Manufacturing Processes

Machine Tools
DR. GOPINATH T.
Assistant Professor
Department of Mechanical Engineering
gopinath.t@[Link]
gopinathfromindia@[Link]

Ver #2
17th March 2026

1
 Machine Tools
CONTENT

Introduction - Classifications of manufacturing processes, characteristics of

material removal processes, need and purpose of conventional material removal
processes.

Lathe – Constructional features, classification, operations- facing, plain turning,

drilling, knurling etc., threading cutting process (single start multiple start) and
gear train, taper turning methods and calculations. Types of tools for various
operations, accessories and attachments, Calculation of Machining time.

Milling – Constructional features, classification, face and peripheral milling, up

milling and down milling processes, Types of tools for various operations, dividing
head attachment, operations on milling machine, gear milling, Machining time.
Numerical based on indexing methods and machining time.

Drilling – Constructional features, classification, Types of tools and work holding

devices, tool holding devices - tapping, quick change chuck, floating holder.
Operations on drilling machine, machining time. Numerical based on machining
time.

Introduction to CNC, Word address format (WAF)

 Introduction
❖ Classifications of Manufacturing Processes

➢Manufacturing Process

▪ A sequence of operations and processes designed to

create a specific product
▪ The process of turning materials into a product
 Introduction
❖ Classifications of Manufacturing Processes

➢Basic Manufacturing Processes

▪ Casting
▪ Forming or Metalworking
▪ Machining
▪ Joining and Assembly
▪ Rapid Prototyping
▪ Other
 Introduction
❖ Classifications of Manufacturing Processes
➢Casting
“Foundry or casting is the
process of producing metal/alloy
component parts of desired
shapes by pouring the molten
metal/alloy into a prepared
mould (of that shape) and then
allowing the metal/alloy to cool
and solidify. The solidified piece
of metal/alloy is known as a
CASTING”.
final products of casting : examples
 Introduction
❖ Classifications of Manufacturing Processes
➢Forming or Metalworking
o Rolling – Material passes
through a series of rollers, reducing
its thickness with each pass

o Forging – Material is shaped by

the controlled application of force
(blacksmith)
Open die forging Closed die forging

o Extrusion – Material is
compressed and forced through a
die to produce a uniformed cross
section
 Introduction
❖ Classifications of Manufacturing Processes
➢Forming or Metalworking

o Wire, rod, and

tube drawing –
Material is pulled
through a die to
produce a uniformed
cross section

o Cold forming and

forging – Slugs of
material are
squeezed into dies
 Introduction
❖ Classifications of Manufacturing Processes
➢Machining
Controlled removal of material from a part to create a specific shape or
surface finish

oTurning Processes
✓ Work piece rotates as cutting tool is
fed into the work
✓ Processes include: Straight, taper,
contour turning, facing, forming,
necking, parting, boring, threading,
and knurling
 Introduction
❖ Classifications of Manufacturing Processes
➢Machining
o Milling Processes
✓Operations that create flat or
curved surfaces by progressively
removing material
✓Cutting tools rotate as the work
piece is secured and fed into the tool
✓Processes include: Surfacing,
shaping, forming, slotting, T-slotting,
angle, straddle, dovetailing, and slab
milling
 Introduction
❖ Classifications of Manufacturing Processes
➢Machining
o Drilling Processes

✓Cutting tools rotate and are fed into

nonmoving secured work pieces
✓Processes include: Drilling, counter
drilling, step drilling, boring, counter
boring, countersinking, reaming, spot
facing, and tapping
 Introduction
❖ Classifications of Manufacturing Processes
➢Machining
o Shearing Processes
✓ A material is placed between a
stationary and movable surface. The
movable surface (blade, die, or punch)
applies a force to the part that shears
away the unwanted material.
✓ Processes include: Shearing,
blanking, cutoff, and parting; punching,
perforating, and slotting; notching,
lacing, and trimming
 Introduction
❖ Classifications of Manufacturing Processes
➢Machining
o Abrasive Machining Processes

✓ Operations in which small particles of materials (abrasives) remove

small chips of material upon contact
 Introduction
❖ Classifications of Manufacturing Processes
➢Machining
o Thermal and Chemical Processes

✓Operations that cut and shape materials through chemical means

✓ No mechanical force is used

✓ Electrical discharge, electrochemical, chemical, laser, electron beam,

flame cutting, and plasma-arc cutting

✓ Processes include: Grinding, sawing, cutting, machining, milling,

blanking, and etching

 Introduction
❖ Classifications of Manufacturing Processes
➢Joining and Assembly Processes

✓ Most products consist of multiple parts that are assembled to form a

finished product.
✓ Typical assembly processes include: Mechanical fastening, welding,
adhesive bonding, soldering and brazing

