|| Jai Sri Gurudev||

Sri Adichunchanagiri Shikshana Trust®

SJB INSTITUTE OF TECHNOLOGY

(Affiliated to Visvesvaraya Technological University, Belagavi & Approved by AICTE, New Delhi.)
Accredited with NAAC ‘A+’ grade
No. 67, BGS Health & Education City, Dr. Vishnuvardhan Road Kengeri, Bengaluru – 560 060

Department of Mechanical Engineering

SEMESTER : 4TH SEMESTER

SUBJECT : MACHINING SCIENCE & JIGS & FIXTURES
BY
MR. UDAY M
ASSISTANT PROFESSOR
 DEPARTMENT VISION & MISSION

Vision of the Department

To become a center of excellence and a platform in
diversified fields for the aspirants in Mechanical
Engineering.

Mission of the Department

To impart comprehensive education in the field of
mechanical engineering to produce highly
accomplished graduates
To endow high profile technical & soft skill trainings
to foster professionalism and ethical values among
students
To inculcate innovative thinking among students 2
through projects and research work
Department of Mechanical Engineering,SJBIT
Course Objective
 To know the various subtractive machining processes in industries.
 To calculate the values of various forces involved in the machining operations.
 To understand and determine tool wear and tool life of different machining processes.
 To know various non-conventional machining and hybrid machining processes.
 To know the design of jigs and fixtures for various industrial/ machining members.

Course Outcome
 Demonstrate the Conventional CNC machines and advanced manufacturing process
operations
 Determine tool life, cutting force, and economy of the machining process.
 Analyze the influence of various parameters on machine tools' performance.
 Select the appropriate machine tools and process, the Jigs, and fixtures for various
applications.

Department of Mechanical Engineering,SJBIT

Course Syllabus
Module – 1
 Introduction to Machining Processes and Machine
Tools:
 Subtractive manufacturing processes and classifications.
 Construction, specification operations of machine tools:– Lathe,
Shaping, Milling, Drilling, Grinding Machine.
 Introduction to CNC machines: CNC Lathe, Milling, Drilling,
Machine Center

Department of Mechanical Engineering,SJBIT

 INTRODUCTION
What is machining?

Machining is a manufacturing process that involves the removal of

material from a workpiece to create a desired shape and size.
Machining can be performed using a variety of tools and processes,
each with its own advantages and limitations.

•Machining is used to make numerous metal items, but it can also be

used to make other materials like wood, plastic, ceramics, and
composites.
•A machinist is a person who specializes in machining.
•A machine shop is a room, building, or company where machining is
done.
•Computer numerical control (CNC), which uses computers to
control the movement and operation of mills, lathes, and other cutting
equipment, is utilized for a lot of modern machining.
•This improves efficiency by allowing the CNC machine to run
unattended, lowering labor expenses for machine shops.
PURPOSE

•Most technical components, such as gears, bearings, clutches, tools,

screws, and nuts, require dimensions and form correctness as well as a
good surface polish to function properly.
•Performing techniques such as casting and forging, for example, are
unable to achieve the required accuracy and polish. Such prepared
parts, known as blanks, require semi-finishing and finishing, which is
accomplished through machining and grinding.
•Grinding is essentially the same as machining. Machining to a high
degree of accuracy and polish allows a product to • meet its functional
requirements • increase its performance • extend its service life.
Classification of Machining processes

Department of Mechanical Engineering,SJBIT

 CONVENTIONAL MACHINING PROCESS
Construction of lathe machine

A lathe machine is a tool that is used to shape materials, such as metal or

wood, by rotating them against a cutting tool
The construction of a lathe machine typically consists of the following
components:

1.Bed: The bed is the base of the machine and provides a stable platform for the other
components. It is typically made of cast iron and is designed to resist deflection and
vibration.
2.Headstock: The headstock is located at one end of the bed and contains the motor,
spindle, and other components that drive the workpiece. It is responsible for rotating the
workpiece at a constant speed.
3.Tailstock: The tailstock is located at the other end of the bed and supports the other
end of the workpiece. It can be moved along the bed to accommodate different lengths
of workpieces and can be locked in place to hold the workpiece securely.
4.Carriage: The carriage is the component that holds the cutting tool and moves along
the bed to make cuts in the workpiece. It consists of a saddle that slides along the bed
and a cross slide that moves perpendicular to the bed.
The construction of a lathe machine typically consists of the following
components:

5. Tool post: The tool post is located on the carriage and holds the cutting tool. It can be
adjusted to change the height and angle of the cutting tool.

6. Chuck: The chuck is a device that is attached to the spindle of the headstock and
holds the workpiece securely in place. It can be opened and closed to grip or release the
workpiece.

