Elements of Mechanical Engineering (ESCF5)

Unit 2: Machine Tools

4.1 Introduction
When machine performs the metal cutting operations by cutting tool mounted on them, they
are called Machine tools.
A machine tool may be defined as power driven machine which accomplishes machining
operations on it.

4.2 Lathe
A lathe is a machine tools employed generally to produce circular objects. It is versatile
machine tool. Lathes are classified as engine lathe, speed lathe, Capstun lathe, Turret lathe,
automatic lathe and CNC lathe.
Engine lathe or centre lathe is a machine driven by the prime mover used to produce circular
objects by manual operations.

4.3 Principle of Working

Lathe is basically turning machine works on the principle that a cutting tool can remove
material in the form of chips from the rotating work piece to produce circular objects. These
is accomplished in a lathe which holds the work piece rigidly and rotate them at high speed
while cutting tool is moved against it.

4.3 Lathe Specifications

The size of the lathe is specified by the following
1. Maximum diameter of the workpiece that can be revolved over the lathe bed.
2. Maximum diameter and width of the workpiece that can swing when the lathe has a
gap in the bed.
3. The maximum length of the workpiece that can be mounted between the centres.
4. Overall length of the bed. It is total length of lathe.
4.5 Major parts of a Lathe and their Functions

The major parts of lathe are

1. Bed: The bed is the foundation part of a lathe and supports all its parts. There will be
inner and outer guideways. The head stock and tail stock are mounted on the inner
guideways which keep them perfectly aligned with each other. The outer guideways
guide longitudinal movement of carriage assembly.
2. Main drive: An electric motor mounted in the left leg of lathe in conjunction with
transmission system from motor to spindle that forms main drive of the lathe.
3. Cone pulley and Back Gear: the cone pulley which drives the main spindle through
the belt driven by motor. Various speed can be obtained by shifting belt on different
steps of cone pulley. Spindle speed can be varied with gear arrangement.
 4. Head stock: It comprises of feed gear box and the cone pulley. It is rigidly mounted
on left side and main spindle projects from the head stock.
5. Tail stock: it is the movable part of lathe and carries dead centre in it. The main
function of the tailstock is to support the free end of the work piece.
6. Lead Screw: It is longitudinal screw rod runs longitudinally. The rotation of lead
screw move carriage to and fro during thread cutting.
7. Feed Rod: the feed rod is stationary rod which facilitated longitudinal movement of
carriage during lathe operations.
8. Carriage Assembly: the carriage assembly serves to support the tool and moves over
the bed longitudinally between head stock and tail stock.
a. Saddle: It serves as support for cross slide.
b. Cross-slide: It is mounted above saddle enables cutting tool movement laterally
by cross feed handle.
c. Compound Rest: It is mounted on cross slide and support the tool post, which
can be swivelled at any angle during taper turning.
d. Apron: It houses carriage and cross slide mechanism. Apron hand wheel moves
carriage manually by means of rack and pinion gear.
e. Tool post: The tool post clamps tool holder in the proper position for machining
operation.
9. Feed gear box: It is mounted on the left side of the lathe bed and below head stock.

4.6 Lathe Operations

1. Plain Turning
➢ The workpiece is supported between to centre which permit the rotation.
➢ The cutting tool is fed perpendicular to axis of workpiece to know predetermined
depth of cut, and then moved parallel to the axis of the workpiece.
➢ The machining operation of workpiece to reduce the cylindrical section of required
diameter as known as turning.

2. Facing
➢ It is defined as on operation performed on lathe to generate flat surface at the end of
the workpiece.
➢ The direction of feed is given perpendicular to the axis of the lathe.
 ➢ The workpiece is held in the chuck and facing tool id fed from outer edge to centre or
vice versa.

3. Knurling
➢ Knurling is defined as an operation performed on lathe to generate serrated surface on
workpiece using knurling workpiece.
➢ This operation is used grip is required to hold the part.
➢ It consists of upper and lower on which desired pattern can be seen.
➢ The upper and lower roller touches the surface of workpiece to be knurled.

