Machine Tools
DR. PRITHVI C
NIE, MYSURU
Definition
Machine tools are a crucial part of the manufacturing and
machining industry. They are devices or machines that use
various techniques to shape, cut, grind, shear, or otherwise
deform and work on materials like metal, plastic, wood, and
composites.
These tools are essential for producing precision
components used in a wide range of industries, from
automotive and aerospace to electronics and construction.
Machine tools are critical for maintaining quality and
precision in manufacturing processes. They have evolved
significantly over the years with the integration of computer
control systems, which has greatly enhanced their accuracy
and efficiency.
CNC machine tools, in particular, have revolutionized the
manufacturing industry by allowing for complex,
automated, and highly precise machining operations.
Classification
Machine tools can be classified by different criteria as given below:
By the degree of automation into
a. Machine tool with manual control
b. Semi-automatic machine tools and
c. Automatic machine tool.
By weight into
a. Light duty machine tools weighing up to 1 tonne.
b. Medium duty machine tools weighing up to 10 tonne and
c. Heavy duty machine tools weighing greater than 10 tonne.
By the degree of specialisation into
a. General purpose machine tools – which can perform various operations on workpiece of different shapes and sizes.
b. Single purpose machine tools – which can perform single operation on work pieces of a particular shape and different
sizes and
c. Special machine tools – which can perform a single operation on workpiece of particular shape and size.
Working Motion
For obtaining the required shape on the workpiece, it
is necessary that the cutting edge of the cutting tool
should move in a particular manner with respect to
the workpiece.
The relative movement between the workpiece and
cutting edge can be obtained either by the motion of
the workpiece, the cutting tool, or by a combination
of the motions of the workpiece and cutting tool.
These motions which are essential to impart the
required shape to the workpiece are known as
working motions.
Working motions can further be classified as: 1. Drive
motion or primary cutting motion 2. Feed motion.
Working motions in machine tools are generally of
two types: rotary & translatory.
Working Motion
1. For lathes and boring machines:
drive motion-rotary motion of workpiece
feed motion-translatory motion of cutting tool in the axial or radial
direction
2. For drilling machines:
drive motion-rotary motion of drill
feed motion-translatory motion of drill
3. For milling machines:
drive motion-rotary motion of the cutter
feed motion-translatory motion of the workpiece
4. For shaping, planing, and slotting machines:
drive motion-reciprocating motion of cutting tool
feed motion-intermittent translatory motion of workpiece
5. For grinding machines:
drive motion-rotary motion of the grinding wheel
feed motion-rotary as well as translatory motion of the workpiece.
Auxiliary Motion
The auxiliary motions do not participate in the process of formation of the required surface but are
nonetheless necessary to make the working motions fulfil their assigned function.
Examples of auxiliary motions in machine tools are clamping and unclamping of the workpiece, idle
travel of the cutting tool to the position from where cutting is to proceed, changing the speed of drive
and feed motions, engaging and disengaging of working motions, etc.
In machine tools, the working motions are powered by an external source of energy (electrical or
hydraulic motor). The auxiliary motions may be carried out manually or may also be power-operated
depending upon the degree of automation of the machine tool.
In general-purpose machine tools, most of the auxiliary motions are executed manually. On the other
hand, in automatic machines, all auxiliary motions are automated and performed by the machine tool
itself.
In between these two extremes, there are machine tools in which the auxiliary motions are
automated to various degrees, i.e., some auxiliary motions are automated while others are performed
manually.
Lathe
A lathe is a machine tool that is used to shape
and cut various materials, such as metal, wood,
plastic, and more. It works by rotating the
workpiece while a cutting tool is moved against
the workpiece to remove material, resulting in
a symmetrical and cylindrical shape. Lathes
come in various sizes and types, and they are
commonly used in machining and
manufacturing processes.
Lathe Types
Lathe Types
Parts of Lathe
Parts of Lathe
Bed: The bed is the horizontal base of the lathe that
supports all the other components. It provides
stability and rigidity to the machine.