Mechanical fastening Welding Adhesive bonding Soldering and brazing

 Introduction
❖ Classifications of Manufacturing Processes

➢ Other Manufacturing Processes

✓ Testing

✓ Transportation

✓ Material handling

✓ Packaging
 Introduction
❖ Material Removal Processes
Material removal processes are the most common route for generating
acceptable dimensional accuracies and surface texture

▪ Classification
 Introduction
❖ Conventional Material Removal Processes
Most important machining operations Other machining operations

Turning Shaping

Drilling Broaching

Milling Sawing

Peripheral milling Face milling

Lathe
 Introduction

• Lathe is a machine, which removes the metal from a

piece of work to the required shape &size
❖ Types of Lathe

❑ Engine Lathe
• The most common form of lathe, motor driven and comes in
large variety of sizes and shapes.
❑ Bench Lathe
• A bench top model usually of low power used to make
precision machine small work pieces.
❑ Tracer Lathe
• a lathe that has the ability to follow a template to copy a
shape or contour.
❖ Component Description
❖ Lathe Operation
• Turning: produce straight, conical, curved, or grooved
work pieces
• Facing: to produce a flat surface at the end of the part or
for making face grooves.
• Boring: to enlarge a hole or cylindrical cavity made by a
previous process or to produce circular internal grooves.
• Drilling: to produce a hole by fixing a drill in the tailstock
• Threading: to produce external or internal threads
• Knurling: to produce a regularly shaped roughness on
cylindrical surfaces
❖ Lathe Operation
❖ Cutting Tools

• Single point cutting tool

❖ Work Holding Devices

▪ Between two centres. The workpiece

is driven by a device called a dog; this
method is suitable for parts with high
length-to-diameter ratio.

▪ A 3 jaw self-centering chuck is used for

most operations on cylindrical work-parts.
For parts with high length-to-diameter
ratio the part is supported by center on
the other end.
❖ Work Holding Devices

Collet consists of tubular

bushing with longitudinal slits.
Collets are used to grasp
and hold bar stock. A collet of
exact diameter is required to
match any bar stock diameter.

A face plate is a device used to

grasp parts with irregular shapes.
❖ Four-Jaw Chuck ❖ Three jaw chuck
▪ This is independent chuck generally has ▪ For holding cylindrical stock
four jaws , which are adjusted individually centered. For facing/center drilling
on the chuck face by means of adjusting the end of your aluminum stock
screws
❖ Magnetic Chuck ❖ Collet Chuck
▪ Thin jobs can be held by means of Collet chuck is used to hold small
magnetic chucks workpieces
❖ Machining Calculations: Turning

• Spindle Speed - N v (rpm)

• v = cutting speed N=
π Do
• Do = outer diameter
• Feed Rate - fr fr = N f (mm/min -or- in/min)
• f = feed per rev

• Depth of Cut - d D − Df (mm/rev -or- in/rev)

• Do = outer diameter d = o
• Df = final diameter 2
• Machining Time - Tm L (min)
• L = length of cut Tm =
fr
• Material Removal Rate - MRR (mm3/min -or- in3/min)
MRR = v f d

3/24/2026 29
Milling
Milling
Machining operation in which work is
fed past a rotating tool with multiple
cutting edges
– Axis of tool rotation is
perpendicular to feed direction
– Usually creates a planar surface;
other geometries possible
either by cutter path or cutter
shape
– Cutting tool called a milling
cutter, cutting edges called
"teeth"
– Machine tool called a milling
machine
 [Feb’15]
Basic Milling Process
Difference between Up milling and Down milling

Up Milling Down Milling

In up milling the cutter rotates against In Down milling, the cutter rotates with
direction of feed. direction of feed.
It is also known as conventional milling. It is also known as climb milling.
In this, chip width size is zero at initial cut In this cutting process, chip size is maximum at
and increase start of cut
with feed. It is maximum at the end of feed. and decrease with the feed. It is zero at the end
of feed.
In up milling, tool wear is more because the In this, tool wear is less compare to the up
tool runs milling, due
against the feed. to the cutter rotate with the feed
Tool life is low. Tool life is high.
Milling operations
Milling operations are classified into two major categories:

❑Peripheral Milling (Side Milling)

Axis of rotation is parallel to the
surface being cut

❑ Face Milling
Axis of rotation is perpendicular
to the surface being cut
Other Milling operations
❑End Milling
The end milling cutter has teeth
on the end as well as the
periphery

PM Cutter FM Cutter EM Cutter

Types of Milling Machines
Peripheral Milling (Horizontal Milling)
Face Milling (Vertical Milling)
Principle Parameters of Milling Machine
Overhanging Arm: It Table rests on the
is mounted on the saddle
column and serves a
bearing support for
Saddle: It is placed at
the arbor.
the top of the knee.
It provides guide
Arbor: It holds ways for the
milling cutter rigidly movement of the
and mounted on table.
the spindle