7. Apron: The apron is located on the front of the carriage and contains the controls for
operating the machine, such as the feed and speed controls
 Operations

Lathe operations refer to the processes performed using a lathe machine to

shape, cut, drill or turn a workpiece. Lathe machines are commonly used in
metalworking and woodworking industries for producing cylindrical parts
or components with high precision

Some of the common lathe operations:

Facing: Turning: Taper turning Boring:

Drilling: Threading: Knurling:

Operations

Some of the common lathe operations:

 CONVENTIONAL MACHINING PROCESS
Construction of Shaping Machine

A shaping machine, also known as a shaper, is a machine tool used for

shaping and cutting metals
The construction of a shaping machine typically consists of the following
components:

1. Base: The base is the foundation of the machine and provides a sturdy
support for the other components.

2. Column: The column is a vertical pillar that supports the other

components and provides a guide for the tool head.

3. Tool head: The tool head is mounted on the column and moves vertically
to adjust the depth of cut. It contains the cutting tool, which can be
adjusted to control the depth and angle of the cut

4. Ram: The ram is a horizontal component that moves back and forth to
control the length of the cut. It is mounted on the tool head and can be
adjusted to change the cutting speed and direction.
The construction of a shaping machine typically consists of the following
components:

4. Table: The table is a flat surface that supports the workpiece and moves
horizontally to control the width of the cut. It can be adjusted to
accommodate different sizes of workpieces and can be locked in place to hold
the workpiece securely.

5. Feed mechanism: The feed mechanism is responsible for moving the

workpiece and the cutting tool during the cutting process. It can be adjusted
to control the rate of feed and the depth of cut.

6. Drive mechanism: The drive mechanism provides the power to rotate the
cutting tool and move the workpiece. It consists of a motor, belts, and gears
that work together to provide the necessary speed and torque
Milling Machine Operations
The following are the milling machine operations:
1.Plain Milling Operation
2.Face Milling Operation
3.Side Milling Operation
4.Straddle Milling Operation
5.Angular Milling Operation
6.Gang Milling Operation
7.Form Milling Operation
8.Profile Milling Operation
9.End Milling Operation
10. Saw Milling Operation
11.Milling Keyways, Grooves and Slot
12.Gear Milling 16
13. Thread Milling
Department of Mechanical Engineering,SJBIT
•Machining Horizontal Surfaces •Machining Vertical Surfaces •Machining Angular Surface

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Department of Mechanical Engineering,SJBIT

 CONVENTIONAL MACHINING PROCESS
Construction of Milling Machine

A milling machine is a machine tool that uses rotating cutters to remove

material from a workpiece to create a desired shape
The construction of a milling machine typically consists of the following
components:

1. Base: The base is the foundation of the machine and provides a sturdy support for
the other components.
2. Column: The column is a vertical pillar that supports the other components and
provides a guide for the spindle.

3. Knee: The knee is a horizontal component that moves up and down along the
column to adjust the height of the worktable.
4. Worktable: The worktable is a flat surface that supports the workpiece and moves
horizontally to control the movement of the workpiece during the milling process.
The construction of a milling machine typically consists of the following
components:

4. Spindle: The spindle is the rotating component that holds the cutting tool
and moves vertically and horizontally to create the desired shape. It is
mounted on the column and can be adjusted to control the depth and
direction of the cut.
5. Arbor: The arbor is a component that connects the cutting tool to the spindle
and provides a way to change the cutting tool quickly and easily.
6. Motor: The motor provides the power to rotate the spindle and move the
worktable and cutting tool. It can be adjusted to control the speed and
torque of the machine.
7. Control panel: The control panel contains the controls for operating the
machine, such as the speed and feed rate controls.
Shaper Machine Operations
The following are the shaper machine operations:
1.Machining horizontal surface
2.Vertical surfaces
3.Angular surfaces
4.Irregular surfaces
5.Cutting slots, grooves, and keyways
6.Machining splines or cutting gears.

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Department of Mechanical Engineering,SJBIT

 CONVENTIONAL MACHINING PROCESS
Construction of Drilling Machine

A drilling machine is a machine tool used to create holes in materials.

