Lecture-01

Conventional Machining

NIKHIL R. DHAR, Ph. D.

DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING
BUET BANGLADESH
Conventional Machining

Turning & Related Operations

Drilling & Related Operations

Milling & Related Operations

Shaping & Related Operations

Grinding & Related Operations

Introduction
Production or manufacturing of any object is a value addition process by which raw material of
low utility and value due to its irregular size, shape and finish is converted into a high utility
and valued product with definite size, shape and finish imparting some desired function ability.
Machining is an essential process of semi-finishing and often finishing by which jobs of desired
shape and dimensions are produced by removing extra material from the preformed blanks in
the form of chips with the help of cutting tools moved past the work surfaces in machine tools.
Machined parts can be classified as rotational or non-rotational. A rotational workpart has
a cylindrical or disk-like shape. The characteristics operation that produces this geometry is
one in which a cutting tool removes material from rotating workpart. Examples include turning
and boring. Drilling is closely related except that an internal cylindrical shape is created and
the tool rotates in most drilling operations.
A non-rotational (also called prismatic) workpart is block-like or plate like. This geometry is
achieved by linear motions of the workpart, combined with either rotating or linear tool
motion. Operations in this category include milling, shaping, planning and sawing

Rotational Non-rotational
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Introduction

Each machining operation produces a characteristics geometry due to two

factors
 the relative motions between the tool and the workpart and
 the shape of the cutting tool. These operations may be classified as generating
and forming.
In generating, the geometry of the workpart is determined by the feed
trajectory of the cutting tool. Examples of generating the work shape in
machining include straight turning, taper turning, contour turning,
peripheral milling and profile milling.
In forming, the shape of the part is created by the geometry of the
cutting tool. In effect, the cutting edge of the tool has the reverse of the
shape to be performed on the part surface. Form turning, drilling, and
broaching are examples of the case.
Forming and generating are sometimes combined in one operation,
such as in thread cutting on a lathe and slot milling.

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Generating Shape in Machining

(a) Straight turning (b) Taper turning (c) Contour turning

(d) Plain milling (e) Profile turning

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Forming Shape in Machining

(a) (b) (c)

Forming to create shape in machining (a) form turning (b) broaching and
(b) drilling

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Forming & Generating Shape

(a)
(b)

Combination of forming and generating to create shape

(a) slot milling and (b) thread cutting

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LECTURE-02
TURNING & RELATED OPERATIONS

NIKHIL R. DHAR, Ph. D.

DEPARTMENT OF INDUSTRIAL & PRODUCTION
ENGINEERING
BUET BANGLADESH
Introduction
Turning is the process whereby a centre lathe is used to produce "solids of
revolution". It can be done manually, in a traditional form of lathe, which
frequently requires continuous supervision by the operator, or by using a computer
controlled and automated lathe which does not. This type of machine tool is
referred to as having computer numerical control, better known as CNC and is
commonly used with many other types of machine tool besides the lathe.

When turning, a piece of material (wood, metal, plastic even stone) is rotated and
a cutting tool is traversed along 2 axes of motion to produce precise diameters and
depths. Turning can be either on the outside of the cylinder or on the inside (also
known as boring) to produce tubular components to various geometries. Although
now quite rare, early lathes could even be used to produce complex geometric
figures, even the platonic solids; although until the advent of CNC it had become
unusual to use one for this purpose for the last three quarters of the twentieth
century. It is said that the lathe is the only machine tool that can reproduce itself.

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Basic Turning Operations

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Basic Turning Operations

Facing: The tool is fed radially into the rotating work

on one end to create a flat surface on the end.

 Contour turning: Instead of Facing

feeding the tool along a straight
line parallel to the axis of rotation
as in turning, the tool follows a
contour that is other than straight,
thus creating a contoured form in Contour turning
the turned part.

 Form turning: In this operation, sometimes called

forming, the tool has a shape that is imparted to the
work by plunging the tool radially into the work.
Form turning
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Basic Turning Operations

Taper turning: Instead of feed

the tool parallel to the axis of
rotation of the work, the tool is
fed at an angle, thus creating a
taper cylinder or conical shape.
Taper turning

 Chamfering: The cutting edge of the tool is used to cut

an angle on the corner of the cylinder, forming what is
called a “chamfer”.

