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Machine Tools Machine Tools Madan Lal Chandravanshi Assistant Professor Indian School of Mines Dhanbad 1 Manufacturing Processes •Material Removal Processes (Machining) •Joining Processes (Welding, Brazing, Soldering) •Casting Processes •Forming Processes 2 Material Removal Processes (Machining) •Cutting tools •Machine Tools •Lathe turning •Drilling •Milling •Grinding •,Sawing, filing •Nontraditional machining process (EDM) 3 Cutting Tool In the context of metalworking , a cutting tool , is any tool that is used to remove metal from the workpiece in form of chips. It frequently refers to a tool bit . Tool material should be harder than the material which is to be cut They must be able to withstand the heat generated in the metal cutting process. They also must have a specific geometry, designed so that the cutting edge can contact the workpiece without the rest of the tool dragging on its surface. The angle of the cutting face is also important . 4 Classification of Cutting tools single point cutting tool multiple point cutting tool. 5 A single-point cutting tool Has only one cutting edge used for increasing the size of holes, or boring, thread making, turning etc. 6 A single-point cutting tool Cutting speed = πDN/1000 meter per minutes 7 8 Single Point Cutting Tool geometry 9 Know the Single Point Cutting Tool Shank: Main body of tool, it is part of tool which is gripped in tool holder Face: Top surface of tool b/w shank and point of tool. Chips flow along this surface Flank: Portion tool which faces the work. It is surface adjacent to & below the cutting edge when tool lies in a horizontal position . Base: Bearing surface of tool on which it is held in a tool holder. Nose radius: Cutting tip, which carries a sharp cutting point. Nose provided with radius to enable greater strength, increase tool life & surface life. Typical Value : 0.4 mm – 1.6 mm Nomenclature of Single Point Lathe Tool The most significant terms in the geometry of a cutting tool angles are: Relief or clearance angle . Side relief . End relief Rake angle . Back Rake angle . Side Rake angle Cutting edge angle . Side Cutting edge angle . End Cutting edge angl . Nose Radius 11 Cutting-Tool Terms Relief or Clearance angle: Ground on the end and side faces of a tool to prevent it from rubbing on the work piece. To enable only the cutting edge to touch the work piece . Side Relief angle: • Angle ground directly below the cutting edge on the flank of the tool End Relief angle: • Angle ground from the nose of the tool 12 Cutting-Tool Terms Rake angle: Ground on a tool to provide a smooth flow of the chip over the tool so as to move it away from the work piece Back Rake angle • Ground on the face of the tool • Influences the angle at which chip leaves the nose of the tool • Generally 8 - 10 0 Side Rake angle • Ground on the tool face away from the cutting edge • Influences the angle at which the chip leaves the work piece • A lathe tool has 14 0 side rake. 13 Back Rake Angle formed between top face of tool and top of tool shank Positive Top face slopes downward away from point Negative Top face slopes upward away from point Neutral 14 Cutting-Tool Terms Nose Radius: • Rounded tip on the point of the tool Functions: • Strengthens finishing point of tool • Improves surface finish on work • Should be twice amount of feed per revolution • Too large – chatter; too small – weakens point 15 Tool Angle Application Factors to consider for tool angles The hardness of the metal Type of cutting operation Material and shape of the cutting tool The strength of the cutting edge Multiple-point cutting tools have two or more cutting edges. Example:- milling cutters, drills, and broaches. 