
tool used for milling purposes (figure 2.2). There are far fewer horizontal milling machines in production
today than vertical machines. Another type of mill is the combination milling machine. This milling
machine is a hybrid of the vertical and the horizontal (figure 2.3). Still another type of specialty milling
machine is the universal milling machine. It is usually a horizontal milling machine with a swiveling table
(Figure 2.4).

2.3 Parts of Milling Machine

The vertical knee mill is the most common milling machine found in machine shops today. Therefore it
will be used as an example to describe the general parts of all mills.

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The head (drive) is that part of the drive system that transforms electrical power from a motor to mechanical
power in the spindle. The drive system also allows the machinist to change the speed of the spindle (RPM)
and therefore the cutting tool. The quill moves vertically in the head and contains the spindle in which
cutting tools are installed. The quill feed hind wheel moves the quill up and down within the head as does
the quill feed lever. The knee moves up and down by sliding on ways that are parallel to the column. The
saddle sits on the knee and allows translation of the worktable. Sitting on the base is the column whose
main function is to hold the turret. The turret allows the milling head to be rotated around the column’s
center. The over arm (ram) slides on the turret and allows the milling head to be repositioned over the table.

The longitudinal traverse hand wheel moves the worktable to the left and right, the cross traverse hand
wheel moves the work table in and out, the vertical movement crank moves the knee, saddle, and worktable
up and down.

2.4 Milling Cutters

A milling cutter is a cutting tool that is used on a milling machine. Milling cutters are available in many
standard and special types, forms, diameters, and widths. The teeth may be straight (parallel to the axis of
rotation) or at a helix angle. The helix angle helps a slow engagement of the tool distributing the forces.
The cutter may be right-hand (to turn clockwise) or left-hand (to turn counterclockwise).The figure shows
a typical end milling cutter.

2.5 Classification of Milling Operations

2. 5. 1 Peripheral Milling

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In peripheral (or 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 work piece surface to be
machined.

2.5.2 Face Milling

In face milling, the cutter is mounted on a spindle having an axis of rotation perpendicular to the work piece
surface. The milled surface results from the action of cutting edges located on the periphery and face of the
cutter.

2.5.3 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.

2.6 Methods of Milling

2.6.1 Up Milling
Up milling is also referred to as 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.

2.6.2 Down Milling

Down milling is also referred to as 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.

The chip formation in down milling is opposite to the chip formation in up milling. The figure for down
milling shows that the cutter tooth is almost parallel to the top surface of the work piece. The cutter tooth
begins to mill the full chip thickness. Then the chip thickness gradually decreases. Other milling operations
are shown in the Figure 2.10.

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2.7 Dividing Heads
A dividing head is a tool that is used to divide a circle into equal divisions. Dividing heads are employed
in operations on knee type milling machine for setting the work piece at the required angle to the table of
the machine, turning the work piece through a pre determined angle, dividing circle into the required
number of parts (indexing) and also for continuous rotation of the work piece in milling helical grooves
with a large lead (Figure 2.11).

2.8 Types of dividing heads

There are dividing heads for direct indexing (called plain dividing heads), optical dividing heads and
universal dividing heads Universal dividing heads are classified as heads with and without an index plate.
Index plate dividing heads are more widely used. Universal dividing heads are setup for:
a. Simple indexing: It consist in turning the spindle through the required angle by rotating the index crank.
b. Differential Indexing: It is employed where simple indexing can not be effected i.e. where an index
plate with the number of holes required for simple indexing is not available.
c. Cutting helical grooves: In milling helical grooves, a complex helical movement is imparted to the
work piece, which involves a straight movement along the work piece axis and rotation of the work
piece about the same axis.