Column: It is a type of rigid Knee: It can be adjusted at

vertical long box. It houses a height on the column. It
driving mechanism of houses the feed
spindle, mechanism of the table
table knee is also fixed to and other controls
the guide ways of column
Base: It provides rest for all parts of
milling machine
Arbor

Mounting a milling cutter on an arbor for use on a horizontal

milling machine
Additional Milling Machines
Bed Type Milling Machine

Schematic illustration of a bed-type milling machine (Usually of larger

size and capacity). Note the single vertical-spindle cutter and two
horizontal-spindle cutters
Additional Milling Machines
Planer Type Milling Machine
•These heavy duty large machines, called plano-miller
• It looks like planing machine where the single point tools are replaced by one
or a number of milling heads; generally used for machining a number of
longitudinal flat surfaces simultaneously, viz., lathe beds, table and bed of
planning machine etc.
Additional Milling Machines
Rotary Table Type Milling Machine
Such open or closed ended high production milling machines possess one large
rotary work-table and one or two vertical spindles as typically shown in Fig.; the
positions of the job(s) and the milling head are adjusted according to the size
and shape of the job.
Nomenclature of Plane Milling Cutter
Nomenclature of Plane Milling Cutter
Standard Milling Cutters
[Link] milling cutter
[Link] milling cutter
[Link] slitting saw A suitable
[Link] milling cutter milling cutter is
selected
[Link] milling cutter according to
6.‘T’ – slot milling cutter the need

[Link] cutter
[Link] cutter
Plain Milling Cutter

▪ Cylindrical in shape
▪ Teeth on the circumferential
surface only
▪ Used for producing flat
surfaces
▪ Teeth may be straight or
helical
▪ Central hole for mounting
arbor
Side Milling Cutter

▪Teeth on periphery also on

one or both sides
▪ Used for removing material
from the sides of w/p
Metal Slitting Saw

▪Teeth on the circumference

of the cutter
▪ Used for cutting narrow,
deep slots and for parting off
operation
▪ The outer diameter of the
cutter will be up to 200mm
and width ranges from
0.75mm to 7mm
Angle Milling Cutter

▪Teeth are not parallel to the

axis but are at the angle to it
▪ Used for inclined surfaces,
bevel and helical grooves
‘T’ Slot Milling Cutter

▪Special form of end mills intended for machining ‘T’ slots

▪ Looks like side milling cutter with a shank
Fly Cutter

Single point
cutting tool

▪ Fly cutter is the simplest form of cutter

▪ Consists of single point cutting tool attached to end of
the arbor
▪ Normally used when standard cutters are not available
Formed Cutter

▪ Concave and convex

milling cutters
▪ Used for making gears
 [ Feb., May 16]
Milling Machine Operations
[Link] milling
[Link] milling
[Link] milling
[Link] milling
[Link] milling
[Link] milling
[Link] milling
[Link] milling
Milling Machine Operations

Plain/slab milling operation Face milling operation Angular milling operation

End milling operation ‘T’ slot milling operation

Straddle Milling Operation

▪ Operation of machining two parallel

surfaces simultaneously on a work piece
▪ By using suitable spacing collars, the
distance between the two cutters is
adjusted correctly.
Gang milling

▪ Gang milling is a horizontal milling operation that utilizes

three or more milling cutters grouped together for the
milling of a complex surface in one pass
 Indexing of
Milling Machine
 Indexing of Milling Machines
• Indexing is the process of evenly dividing the
circumference of a circular work piece into
equally spaced divisions.
• It is used in cutting gear teeth, cutting splines,
milling grooves in reamers and taps, and
spacing holes on a circle.
 Indexing or Dividing head
• The indexing head of the indexing fixture contains
an indexing mechanism which is used to control
the rotation of the index head spindle to space or
divide a work piece accurately.
Indexing or Dividing head
• A simple indexing mechanism consists of a 40 teeth worm
wheel fastened to the index head spindle, a single – cut worm, a
crank for turning the worm shaft, an index plate and a sector.
 Indexing or Dividing head
 Since there are 40 teeth in the worm wheel,
one turn of the index crank causes the worm
wheel, and the index head spindle to make
1/40 of a turn.
 So, 40 turns of the index crank revolve the
spindle one full turn.
Index Plate
• The indexing plate is a round plate with a series
of six or more circles of equally spaced holes.
• The index pin on the crank can be inserted in any
hole in any circle.
• With the interchangeable plates regularly
furnished with most index heads, the spacing
necessary for most gears, bolt heads, milling
cutters, splines can be obtained.
Index Plate : Direct indexing Plate

 Direct indexing plate usually contains three

sets of hole circles or slots: 24, 30, and 36.
 Number of divisions possible to be indexed
are limited to numbers that are factors of 24,
30, 36.

