Machine tools and

Manufacturing processes

PATIL S B
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGG.
COLLEGE OF ENGINEERING, PUNE
 Manufacturing processes

• Manufacturing is the application of

mechanical/chemical/electrical energy to alter
the geometry, properties and appearance of a
given starting material to make parts/products.

• Classification of Manufacturing Processes

• Forming processes
• Machining processes
• Joining processes

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 Forming processes

– Rolling

– Forging

– Extrusion

– Wire drawing

– Bending

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 Machining processes

– Turning

– Drilling

– Milling

– Grinding

– Shaping

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 Joining processes

– Welding

– Soldering

– Brazing

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 Machine Tools
• Conventional or traditional machine tools (GPM)
like Lathes, Milling machines, etc. Mechanical energy

• Non-conventional or non-traditional machine

tools: like EDM, ECM, USM, etc. Mechanical,
chemical, electrical or combination of energies

• Computer controlled machine tools: Like CNC

lathe, CNC milling

• Special purpose machine tools (SPM)

 General Purpose Machine Tools
The basic machine tools which are commonly used for
general purposes are:
1. Lathe
2. Drilling machine
3. Shaping machines
4. Planning machine
5. Slotting machine
6. Milling machine
7. Boring machine
8. Hobbing machines
[Link] machine
 Working principle of centre lathe
• Lathe is a machine, which removes the metal from a
work piece in the form of chips to produce the
required shape &size
• The work is held and rotated on its axis.
• Single point cutting tool is advanced along the line
of cut to produce the desired shape on the work.
• The tool may move parallel/normal/at an angle to
the axis of rotation.

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 Parts of a centre lathe
• BED
– Base/foundation of the Lathe
– Heavy rigid casting made in one piece
– Holds/supports all parts like head stock, tail stock and
carriage
– Top of bed has guide ways for carriage and tail stock.
• HEAD STOCK
– Hollow in section and fixed to the left end of the bed
– Consists of spindle and driving arrangements
– Lathe receives power from the head stock
– Spindle used to attach various work holding devices
like chuck, live centre
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 Parts of a centre lathe contd…
• TAIL STOCK
– Fitted on the Lathe bed opposite to the head stock ie
on the right side
– To hold a centre (called dead centre) when turning
between centers i.e. acts as a support at the end of
the long work pieces
– Also used for supporting and feeding drills, reamers
etc.
• CARRIAGE
– It is fit in Lathe bed guide ways
– Can move along the guide ways
– Movement provided through a gear meshing in a rack
fastened to Bed 12
 Parts of a centre lathe contd…
– Carriage supports cross slide, compound slide and
tool post
– The driving mechanism is fitted in front of the
carriage, called apron
– Carriage provided with some form of locking device to
lock it to the bed
– Carriage can be moved to provided feed parallel to
the work ie. Longitudinal feed
– Cross slide moved manually to provide cross
movement for the tool
– Compound slide can be swiveled to an ange to
provide angular feed of tool
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 Parts of a centre lathe contd…
• FEED MECHANISM
– Employed to impart various feeds to the tool
– Feed mechanism consists of Feed gear box, Feed
rod and Lead screw
– Feed gear box consists of number of different size
gears to change the rate of feed etc
– Feed rod is a long shaft extending from feed box. It is
used to move the carriage, cross slide
– Lead screw is a long threaded shaft brought into
operation only for thread cutting operation. At all other
times it remains disengaged from the gear box

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 Lathe operations
• Turning: to produce cylindrical surface

• 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

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 Turning

Turning means to remove extra material from the work-

piece to produce a cylindrical/conical surface

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 Facing

• Machining the ends of a

workpiece to produce flat
surface.
• Also used to cut the work to the
required length
• Tool fed perpendicular to the
axis of rotation of the workpiece
• A properly ground facing tool is
mounted in the tool holder on
the tool post.

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Parting (Cutoff) / Grooving

• Reducing the diameter

of the workpiece over a
very narrow surface
• Grooving tool of required
shape is fed straight into
the work

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 knurling

• Knurling forms raised

diamond shaped or straight
line projections on a work
piece.
• It is used on some types of
screws, tools and machine
handles to provide a non slip
gripping surface or simply to
improve appearance.