2.9 Setting up a universal dividing head for milling helical grooves.

In milling helical grooves, a complex helical movement is imparted to the work piece, which involves a
straight movement along the work piece axis and rotation of the work piece about the same axis. The work
piece receives the straight movement with the work table of the machine, and rotation, from the work-table
lead screw through the change gears. The table is set to the spindle axis at an angle ω equal to the helix
angle of the groove being cut. In milling a left-hand groove, the table is swivelled clock-wise at an angle
ω, and in cutting a right hand groove, counterclockwise (Figure 2.12)

The set angle for the table is,

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 D
ω = arctan
Ph. g
Where D= diameter of the work piece being cut; Ph.g. = Lead of heilcal groove. If the helix is determined
by the lead angle α, the table should be set at an angle of 900 – α. Slow rotation is imparted to the diving
a1 c1
head spindle along the kinematic ba1ance equation of this chain for setting up change-gear train
b1 d1
worked out provided that for every revolution of the work piece the work table of the machine travels by
an amount equal to the lead Ph.g. of the groove being cut.

z0 a c
1.1.1 1 1 pl .s  P h. g
Z b1 d1
With Z=1m we obtain,
a1 c1 Ph.. g
=
b1 d1 z 0 pl .s

Where Pl.s is the lead of work table lead screw, mm.

References
1. Boothroyd G. & Knight., Fundamentals of Machining and Machine Tools
2. Kalpagjian S., Introduction to Manufacturing processes
3. Chernov S., Machine tools
4. DeGarmo E. paul, Material and process engineering

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Experiment 3: Study of a drilling machine and cutting a stepped hole using a column drill
machine.

Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter
called DRILL.
 The machine tool used for drilling diferent sized holes is called drilling machine.
 The drilling operation can also be accomplished in lathe, in which the drill is held in
tailstock and the work is held by the chuck.
 The most common drill used is the twist drill.

 Drilling Machine
 It is the simplest and accurate machine used in production shop.
 The work piece is held stationary ie. Clamped in position and the drill rotates to make a
hole.
 Types

Drilling machines can classified based on several parameters and they are-

1. Based on construction
 Portable
 Sensitive
 Radial,
 up-right,
 Gang,
 Multi-spindle

2. Based on Feed
 Hand driven
 Power driven
 Components of Drilling Machine

1. Spindle- The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve.
2. Sleeve- The sleeve or quill assembly does not revolve but may slide in its bearing in a direction
parallel to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the
cutting tool is fed into the work: and when it’s moved upward, the cutting tool is withdrawn
from the work. Feed pressure applied to the sleeve by hand or power causes the revolving drill
to cut its way into the work a fraction of an mm per revolution.
3. Column- The column is cylindrical in shape and built rugged and solid. The column supports
the head and the sleeve or quill assembly.
4. Head- The head of the drilling machine is composed of the sleeve, a spindle, an electric motor
and feed mechanism. The head is bolted to the column.
5. Worktable- The worktable is supported on an arm mounted to the column. The worktable can
be adjusted vertically to accommodate different heights of work or it can be swung completely
out of the way. It may be tilted up to 90 degree in either direction, to allow long pieces to be
end or angle drilled.
6. Base- The base of the drilling machine supports the entire machine and when bolted to the
floor, provides for vibration-free operation and best machining accuracy. The top of the base
is similar to the worktable and may be equipped with t- slot for mounting work too larger for
the table.

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7. Hand Feed- These are light duty machine that are operated by the operator, using a feed
handled, so that the operator is able to “feel” the action of the cutting tool as it cuts through the
work piece. These drilling machines can be bench or floor mounted.
8. Power feed- The power feed drilling machine are usually larger and heavier than the hand feed
ones they are equipped with the ability to feed the cutting tool in to the work automatically,
these machines are used in maintenance for medium duty work or the work that uses large
drills that require power feed larger work pieces are usually clamped directly to the table or
base using t –bolts and clamps by a small work places are held in a vise. A depth –stop
mechanism is located on the head, near the spindle, to aid in drilling to a precise depth.