The construction of a drilling machine typically consists of the following
components:

1. Base: The base is the foundation of the machine and provides a sturdy support for
the other components.
2. Column: The column is a vertical pillar that supports the other components and
provides a guide for the drill head.
3. Drill head: The drill head is mounted on the column and contains the drilling tool,
which rotates to create the hole in the workpiece. It can be adjusted to control the
depth and angle of the hole.
4. Spindle: The spindle is the rotating component that holds the drilling tool and
moves vertically to create the hole in the workpiece. It is mounted on the drill head
and can be adjusted to control the speed and torque of the machine
The construction of a grinding machine typically consists of the following
components:

5. Worktable: The worktable is a flat surface that supports the workpiece and
can be adjusted to control the movement of the workpiece during the
drilling process.
6. Feed mechanism: The feed mechanism is responsible for moving the
drilling tool and the workpiece during the drilling process. It can be
adjusted to control the rate of feed and the depth of the hole.
7. Motor: The motor provides the power to rotate the drilling tool and move
the worktable and drill head. It can be adjusted to control the speed and
torque of the machine.
 Following are the different types of operations performed on the drilling machine:

1. Drilling operation
2. Reaming operation
3. Boring operation
4. Counter boring operation
5. Countersinking operation
6. Spot facing operation
7. Tapping operation
8. Lapping operation
9. Grinding operation
10. Trepanning operation

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Department of Mechanical Engineering,SJBIT

 CONVENTIONAL MACHINING PROCESS
Construction of grinding Machine

A grinding machine is a machine tool that uses abrasive wheels to remove

material from a workpiece to create a desired surface finish
The construction of a grinding machine typically consists of the following
components:

1. Base: The base is the foundation of the machine and provides a sturdy support for
the other components.
2. Column: The column is a vertical pillar that supports the other components and
provides a guide for the wheel head.
3. Wheel head: The wheel head is mounted on the column and moves vertically and
horizontally to adjust the position of the grinding wheel. It contains the grinding
wheel, which rotates at a high speed to remove material from the workpiece.
4. Worktable: The worktable is a flat surface that supports the workpiece and can be
adjusted to control the movement of the workpiece during the grinding process.
The construction of a grinding machine typically consists of the following
components:

5. Grinding wheel: The grinding wheel is the abrasive wheel that removes
material from the workpiece. It can be made of various materials,
including aluminum oxide, silicon carbide, and diamond.
6. Wheel dresser: The wheel dresser is a tool that is used to shape the grinding
wheel to the desired profile. It is mounted on the machine and can be
adjusted to control the shape and angle of the wheel.
7. Motor: The motor provides the power to rotate the grinding wheel and
move the worktable and wheel head. It can be adjusted to control the speed
and torque of the machine.
8. Coolant system: The coolant system is used to cool the grinding wheel and
workpiece during the grinding process. It can be adjusted to control the
flow and temperature of the coolant
Grinding Machine Operations
•Surface Grinding Operation
•Cylindrical Grinding Operation
•Internal /External Grinding
•Centerless Grinding

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INTRODUCTION TO CNC
 CNC : Computerised Numerical Control (Computer +
Numerical Control)

 Numerical control is a programmable automation in

which process is controlled by Numbers, Letters, and
symbols.

 CNC Machining is a process used in the

manufacturing sector that involves the use of
computers to control machine tools like lathes, mills
and grinders. 33

Department of Mechanical Engineering,SJBIT

INTRODUCTION TO CNC
Why is CNC Machining necessary?
 To manufacture complex curved geometries in 2D or 3D was
extremely expensive by mechanical means (which usually would
require complex jigs to control the cutter motions)

 Machining components with high Repeatability and Precision

 Unmanned machining operations

 To improve production planning and to increase productivity

 To survive in global market CNC machines are must to achieve

close tolerances. 34

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Department of Mechanical Engineering,SJBIT

INTRODUCTION TO CNC-LATHE
 CNC lathe is a computer-numeric controlled machine
tool specialized in CNC turning machining, including
taper turning, hard turning, spherical generation,
facing, cutting off, knurling, drilling, grooving, etc.

 Compared to a conventional lathe, CNC lathes are

operated with precise design instructions and
programs to improve the productivity and precision
of CNC machining demands.

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Department of Mechanical Engineering,SJBIT

DIFFERENT PARTS OF A CNC LATHE
MACHINE
 In general, CNC Lathe machines comes in the following
main configurations:
 Machine Bed
 Main Spindle
 Sub-Spindle/ Second Spindle
 Chuck
 Guide Way
 Headstock
 Tailstock

 Tool Turret
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Department of Mechanical Engineering,SJBIT

MAJOR COMPONENTS RELATED TO CNC MACHINE TOOLS

Any CNC machine tool essentially consists of the following parts:

Part program:
• A series of coded instructions required to produce a part.

• Controls the movement of the machine tool and on/off control of

auxiliary functions such as spindle rotation and coolant.

• The coded instructions are composed of letters, numbers and

symbols

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Department of Mechanical Engineering,SJBIT

 Program input device
 • The program input device is the means for part
program to be entered into the CNC control.
 • Three commonly used program input devices
are punch tape reader, magnetic tape reader, and
computer via RS-232-C communication.

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Department of Mechanical Engineering,SJBIT

Machine Control Unit
The machine control unit (MCU) is the heart of a CNC system. It is
used to perform the following functions:

• To read the coded instructions.

