Elements Of Mechanical

Engineering

Introduction to Manufacturing Engineering

Dr. Prashant Todmal

prashant.todmal@polimi.it
Introduction

Machine Design Thermal Engineering

Manufacturing Engineering
Manufacturing Engineering
It Includes basic workshop processes:-
 Bench work and fitting,
 Sheet metal,
 Carpentry,
 Pattern making,
 Mould making,
 Foundry,
 Smithy,
 Forging,
 Metal working and heat treatment,
 welding,
 fastening,
 machine shop,
 surface finishing and coatings,
 assembling
 Inspection and quality control.
Metal cutting processes

Lathe:-
Schematic diagram of lathe machine
Machining Operation
 Lathe:-
Basic working principles:-
 Lathe removes undesired material from a rotating work piece
in the form of chips with the help of a tool which is traversed
across the work and can be fed deep in work.
 The tool material should be harder than the work piece and
the latter held securely and rigidly on the machine.
 The tool may be given linear motion in any direction. A
lathe is used principally to produce cylindrical surfaces and,
at right angles to the axis of rotation.
 It can also produce tapers and bellows etc.
 Operation of turning is done on parts as small as those used
by watches to huge parts weighing several tons.
 A lathe basically consists of a bed to provide support, a
headstock, a cross slide to traverse the tool, a tool post
mounted on the cross slide.
 The spindle is driven by a motor through a gear box to
obtain a range of speeds.
 The carriage moves over the bed guide ways parallel to
the work piece and the cross slide provides the transverse
motion.
 A feed shaft and lead screw are also provided to power
the carriage and for cutting the threads respectively.
TERMS USED IN LATHE MACHINING
 The following terms are commonly used while machining a work
piece on lathe.
 Cutting speed:
 It is defined as the speed at which the metal is removed by the tool
from the work piece.
 In other words, it is the peripheral speed of the work past the cutting
tool. It is usually expressed in meters per minute.
 2. Feed:
 It is defined as the distance which the tool advances for each
revolution of the work.
 It is usually expressed in millimeters.
 3. Depth of cut:
 It is defined as the depth of penetration of the tool into the work
piece during machining.
 In other words, it is the perpendicular distance measured from the
machined surface to the unmachined surface of the work piece.
 It is usually expressed in millimeters.
Operations performed on lathe:-
The most common operations which can be performed on the
lathe are
1. Facing,
2. Turning,
3. Taper turning,
4. Eccentric turning,
5. Boring, drilling,
6. Reaming,
7. Threading,
8. Knurling
Facing:-

 This operation is almost essential for all works.

 The work piece is held in the chuck and the facing tool is fed
from the outer surface to the centre, with the help of a cross-
slide.
Plain Turning:-

 It is an operation of removing excess amount of material from the

surface of the cylindrical work piece.
 The work is held either in the chuck or between centres and the
longitudinal feed is given to the tool either by hand or power.
Step Turning:-

 It is an operation of producing various steps of different

diameters in the work piece.
 This operation is carried out in the similar way as plain turning.
Taper Turning:-

 It is an operation of producing an external conical surface on

a work piece.
 A small taper may be produced with the help of a forming
tool or chamfering tool, but the larger tapers are produced by
swivelling the compound rest. at the required angle or by
offsetting the tailstock or by taper turning attachment.
 If D is the larger diameter, d is the smaller diameter and L is
the length of taper, then
Drilling:-

 It is an operation of making a hole in a work piece with the

help of a drill.
 The work piece is held in a chuck and the drill is held in the
tailstock. The drill is fed manually, into the rotating work
piece, by rotating the tailstock hand wheel.
Drilling Operations:-
Drilling: It is an operation of producing a circular hole in a work
piece by forcing a drill against it.

Boring: It is an operation of enlarging a hole that has already been

drilled by a single point tool, so as to make it we to the required
size.

Reaming: It is an operation of slightly enlarging a machined hole

to proper size with a smooth finish. The reamer is an accurate
tool and is not designed to remove much metal. The reaming
allowance is usually 0.2 mm only.
Boring:-

 It is an operation of enlarging of a hole already made in a work

piece.
 In this operation, a boring tool or a bit mounted on a rigid bar is
held in the tool post and fed into the work by hand or power in
the similar way as for turning.
 Reaming:-

 It is an operation of finishing the previously drilled hole.

 In this operation a reamer is held in the tailstock and it is fed
into the hole in the similar way as for drilling.
Tapping:
 It is an operation of producing internal threads in a hole by
means of a tool called tap.
Counter boring:
 It is an operation of enlarging the mouth of a drilled hole to set
bolt heads and nuts below the surface so that they may not project
out from the surface level.
 which is similar to an end mill or a single blade ground to give
two cutting edges and is guided by a pilot pin which fits into the
drilled hole.
Spot facing:
 It is an operation to finish off a small portion of rough surface
around a drilled hole to provide smooth seat for bolt head.