4.7 Drilling Machines

➢ Drilling is a metal cutting process carried out by a rotating cutting tool to make
circular holes in solid materials.
➢ The tool which makes the hole is called drill.
 ➢ Drilling machine is power operated machine tool which holds the drill in its spindle
rotating at high speeds when manually actuated to move linearly simultaneously
against the workpiece produces a hole.
4.8 Types of drilling Machines
1) Portable Drilling Machine
2) Bench Drilling Machine
3) Pillar Drilling Machine
4) Radial Drilling Machine
5) Gang Drill
6) Multiple Drilling Machine
4.9 Bench Drilling Machine
➢ Bench drilling machine are light duty drilling machines widely used in small
workshops.
➢ It is also called as sensitive drilling machine because of accurate and well balanced
spindle. Generally, holes of size up to 15 mm are drilled in these machines.
➢ It consists of vertical column mounted over the base. The vertical column carries a
moving head housing in it a speed gear box and spindle feeding mechanism and work
table which can also be raised or lowered.
➢ An electric motor is mounted at the top end of vertical column on its rear side.
➢ The power is transmitted to main spindle through stepped cone pulley.
➢ A drill chuck is fitted in to spindle at its lower end.
➢ The workpiece is mounted on the work table and clamped to it, which can raise or
lowered and locked in that position.
➢ The tip of the drill is aligned with the centre of the hole to be drilled and by feed
handle rotating spindle is rotated to perform drilling operations.
4.10 Drilling Operations
➢ The number of other operations performed on a drilling machines are
1) Boring
2) Counterboring
3) Countersinking
4) Spot facing
5) Tapping
6) Reaming
Reaming is the process of smoothening the surface of the drilled hole with a reamer. The
reamer is placed in place of twist drill and speed is reduced to half of that the drilling, it is
done in the same way as drilling.
1. Boring
Boring is done on the drilling machine to increase the size of already drilled hole. By
lowering the tool while continuously rotating the size of the hole is increased to its entire
depth.
 2. Tapping
Tapping is the process of cutting internal threads with threads cutting tool called tap.
Before tapping, hole slightly smaller than the size of tap is drilled, tap is fitted to drilling
machine spindle and threads are cut in the same way as drilling.

4.11 Milling Machine

➢ Milling is a metal cutting operation in which cutting tool is a slow revolving cutter
having cutting teeth formed on its periphery.
➢ The milling cutter is a multipoint cutting tool..
➢ The workpiece will be fed against the revolving cutter to perform the cutting
operation.
➢ A milling Machine is a power operated machine tool in which the workpiece
mounted on the moving table is machined t various shapes when moved under a
slowling revolving cutter.

4.12 Principle of Milling Machine

➢ When the workpiece is fed in the opposite direction to the cutter tooth at the point
of contact, the process is called up milling or conventional milling.
 ➢ In this process as the workpiece is fed against rotating cutter, chip that is removed
progressively thicker.
➢ When the workpiece is fed in the same direction as that of cutter, at the point of
contact, the process is called climb or down milling.
➢ In this process cutter enters top of the workpiece and removes the chip that gets
progressively thinner.
➢ More material is removed than conventional milling.

4.13 Types of Milling Machines

The milling machines are broadly classified in to
1. Plain or Horizontal Milling Machine
2. Vertical Milling Machine
3. Universal Milling Machine
4. Planer Type Milling Machine
5. Profile Cutting Milling Machine
4.14 Horizontal Milling Machines
The different parts of horizontal milling machines are
1. Column
2. Spindle
3. Arbor
4. Knee
5. Saddle
6. Table
 1. Column: The column is combined with the base in to single casting. The column
houses the spindle, transmission systems from the electric motor the front of the
vertical face of the column is provide with a vertical slide. The Knee moves up and
down on this slide. At the top of column accommodates a cast overarm which
supports the arbor.
2. Arbor: It is a horizontal shaft with straight body and tapered shank. Rotating cutters
are mounted on the straight portions of the arbor. The taper end fits in to the tapered
hole of spindle. The other end of the arbor is mounted in a bearing housed in a
projecting overarm.
3. Knee: The knee is the casting mounted on the front slide of vertical column and is
moved up and down by an elevating screw. The upper face of knee is provided with
guideways so as to mount the saddle.
4. Saddle: The saddle is provided wit two slides on at top and other at bottom. The
lower slide fits with top guideways of knee and upper slide receives guides of the
bottom of table.
5. Table: The table is mounted on the top of the saddle. The bottom of table fits in to top
slide ways of the saddle. It is provided with work holding fixtures.
The horizontal milling machine has its cutter axis horizontal. The workpiece is held
on the table mounted on the saddle. The feed is given by moving the table against the
revolving cutter. The cross feed handle enables entire table to move across knee. The
knee can be moved up and down by an elevating screw
4.15 Milling Operations
A variety of milling operations are performed on the milling machine to produce
horizontal, vertical, inclined surface, keyways, slots, gear teeths.
1. Slot Milling: it is the process of milling slots using different types of cutter called
slot drill which has a capacity to cut in to solid materials.

2. Angular Milling: it is used to mill flat surfaces that are neither parallel nor
perpendicular to milling cutter axis. In this inclined surfaces are produced by milling
cutter having their teeth inclined to their axes.

3. Form Milling: It is milling process used to machine special contours consisting of

curves using special form milling cutter. Which are shaped exactly to the contour that
is to form milled.