MODULE 2

1 Explain the working principle of Lathe with a line diagram.

Cylindrical Turning: (Plain Turning)

It is also called as plain turning or straight turning which is the operation of removing
excess material from the work piece to produce a cylindrical surface of required
diameter. The work piece is supported in between the two centers which permit the
rotation of the work piece. A single point cutting tool is fed perpendicular to the axis
of work piece to a known predetermined depth of cut and is moved parallel to the axis
of the work piece.
Explain the following lathe operations with neat sketch: i) Knurling ii)Facing iii)
Boring
i) Knurling:

It is the process of embossing diamond shaped pattern on the surface of the work
piece. It provides an effective means of gripping the work piece while handling. In
knurling, the knurling tool is fed perpendicular to the axis of a slowly turning work
piece which produce diamond pattern on it.
 ii) Facing
Facing:

Facing is an operation performed on lathe machine to generate either flat surfaces or

shoulders at the end of the work piece. Here the tool is moved perpendicular to the
axis of the work piece to obtain the required dimension. The length of the work piece
can be reduced in steps by performing lathe operation.

iii.) Boring

Illustrate the following operations of drilling with sketches. i) Boring ii) Drilling iii)
Reaming
Boring:

• Boring is a machining process carried out for enlarging a previously drilled hole by
means of an adjustable cutting tool having only one cutting edge. shown figure below.
• Boring is usually performed when a drill bit of the required dimension is not
available.
• In such cases, a hole is first drilled to the nearest dimension and then a single point
cutting tool is fastened and adjusted to a boring bar to enlarge the size of the existing
hole to the required dimension.
• While boring, the tool is rotated at speeds slower than that of reaming.
Drilling:
Drilling is a cutting process where a drill bit is spun to cut a hole of circular cross-
section in work piece. The drill bit is usually a rotary cutting tool, often multi-point.
The bit is pressed against the workpiece and rotated at rates from hundreds to
thousands of revolutions per minute.

Reaming :
The holes that are produced by drilling are rarely straight and cylindrical in form. To
produce accurate and smooth holes, the drilled holes are reamed by a tool called
reamer. The reamer is a cutting tool having several cutting edges in straight or helix
shape.
With neat sketch explain the following machine tool operations i) Boring ii) Plane
milling iii) Slot milling

Boring:

• Boring is a machining process carried out for enlarging a previously drilled hole by
means of an adjustable cutting tool having only one cutting edge. shown figure below.
• Boring is usually performed when a drill bit of the required dimension is not
available.
• In such cases, a hole is first drilled to the nearest dimension and then a single point
cutting tool is fastened and adjusted to a boring bar to enlarge the size of the existing
hole to the required dimension.
• While boring, the tool is rotated at speeds slower than that of reaming.

Plain Milling
Also called as slab milling is a process used to mill flat surfaces of work piece in
such a way that the milling cutter axis is parallel to the surface that is being milled.

Slot Milling:

It is a process to produce desired slots, grooves and keyways using suitable cutters.
Figure illustrates groove milling operation using a milling cutter, which has teeth on
its periphery. Similarly open slots and closed slots can be cut by using plain milling
cutters and end milling cutters respectively.
Explain the components of CNC with block diagram
CNC Machine basically consists of three components:
1. Part Program and Program Input Device
2. Controller unit or Machine Control Unit (MCU)
3. Machine Tool

Part Program and Program Input Device: In a CNC machine, the part program is
done either manually on punched tapes and then fed into the memory of the
computer or with the aid of various computer software that automatically generates
the program required to produce the desired part.
 Machine Control Unit (MCU): In modern CNC technology, the machine control unit
consists of a microcomputer and related control hardware that stores the program of
instructions and executes it by converting each command into mechanical actions
of machine tool, one command at a time. The MCU includes system software,
calculation algorithm and transition software to convert the part program into a
usable format for the MCU. It also acts as a feedback controller for precise
positioning of machine table or spindle.
Machine Tool: The machine tool performs the actual machining operation and can
be of any type like lathe, drilling machine, milling machine, etc. The machine tool
mainly consists of worktable and tool spindles whose motion can be controlled
accurately by the driving system that receives commands from the MCU.
What are the advantages and applications of CNC?
Advantages of CNC
• CNC machines can be used continuously 24 hours a day, 365 days a year.
• CNC machines are programmed with a design which can then be
manufactured hundreds or even thousands of times.
• Each manufactured product will be the same.
• Modern design software allows the designer to simulate the manufacturing,
as there is no need to make a prototype or a model. This saves time and money.
• A person can control many CNC machines as once programmed, they can
do the tasks efficiently without human intervention.