Slots Direct indexing divisions

24 2 3 4 6 8 12 24
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
Index Plate
• Brown and Sharp type set of index plates
consists of 3 plates of 6 circles.
Plate – I is having 15, 16, 17, 18, 19, 20 holes.
Plate – II is having 21, 23, 27, 29, 31, 33 holes.
Plate – III is having 37, 39, 41, 43, 47, 49 holes.
Index Plate
• Cincinnati type consists of one plate drilled on
both sides with circles divided as follows.
First side –
24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43 holes.
Second side –
46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66 holes.
Direct Indexing
To mill eight flutes on a reamer blank
Since the 24-hole circle is the only
one divisible by 8 (the required
40
number of divisions), it is the Indexing =
only circle that can be used in this N
case. The indexing required
to cut eight flutes
Slots Direct indexing divisions
24 2 3 4 6 8 12 24 40
= 5 full turns of index crank
8
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
Direct Indexing
▪ Example 2
To mill 10 teeth gear
Calculate the full turns of index crank.

Slots Direct indexing divisions

24 2 3 4 6 8 12 24
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
Direct Indexing
▪ Example 2
To mill 10 teeth gear
- Select a circle with 30 holes
40
Indexing =
N
40
= 4 full turns of index crank
10

Slots Direct indexing divisions

24 2 3 4 6 8 12 24
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
• The indexing required to cut seven flutes
?
Slots Direct indexing divisions
24 2 3 4 6 8 12 24 NO
30 2 3 5 6 10 15 30
Seven
36 2 3 4 6 9 12 18 36

Simple (Plain) indexing

Simple (Plain) indexing
• The indexing required to cut seven flutes
40 5
= 5 turns of index crank
7 7

• How to do it ?
Simple (Plain) indexing 40 5
=5
Indexing for Seven Flutes 7 7

Index-plate hole circles Choose any hole

Brown & Sharpe circle that is divisible
by denominator 7
Plate 1 15-16-17-18-19-20 5
 21 = 15
Plate 2 21-23-27-29-31-33 7
Plate 3 37-39-41-43-47-49
So, 5 full turns plus
Cincinnati Standard Plate
15 holes on 21 hole
One side circle.
24-25-28-30-34-37-38-39-41-42-43
The five-sevenths turn
Other side
involves use of an index
46-47-49-51-53-54-57-58-59-62-66 plate and sector arms.
Solve: Index Eleven Flutes
Slots Direct indexing divisions
24 2 3 4 6 8 12 24
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
Brown & Sharpe
Plate 1 15-16-17-18-19-20
Plate 2 21-23-27-29-31-33
Plate 3 37-39-41-43-47-49
Cincinnati Standard Plate
One side - 24-25-28-30-34-37-38-39-41-42-43
Other side - 46-47-49-51-53-54-57-58-59-62-66
Solve: Index Eleven Flutes
Slots Direct indexing divisions
40 7
24 2 3 4 6 8 12 24 =3
11 11
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36 Choose any hole
circle that is divisible
Brown & Sharpe by denominator 11
Plate 1 15-16-17-18-19-20 7
 33 = 21
Plate 2 21-23-27-29-31-33 11
Plate 3 37-39-41-43-47-49
So, 3 full turns plus
Cincinnati Standard Plate 21 holes on 33 hole
One side - 24-25-28-30-34-37-38-39-41-42-43 circle.
Other side - 46-47-49-51-53-54-57-58-59-62-66
Solve: Index Thirteen Flutes
Slots Direct indexing divisions
24 2 3 4 6 8 12 24
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
Brown & Sharpe
Plate 1 15-16-17-18-19-20
Plate 2 21-23-27-29-31-33
Plate 3 37-39-41-43-47-49
Cincinnati Standard Plate
One side - 24-25-28-30-34-37-38-39-41-42-43
Other side - 46-47-49-51-53-54-57-58-59-62-66
Solve: Index Thirteen Flutes
Slots Direct indexing divisions
40 1
24 2 3 4 6 8 12 24 =3
13 13
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36 Choose any hole
circle that is divisible
Brown & Sharpe by denominator 13
Plate 1 15-16-17-18-19-20 1
 39 = 3
Plate 2 21-23-27-29-31-33 13
Plate 3 37-39-41-43-47-49
So, 3 full turns plus
Cincinnati Standard Plate 3 holes on 39 hole
One side - 24-25-28-30-34-37-38-39-41-42-43 circle.
Other side - 46-47-49-51-53-54-57-58-59-62-66
Solve: Index Twenty Six Flutes
Slots Direct indexing divisions
24 2 3 4 6 8 12 24
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
Brown & Sharpe
Plate 1 15-16-17-18-19-20
Plate 2 21-23-27-29-31-33
Plate 3 37-39-41-43-47-49
Cincinnati Standard Plate
One side - 24-25-28-30-34-37-38-39-41-42-43
Other side - 46-47-49-51-53-54-57-58-59-62-66
Solve: Index Twenty Six Flutes
Slots Direct indexing divisions
40 8
24 2 3 4 6 8 12 24 =1
32 32
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36
8
Brown & Sharpe 16 = 4
32
Plate 1 15-16-17-18-19-20
Plate 2 21-23-27-29-31-33 So, 1 full turns plus
Plate 3 37-39-41-43-47-49 4 holes on 16 hole
Cincinnati Standard Plate circle on Brown &
Sharpe Plate 1
One side - 24-25-28-30-34-37-38-39-41-42-43
Other side - 46-47-49-51-53-54-57-58-59-62-66
Angular Indexing