Chamfering
 Cutoff: The tool is fed radially
into the rotating work at some
location along its length to cut
off the end of the part. This
operation is sometimes referred
to as parting. Cutoff

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Basic Turning Operations

Boring: A single point is fed

linearly. parallel to the axis of
rotation, on the inside diameter
of an existing hole in the part.
Boring
 Threading: A pointed tool is fed linearly across the outside
surface of the rotating workpart in a direction parallel to the axis
of rotation at a large effective feed rate, thus creating threads in
the cylinder. Threading
 Drilling: Drilling can be
performed on a lathe by feeding
the drill into the rotating work
along its axis. Reaming can be
Drilling
performed in a similar way.

 Knurling: This is not a machining operation because it does not

involve cutting of material. Instead, it is a metal forming
operation used to produce a regular cross hatched pattern in the
work surface. Knurling

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Basic Turning Operations

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Types of Lathe
Speed Lathes
 Limited to headstock, tailstock, and simple tool post.
 Limited to 3-4 speeds
 High spindle speeds,
 For light work such a wood turning, metal polishing, or metal spinning
Engine Lathes
 Most common type
 Variable in design from low to high power designs
 Broad range of lengths up to 60ft long
Tool room Lathes
 Specialized Engine lathe with greater accuracy.
 Broader range of speeds and feeds
 Greater versatility for tool and die manufacturing
Turret Lathes
 Turret on tool post rotates to position a variety of tools
 Capstan wheel used to pull to away from work piece to position next tool
 A number of tools set up on machine, each brought up in quick succession to complete
the part in a single setup

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Lathe Components
Bed: supports all major components
Carriage: slides along the ways and consists of the cross-slide, tool post, apron
Headstock – Holds the jaws for the work piece, supplies power to the jaws and has
various drive speeds
Tailstock – supports the other end of the workpiece
Feed Rod and Lead Screw-Feed rod is powered by a set of gears from the
headstock

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Lathe Design and Terminology
Bed
 Gray cast for vibration dampening
Headstock assembly
 Spindle
 Transmission
 Drive motor
Tailstock assembly
 Longitudinal way clamp
 Transverse way clamp
 Quill for cutting tools, live centers,
or dead centers
Quick-change gearbox
 Powers Carriage Assembly
movement with lead screw
Carriage Assembly
 Fixed to cross slide
 Holds tool post at variable orientations
 Provides longitudinal and transverse movement of tooling
Ways
 Provides precise guidance to carriage assembly and tailstock

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Computer Numerical Controls (CNC) Lathe
In the most advanced lathes, movement and control of the machine and its
components are actuated by computer numerical controls (CNC); the features of
such a lathe are shown in the following Figure.

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 Vice: This holds the material to be cut or
shaped. Material must be held securely otherwise
it may 'fly' out of the vice when the CNC begins
to machine. Normally the vice will be like a clamp
that holds the material in the correct position.
Guard: The guard protects the person using the
CNC. When the CNC is machining the material
small pieces can be 'shoot' off the material at
high speed. This could be dangerous if a piece hit
the person operating the machine. The guard
completely encloses the dangerous areas of the
CNC.
Chuck: This holds the material that is to be
shaped. The material must be placed in it very
carefully so that when the CNC is working the
material is not thrown out at high speed.
Motor: The motor is enclosed inside the
machine. This is the part that rotates the chuck
at high speed.
Lathe Bed: The base of the machine. Usually a
CNC is bolted down so that it cannot move
through the vibration of the machine when it is
working.
Cutting Tool: This is usually made from high
quality steel and it is the part that actually cuts
the material to be shaped.