Disadvantages of CNC
• Expensive
• Requires programming skills
• Requires skills for setting up the machines
• Leads to unemployment
• Software compatibility issues can cause some programs to run in one
machine, which can/cannot run in another

Applications of CNC
• Embroidery machines
• Woodcutters
• Wire-bending machines
• Foam cutters
• Laser cutters

Explain the working principle of Milling with schematic diagram.

• The milling cutter is a multipoint cutting tool. The work piece is mounted on a
movable worktable which will be fed against the revolving milling cutter to perform the
cutting operation
• The difference between drilling and milling is that, in drilling a rotating drill is fed
against a stationary work piece, while in milling the work piece is fed against a milling
cutter which only revolves.
• Similarly, it also differs from the lathe operation because the lathe tool is fed against
rotating work piece.

Write a short note on 3D printing.

Define Additive Manufacturing. List the various steps involved in additive
manufacturing
3D printing, commonly known as Additive manufacturing creates 3-
dimensional objects by successively layering materials under computer control. 3D
printing involves layering materials like plastics, composites, or biomaterials to
create objects that range in shape, size, rigidity, and color.

Working process of a 3D printer:

• 3D Model Design - The process begins with creating a 3D model of the object
using computer-aided design (CAD) software. The model is sliced into layers.
• Machine Preparation - The 3D printer is loaded with the required raw
materials like plastic filament, resin, metal powder etc. based on the printing
technology used.
• Printing Materials - Unlike inkjet and laser printers, a 3D printer does not use
liquid ink or solid powder. It deposits layers of molten plastic, metal
wire, or powder and fuses them with the existing structure using adhesives or
ultraviolet light.
• Layer-by-Layer Printing - The 3D printer deposits and fuses together material
layer-by-layer as per the design file. The build platform lowers, and the
process is repeated until the object is formed.
• Post-Processing - Printed objects may require additional steps like cleaning,
smoothening, baking, and polishing. Support structures are removed.
• Quality Checks - Printed objects are checked for dimensional accuracy and
compliance with design specifications. Defects may require re-printing.
• Application - The final 3D printed part can then be put to functional use or for
other applications like prototyping, education, art and so on.
• Materials: A range of materials are used for 3D printing including plastics like
ABS, PLA, nylon, photopolymers, metals including titanium, aluminum, steel,
gold, silver, alloys, ceramics, paper, wax, and even food materials like
chocolate.
Explain the various components used in 3 D Printing
Basic 3D Printer Layout:
• Print Bed: The print bed is the surface that your objects are printed on to.
Typically, it will consist of a sheet of glass, a heating element, and some kind of
surface on top to help the plastic stick.
Filament: This is the plastic that's consumed by the printer. It comes on a
spool.
• Extruder: The extruder is the core of the printer. It is where the plastic gets
drawn in, melted, and pushed out.
Heater Cartridge: It heats the plastic.
Thermistor/Thermocouple/RTD: These are all various types of sensors for
determining the temperature of the hot end
Nozzle: The nozzle is simply a piece with a small hole for the melted filament
to come out of. Nozzles are interchangeable and come in various sizes
Stepper Motors: Stepper motors rotate in increments and gives precise
control over their position.
Power Supply: This takes the 120V AC electricity from the wall and converts
it to low voltage DC power.
Controller Board: It takes the commands given to it by your computer and
orchestrates their execution. It contains a microcontroller and all the circuitry
needed for running the motors, reading the sensors, and talking to your computer.
Explain the applications of 3 D Printing
Applications of 3D Printing
• Aerospace: Lightweight printed aircraft and spacecraft parts can replace
traditionally manufactured parts to reduce weight and material needs.
• Automotive: The automotive industry uses 3D printing for rapid prototyping
and to produce specialized parts and tools. Printed parts help improve design
and can reduce weight.
 • Construction: 3D printing technology is being used to construct scale
models of buildings, bridges, and even full-scale houses and other structures
using concrete and other materials.
• Healthcare: 3D printing is revolutionizing healthcare with customized
prosthetics, implants, anatomical models for surgery practice, and
pharmaceuticals.
• Consumer: With 3D printing, products can be easily customized or
personalized to an individual's specs.
• Public Infrastructure: India's first 3D printed post office built in just 45 days
by L&T and IIT Madras demonstrates rapid construction capabilities.
Differentiate between UP Milling and Down Milling