• To decode the coded instructions.

• To implement interpolations (linear, circular, and helical) to

generate axis motion commands.

• To feed the axis motion commands to the amplifier circuits for

driving the axis mechanisms.

• To receive the feedback signals of position and speed for each drive
axis.

• To implement auxiliary control functions such as coolant or spindle 41

on/off and tool change
Department of Mechanical Engineering,SJBIT
 Machine Tool

 • CNC controls are used to control various types

of machine tools.
 • Regardless of which type of machine tool is
controlled, it always has a slide table and a
spindle to control position and speed.
 • The machine table is controlled in the X and Y
axes, while the spindle runs along the Z axis

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Department of Mechanical Engineering,SJBIT

 Feed Back System

 • The feedback system is also referred to as the

measuring system.

 • It uses position and speed transducers to

continuously monitor the position at which the
cutting tool is located at any particular instant.

 • The MCU uses the difference between reference

signals and feedback signals to generate the control
signals for correcting position and speed errors

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Department of Mechanical Engineering,SJBIT

 Drive System

 • Drives are used to provide controlled motion to CNC

elements

 • A drive system consists of amplifier circuits, drive

motors, and ball lead-screws.

 • The MCU feeds the control signals (position and

speed) of each axis to the amplifier circuits.

 • The control signals are augmented to actuate drive

motors which in turn rotate the ball lead-screws to
position the machine table

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Department of Mechanical Engineering,SJBIT

 Drive System

 • Drives are used to provide controlled motion to CNC

elements

 • A drive system consists of amplifier circuits, drive

motors, and ball lead-screws.

 • The MCU feeds the control signals (position and

speed) of each axis to the amplifier circuits.

 • The control signals are augmented to actuate drive

motors which in turn rotate the ball lead-screws to
position the machine table

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Department of Mechanical Engineering,SJBIT

CNC MILLING MACHINE
 CNC milling machines are one of the most
popular tools for machining metals to get the
desired workpiece.

 These rigid and powerful machines consist of

various parts that work in synchronization to
perform the desired milling operation.

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Department of Mechanical Engineering,SJBIT

A CNC MILLING MACHINE COMPRISES
SEVERAL COMPONENTS

 CNC Controller
 The CNC controller is the brain of a CNC milling machine.
The electronic system executes all the commands
entered by the CNC programmer.It eliminates the need
to manually move or interact with components,
as it carries out the input in an instance.
 Column and Base

 The column and base are the heaviest elements

in a milling machine as they support the load of
all other parts of a CNC milling machine.
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Department of Mechanical Engineering,SJBIT

 Knee
 The knee is generally made of cast iron and is
connected to the column.
 It consists of a dovetail slide with vertical
positioning screws to move the worktable up and
down, i.e., the knee facilitates the vertical
movement of the milling table.
 CNC milling machines consist of an automatic
mechanism to position the knee accurately based
on the input received from the CNC controller
and a manual hand wheel to position it manually.

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Department of Mechanical Engineering,SJBIT

 Saddle
 A saddle is a cast iron component that rests above the
knee.
 It facilitates the to-and-fro movement of the
worktable to machine the workpiece along the X and
Y axes.
 Feed Mechanism

 CNC milling machines consist of an

electromechanical system that controls the three-
dimensional movement of the feed mechanism.
 It consists of electrical motors that take the input
from the controller and produce the required
movement in the workpiece to get the required cut.
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Department of Mechanical Engineering,SJBIT

 Work Table
 Milling table with T-slots for work holding
 The worktable is a flat surface made of cast iron,
with T-slots on it.
 Overhanging Arm
 An overhanging arm is a cast iron component
supported by the column and dovetail slides.
 Similar to ram in vertical machining centers, the
overhanging arm is found in horizontal milling
machines to house and support the milling tool
assembly.
 Spindle
 The high carbon chromium steel spindle is a
fundamental component of a CNC machine that drives51
the milling tool.
Department of Mechanical Engineering,SJBIT
CNC MACHINE CENTER
 The CNC machine center (cnc turning center) is an
advanced manufacturing machine tool. Machinery can
perform various machining operations.
 The CNC machine tool center (machine centre) is an
advanced manufacturing machine tool that can perform a
variety of machining operations with high precision, high
quality, and high surface finish. A CNC machine tool center
(CNC turning center) can perform drilling, milling,
and lathe operations.

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Department of Mechanical Engineering,SJBIT

 The main purpose of the CNC machine
center is to reduce production time and
advanced mechanisms in the CNC machine
center.
 ATC (automatic tool changer)

 APC (automatic pallet changer)

 CNC servo system

 Feedback system

 Re-circulating ball screw and nut

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Department of Mechanical Engineering,SJBIT