Headstock: The headstock is located at one end of
the bed and contains the motor, spindle, and
gearbox. It is responsible for rotating the workpiece.
Spindle: The spindle is a rotating component within
the headstock that holds and rotates the workpiece.
Various types of chucks or collets can be attached to
the spindle to secure the workpiece.
Tailstock: The tailstock is located at the other end of
the bed, opposite the headstock. It can be moved
along the bed to support and align the workpiece,
providing additional stability and precision.
Tool Rest: The tool rest is a horizontal platform that
supports the cutting tool. It can be adjusted to
control the depth and angle at which the tool
contacts the workpiece.
Carriage: The carriage is a moving assembly that
holds the cutting tool and can be moved along the
length of the bed to cut or shape the workpiece.
Lathe Operations
Lathe Operations
Lathes can perform various operations, including:
Turning: The most basic operation, where the workpiece is rotated, and the cutting
tool removes material to create cylindrical shapes.
Facing: Cutting perpendicular to the workpiece's axis to create flat surfaces on the
end.
Tapering: Creating a gradual change in diameter along the length of the workpiece.
Drilling: Boring holes into the workpiece.
Knurling: Adding textured patterns to the workpiece, often for better grip.
Threading: Cutting threads on the workpiece to create screw threads.
Lathe Operations
1. Turning: Turning is the primary operation in a lathe machine. It involves removing material from the workpiece's outer surface
to reduce its diameter or create a smooth, cylindrical shape.
2. Facing: Facing is the process of cutting a flat surface at a right angle to the axis of the workpiece. It is often used to make the
end of the workpiece flat and perpendicular to its axis.
3. Taper Turning: Taper turning is the process of machining a workpiece to produce a conical shape. This is achieved by adjusting
the lathe's tool or the workpiece's angle to the lathe axis.
4. Boring: Boring involves enlarging an existing hole or creating a precise, internal cylindrical surface. Boring bars with cutting
tools are used for this operation.
5. Thread Cutting: Lathe machines can be used to cut threads on the workpiece. This can be done through various methods,
including single-point threading and thread chasing.
6. Knurling: Knurling is a process that creates a pattern of diamond-shaped or straight-line ridges on the workpiece's surface for
improved grip or aesthetics.
7. Parting: Parting is the operation of cutting off a portion of the workpiece to create separate pieces. This is commonly done
using a parting tool.
8. Drilling: While drilling is typically associated with drilling machines, lathes can be equipped with a drill chuck and used to
create holes in a workpiece.
9. Grooving: Grooving involves cutting narrow, deep recesses or grooves on the workpiece's surface. It is often used for creating
oil seals, retaining rings, and other specialized features.
10. Threading: While thread cutting was mentioned earlier, threading can also refer to creating external threads on the
workpiece, such as for attaching nuts or bolts.
Drilling
Drilling is a cutting process where a drill bit is spun to cut a hole of circular cross-section in solid materials.
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. This forces the cutting edge
against the work-piece, cutting off chips (swarf) from the hole as it is drilled.
Drilling Machine Components
• Base: The base provides stability and support for the
entire machine.
• Column: The column is a vertical part that supports
the drilling head and can often be adjusted in height.
• Drilling Head: The drilling head contains the motor,
spindle, and controls for driving the drilling tool.
• Table: The table is where the workpiece is placed,
and it can usually be moved vertically and
horizontally for precise positioning.
• Spindle: The spindle is a rotating shaft that holds the
drill bit and is responsible for creating holes in the
workpiece.
Drilling Machine - Types
• Bench Drilling Machine: A bench drilling machine is a compact, stationary machine typically used for light to
medium-duty drilling tasks. It is mounted on a workbench or stand and is manually operated.
• Pedestal Drilling Machine: Similar to the bench drilling machine, the pedestal drilling machine is mounted on
a pedestal or stand for added stability. It is often used for larger workpieces and heavier drilling tasks.