17 Milling cutters 18 Milling tool geometry Face cutter Chamfering cutter Cutting Tool Materials •Tool Steels •High Speed Steel (HSS) •Carbides •Coated Carbide •Ceramics and cermet •TiN Coated High-Speed Steel •CBN •Diamond tool 20 Machine Tool 21 Machine tools Lathe turning Drilling Milling Shaper Planer Grinding Broaching, sawing, filing Nontraditional machining process (ex EDM) 22 Lathe Turning 23 Lathe Turning Turning 24 Lathe 25 Gear System 26 Tailstock 27 Long Job is supported by tailstock 28 Drilling in lathe machine 29 Cutting parameters Speed Cutting speed is defined as the speed at which the work moves with respect to the tool (usually measured in feet per minute). Feed Feed rate is defined as the distance the tool travels during one revolution of the part. Depth of Cut 30 Cutting speed and feed determines the surface finish, power requirements, and material removal rate. The primary factor in choosing feed and speed is the material to be cut. However, one should also consider material of the tool, rigidity of the workpiece, size and condition of the lathe, and depth of cut. 31 Lathe Turning Facing 32 Lathe Turning 33 Specification of Lathe Machine 1. Swing over carriage 2. Distance between centers 3. Hole through spindle 4. Travel of cross-slide 5. Taper of tailstock spindle 6. Length overall 7. Width overall 8. Height overall 9. Shipping weight 10. Motor/Speed Control 11. Spindle speed range 34 Milling Machine tool 35 Milling Machine Tool Milling is one of the basic machining processes. Milling is a very versatile process capable of producing simple two dimensional flat shapes to complex three dimensional interlaced surface configurations. 36 Process The milling process: Typically uses a multi-tooth cutter Work is fed into the rotating cutter Capable of high MRR Well suited for mass production applications Cutting tools for this process are called milling cutters 37 Vertical Mill 38 Horizontal Mill 39 40 Classification of Milling Peripheral Milling (SLAB Milling) Face Milling End Milling 41 Peripheral Milling (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 workpiece surface to be machined. 42 Face Milling The cutter is mounted on a spindle having an axis of rotation perpendicular to the workpiece surface. The milled surface results from the action of cutting edges located on the periphery and face of the cutter 43 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. 44 METHODS OF MILLING Up Milling Down Milling 45 UP MILLING (conventional milling) The direction of the cutter rotation opposes the feed motion. For example, if the cutter rotates counterclockwise , the work-piece is fed to the right in up milling. 46 47 DOWN MILLING (climb milling) The direction of cutter rotation is same as the feed motion. For example, if the cutter rotates clockwise , the work-piece is fed to the right in down milling. 48 Grinding Machine 49 Grinding Machine The primary purpose of a grinding wheel is to sharpen tools (eg. drill bits). The hard abrasive of the wheel is made for removing very hard materials like high speed steel. Never grind on the side of the wheel. Never grind a soft material such as Aluminum. The material will coat the wheel and prevent the abrasive from working properly. (SHOW) 50 51 52 Cavity 53 Grinding Wheel Specification 54 Safety Measures Safety Glasses EVERYONE MUST WEAR SAFETY GLASSES IN THE SHOP. Clothes and Hair Check your clothes and hair before you walk into the shop. In particular: IF YOU HAVE LONG HAIR OR A LONG BEARD, TIE IT UP. If your hair is caght in spinning machinery, it will be pulled out if you're lucky. If you're unlucky, you will be pulled into the machine. NO LOOSE CLOTHING. Ties, scarves, loose sleves, etc. are prohibited 55 Safety Measures (Cont..) NO GLOVES REMOVE JEWELERY WEAR APPROPRIATE SHOES No open toed sandals. Wear shoes that give a sure footing. Safe Conduct in the Shop Be aware of what's going on around you. For example, be careful not to bump into someone while they're cutting with the bandsaw (they could lose a finger!). 56 Safety Measures (Cont..) Machining IF YOU DON'T KNOW HOW TO DO SOMETHING, ASK! BEFORE YOU START THE MACHINE: Study the machine. Know which parts move, which are stationary, and which are sharp. Double check that your work-piece is securely held. Remove chuck keys and wrenches. DO NOT LEAVE MACHINES RUNNING UNATTENDED! CLEAN UP MACHINES AFTER YOU USE THEM! A dirty machine is unsafe and uncomfortable to work on. 57.
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