MACHINING PROCESS AND

MACHINES
• Changing the shape of a material/metal by removing the material
from it.
• The unwanted portion is called CHIPS
• The process is carried out in machines (machine tool).
• The common processes come under this category are:
• TURNING
• SHAPING
• DRILLING
• GRINDING
• MILLING etc.
 TURNING
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• Removal of metal from the periphery of a work piece to obtain a cylindrical
surface.
• The commonly using machine is called LATHE
• A single point cutting tool is used for turning
• The work piece is held in a device called chuck
 DRILLING
• The operation of producing a circular hole using a too
called DRILL.
• The commonly using machine is called DRILLING
MACHINE
• A multi point cutting tool is used for drilling

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 MILLING
• The process of removing metal by feeding the work piece against a rotating
multipoint cutter.
• As the cutter rotates each cutting edge removes a small amount of material from
work piece.
• The commonly using machine is called MILLING MACHINE

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 GRINDING
• The process of metal removal in which the cutting tool is an abrasive wheel.
• Very small amount of material is removed during grinding.
• Grinding is to obtain better surface finish
• To sharpen the cutting tools.

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LATHE MACHINE
• Lathe is the most general purpose machine
• The work piece is held and rotated and suitable cutting tool is
used to remove the metal.
• The major components of a lathe are:

1. BED : The bed forms its body and is supported at a convenient

height.
The other components are mounted on the bed.
It provides the required strength and rigidity to the machine.

2. Head stock
Head stock is mounted on the left end of the bed.
The gear box for changing the speed of rotation of the spindle is
provided inside it.

3. Tail stock
It is mounted on the right end of the bed.
It supports on end of the work piece.
It is also used for holding tools like drilling,
reaming etc.
4. The carriage
• Carriage consists of the cutting tool and mechanisms to
control the action of the cutting tool.
• It can be moved along the bed ways provided at the top
of the bed.
5. Tool post
• It is mounted on the carriage.
• It holds the cutting tool

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LATHE OPERATIONS
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DRILLING MACHINE
 Majour Components
1. Base : Base is a rectangular casting on which the machine is supported.

1. Column : Is a vertical member which supports the table.

The head supporting the motor and spindle is mounted on the top
of the column.
The column is supported by the base.

3. Table : It supports the work piece and work holding device

It can be moved up and down on the column.

4. Drill Head : Mounted on the top of the column and which supports the motor and
spindle.
The drill chuck is mounted on the spindle
The drill chuck carry the drill.
MILLING MACHINE
 Components
1. Base: It is the foundation for all other parts. It gives the machine the
required rigidity and strength.

2. Column : It is the main supporting frame, mounted vertically on the base.

The front face of the column has vertical guide ways.

3. Knee : Is a rigid casting, that slides up and down on vertical guide ways on the column.
It has horizontal guide ways on top surface.
4. Saddle : Supports and carries table and is adjustable on guide ways on top of the knee.

4. Over arm: mounted on the top of the column. The arbor support provided at the free end
of the overarm can be moved horizontally on the guide ways at the bottom of
the overarm.
6. Arbor : It is a rod on which the cutter is mounted.

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CNC MACHINE
• Numerical controlled machines (NC) are machines operating based on
numerical data.

• Numerical control can be defined as a form of programmable automation.

• Machines are controlled by using numbers, symbols etc.

• Numbers, letters and symbols are logically organized to direct a machine

for a specific task.

• It is a conventional machine tool where the operator is replaced by NC

programs.

• This is accomplishes by means of servo motors.

• Control units are used in this machines
 • Computer Numerical Controlled (CNC)machines
• Computers are used instead of control units in CNC machines
• CNC machine in which a dedicated computer is used to perform the
functions in accordance with programs stored in the memory of the
computer.

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• Advantages
• High accuracy
• Can produce complicated components
• Reduction in time for setup the machine for a job
• Reduced operation time.
• Increased consistency and quality in products
• Easy to make design changes
• Ideal for mass production

• Dis advantages
• High initial cost
• Additional skill is required for programming
 CAD and CAM
CAD (Computer Aided Designing)
• The use of computers to perform in the design of components.
• Creation and modification of drawings
• Modelling and analysis of components etc. are performed using computers.
• Different softwares are used to perform this operation.

• Some of the CAD softwares are:

• AUTOCAD, ANSYS, PRO-E, MATLAB, CATIA, SOLID WORKS etc.
 CAM(Computer Aided Manufacturing)
• After designing and analysing a product, it is manufactured where
computers are involved in manufacturing.
• On the other hand, Computer-aided manufacturing (CAM) involves the use
of computers
• for assisting managers,
• manufacturing engineers, and
• production workers
by automating production tasks and it also controls machines and systems.

CAM can be defined as the use of computers to plan, manage

and control the operations in a manufacturing process.

Siemens NX, Power MILL, WorkNC, SolidCAM are some the examples for CAM software.
 Rapid Prototyping (RP)/ (Rapid Manufacturing)
• Rapid prototyping is the technique of fabricating a prototype model from a
CAD file.

• Rapid prototyping is the fast fabrication of a physical part, model or

assembly using 3-D computer aided design.

• In manufacturing, rapid prototyping is used to create a three-dimensional

model of a part or product.

• Rapid prototyping can be used to test the efficiency of a part or product

design, before it is manufactured in larger quantities.
 3D printing / Additive Manufacturing(AM)
• Additive manufacturing is the most common rapid prototyping process.

• Prototypes are often created with additive layer manufacturing technology,

also known as 3-D printing.
• Additive manufacturing in which the part to be produced is constructed by the
addition of material.
• The construction is carried out in layers.
• Additive manufacturing thus enables the creation of 3D objects.
• In 3D metal printing, for example, a metal (or several metals) is reduced to a
powder before it is fed into the chamber and rebuilt.
• Applications in automotive, aerospace, medical industries.
 Materials used in Additive Manufacturing
• Bio chemicals: Silicon, Calcium phosphate, Zinc etc.

• Ceramics : Alumina, Zirconia, powdered glass with adhesives

• Metals : Gold, silver, stainless steel, titanium etc.

• Thermoplastics: Polymers
3-D printing
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• Additive manufacturing
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