• Radial Drilling Machine: A radial drilling machine is versatile and allows the drilling head to be moved both
horizontally and vertically. This flexibility is useful for drilling holes at various angles and positions.
• Magnetic Drill (Magnetic Base Drilling Machine): Magnetic drills are portable and designed for drilling on
vertical, horizontal, or overhead surfaces. They use a magnetic base to securely attach to the workpiece.
• Sensitive Drilling Machine: Sensitive drilling machines are lightweight, precision machines designed for small
and delicate drilling operations.
• Drill Press (or Pillar Drill): A drill press is a stationary machine that can be mounted to the floor or a
workbench. It's used for a wide range of drilling tasks and often features adjustable speed settings and depth
stops.
• Multiple Spindle Drilling Machine: These machines have multiple spindles, allowing multiple holes to be
drilled simultaneously. They are often used in mass production.
Drilling Machine - Types
Drilling Machine- Operations
1. Drilling: This is the primary and most common operation on a drilling machine. It involves creating a hole in a workpiece
by rotating a cutting tool, typically a drill bit, while applying axial force. The size of the hole is determined by the
diameter of the drill bit used.
2. Reaming: Reaming is used to improve the accuracy and finish of a previously drilled hole. It involves using a reamer tool
to create a smoother, more precise hole with a specific diameter. Reaming is often used for creating holes that require
high precision, such as for fitting bearings or pins.
3. Countersinking: Countersinking is the process of creating a conical-shaped recess at the top of a hole. This allows screws
or bolts to sit flush with or below the surface of the workpiece, preventing them from protruding.
4. Counterboring: Counterboring is similar to countersinking but involves creating a cylindrical recess at the top of a hole. It
is often used to provide a seat for a bolt head, washer, or nut, allowing it to sit below the workpiece's surface.
5. Tapping: Tapping is the process of creating internal threads in a hole, allowing it to receive a screw or bolt. A tap is used
to cut the threads, and the size and pitch of the threads must match the screw or bolt being used.
6. Boring: Boring on a drilling machine involves enlarging an existing hole to a precise diameter using specialized boring
tools. It is often used for creating large-diameter holes in workpieces.
7. Grinding: Some drilling machines can be equipped with grinding attachments to sharpen cutting tools or to grind the
workpiece's surface for finishing and deburring.
8. Deburring: After drilling, deburring is often necessary to remove sharp edges, burrs, or irregularities around the hole.
This can be done using various deburring tools or techniques.
Drilling Machine- Operations
Milling
Milling is a machining process that involves the removal of
material from a workpiece using rotary cutters. This process is
commonly used in various industries, including
manufacturing, metalworking, woodworking, and more.
Milling machines are the primary tools used for milling
operations, and they come in various types, including vertical
milling machines, horizontal milling machines, and CNC
(computer numerical control) milling machines.
The basic idea behind milling is to use rotating cutting tools,
often with multiple cutting edges, to gradually remove
material from a workpiece to create a desired shape, surface
finish, or feature. The workpiece is securely held in place on a
worktable or fixture, and the cutting tool is brought into
contact with the workpiece. The cutter rotates, and the
workpiece is fed into the cutter, allowing it to remove
material. The relative motion between the workpiece and the
cutter can be achieved in various ways, depending on the type
of milling machine and the specific operation.
Vertical Milling Machine
In vertical mills, we fix the workpiece on a bed and
carry out machining by a movable tool.
There are two main types of vertical milling machines
– turret mills and bed milling machines.
Turret milling machines: In a turret mill, the vertical
spindle remains fixed while the bed portion can move
horizontally as well as vertically. A turret mill usually
works on a small part.
Bed milling machines: In a bed mill, the bed can only
move in the horizontal direction whereas the spindle
moves up and down as needed. These machines are
better for bigger workpieces.
Horizontal Milling Machine
In horizontal milling machines, the part is
again fixed on the bed. The machining takes
place horizontally or at a required angle if
the machine is equipped with a universal
table.
This table allows the cutting head to
approach the workpiece from a variety of
angles.