• Setup for simple indexing may be used

– Must calculate indexing with angular distance
between divisions instead number of divisions
• One complete turn of index crank turns
work 1/40 of a turn
– 1/40 of 360º equals 9 degrees

no. of degrees required

Indexing in degrees =
9

68-78
Examples of Angular Indexing

1. Calculate indexing for 60º

Brown & Sharpe

Plate 1 15-16-17-18-19-20
Plate 2 21-23-27-29-31-33
Plate 3 37-39-41-43-47-49
Examples of Angular Indexing

1. Calculate indexing for 60º

60 2
Indexing = =6
9 3
Brown & Sharpe 2
18 = 12
Plate 1 15-16-17-18-19-20 3
Plate 2 21-23-27-29-31-33 So, 6 full turns plus
Plate 3 37-39-41-43-47-49 12 holes on 18 hole
circle on Brown &
Sharpe Plate 1
Examples of Angular Indexing

2. Calculate indexing for 40º

Brown & Sharpe

Plate 1 15-16-17-18-19-20
Plate 2 21-23-27-29-31-33
Plate 3 37-39-41-43-47-49
Examples of Angular Indexing

2. Calculate indexing for 40º

40 4
Indexing = =4
9 9
Brown & Sharpe 4
18 = 8
Plate 1 15-16-17-18-19-20 9
Plate 2 21-23-27-29-31-33
So, 4 full turns plus
Plate 3 37-39-41-43-47-49 8 holes on 18 hole
circle on Brown &
Sharpe Plate 1
Examples of Angular Indexing

3. Calculate indexing for 24º30'

Examples of Angular Indexing

3. Calculate indexing for 24º30'

• First, convert angle into minutes

(24 x 60') = 1440' now add 30' = 1470'

Divide by 9x60' 1470'/540' = 2 13/18
So 2 full turns and 13 holes on 18 hole circle
Examples of Angular Indexing

4. Calculate indexing for 26º30'

Examples of Angular Indexing

3. Calculate indexing for 26º30'

• First, convert angle into minutes

(26 x 60') = 1560' now add 30' = 1590'

Divide by 9x60' 1590'/540' = 2 17/18
So 2 full turns and 17 holes on 18 hole circle
Milling Calculations
l
T = Time /cut
B
N = Cutter rpm O C W
Z = number of teeth on cutter R
A
ft = feed mm/tooth
AP1
fm = table feed in mm/min
 f m = ft  Z  N
l= length of w/p
f = feed mm/rev
AP = Approach
 fm = f  N
OT = Over travel
L = l + AP + OT + AP1 AP1 = Compulsory approach
L = Length of tool travel D = Diameter of milling cutter
W = Width of w/p
1. Approach Length of Face Milling Cutter

B
O C W
R
A

AP1

OAB,
(OA)2 = ( AB )2 + (OB )2 AP1 = BC = OC − OB
2 2
 D  W  2 2
  =   + (OB )  D   D  W 
2
AP1 =   −   −  
2  2 2 2  2

 
2 2
 D  W  1
OB =   −    AP1 = D − D 2 − W 2
2  2 2
2. Approach Length of Plain Milling Cutter

O
R
A
B
d

AP1

D OAB,
OA = R = 2 2
2 D D 
  =  − d  + ( AP1)
2
( AP1)2 = Dd − d 2
D 2 2 
OB = − d AP1 = d ( D − d )
2
 D   D  
2 2
D
AP1 = AB ( AP1) =   −   − 2     d + d 
2 2

 2   2  2 
Numerical 1:
A straight teeth slab milling cutter of 100 mm diameter and 10 teeth
rotating at 200 rpm is used to remove a layer of layer of 3 mm
thickness from a steel bar. If the feed is 400 mm/min the feed per
tooth in this operation will be.
Numerical 1:
A straight teeth slab milling cutter of 100 mm diameter and 10 teeth
rotating at 200 rpm is used to remove a layer of layer of 3 mm
thickness from a steel bar. If the feed is 400 mm/min the feed per
tooth in this operation will be.

