Introduction to Mechanical Engineering

Module-4
Machine Tool Operations:
Working Principle of lathe, Lathe operations: Turning, facing, knurling. Working principles of Drilling
Machine, drilling operations: drilling, boring, reaming. Working of Milling Machine, Milling
operations: plane milling and slot milling. (No sketches of machine tools, sketches to be used only for
explaining the operations).
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Machine Tool Operations:

Lathe Machine:
It is the oldest of all machine tools and perhaps the most basic tool used in industries. A Lathe is
defined as a machine tool used to remove excess material by forcing a cutting tool against a rotating
work piece. Lathes are also called as Turning Machines, as the work piece is turned or rotated between
two centres. They are primarily used to produce cylindrical, plain and tapered surfaces and also used for
knurling and thread cutting on metal parts. Besides these operations, they can also be used to perform
various operations such as drilling, boring, reaming, grinding, etc.

Parts of Lathe Machine:

Figure: Parts of Lathe Machine

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Headstock:
The headstock is usually located on the left side of the lathe and is equipped with gears, spindles,
chucks, gear speed control levers, and feed controllers.
Tailstock:
Usually located on the right side of the lathe, the work piece is supported at the end.
Bed:
The main parts of the lathe, all parts are bolted to the bed. It includes the headstock, tailstock, carriage
rails and other parts.
Carriage:
The carriage is located between the headstock and the tailstock and contains apron, saddle, compound
rest, cross slide and tool post.
Lead Screw:
Lead screw is used to move the carriage automatically during threading
Feed Rod:
It is used to move the carriage from left to right and vice versa
Chip Pan:
It is present at the bottom of the lathe. Chip pan is used to collect the chips that are produced during the
lathe operation.
Hand Wheel:
It is the wheel which is operated by hand to move cross slide, carriage, tailstock and other parts which
has hand wheel.
Specification of Lathe:

Figure: Specification of Lathe Machine

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Lathe Operations:
Cylindrical Turning:

Figure: 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 centres 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.

Facing:

Figure: 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.

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Knurling:

Figure: 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.
Taper Turning:
It is the operation performed on lathe to obtain a conical surface on the work piece. In a tapered work
piece, the diameter of the rod will be gradually increased or decreased from a smaller diameter to
bigger diameter or vice-versa. Taper turning can be done by using different methods on lathe machine.
Taper Turning by Compound Rest Swivelling Method:

Figure: Taper Turning by Compound Rest Swivelling Method

Taper Turning by Swivelling the Compound Rest method, uses the principle of taper turning by rotating
the work piece on the lathe axis and feeding the tool at an angle to the axis of rotation of the work
piece. The tool is mounted on the compound rest which is attached to a circular base, graduated in
degrees. The compound rest can easily be swivelled or rotated and clamped at any desired angle. Once
the compound rest is set at the desired half taper angle, rotation of the compound slide screw will cause
the tool to be fed at that angle and generate a corresponding taper. This method is limited to turn a short
but steep taper because of the limited movement of the cross-slide.
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Milling Machine:
It is a metal cutting operation in which the operating tool is a slow revolving cutter having cutting teeth
formed on its periphery. The milling cutter is a multipoint cutting tool. A milling machine is a power
operated machine tool in which the work piece mounted on rotating table is machined to various shapes
when moved under a slow revolving notched cutter.
Principle of Milling:
The milling cutter is mounted on a rotating shaft known as arbor. The work piece which is mounted on
the table can be fed either in the direction opposite to that of the rotating cutter or in the same direction
as that of the cutter.

Figure: Up-Milling
When the work piece is fed in the opposite direction to the cutter tooth at the point of contact, the
process is called as up milling. Here the chip that is removed gets proportionately thicker.

Figure: Down-Milling
When the work piece is fed in the same direction to the cutter tooth at the point of contact, the process
is called as down milling. Here the chip that is removed gets proportionately thinner

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Horizontal Milling Machine:

Figure: Horizontal Milling Machine

Above figure shows the different parts of a horizontal milling machine.
1. Column: It is a cast iron frame made of single casting with the base. The column is mounted on
the bed and houses the motor and other driving mechanisms including spindle. The knee can be
slide up and down using knee elevating handle on the guide ways.
2. Base: It is the foundation of the machine made of cast iron. All other components of the
machine are mounted on the base. It gives mechanical strength and rigidity.
3. Over arm: It is an integral part of the machine. It is mounted on the vertical column and gives
the much needed support to the arbor.
4. Knee: It is projected from the column and can be slide up and down on the vertical column face.
5. Arbor: It is the horizontal shaft used for holding and driving the cutter.
6. Saddle: The saddle is placed on the top of the knee which slides in guideways set exactly
perpendicular to the column face.
7. Table: It rests over the saddle as shown in the figure and it supports the workpiece, fixture and
all other equipment.
A horizontal mill has the cutters mounted on a horizontal spindle across the table. Many horizontal
mills also feature a built-in rotary table that allows milling at various angles; this feature is called
a universal table. Several cutters may be ganged together on the arbor to mill a complex shape of slots
and planes.