The machine may also be equipped with
special cutters to machine bevels, gears,
radii, and grooves. Simplex horizontal mills
have one spindle, while duplex has two.
Milling Operations
Face Milling: In this operation, the milling cutter is used to
create flat surfaces on the workpiece.
Peripheral Milling: Also known as slab milling, this operation
involves cutting along the periphery of the workpiece to
create a flat or contoured surface.
End Milling: End mills are used to create features such as
slots, holes, and profiles on the end face of the workpiece.
Slot Milling: This operation is used to create slots or grooves
in the workpiece.
Contour Milling: Contour milling involves cutting along a
specific path to create a contoured or irregular shape on the
workpiece.
Drilling: While not strictly milling, drilling can be performed
on milling machines to create holes in the workpiece
Computer Numerical Control - CNC
A CNC (Computer Numerical Control) machine is a computer-
controlled manufacturing device used for various machining and
cutting operations in industries such as manufacturing, aerospace,
automotive, and more.
CNC machines are versatile and highly precise, making them essential
in modern manufacturing processes.
A CNC machine is a motorized maneuverable tool and often a
motorized maneuverable platform, which are both controlled by a
computer, according to specific input instructions. Instructions are
delivered to a CNC machine in the form of a sequential program of
machine control instructions such as G-code and M-code, and then
executed. The program can be written by a person or, far more often,
generated by graphical computer-aided design (CAD) or computer-
aided manufacturing (CAM) software.
Key Features
Computer Control: CNC machines are controlled by computers that follow a set of instructions, often in the form of a G-code
program. These instructions dictate the movements and actions of the machine's cutting or shaping tools.
Motors and Axes: CNC machines have motors that move the cutting or shaping tools along multiple axes, typically three or
more. Common configurations include three-axis (X, Y, and Z) for milling and drilling, while some machines can have additional
axes for more complex operations.
Cutting/Tooling Heads: The specific tooling or cutting heads vary depending on the machine's purpose. For example, milling
machines use rotating cutting tools, lathes use turning tools, and laser-cutting machines employ laser beams.
Workpiece Fixture: The workpiece, or the material being machined, is securely held in place on the machine's worktable using
fixtures, clamps, or other mechanisms.
CAD/CAM Software: To create the G-code programs that control CNC machines, designers and engineers use Computer-Aided
Design (CAD) and Computer-Aided Manufacturing (CAM) software. CAD software is used for designing parts, while CAM
software generates the toolpaths and G-code instructions.
Precision and Accuracy: CNC machines offer high precision and accuracy, making them suitable for intricate and repeatable
tasks. They can create complex 3D shapes and cut materials with tight tolerances.
Types of CNC
CNC Milling Machines: These machines remove material from a workpiece by rotating cutting tools. They
are used for tasks like making holes, slots, and complex shapes.
CNC Lathes: Lathes rotate the workpiece, allowing cutting tools to shape it. They are commonly used for
cylindrical and symmetrical parts.
CNC Laser Cutters: Laser cutting machines use a focused laser beam to cut or engrave materials like
metal, plastic, and wood.
CNC Plasma Cutters: These machines use a plasma torch to cut through electrically conductive materials,
such as metal.
CNC Routers: Routers are used for precision cutting and shaping of wood, plastic, and other materials.
They are commonly used in woodworking and cabinetry.
CNC Wire EDM (Electrical Discharge Machining): Wire EDM machines use electrical discharges to
precisely cut intricate shapes in conductive materials.
Types of CNC’s
Difference between CNC and Conventional
Machine
CNC machines can be used continuously for long intervals and only need to be switched off for
occasional maintenance. Conventional machines are difficult to operate for several hours at a stretch.
the operator has to continuously focus on the job at hand.
CNC machine can produce several products all similar and deadly accurate. The resemblance of the
products formed depends on the skill of the operator.
Less skilled or trained persons can easily operate CNC machines. It requires highly skilled operators to
work on conventional machines.