Given:
D = 100 mm
Z = 10
N = 200 rpm
d = 3mm
fm = 400 mm/min

ft =?
Numerical 2:
A face milling cutter of 100 mm diameter has 10 teeth. The cutting
speed is 22 m/min, if the feed/tooth/rev is 1mm. What will it take for
one cut along a work piece of CI 1400 mm long.
Numerical :
A face milling cutter of 100 mm diameter has 10 teeth. The cutting
speed is 22 m/min, if the feed/tooth is 1mm. What will it take for one
cut along a work piece of CI 1400 mm long.

Given:
D = 100 mm
Z = 10  DN
V = 22 m/min V=
ft = 1mm/tooth 1000
l = 1400mm L
T=
T =? f N
f = ft  Z
Numerical 3:
A rectangular block 200 x 80 x 60 mm is to be face milled on a
vertical milling machine. A face milling tool of 100 mm diameter,
having 12 teeth of carbide inserts is used for machining the 200 x 80
mm face. Suggested cutting speed is 50 m /min and feed per tooth
0.1 mm. Calculate the cutting time, for one pass removing a material
of 2 mm thickness from surface. Take AP=OR= 5mm.
Numerical 4:
The following data refers to slab milling operation

Diameter of cutter = 50mm

Number of teeth on cutter = 12
Cutter spindle speed = 300 rpm
Depth of cut = 2mm
Length of job = 500mm
Longitudinal table feed = 200 mm/min

Find:
(i) Feed per tooth during the milling operation
(ii) If cutter over travel is 2mm, the machining time for single pass of
milling operation
Drilling
 Introduction
❖ Drilling
The drilling machine or drill press is one of
the most common and useful machine
employed in industry for producing forming
and finishing holes in a work piece. The unit
essentially consists of:
1. A spindle which turns the tool (called drill)
which can be advanced in the work piece
either automatically or by hand.
2. A work table which holds the work piece
rigidly in position.
❖ Working Operation

The rotating edge of the drill exerts a

large force on the work piece and the
hole is generated.
The removal of metal in a drilling
operation is by shearing.

Use:- Drilling machine is used to

drill blind and through holes in work
pieces.
❖ Construction

The machine has only a hand feed

mechanism for feeding the tool into the work
piece.
This enables the operator to feel how the
drill is cutting and accordingly he can control
the down feed pressure.
Sensitive drill presses are manufactured in
bench or floor models, i.e., the base of
machine may be mounted on a bench or floor.
The main operating parts of a sensitive
machine/drill press are Base, Column, Table,
and Drill Head.
❖ Construction
Bench Drilling Machine :- The simplest
type of sensitive drilling machine is shown in
figure. This is used for light duty drilling work.
This machine is capable to drill hole up to
12.5mm diameter
1. Motor :- An electric motor supplies the
required driving force to stepped pulley.
2. Base :- Base is the bottom part of
machine in which the column is fitted upright.
3. Feed handle :- Handle is provided to
feed the drill in to the work piece. A rake and
pinion mechanism is provided to drive the
chuck.
❖ Construction

[Link]:- Column is the main cylindrical part

of drill machine on which the other components
are mounted.
[Link] guard:- Belt guard is provided to cover
the belt and pulley drive mechanism to minimize
the hazard of accident.
[Link]:- Chuck is provided to hold the drill
of different sizes up to 6.5 mm. Drill size of more
than 6.5 mm are to be fitted directly in the Morse
taper of spindle
[Link] Table:- Work pieces are mounted and
held in position by the table. This table can be
tilted for drilling at an angle.
Drill Bit-Holding Devices
• Drills and similar tools with
parallel shanks are held in a
drill chuck.
• By rotating the outer
sleeve, the jaws can be
opened and closed.
• To ensure maximum grip,
the chuck should be
tightened using the correct
size of chuck key. This
prevents the drill from
spinning during use and
chewing up the drill shank.
Types of Drill Chucks
• Key-type
▪ - Most common.
– - Three jaws move
simultaneously when outer
sleeve turned
• - Tighten with key
• - Different size keys for
different size chucks
Types of Drill Chucks
• Keyless
– Chuck loosened or
tightened by hand
without key

• Precision keyless
– Holds smaller drills
accurately
❖ Types of Drilling Machines

▪ Portable Drilling Machine

▪ Sensitive or Bench Drill
▪ Upright Drilling Machine(Single Spindle)
▪ Upright Drilling Machine(Turret Type)
▪ Radial Drilling Machine
▪ Multiple Spindle Drilling Machine
▪ Deep Hole Drilling Machine
▪ Gang Drilling Machine
▪ Horizontal Drilling Machine
▪ Automatic Drilling Machine
❖ Portable Drilling Machine