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Vertical Milling Machine:

Figure: Vertical Milling Machine

In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and
rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the
same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed
mill and the turret mill.
In this machine, unlike the horizontal milling machine, the work piece can be moved only in the
horizontal plane both longitudinal and transverse direction but not in vertical direction.
Comparison between Horizontal and Vertical Milling Machine:
Sl. No. Horizontal Milling Machine Vertical Milling Machine
1 The spindle is horizontal The spindle is vertical
2 The operations are performed in The milling cutter plane is operated at
horizontal plane direction perpendicular to the worktable
3 The milling cutter works/rotates on its The milling cutter can be moved upward
own axis and downward
4 The cutter is supported by over arm The cutter is mounted directly to spindle
5 The spindle cannot be tilted The spindle can be tilted
6 The operations performed are, Gear The operations that can be performed are,
teeth cutting, Plain milling, Straddle Slot milling, Angular milling, Keyway
milling, Gang milling, etc. milling, End milling, etc.

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Milling Operations
Plain Milling:

Figure: 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:

Figure: Slot Milling

Slot milling is the process of milling slots using a different type of cutter called as ‘slot drill’, which has
capacity to cut into solid materials. Space is limited for other machining operation and slot milling is
used.

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DRILLING MACHINE

Figure: Drilling Machine

Drilling Machine:
It is a machine which is used to drill the holes on the components or workpiece with the help of drill
bits.
Construction of Drilling Machine
[Link] (Bed):
The base is made up of Cast Iron which has the capability of high compressive strength, good wear
resistance and good absorbing capability (i.e. absorb the vibrations induced during working condition)
and for these reasons, it acts as a base to the drilling machine.

2. Column: It is exactly placed at the center of the base which can act as a support for rotating the
Swivel table and holding the power transmission system

3. Swivel Table: It is attached to the column which can hold the machine vice in the grips and thereby,
the workpiece is fixed in the machine vice to carry out the drilling operation.
The Swivel table can move up and down by means of rotational motion and can be locked to the
column by means of locking nut.

4. Power Transmission system: It consists of motor, stepped pulley, V-belt and the Spindle. The power
transmission is explained in the working of the drilling machine.
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5. Hand wheel: By the rotation of hand-wheel, the spindle moves up and down in the vertical direction
in order to give the necessary amount of feed to the work.
Here, the rotational motion is converted into linear motion by means of a Rack and Pinion mechanism
which was explained below.

6. Chuck: It is used to hold the drill bit.

Working Principle of Drilling Machine

• When the power is given to the motor, the spindle rotates
• Now the drill bit also rotates which was placed in the chuck and which was in connection with
the spindle.
• As the Pulleys rotates, the spindle also rotates which can rotate the drill bit.
• Now, by the rotation of hand-wheel, the spindle moves up and down in the vertical direction in
order to give the necessary amount of feed to the work and this drill bit is used to make the
holes on the component placed in the machine vice.

Drilling Machine Application or Uses

• The Drilling machine used in almost every manufacturing industry for making holes in the
workpiece as per the requirement.
• This is also used in carpentry work for drilling the holes in the wood and fixing the wood
structures.
• They are used in construction sites, glasswork.
• Hand drill or portable drills are used for screwing and fastening.
• This machine tool can perform a variety of operations like reaming, boring, counter-boring,
tapping, and many others, which makes it applicable in vast fields.

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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 work-
piece and rotated at rates from hundreds to thousands of revolutions per minute
Boring
Boring is the operation of truing and enlarging a previously drilled hole by means of a single point
cutting tool. Boring is done on drilling machine to perform the following tasks on a hole already drilled

Counter boring
Counter boring is the operation of enlarging one end of an existing hole concentric with the original
hole with square bottom. It is done to accommodate the heads of bolts, studs and pins. The cutting
edges of the counter-bore (tool used for counter boring) may have straight or spiral teeth.

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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.

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