 Sensitive or Bench Drilling Machine

 This type of drill machine is used for very light works. Fig.1 illustrates the sketch of
sensitive drilling machine.
 The vertical column carries a swiveling table the height of which can be adjusted according
to the work piece height.
 The table can also be swung to any desired position.
 At the top of the column there are two pulleys connected by a belt, one pulley is mounted
on the motor shaft and other on the machine spindle.
 Vertical movement to the spindle is given by the feed handle by the operator.
 Operator senses the cutting action so sensitive drilling machine.
 Drill holes from 1.5 to 15mm

Fig. 1 Sensitive Drilling Machine

 Up-Right Drilling Machine

 These are medium heavy duty machines.
 It specifically differs from sensitive drill in its weight, rigidity, application of power feed
and wider range of spindle speed. Fig.2 shows the line sketch of up-right drilling machine.
 This machine usually has a gear driven mechanism for different spindle speed and an
automatic or power feed device.
 Table can move vertically and radially.
 Drill holes up to 50 mm

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 Fig. 2 Up- Rigth Drilling Machines
 Radial Drilling Machine
 It the largest and most versatile used for drilling medium to large and heavy work pieces.
 Radial drilling machine belong to power feed type.
 The column and radial drilling machine supports the radial arm, drill head and motor. Fig.3
shows the line sketch of radial drilling machine.

Fig. 3 Radial Drilling Machine

 The radial arm slides up and down on the column with the help of elevating screw provided
on the side of the column, which is driven by a motor.
 The drill head is mounted on the radial arm and moves on the guide ways provided the
radial arm can also be swiveled around the column.
 The drill head is equipped with a separate motor to drive the spindle, which carries the drill
bit. A drill head may be moved on the arm manually or by power.
 Feed can be either manual or automatic with reversal mechanism.

 Drill Materials

The two most common types are

 HSS drill- Low cost
 Carbide- tipped drills - high production and in CNC machines
Other types are Solid Carbide drill, TiN coated drills, carbide coated masonry drills, parabolic
drills, split point drill. Fig.4 shows various types of drills
 Drill fixed to the spindle

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 Fig. 4 Drill fixed to a spindle

 Tool Nomenclature

Fig. 5 Nomenclature of twist drill

 Drilling operations
Operations that can be performed in a drilling machine are
 Drilling
 Reaming
 Boring
 Counter boring
 Countersinking
 Tapping

1. Drilling- It is an operation by which holes are produced in solid metal by means of revolving
tool called ‘Drill’. Fig. 9 shows the various operations on drilling machine.
2. Reaming-Reaming is accurate way of sizing and finishing the pre-existing hole. Multi tooth
cutting tool. Accuracy of 0.005mm can be achieved
3. Boring- Boring is a process of enlarging an existing hole by a single point cutting tool. Boring
operation is often preferred because we can correct hole size, or alignment and can produce
smooth finish. Boring tool is held in the boring bar which has the shank. Accuracy of
0.005mm can be achieved.

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 .

Fig. 6 Various operations on drilling machine

4. Counter Boring- This operation uses a pilot to guide the cutting action to accommodate the
heads of bolts. Fig. 10 illustrates the counter boring, countersunk and spot facing processes.
5. Countersinking- Special angled cone shaped enlargement at the end of the hole to
accommodate the screws. Cone angles of 60°, 82°, 90°, 100°, 110°, 12
6. Tapping- Tapping is the process by which internal threads are formed. It is performed either
by hand or by machine. Minor diameter of the thread is drilled and then tapping is done. Fig.
11 show the tapping processes.

Fig. 7 Hand taps and tapping process using tap wrench

 Work Holding Devices

1. Machine Table Vice
The machine vice is equipped with jaws which clamps the work piece. The vice can be bolted
to the drilling table or the tail can be swung around swung around. Fig. 13 shows the standard
and swivel vice.The swivel vice is a machine wise that can be swivel through 360° on a
horizontal plane.