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Advantages of CNC Machines
CNC machines can be used continuously 24 hours a day, 365 days a year and only need to be
switched off for occasional maintenance.
CNC machines are programmed with a design which can then be manufactured hundreds or
even thousands of times. Each manufactured product will be exactly the same.
Less skilled/trained people can operate CNCs unlike manual lathes / milling machines etc.. which
need skilled engineers.
CNC machines can be updated by improving the software used to drive the machines
Training in the use of CNCs is available through the use of ‘virtual software’. This is software that
allows the operator to practice using the CNC machine on the screen of a computer. The
software is similar to a computer game.
CNC machines can be programmed by advanced design software such as Pro/DESKTOP®,
enabling the manufacture of products that cannot be made by manual machines, even those
used by skilled designers / engineers.
Modern design software allows the designer to simulate the manufacture of his/her idea. There
is no need to make a prototype or a model. This saves time and money.
One person can supervise many CNC machines as once they are programmed they can usually
be left to work by themselves. Sometimes only the cutting tools need replacing occasionally.
A skilled engineer can make the same component many times. However, if each component is
carefully studied, each one will vary slightly. A CNC machine will manufacture each component
as an exact match.

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Disadvantages of CNC Machines
CNC machines are more expensive than manually operated machines,
although costs are slowly coming down.
The CNC machine operator only needs basic training and skills, enough to
supervise several machines. In years gone by, engineers needed years of
training to operate centre lathes, milling machines and other manually
operated machines. This means many of the old skills are been lost.
Less workers are required to operate CNC machines compared to manually
operated machines. Investment in CNC machines can lead to
unemployment.
Many countries no longer teach students how to use manually operated
lathes / milling machines etc... students no longer develop the detailed
skills required by engineers of the past. These include mathematical and
engineering skills.

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Reaming
Reams remove small amounts of material to ensure exact hole size and
improve hole surface finish
Reams are either hand operated or machined at slow speed
Ream types
 Shell reams
 Expansion reams
 Adjustable reams
 Tapered reams

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Ream Geometry

Figure: Standard nomenclature for hand and chucking reamers.

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Boring
Boring consists of producing circular internal profiles in hollow workpieces or on a hole
made by drilling or another process and is carried out using cutting tools that are
similar to those used in turning. However, because the boring bar has to reach the full
length of the bore, tool deflection and hence maintenance of dimensional accuracy
can be a significant problem. A vertical boring machine is similar to a lathe is shown
in the following Figure.

Figure: Schematic illustration of the components of a vertical boring mill

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Cutting Tools for Lathes
Tools consists of cutting surface and support
 Cutting surfaces can be of same material as support or a separate insert
 Supports materials must be rigid and strong enough to prevent tool deflection during cutting
 Cutting materials are typically carbides, carbide coatings, ceramics, or high carbon steels
 Inserts are used to decrease cost in that the insert is disposed of, and the support reused.

Figure: Common types of forged tool holders: (a) right-hand turning, (b) facing, (c) grooving
cutoff, (d) boring, (e) threading.

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Quick Change Tool Holders
Tool changing can take over 50% of manual lathe operations
Quick Change holders are used to reduce manual tool change time and increase
production

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Workholding Devices for Lathes
Work pieces can be held by various methods
 Work piece mounted between centers
 Work piece mounted within a single chuck
 Work piece mounted within a collet
 Work piece mounted on a faceplate

Lathe Centers
A lathe center hold the end of the work piece, providing support to
preventing the work piece from deflecting during machining
Lather centers can be mounted in the spindle hole, or in the tailstock quill
Lathe centers fall into two categories
 Dead Center: solid steel tip that work piece spins against
 Live Center: centers contact point is mounted on bearings and allowed to spin
with work piece

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Lathe Chucks
Lathe Chucks are adjustable
mechanical vises that hold the work
piece and transfer rotation motion
from the drive motor to the work
piece
Lathe Chucks come in two basic
types
 Three-jaw self-centering chucks
Used to center round or
hexagonal stock
 Four-jaw independent chucks
Each jaw moves independently to
accommodate various work piece
shapes

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Lathe Collets
Collets are used to hold round stock of standard sizes
Most accurate holding method for round stock
 Run out less than 0.0005 inch
 Stock should be no more than 0.002 inch larger or 0.005 smaller than the collet
 Typically used for drill-rod, cold-rolled, extruded, or previously machined stock

Several types of lathe collets

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 THANK YOU FOR YOUR ATTENTION

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