Counter sinking:
 It is an operation to bevel the top of a drilled hole for making
a conical seat for a flat head screw. Ordinary flat drill ground
to correct angle is used for countersinking holes.
Undercutting or Grooving:-

 It is an operation of reducing the diameter of a work piece over

a very narrow surface.
 A tool of appropriate shape is fed into the revolving work piece
to the desired depth at right angles to the centre line of the work
piece.
Threading:-

 It is an operation of cutting helical grooves on the external

cylindrical surface of work piece.
 In this operation the work is held in a chuck or between
centres and the threading tool is fed longitudinally to the
revolving work.
 The longitudinal feed is equal to the pitch of the thread to be
cut.
Knurling:-

 It is an operation of providing knurled surface on the work

piece.
 In this operation, a knurled tool is moved longitudinally to a
revolving work piece surface. The projections on the knurled
tool reproduce depressions on the work surface.
Knurling operation
 Cutting Tool
 Cutting tools performs the main machining operation. They comprise
of single point cutting tool or multipoint cutting tools.
 It is a body having teeth or cutting edges on it.
 A single point cutting tool (such as a lathe, shaper and planner and
boring tool) has only one cutting edge.
 Whereas a multi-point cutting tool (such as milling cutter, drill,
reamer and broach) has a number of teeth or cutting edges on its
periphery.
Single Point Cutting Tool
Nomenclature of single point tool
Metal cutting operation
Cutting Fluids
The important functions of cutting fluids are:
(i) Cutting fluid washes away the chips and hence keeps the cutting
region free.
(ii) It helps in keeping freshly machined surface bright by giving a
protective coating against atmospheric, oxygen and thus protects
the finished surface from corrosion.
(iii) It decreases wear and tear of cutting tool and hence increases tool
life.
Shaper machine
Shaper machine
Principal components of a shaper
 Principal Parts of a Shaper
1. Base: It is a heavy structure of cast iron which supports
other parts of a shaper.
2. Column: It is a box-like structure made up of cast iron
and mounted upon the base. It contains the driving
mechanism and is provided with two machined guide
ways on the top of it on which the ram reciprocates.
3. Ram: It is a reciprocating member which reciprocates on
the guide ways provided above the column. It carries a
tool-slide on its head and a mechanism for adjusting the
stroke length.
4. Tool head: It is attached to the front portion of the ram
with the help of a nut and a bolt. It is used to hold the
tool rigidly, it also provides the vertical and angular
movements to the tool for cutting.
5. Cross-rail: It is attached to the front vertical portion of the
column. It is used for the following two purposes:
(a) It helps in elevating the table over the column in the
upward direction, and
(b) The table can be moved in a direction perpendicular to
the axis of the ram over this cross rail.

6. Table: It is used for holding the work piece.

Working principal
Tool motion
Classifications of Shapers
1. According to the ram driving mechanism
(a) Crank shaper: In a crank shaper, a crank and a slotted lever quick
return motion mechanism is used to give reciprocating motion to the
ram.
(b) Geared shaper: In a geared shaper, the ram carries a rack below it,
which is driven by a spur gear. This type of shaper is not widely
used.
(c) Hydraulic shaper: In a hydraulic shaper, a hydraulic system is used
to drive the ram. This type of shaper is more efficient than the crank
and geared shaper.

2. According to position and travel of ram

(a) Horizontal shaper: In a horizontal shaper, the ram moves or
reciprocates in a horizontal direction. This type of shaper is mainly
used for producing flat surfaces.
(b) Vertical shaper: In a vertical shaper, the ram reciprocates vertically
in the downward as well as in upward direction. This type of shaper is
very convenient for machining internal surfaces, keyways, slots or
grooves.
Specifications of a Shaper

1. Maximum length of stroke in millimeters,

2. Size of the table, i.e., length, width and depth of the table,
3. Maximum vertical and horizontal travel of the table,
4. Maximum number of strokes per minute,
5. Power of the drive motor,
6. Type of quick return mechanism,
7. Floor space required, and
8. Weight.
 Drilling mahine
 Drilling is a metal cutting process carried out by a rotating cutting
tool to make circular holes in solid materials.
 A power operated machine tool which holds the drill in its spindle
rotating at high speeds and when actuated move linearly against the
work piece produces a hole.
 Tool which makes hole is called as drill bit or twist drill.
Types of drilling machine.
 Portable drilling machine
 Bench drilling machine
 Radial drilling machine
 Pillar drilling machine
 Gang drilling machine
 Multiple drilling machine
Portable drilling machine
Bench drilling machine
 These are light duty machines used in small workshops.
 Also called Sensitive drilling machines because of its accurate and
well balanced spindle.
 Holes of diameter 1 mm to 15 mm.
Parts
 Vertical main column
 Base
 Moving drill head
 Work table
 Variable speed gear box and spindle feed mechanism.
 Electric motor
 Radial drilling machine
 These are heavy duty and versatile drilling machine used to perform
drilling operate on large and heavy work piece. Holes up to 7.5 cm.
Radial Arm drilling Machine
 Specification of a radial drilling machine
 Power capacity eg: 1.5 hp for drilling motor and 0.5 hp
for elevating motor.
 The range of speed of spindle eg: 50 to 2800 rpm.
 Length of arm on which drill head can traverse. eg: 600
mm.
 Vertical movement of the arm eg: 500 mm.
 Angular swing of arm eg: 360˚
 Range to which drill bit can reach eg: 350 mm to 900
mm.
 Drill depth eg: 32 mm for steel.
Working

 Work piece is marked for exact location and mounted on the work
table.
 Drill bit is then located by moving the radial arm and drill to the
marked location.
 By starting drill spindle motor holes are drilled.