Fig. 8 Machine Table vice.

2. Step Blocks- These are built to allow height adjustment for mounting the drilling jobs and are
used with strap clamps and long T-slot bolts.

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3. Clamps- These are small, portable vises , which bears against the work piece and holding
devices. Common types of clamps are C-clamp, Parallel clamp, machine strap clamp, U-clamp
etc.. Fig. 14 shows the correct and incorrect methods of mounting the work piece.

4. V-Blocks- These are designed to hold round work pieces.

5. Angles- Angle plates are made in a 90°angle with slots and bolt holes for securing work to the
table.

6. Jigs- The jig guides the drill through a bushing to locate and drill holes accurately.

7. T- Slots Bolt- These are special bolts which has a T shaped head, which slides into the T slots
of drilling machine work table.

 Definitions

1. Cutting Speed (v)- It is the peripheral speed of the drill.The cutting speed depends upon
the properties of the material being drilled, drill material, drill diameter, rate of speed,
coolant used etc. Cutting speed is calclated by the formula following.
v = *D*N/1000 where
D = dia. of the drill in mm
N = Speed of rotation in rpm
2. Feed Rate (f)- It is the movement of drill along the axis (rpm)

3. Depth of Cut (d)- The distance from the machined surface to the drill axis.

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Experiment 4: Study of a shaping machine and shaping a rectangular block using a
horizontal push cut shaper

 Shaping and Planing among the oldest techniques

 Shaping is where the workpiece is fed at right angles to the cutting motion between
successive strokes of the tool.
 Planing the workpiece is reciprocated and the tool is fed at right angles to the cutting
motion.
 These process require skilled operators and for the most part have been replaced by other
processes

Classification of Shaper
 Horizontal-push cut
 Plain (Production work)
 Universal (Tool room work)
 Horizontal-draw cut
 Vertical
 Slotter
 Key seater
 Special purpose-as for gear cutting

The shaper is a relatively simple machine. It is used fairly often in the toolroom or for machining
one or two pieces for prototype work. Tooling is simple, and shapers do not always require operator
attention while cutting. The horizontal shaper is the most common type, and its principal
components are shown below, and described as follows:

 Ram: The ram slides back and forth in dovetail or square ways to transmit power to the
cutter. The starting point and the length of the stroke can be adjusted.
 Toolhead: The toolhead is fastened to the ram on a circular plate so that it can be rotated
for making angular cuts. The toolhead can also be moved up or down by its hand crank for
precise depth adjustments.
 Clapper Box: The clapper box is needed because the cutter drags over the work on the
return stroke. The clapper box is hinged so that the cutting too] will not dig in. Often this
clapper box is automatically raised by mechanical, air, or hydraulic action.
 Table: The table is moved left and right, usually by hand, to position the work under the
cutter when setting up. Then, either by hand or more often automatically, the table is moved
sideways to feed the work under the cutter at the end or beginning of each stroke.

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  Saddle: The saddle moves up and down (Y axis), usually manually, to set the rough
position of the depth of cut. Final depth can be set by the hand crank on the tool head.
 Column: The column supports the ram and the rails for the saddle. The mechanism for
moving the ram and table is housed inside the column.
 Tool holders: Tool holders are the same as the ones used on at engine lathe, though often
larger in size. The cutter is sharperred with rake and clearance angles similar to lathe tools
though the angles are smaller because the work surface is usually flat. These cutters are
fastened into the tool holder. just as in the lathe, but in a vertical plane.
 Workholding: Workholding is frequently done in a vise. The vise is specially designed for
use in shapers and has long ways which allow the jaws to open up to 14" or more, therefore
quite large workpieces can be held. The vise may also have a swivel base so that cuts may
be made at an angle. Work that cannot be held in the vise (due to size or shape) is clamped
directly to the shaper table in much the same way as parts are secured on milling machine
tables.
 Shaper Size: The size of a shaper is the maximum length of stroke which it can take.
Horizontal shapers are most often made with strokes from 16- to 24" long, though some
smaller and larger sizes are available. These shapers use from 2- to 5-hp motors to drive
the head and the automatic feed.
 Shaper Width: The maximum width which can be cut depends on the available movement
of the table. Most shapers have a width capacity equal to or greater than the length of the
stroke. The maximum vertical height available is about 12" to 15".