It is a very small, compact and self

contained unit carrying a small electric
motor inside it.
It is very commonly used for drilling holes
in such components that cannot be
transported to the shop due to their size or
weight or where lack of space does not
permit their transportation to the bigger type
of drilling machine.
In such cases, the operation is performed
on the site by means of the portable electric
drill.
❖ Sensitive or Bench Drill

This type of drilling machine is used

for very light work.
Its construction is very simple and
so is the operation .
It consists of as shown in fig. of a
cast iron having a fixed table over it.
❖ Radial Drilling Machine

This machine is very useful

because of its wider range of
action.
Its principal use is in drilling
holes on such work is difficult to
be handled frequently.
With the use of this machine,
the tool is moved to the desired
position instead of moving the
work to bring the latter in position
for drilling.
❖ Gang Drilling Machine

It is nothing but a type of multiple

spindle drilling machine, in which the
spindles are arranged in a row.
These spindles may be driven either
separately or collectively.
This machine is very useful when the
nature of work is such that a number of
operations like drilling, reaming, counter
boring and tapping, etc. are to be
performed in succession on it.
❖ Operations of Drilling Machine

• Drilling
• Reaming
• Boring
• Counter Boring
• Counter Sinking
• Spot Facing
• Tapping
❖ Operations of Drilling Machine

Drilling :- It is the main operation done

on this machine. It is the operation of
producing a circular hole in a solid metal by
means of a revolving tool called drill.
Boring :- It is an operation used for
enlarging a hole to bring it to the required
size and have a better finish.
Counter sinking :- It is the operation
used for enlarging the end of a hole to give it
a conical shape for a short distance.
❖ Operations of Drilling Machine

• Reaming :- It is the operation of finishing

a hole to bring it to accurate size and have a
fine
surface finish . This operation is performed by
means of a multi tooth tool called reamer.
• Counter boring :- This operation is used
for enlarging only a limited portion of the hole
is called counter boring .
• Tapping:- It is the operation done for
forming internal threads by means of the tool
called tap.
Drilling Calculations
1. Cutting Velocity (V)

 DN
V= m/s
60
Where,
D = Drill diameter in meter
N = Rotational speed of the drill in rpm
Drilling Calculations
2. Machining Time(T)

L
T=
f N

Where,
T = Machining time per hole
L = Length of the tool travel
f = feed in mm/rev
N = rotational speed of the drill

f .N = Feed Velocity
Drilling Calculations
D
Length of the tool travel
D/2
L = t + AP1 + AP + OR B C
θ AP1
A
Where, t
t = thickness of w/p
AP = approach of drill OR
OR = over travel
AP1 = Compulsory approach to
complete drilling of the hole In Triangle ABC,
θ = half of point angle
tan  =
( D / 2)
D = Drill diameter AP1
Numerical
1) A hole of 30 mm diameter and 75 mm depth
is to be drilled. The suggested feed 1.3 mm
per revolution and the cutting speed 62
m/min. Tool approach is 6 mm and tool over
travel is 6 mm. Take AP1 = 0.5D,
calculate
(i) Spindle rpm
(ii) Feed speed
(iii) Cutting time
2) Calculate the time taken to drill a hole
through a 25 mm thick plate with the drill
rotating at 300 rpm and moving at a feed rate
of 0.25 mm/rev. Take AP=AP1=OR=0
3) Through hole of 10 mm diameter is to be
drilled in a steel plate of 20 mm thickness.
Drill spindle speed is 300 rpm, feed 0.2
mm/rev and drill point angle is 120o.
Assuming drill over travel of 2mm, the time
for producing a hole will be? Take AP=0.
4) Calculate the machining time required for
producing 20 holes on M.S. plate of 40 mm
thickness with following data.
Drill diameter = 30 mm
Feed = 0.1 mm/rev
Cutting speed = 25 m/min
Over travel = 0.5 x drill diameter in mm
AP1= 0.5 x drill diameter in mm
AP = 0
CNC, WAF
Numerical Control (NC) Machines
❑ Programmable automation in which the mechanical actions of a
‘machine tool’ are controlled by a program containing coded
alphanumeric data that represents relative positions between a
work head (e.g., cutting tool) and a work part
Classification of NC Machine Tool System
1. According to control loop Feedback System
• Open loop system
• Closed loop system

2. According to Type of Tool Motion Control

• Point to point positioning
• Continuous path system

3. According to the Programming

• Absolute
• Incremental
Classification of NC Machine Tool System
• Open loop system and Closed loop system
Classification of NC Machine Tool System

movement
Classification of NC Machine Tool System
Punched Tape
Comparison Between NC, CNC and DNC
Sr.
No. Parameters NC CNC DNC
Central
Computer computer
Tape controlled
1 Type of control controlled controlling
machine
machine other CNC
machines
Editing can be Easy editing on
2 Editing facility Not possible at site
done on site site