Drilling machine operation

 Reaming
 Boring
 Counter boring
 Counter sinking
 Spot facing
 Tapping
Reaming
 It is a process of smoothing the surface of drilled holes with a tool.
 Tool is called as reamer.
 Initially a hole is drilled slightly smaller in size.
 Drill is replaced by reamer.
 Speed is reduced to half that of the drilling.
Boring
It is process carried on a drilling machine to increase the size of
an already drilled hole.
Initially a hole is drilled to the nearest size and using a boring
tool the size of the hole is increased.
Counter boring
This process involves increasing the size of a hole at only one
end.
Cutting tool will have a small cylindrical portion called pilot.
Cutting speed = two-thirds of the drilling speed for the same
hole.
 Counter sinking

This is an operation of making the end of a hole into a conical

shape.
Cutting speed = half of the cutting speed of drilling for same
hole.
Spot facing
It is a finishing operation to produce flat round surface usually
around a drilled hole, for proper seating of bolt head or nut.
It is done using a special spot facing tool.
Spot facing
Tapping
 Process of cutting internal threads with a thread tool called as
tap.
 Tap is a fluted threaded tool used for cutting internal thread
 Cutting speed is very slow.
 Grinding:-

 Grinding is an abrasive machining process that uses a grinding

wheel as the cutting tool.
 It can produce very fine finishes and very accurate
dimensions; yet in mass production contexts it can also rough
out large volumes of metal quite rapidly.
 Grinding
 It is metal cutting process which makes use of an abrasive tool
called the grinding wheel.
 It is made of abrasive grains having high hardness and heat
resistance and is held together by a bonding material.
 The grinding process provides high accuracy and good surface finish
so they are used for finishing operations.
 The material removal rate in this process is quite less, normally from
0.25 mm to 0.55 mm. Tolerances, as small as 0.002 can be
maintained.

Abrasive Materials:
 silicon carbide and aluminum oxide.
Surface Grinding
 Operation Performed on Grinding Machine

(a) Polishing:
 This process is used for removing scratch marks and tool marks on
the work piece to give a good look.
 For this process, polishing wheels made of canvas, leather or paper
are used.
 The work piece is brought in contact with the revolving wheel to
remove the marks on the work piece.

(b) Buffing:
 This is also a surface finishing process and is used to produce lustrous
surface of attractive appearance.
 In this process, a very small amount of material is removed.
 The buffing wheel is made of felt, cotton and powered abrasives are
applied on the surface of the wheel.
c) Lapping:
 This process is used for producing extremely accurate highly finished
surfaces.
 Lapping is carried out by means of shoes called Laps. The Laps are
made up of soft cast iron, copper, lead and brass.
 Fine abrasive particles are charged into the lap. Silicon carbide,
aluminum oxide and diamond dust are the commonly used lapping
powders.
 Oil and greases are used to spread the abrasive powders.
 The charged lap is rubbed against the work piece surface and the
abrasive particles in the surface of the lap remove small amounts of
material from the work piece surface.
 The material removed by lapping is usually less than 0.025 mm.
(d) Honing:
 Honing is an abrasing process used for finishing internal cylindrical
surfaces like drilled or bored holes.
 Honing stones are manufactured by bonding abrasives like aluminum
oxide or silicon carbide. Materials like sulphur, resin or wax are
added to improve the cutting action.
 Honing can be done manually or by machines. The preferred method
is by using machines.
 The stones are held in a honing head. This head is directed to move in
and out of the hole for carrying out operation.
 Honing is both a sizing and finishing operation and is generally used
for removing the scratch marks produced by grinding.
 The material removal is less than 0.125 mm.
(e) Super finishing:
 It is an abrasive process for removing scratches produced by
machining and other surface irregularities.
 It is used for producing extremely high quality surface finish.
 The amount of material removal is 0.005 to 0.0025 mm.
 In super finishing, an abrasive stick is retained in a suitable holder and
applied to the surface of the work piece with a light pressure.
 This process is normally carried out for finishing outer surfaces.
 The abrasive block reciprocates across the rotating work piece. These
two motions produce a high degree of accuracy.
 The abrasive used are aluminum oxide for materials like alloy and
high speed steels. Silicon carbide abrasives are used for materials like
cast iron, aluminium, brass.
 Bonded diamond dust is used for finishing carbide tools.
NC And CNC Machines:
NC Machines:

 NC stands for Numerical Control.

 It is defined as the machine which is controlled by the set of
instructions in the form of numbers, letters and symbols.
 The set of instructions is called as program.
 CNC Machines:

 CNC stands for Computer Numerical Control.

 It is defined as the machine which is used to control the
motions of the workpiece and tool with the help of prepared
program in computer. The program is written in
alphanumeric data.