Quick Return Mechanism

 The shaping machine is used to machine flat metal surfaces especially where a large
amount of metal has to be removed. Other machines such as milling machines are much
more expensive and are more suited to removing smaller amounts of metal, very accurately.
 The reciprocating motion of the mechanism inside the shaping machine can be seen in the
diagram. As the disc rotates the top of the machine moves forwards and backwards,
pushing a cutting tool. The cutting tool removes the metal from work which is carefully
bolted down.

Fig. Quick return mechanism

Common Shaping Planing Geometry

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Page 21 of 24
Experiment 5: Finishing a rectangular block using a surface grinding machine

 The grinding process consists of removing material from the workpiece by the use of a
rotating wheel that has a surface composed of abrasive grains. Grinding is considered to be
the most accurate of the existing machining processes. Grinding processes are used when
high accuracies, close dimensional tolerances, and a fine surface finishes are required.
Grinding processes also allow for high production rates. This allows for a lowered cost of
production. Hard materials can also be machined.
 Grinding may be classified as non-precision or precision, according to purpose and
procedure.
 Non-precision grinding: The common forms are called, snagging and off-hand
grinding. Both are done primarily to remove stock that can not be taken off as
conveniently by other methods. The work is pressed hard against the wheel or vice
versa. The accuracy and surface finish are of secondary importance.
 Precision grinding: Precision grinding is concerned with producing good surface
finishes and accurate dimensions. Three types of precision grinding exists
 External cylindrical grinding
 Internal cylindrical grinding
 Surface grinding
 Surface grinding is most common of the grinding operations. A rotating wheel is used in
the grinding of flat surfaces. Types of surface grinding are vertical spindle and rotary
tables.

Figure: Schematic illustration of surface-grinding operations. (a) Traverse grinding with a

horizontal-spindle surface grinder. (b) Plunge grinding with a horizontal-spindle surface grinder,
producing a groove in the workpiece. (c) Vertical-spindle rotary-table grinder (also known as the
Blanchard-type grinder).

 Cylindrical grinding is also called center-type grinding and is used in the removing the
cylindrical surfaces and shoulders of the workpiece. Both the tool and the workpiece are
rotated by separate motors and at different speeds. The axes of rotation tool can be adjusted
to produce a variety of shapes.

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 Internal grinding is used to grind the inside diameter of the workpiece. Tapered holes can
be ground with the use of internal grinders that can swivel on the horizontal.

 Centerless grinding is when the workpiece is supported by a blade instead of by centers

or chucks. Two wheels are used. The larger one is used to grind the surface of the
workpiece and the smaller wheel is used to regulate the axial movement of the workpiece.
Types of centerless grinding include through-feed grinding, in-feed/plunge grinding, and
internal centerless grinding.

 Grinding is basically a chip removal process in which the cutting tool is an individual
abrasive grain. The mechanics of grinding and the variables involved can be studied by

D= Grinding wheel diameter

d= Wheel depth of cut
V= Tangential velocity
v= Workpiece velocity
t= Undeform thickness (grain depth of
cut) Page 23 of 24
analyzing the surface grinding operation as shown in the following Figure.

Undeformed chip length, l  Dd

 4v   d 
Undeformed chip thickness , t     
 VCr   D 
 v d 
Grain force   
 VC D 
1/ 2
 VC 
Temperatur e rise  D1/ 4 d 3 / 4  
 v 
Volume of material removed
Grinding ratio, G 
Volume of wheel wear

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