PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Introduction To
Machine Tools
Section 1

Copyright © The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.
 PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

History of Machines
Unit 1

Copyright © The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.
 1-3

Objectives

• The development of tools throughout history

• The standard types of machine tools used in
shops
• The newly developed space-age machines
and processes
 1-4

History of Machine Tools

• Began during stone age (<50,000 years ago)
– Hand tools of wood, animal bones, or stone
• Bronze age (4500 to 4000 b.c.)
– Copper and bronze implements
– Power-operated (animal power)
• Iron age (1000 b.c.)
– Iron replaced bronze
– Domesticated animals provided power
– Commodities handmade by skilled craftspeople
 1-5

History of Machine Tools

• Machine age (~300 years ago)
– Explored new sources of energy (water)
• Industrial age began when James Watt
produced first steam engine (1776)
– Steam engine provided power to other areas
– Machines improved
• Steam/steel in ships, railroads, steam tractors
• New power – electricity produced by generators
• Diesel and gasoline engines
 1-6

History of Machine Tools

• Progress continued slowly during first part of
20th century
– Spurts during the two world wars
• Since 1950s, progress rapid
• Now in space age
– Atom harnessed: nuclear power
– Journey to moon and outer space
– Calculators, computers, robots commonplace
– Can mass produce parts to millionths of an inch
 1-7

Improved Production
• Constant improvement made modern machine
tools more accurate and efficient
• Improved production and accuracy
– Hydraulics
– Pneumatics
– Fluidics
– Electronic devices
 1-8

Common Machine Tools

• Generally power-driven metal-cutting or -
forming machines used to shape metals
– The removal of chips
– Pressing, drawing, or shearing
– Controlled electrical machining processes
 1-9

Machine Tool Capabilities

• Holding and supporting the workpiece
• Holding and supporting a cutting tool
• Imparting a suitable movement (rotating or
reciprocating) to the cutting tool or the work
• Feeding the cutting tool or the work so that
the desired cutting action and accuracy will
be achieved
 1-10

Machine Tool Categories

• Four broad categories
– Chip-producing machines
– Non-chip-producing machines
– New-generation machines
– Multi-tasking machines
 1-11

Chip-producing Machine
• Form metal to size and shape by cutting away
unwanted sections
• Generally alter shape of steel-produced
products
– Casting
– Forging
– Rolling
 1-12

Non-chip-producing Machines

• Form metal to size and shape by pressing,

drawing, punching, or shearing
• Produce parts by compressing granular or
powdered metallic materials
 1-13

New-Generation Machines

• Perform operations that cannot be done on

chip- or non-chip-producing machines
• Use either electrical or chemical energy
 1-14

Multi-tasking Machines
• Combined machining and turning center
• Can produce virtually any shape part from
rough to finish
• Consists of turning center with two
independent spindles and vertical machining
center with rotary tool spindle
• Combine Information Technology (IT) and
Manufacturing Technology (MT)
 1-15

Machine Tool Performance

• Metal-removal rate
– Depends upon cutting speed, feed rate, and depth
of cut
• Accuracy
– How precisely machine can position cutting tool
to given location once
• Repeatability
– Ability of machine to position cutting tool
consistently to any given position
 1-16

General Machine Shop Tools

• Tools basic to production of metal
components
• Operations most commonly performed:
turning, boring, threading, drilling, reaming,
sawing, milling, filing, and grinding
• Basic Machine tools
– Drill press, engine lathe, power saw, milling
machine and grinder
 1-17

Drill Press
• First mechanical device developed
• Used primarily to produce round holes
• Function to grip and revolve cutting tool
• Common operations
– Drilling, reaming, spot facing, countersinking,
counterboring, and tapping
 1-18

Engine Lathe
• Used to produce round work
• Workpiece held and mounted on lathe spindle
which is revolved against cutting tool
• Common operations
– Straight turning, tapering, facing, drilling, boring,
reaming, and thread cutting
 1-19

Two Types of Metal Saw

• Reciprocating cutoff saw
– Used to cut work to length only
• Bandsaw Material in vise and saw blade
– Horizontal brought into contact with work
• Used to cut work to length
– Vertical
• Used to cut work to length and shape
Material on table and brought into contact
with continuous-cutting saw blade
 1-20

Milling Machine
• Two types: horizontal and vertical milling
• Use one or more rotating milling cutters with
single or multiple cutting edges
• Workpiece fed into revolving cutter
• Accessories allow wide variety of operations
– Drilling, reaming, boring, counterboring and spot
facing
 1-21

Grinder
• Use abrasive cutting tool on workpiece
– Bring to accurate size
– Produce high surface finish
• Surface of work brought into contact with
revolving grinding wheel
 1-22

Common Types of Grinders

• Surface
– Used to produce flat, angular, or contoured surfaces
• Cylindrical
– Used to produce internal and external diameters
• Cutter and Tool
– Used to sharpen milling machine cutters
• Bench or Pedestal
– Used for offhand grinding and sharpening
 1-23

Special Machine Tools

• Designed to perform all operations necessary
to produce single component
• Include
– Gear-generating machines
– Centerless, cam and thread grinders
– Turret lathes
– Automatic screw machines
 1-24

Computer Numerical Control

Machines (CNC)
• Brought tremendous changes
• Computer control of machines has allowed
speed of production and undreamed of
accuracies
– Operating commands executed with speed,
accuracy, efficiency and reliability
• Replacing conventional machine tools
operated by hand
 1-25

CNC Equivalent of Engine

Lathe
• Capable of machining round parts in one
sixth time of skilled machinist
• Two centers
– Chucking
• Designed to machine parts in a chuck (holding and
driving device)
– Turning
• Designed mainly for shaft-type workpieces supported
by some type of tailstock center
 1-26

Machining Centers
• CNC equivalent of milling machine
– Can change cutting tools
• Two types of machining centers
– Vertical
• Used for flat parts where three-axis machining
required
– Horizontal
• Spindle in horizontal position
• Allows parts to be machined on any side in one setup
if equipped with indexing table
 1-27

Electrical Discharge Machines

• Use controlled spark erosion process between
cutting tool and workpiece to remove metal
• Two most common EDM machines
– Wire-cut
• Uses traveling wire to cut internal and external shapes
of workpiece
– Vertical ram (die sinking machine)
• Feeds form tool down into workpiece
 1-28

Machining New Space-age

Materials
• Produce shapes which were difficult or
impossible to produce by other methods
• Four new machine tools
– Electro-discharge machining
– Electochemical machining
– Electrolytic grinding
– Laser machining
 1-29

Robotics
• One of fastest-growing areas of
manufacturing industry
• Numerical control applied to robots
• Capable of handling materials and changing
machine tool accessories easily and
efficiently
 1-30

Lasers
• Used increasingly for cutting and welding
• Used in sensing devices for extremely
accurate measuring and surveying
• Used for many materials beyond metals
 1-31

Past Half Century Developments

• Slow development until early 1930s
• After 1932 automation introduced
• Great Depression provided lull in production
and time used to upgrade machines
• AMT (Association for Manufacturing
Technology) list of important developments
in metalworking in text