1. Associate Professor (Workshop)
Machine Tools
Dr. N.K. Singh
Associate Professor (Workshop)
Indian School of Mines
Dhanbad

2. Manufacturing Processes
Material Removal Processes (Machining)
Joining Processes (Welding, Brazing, Soldering)
Casting Processes
Forming Processes

3. Material Removal Processes (Machining)
Cutting tools
Machine Tools
Lathe turning
Drilling
Milling
Grinding
Broaching, sawing, filing
Nontraditional machining process (EDM)

4. Cutting Tool
In the context of metalworking, a cutting tool, is any tool that is used to remove metal from the workpiece in form of chips. It frequently refers to a tool bit.
Tool material should be harder than the material which is to be cut
They must be able to withstand the heat generated in the metal cutting process.
They also must have a specific geometry, designed so that the cutting edge can contact the workpiece without the rest of the tool dragging on its surface. The angle of the cutting face is also important.

5. Classification of Cutting tools
single point cutting tool
multiple point cutting tool.

6. A single-point cutting tool
has only one cutting edge
used for increasing the size of holes, or boring, thread making, turning etc.

7. A single-point cutting tool

9. Nomenclature of cutting tool

10. Multiple-point cutting tools
have two or more cutting edges.
Example:- milling cutters, drills, and broaches.

11. Milling cutters

12. Cutting Tool Materials
Tool Steels
High Speed Steel (HSS)
Carbides
Coated Carbide
Ceramics and cermet
TiN Coated High-Speed Steel
CBN
Diamond tool

13. Machine Tool

14. Machine tools Lathe turning Drilling Milling Shaper Planer Grinding
Broaching, sawing, filing
Nontraditional machining process (ex EDM)

15. Lathe Turning

16. Lathe Turning
Turning

17. Lathe

18. Gear System

19. Tailstock

20. Long Job is supported by tailstock

21. Drilling in lathe machine

22. Cutting parameters Speed
Cutting speed is defined as the speed at which the work moves with respect to the tool (usually measured in feet per minute).
Feed
Feed rate is defined as the distance the tool travels during one revolution of the part.
Depth of Cut

23. Cutting speed and feed determines the surface finish, power requirements, and material removal rate.
The primary factor in choosing feed and speed is the material to be cut.
However, one should also consider material of the tool, rigidity of the workpiece, size and condition of the lathe, and depth of cut.

24. Lathe Turning
Facing

25. Lathe Turning

26. Lathe Turning

27. Specification of Lathe Machine
Swing over bed
Swing over carriage
Distance between centers
Hole through spindle
Travel of cross-slide
Taper of tailstock spindle
Length overall
Width overall
Height overall
Shipping weight
Motor/Speed Control
Spindle speed range

28. Milling Machine tool

29. Milling Machine Tool
Milling is one of the basic machining processes. Milling is a very versatile process capable of producing simple two dimensional flat shapes to complex three dimensional interlaced surface configurations.

30. Process The milling process: Typically uses a multi-tooth cutter
Work is fed into the rotating cutter
Capable of high MRR
Well suited for mass production applications
Cutting tools for this process are called milling cutters

31. Vertical Mill

32. Horizontal Mill

34. Classification of Milling
Peripheral Milling (SLAB Milling)
Face Milling
End Milling

35. Peripheral Milling (SLAB Milling)
The milled surface is generated by teeth located on the periphery of the cutter body.
The axis of cutter rotation is generally in a plane parallel to the workpiece surface to be machined.

36. Face Milling
The cutter is mounted on a spindle having an axis of rotation perpendicular to the workpiece surface.
The milled surface results from the action of cutting edges located on the periphery and face of the cutter

37. End Milling
The cutter in end milling generally rotates on an axis vertical to the workpiece.
It can be tilted to machine tapered surfaces.
Cutting teeth are located on both the end face of the cutter and the periphery of the cutter body.

38. METHODS OF MILLING
Up Milling
Down Milling

39. UP MILLING (conventional milling)
The direction of the cutter rotation opposes the feed motion.
For example, if the cutter rotates clockwise , the workpiece is fed to the right in up milling.

41. DOWN MILLING (climb milling)
The direction of cutter rotation is same as the feed motion.
For example, if the cutter rotates counterclockwise , the workpiece is fed to the right in down milling.

42. Other Milling Operations

43. Grinding Machine

44. Grinding Machine
The primary purpose of a grinding wheel is to sharpen tools (eg. drill bits).
The hard abrasive of the wheel is made for removing very hard materials like high speed steel.
Never grind on the side of the wheel.
Never grind a soft material such as Aluminum. The material will coat the wheel and prevent the abrasive from working properly. (SHOW)

47. Cavity

48. Grinding Wheel Specification

49. Safety Measures
Safety Glasses EVERYONE MUST WEAR SAFETY GLASSES IN THE SHOP.
Clothes and Hair Check your clothes and hair before you walk into the shop. In particular:
IF YOU HAVE LONG HAIR OR A LONG BEARD, TIE IT UP. If your hair is caght in spinning machinery, it will be pulled out if you're lucky. If you're unlucky, you will be pulled into the machine.
NO LOOSE CLOTHING. Ties, scarves, loose sleves, etc. are prohibited

50. Safety Measures (Cont..)
NO GLOVES
REMOVE JEWELERY
WEAR APPROPRIATE SHOES No open toed sandals. Wear shoes that give a sure footing.
Safe Conduct in the Shop Be aware of what's going on around you. For example, be careful not to bump into someone while they're cutting with the bandsaw (they could lose a finger!).

51. Safety Measures (Cont..)
Machining IF YOU DON'T KNOW HOW TO DO SOMETHING, ASK! BEFORE YOU START THE MACHINE:
Study the machine. Know which parts move, which are stationary, and which are sharp.
Double check that your workpiece is securely held.
Remove chuck keys and wrenches.
DO NOT LEAVE MACHINES RUNNING UNATTENDED!
CLEAN UP MACHINES AFTER YOU USE THEM! A dirty machine is unsafe and uncomfortable to work on. Do not use compressed air to blow machines clean. This endangers people's eyes and can force dirt into machine bearings