3 Flexibility Less High High

Number of Multiple at a Multiple at a

4 One at a time
programmes stored time time

5 Initial cost Low High Highest

Benefits of CNC:

• Uniform quality
• Reduced set up time
• Reduced lead time: Proven part programmes
• Accuracy and repeatability
• Simplified tooling
• Consistent cutting time
• Increased productivity
• Reduced inventory: Smaller batch production
• Contouring of complex parts
CNC Program Codes

Letter Codes
• Each instruction to the machine consists
of a letter followed by a number.
• Each letter is associated with a specific
type of action or piece of information
needed by the machine.
• Letters used in Codes

N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
CNC Program Codes

Letter Codes – G & M Codes

•G-codes : Preparatory Functions
– involve actual tool moves
• M-codes : Miscellaneous Functions
– involve actions necessary for
machining (i.e. spindle on/off, coolant
on/off)
CNC Program Codes
Letter Codes – G Codes
◼ G90 - Absolute Coordinates
◼ G91 - Relative Coordinates
◼ G00 - Rapid Traverse (non-cutting move)
◼ G01 - Straight Line Interpolation (cutting move
◼ G02 - Circle Interpolation (clockwise)
◼ G03 - Circle Interpolation (c-clockwise)
◼ G04 - Dwell (wait) Pause between motions on all axis.
Time in seconds - G04F2 - pause for 2 sec.
◼ G05 - Pause - waits for user intervention.
◼ G20 – Inch Units
◼ G21 – Metric Units
CNC Program Codes

Letter Codes – M Codes

CNC Program Codes
Tool Motion Codes
• Generally, three types of tool motion are used on a CNC machine:

G00 Rapid tool move.

G01 Straight-line feed move. Linear interpolation. Coordinated
moves at a controlled feed rate.

G02/G03 Two-dimensional arc feed moves. Circular interpolation.

CNC Program Codes

Letter Codes – N Codes

• N-codes: Gives an identifying
number for each block of
information.
• It is generally good practice to
increment each block number by 5 or
10 to allow additional blocks to be
inserted if future changes are
required.
CNC Program Codes

Letter Codes – X Y & Z Codes

• X, Y, and Z codes are used to specify
the coordinate axis.
• Number following the code defines
the coordinate at the end of the move
relative to an incremental or absolute
reference point.
CNC Program Codes

Letter Codes – F, S & T Codes

• F-Code: used to specify the feed
rate
• S-Code: used to specify the
spindle speed
• T-Code: used to specify the tool
identification number associated
with the tool to be used in
subsequent operations.
Sample NC Program Block

N00 G90 G01 X.5 Y.5 Z0 F1

FEED RATE (IN/MIN)
Z COORDINATE
Y COORDINATE
X COORDINATE
PREP CODE - SL INTERPOL
PREP CODE - ABSOLUTE
BLOCK SEQUENCE #
SAMPLE PART

ABSOLUTE COORD.
A 0.5 0.5
B 0.5 1.5
C 0.875 1
D 1.25 1.5
E 1.25 0.5
F 1.75 1.5
H 1.75 0.5
I 1.75 1
SAMPLE PROGRAM
N00 G90 ; ABSOLUTE COORDINTAES
N01 M06T1 ; LOAD TOOL 1
N02 M03 S3000 ; TURN SPINDLE ON TO 3000 RPM
N03 G00 Z .1; RAPID TO .1 ABOVE PART
N04 G00 X.5Y.5 ; RAPID TO POINT A
N05 G01 Z-.0625F9 ; PLUNGE 1/16 AT 9 IN/MIN.
N06 G01 X.5Y1.5; STRAIGHT LINE INTERP TO B
N07 G01 X.875Y1; STRAIGNT LINE INTERP TO C
N08 G01 X1.25Y1.5; STRAIGHT LINE INTERP TO D
N09 G01 X1.25Y.5; STRAIGHT LINE INTERP TO E
N10 G01 Z.1; RETRACT CUTTING TOOL
Sample Program Continued
N11 G00 X1.75Y1.5; RAPID TO POINT F
N12 G01 Z-.0625F9; PLUNG AT 9 IN/MIN.
N13 G01 X1.75Y.5; STRAING LINE INTERP TO H
N14 G03 X1.75Y1.5I1.75J1; CCW CIRCLE INTERP.
N15 G01Z.1; RETRACT CUTTING TOOL
N16 M05; TURN OFF SPINDLE
N17 M06T00; UNLOAD CUTTING TOOL
N18 G00X4Y3Z3; MOVE TABLE TO UNLOADING POSITION
N19 M02; END OF PROGRAM
Write a manual part program for finishing a component as shown
below. Assume spindle speed 300rpm and feed 0.5mm/rev

50 40 20

20
20
20