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Lathe operations

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 Drilling machine
• Drilling is the operation of producing a cylindrical hole.
• The hole is generated by the rotating edge of a cutting
tool known as the drill.
• Sensitive drilling machine
• It is a high speed machine used for drilling small holes
upto 15 mm diameter.
• Parts and working
• Base
• Made up of cast iron and is bolted to the floor
• Has slotted grooves for securing the work holding
device
• Is quite heavy and provides stability to the machine and
a rigid support to the column.
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Drilling machine

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 Sensitive drilling machine
• Column
• Cylindrical post, supports the table, spindle head,
the motor and the drilling mechanism.
• Their position is adjustable on the column
• Table
• Table attached to the column
• Its position is adjustable vertically along the
column or radially about the column
• Table may be circular or rectangular in shape
and is provided with slots for securing work-piece
or vice on it
• Spindle Head
• Spindle head contains mechanism to hold the
cutting tool to revolve it and advance it into the
work
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 Sensitive drilling machine
• Driving mechanism
• Electric motor provides the power to the
spindle headt through a gear box
• Usually 3 to 10 speeds are provided range
being from 50 to 2000 rpm

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 Drilling machine operations
• Drilling
• Operation of producing cylindrical hole by
removing metal by the rotating edge of a cutting
tool called drill
• Before drilling, centre of the hole located by
drawing two lines at right angles to each other
• An indentation produced at the centre by the
centre punch
• Hole generated is rough. It may need some
finishing operation

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 Drilling machine operations contd…
• Reaming
• An accurate way of sizing and finishing an already drilled hole
• To perform the reaming operation the original hole is drilled slightly
undersize.
• It is a slow process as compared to drilling and automatic feed may
be employed
• Tool used is called a Reamer, having multiple cutting edges
• Reamer can not originate a hole. It follows the path of already drilled
hole

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 Drilling machine operations contd…
• Tapping
• Operation of cutting internal threads
• Tool used is called Tap
• A Tap may be considered as a bolt with accurate
threads cut on it
• The threads act as cutting edges
• When Tap screwed into the hole it removes metal
and cuts internal threads

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 Drilling machine operations contd…
• Counter boring
• Operation of enlarging the end of a hole cylindrically
• This is required in some cases to accommodate the
heads of bolts, studs and pins
• Tool is called a Counter bore
• Spot facing is done to provide seating for Washer

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 Drilling machine operations contd…
• Counter sinking
• Operation of making a cone shaped enlargement
of the end of a hole to provide a recess for head of
a screw or countersunk rivet fitted into the hole.
• The tool is called a countersink

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 Milling machine
• A rotating tool with multiple cutting edges is moved
slowly relative to the material to get a plane/straight
surface
• Cutting tool fit on the spindle and workpiece attached to
the table directly or in a holding device clamped to the
table
• Workpiece brought into contact with the rotating cutter