The software to drive the machines usually updates the CNC machine process. Chances for a major
improvement in the same conventional machines are very less.
One person can supervise several CNC machines, and they can be left to work themselves.
CNC machines operations are safer as machining takes place inside enclosed chamber.
Parts of
CNC
Lathe
Codes Used:
N-CODE: Sequence number, used to identify each block within an NC program and provides a means
by which NC commands may be rapidly located. It is program line number. It is a good practice to
increment each block number by 5 to 10 to allow additional blocks to be inserted if future changes are
required.
G-CODE: Preparatory Word, used as a communication device to prepare the MCU. The G-code
indicates that a given control function such as G01, linear interpolation, is to be requested.
X,Y&Z-CODES: Coordinates. These give the coordinate positions of the tool.
F-CODE: Feed rate. The F code specifies the feed in the machining operation.
S-CODE: Spindle speed. The S code specifies the cutting speed of the machining process.
T-CODE: Tool selection. The T code specifies which tool is to be used in a specific operation.
M-CODE: Miscellaneous function. The M code is used to designate a particular mode of operation for
an NC machine tool.
I,J&K-CODES: They specify the centre of arc coordinates from starting.
Codes Used:
Applications in Mechanical Processing Technology
Part Manufacturing: A CNC machine can produce highly complex three-dimensional parts by using 3D models
made with CAD or other mechanical design software and generating CNC programs through CAM software. It
can achieve high-precision part manufacturing, thus saving R&D costs and time and improving production
efficiency.
Carving and Decoration: CNC machining can be used for carving and decoration, such as wood, stone, plastic,
etc. Due to its precise control over the tool's curve trajectory, it can achieve complex carving, such as high
relief effects, making it more beautiful.
Mold Manufacturing: The CNC machining process is the best choice for manufacturing molds because molds
require high precision, repeatability, and mass production, which are the strengths of CNC technology. Using
CNC machining to manufacture molds can achieve efficient production and larger production batches.
Part Finishing: In mechanical processing, part finishing usually requires manual processing, such as using files
and sandpaper, which may result in irregular surfaces and complex geometric shapes. CNC machining can
complete these tasks while ensuring smooth surfaces, high precision, and high efficiency.
Automated Production Processes: CNC machining can also be used in computer-integrated manufacturing
(CIM) or computer-aided manufacturing (CAM) production lines. This makes mechanical production
completely automated, thereby reducing production costs, improving production efficiency and quality, and
enhancing the reliability and consistency of part manufacturing.
Applications in Automotive
Industries:
In the automotive industry, CNC machines
produce parts that require tight tolerances and
exact specifications, such as engine blocks,
transmission housings, and suspension
components. CNC machines can also create
custom parts unique to a particular vehicle
model.
Applications in Aerospace
Industries:
CNC machines produce aircraft, spacecraft, and
satellite parts in the aerospace industry. These
parts must be lightweight, durable, and
withstand extreme conditions. CNC machines
can create complex shapes and contours that
cannot be achieved with traditional machining
methods.
Applications in Medical Industry:
CNC machines produce surgical instruments,
prosthetics, and implants in the medical
industry. These parts must be precise and
reliable to ensure patient safety. CNC machines
can have parts with intricate designs and tight
tolerances essential in medical applications.
Applications in Electronics
Industry:
CNC machining is an indispensable technology
in the electronics industry, used to produce a
wide range of electronic components and
devices with high precision and accuracy. It is
used for cutting and drilling printed circuit
boards, shaping enclosures and connectors,
producing heat sinks, creating electronic
components, and prototyping.
Applications in Energy Industry:
In the energy industry, CNC machining produces
intricate parts for various applications such as
turbines, oil and gas drilling equipment, nuclear
power plant components, and solar panel
frames. The process guarantees high precision,
accuracy, durability, and resistance to wear and
tear.
“One machine can do the work of fifty
ordinary men. No machine can do the work
of one extraordinary man.”
Elbert Hubbard
Thank You