Need of Manufacturing

Manufacturing is defined as value addition processes by which raw materials of low utility and value due to its inadequate material properties and poor or irregular size, shape and finish are converted into high utility and valued products with definite dimensions, forms and finish imparting some functional ability.

Need of Manufacturing

What is Machining??
Purpose of Machining Most of the engineering components such as gears, bearings, clutches, tools, screws and nuts etc. need dimensional and form accuracy and good surface finish for serving their purposes. Performing like casting, forging etc. generally cannot provide the desired accuracy and finish. For that such preformed parts, called blanks, need semi-finishing and finishing and it is done by machining and grinding. Grinding is also basically a machining process. Machining to high accuracy and finish essentially enables a product  fulfill its functional requirements  improve its performance  prolong its service

Requirements of Machining

Chapter 1

Machining Tool
A machine tool is a non-portable power operated and reasonably valued device or system of devices in which energy is expended to produce jobs of desired size, shape and surface finish by removing excess material from the preformed blanks in the form of chips with the help of cutting tools moved past the work surface(s).

Classification of machine tools

Types of machining processes

Classification of Tools
According to the method of manufacturing the tool: (a) Forged tool. (b) Tipped tool brazed to the carbon steel shank. (c) Tipped tool fastened mechanically to the carbon steel shank According to the method of holding the tool:(a) Solid tool (b) Tool bit inserted in the tool According to the method of using the tool:(a) Turning (f) Forming (b) Chamfering (g) Boring (c) Thread cutting (h) Internal thread cutting (d) Facing (i) Parting-off (e) Grooving According to the method of applying feed:(a) Right-hand (b) Left-hand (c) Round Nose

Motions in Machining
In machining operation, the work piece and the tool must have relative motion in order to remove the metal. Suppose we want to drill a hole, we have to rotate the drill or work piece. We have to press the drill against the work piece so that it penetrates the work piece. First motion, i.e. rotation of drill or work piece is called the primary motion (cutting motion) and the second one know as feed motion. During turning motion, the cutting motion is obtained by rotation of the work piece and feed motion from the motion of tool parallel or perpendicular to work piece axis and normal to the cutting motion.

Motions in Machining
Auxiliary (Or handling motion) To facilitate the handling and clamping of the work piece in the machine Advancing the tool to engage the work piece Positioning it in a desired operation with respect to the work piece Disengaging the tool from the cut Withdrawing the tool and removing the machined work piece from the machine. Auxiliary motion is generally operated manually. Automation may be achieved through mechanical means such as arms and limit switches, pneumatic and hydraulic cylinders and motors. In NC and CNC machines, this is done by computers.

Cutting Speed, Depth of cut & feeds

Cutting Speed, CS
o Cutting speed or rate is the surface speed at which the workpiece passes the cutter. o Mathematically, o Where, o CS = Cutting speed in m/min o D = Diameter of the workpiece in mm o N = Number of revolution per speed o It is difficult to standardized the cutting speed of material as it depends upon many factors such as material properties, tool material, surface finish required , depth of cut, feed required etc. o Typical cutting speeds for various material is shown

Cutting Speed, Depth of cut & feeds

Cutting Speed, CS

Cutting Speed, Depth of cut & feeds

Depth of Cut, dc
o Depth of cut refers to the advancement of the tool in the job in the direction perpendicular to the surface being machined. o Mathematically,

o Where, o D = Initial diameter of the workpiece o d = Final diameter of the workpiece o Depth of cut varies from 0.30 to 10 mm. o Finish depth cut = 0.30 2.5 mm o Rough depth cut = 5 10 mm

Cutting Speed, Depth of cut & feeds

Feed, f
o Feed refers to the tool advancement per revolution of the job parallel to the surface of the job to be machined. o It is expressed in millimeters per revolutions.

 Machining time
T= l/f x N

Where f is feed in mm/rev l is length in mm N is speed in rpm

ASSIGNMENT-1
1. 2. 3. 4. Differentiate between primary and auxiliary motion. What is a machine tool ? How the machine tools are classified. Define the terms Cutting speed Depth of cut Feed