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Plane milling machine

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 Parts of Plane milling machine
• Base
• Iron casting, serves as foundation and base for all other
parts
• On its one end, it carries the column
• Column
• Main supporting frame mounted vertically on the base
• Column is box shaped and houses all driving
mechanisms for the spindle and the table feed
• The front vertical face of the column is accurately
machined and is provided with guideways for supporting
the knee
• Top of column holds an overarm that extends outward at
the front of the machine
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 Parts of Plane milling machine contd…
• Knee
• Rigid iron casting that slides up and down on the
vertical ways of the column
• The height adjustment is also effected by an
elevating screw that also supports the knee
• Knee houses the feed mechanism of the table and
its controls
• Top face of knee forms a slideway for the saddle to
provide cross feed of the table
• Table
• Table rests on ways in the saddle
• Top of the table has T slots for clamping the work
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 Parts of Plane milling machine contd…
• Overhanging arm
• Mounted on top of the column, serves as a bearing
support for the other end of the arbor
• The arm is adjustable so that the bearing support
may be provided nearest to the support
• Spindle
• Located in the upper part of the arm
• Receives power from the motor through gears and
transmits to the arbor
• Spindle is provided with provision for a cutting tool.
• Accuracy of cutting depends on the accuracy,
strength and rigidity of the spindle
• Arbor
• An extension of the machine spindle on which
cutters are securely mounted and rotated
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 Casting process
• Casting is the process of pouring the molten
metal in a mold(or cavity) and allowing it to
solidify to make the required component.
• Advantages of Casting process
– Components of complicated shapes can be casted
easily and in less time
– Molten metal flows into any small section in the mold
cavity and so intricate internal or external features
can be made
– The cast components may not require further
finishing operation hence reducing the overall
production time
• Application
• Typical applications of sand casting process are
• Cylinder blocks, pistons, piston rings, machine
tool beds, wheels etc.
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 Casting process contd…
• The whole process of casting may be classified into
five stages
1. Pattern making
2. Moulding and core making
3. Melting and casting
4. Fettling
5. Testing and inspection
Moulding tools and equipments:
Classified into three groups namely hand tools, flasks
and mechanical tools

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 Casting process contd…
• Various Hand tools are shovel, Riddle, Rammer, Slick,
Lifter, Strike-off bar, bellow, Gate cutter, Mallet, Clamps
etc.
• Moulding board is a smooth wooden board on which the
flask and patterns are placed
• Sand moulds are prepared in boxes called flasks
(wooden or metallic). It gives necessary rigidity and
strength to the sand in the moulding. Top part is called
cope and bottom one drag.
• Sand moulding procedure:
– Pattern with necessary allowance is kept over a
moulding board
– Drag placed on moulding board
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 Casting process contd…
– Conditioned moulding sand poured over the pattern
in the drag
– Sand is rammed to get perfect packing
– Drag is leveled off with a strike rod
– Vent holes are made with vent holes to let out the
escape gases
– Little sand sprinkled over the mould and bottom
board placed over the drag
– Drag turned over. The moulding board taken off.
– Parting sand sprinkled over and cope placed over
the drag such that pins fit in proper position and
cope and drag interlocked
– A sprue pin kept vertically and taken out later to
leave a passage for the molten metal to be poured
through
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 Casting process contd…
– Cope filled with moulding sand, rammed and
properly packed and vent holes made
– Sprue pin withdrawn first.
– Cope lifted off carefully. Pattern removed
carefully
– A gate is cut connecting the bottom of the
sprue opening to the cavity for molten metal
to flow to the cavity
– The cope put over drag again to get the two
halves of the mould together.
– Metal is poured to get the casting
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 Forging process
• Process of shaping heated metal by the
application of impact/gradual pressure
• A forging machine applying impact load- forging
hammer
• A forging machine applying gradual load-
Forging press
• Small parts are forged with pneumatic power
hammers, very large parts are forged in hydraulic
presses
• Hand forging
• Power forging
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 Forging process contd…
• Press Forging: Steady high pressure is applied on
hot metal work piece, slow squeezing instead of
giving heavy blows, more accurate.
• In a hydraulic press, Ram is raised or lowered by
large pistons driven by high pressure oil. Press
action is slow in comparison to hammer but
reduction in the size of heavy parts is
comparatively rapid.
• In hammer forging, the blow works the metal only
in the surface layers of the work piece so
deformation does not penetrate into the volume of
the metal. While in case of a press, the pressure is
applied gradually and it penetrates deep into the
metal 46
Forging process contd…

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 Joining processes
• Metal fabrication involves joining of two metals together
depending on the material to be joined and degree of
permanency required.
• Welding is a process of joining two (or more ) metal pieces by
application of heat with or without application of pressure and
addition of filler material.
• Welding is extensively used in the fabrication work.
• Application of Welding: fabrication of bridges, electric towers,
manufacturing of automobile bodies, building of ships and air
crafts, manufacturing of boilers, storage tanks, pipelines etc.
• In pressure welding, the parts to be joined are heated up to the
plastic state and fused together by applying external pressure
like forge welding, resistance welding etc
• In fusion welding, the joint of the two parts is heated to the
molten state and allowed to solidify like gas welding, arc welding
etc
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 Oxy acetylene gas welding

• Melting the edges to be joined by gas flame

allowing the molten metal to flow together hence
forming a continuous joint upon cooling
• Suitable for joining two plates of 2 to 50 mm
thickness. 49
 Oxy acetylene gas welding contd…
• >15 mm thick plates, filler metal added to the weld in the
form of weld rod
• To remove impurities and oxides present on the surface, a
flux is added.
• Various gas mixtures like oxygen and acetylene, oxygen
and hydrogen etc are used
• The max temperature in oxy acetylene flame is about 3200
deg C.
• Welding equipment:
• Welding torch
• Welding tip
• Pressure regulator
• Hose and hose fittings
• Goggles, gloves and spark lighter
• Gas cylinders

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Arc welding

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 Arc welding contd…
• Principle of arc welding:
• When two conductors of an electric circuit are touched
together momentarily and then separated slightly,
assuming there is sufficient voltage in the circuit to
maintain the flow of current, an electric arc is formed.
Concentrated heat is produced through out the length of
the arc of the order of 5000 to 6000 deg C.
• Filler metal provided in two ways: consumable
electrodes, non consumable electrodes
• An arc welding equipment comprises ac/dc power
supply, electrode, electrode holder, cables, safety
devices etc

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 Resistance welding
• In resistance welding the metal parts to be joined are
heated to a plastic state over a limited area by their
resistance to flow of an electric current and mechanical
pressure is used to complete the weld.

• Resistance welding methods are

– 1. Butt welding
– 2. Spot welding
– 3. Seam welding
– 4. Projection welding
– 5. Precision welding

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 Butt welding

• Upset and flash are the

two types of butt welding
• In making of upset butt
welding the parts to be
welded are clamped edge
to edge in copper jaw
welding machine and
brought together in a
solid contact forms a
locality of high electric
resistance while current
flows to heat the joint.
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 Spot welding

• Spot welding is employed

to join overlapping strips,
sheets or plates of metal
at small areas.
• The pieces are
assembled and placed
between two electrodes,
which must possesses
high thermal and electric
conductivities and retain
the required strength at
high temperatures.
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 Seam welding

• Seam welding is a
method of making a
continuous joint between
two overlapping pieces of
sheet metal.
• The electrodes employed
are wheel electrodes.
• Steel plates up to 10 mm
thickness can be seam
welded.

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 Soldering and brazing

• Soldering is a method of uniting two metal pieces using a

fusible alloy/metal applied in the molten state.
• Soft soldering used in sheet metal work for joining parts
not exposed to high temperature and excessive loads,
also for joining wires and small parts. Also employed for
joining wires and small parts. Solder used is lead and tin
alloy (melting range 150 to 350 °C)
• Hard soldering employs solders that are stronger.
Solders like silver based alloys ( melting range 600 to
900 °C) are used.

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 Soldering and brazing

• Brazing is a method of joining two similar or dissimilar

metals using a special fusible alloy. It produces a clean
and stronger joint than soldering. Main difference is the
use of a harder filler material called spelter (copper
based and silver based alloys)
• Material used in brazing are copper and silver based
alloys
• Before brazing the parts/ surfaces to be brazed are
cleaned removing oxides/grease etc.
• Strength of brazed joint is lesser than welded joint but
relatively good.

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 Difference between Soldering and brazing
No Brazing Soldering
1 Filler metal’s melting point Filler metal’s melting point
is greater than 800 ° F is less than 800 ° F
2 Copper and silver base Tin and lead base alloys
alloys are used as filler are used as filler metal
metal
3 Joint strength is relatively Joint strength is relatively
high. low.
4 CI and steel parts are Iron, steel, copper and
brazed nickel alloys are soldered
5 Borax and borax & boric Aluminium chloride, zinc
acid used as fluxes chloride, plus alcohol are
used as fluxes 60