Manufacturing Machines ETME-206

Anil Dahiya

Assignment No .1 Manufacturing Machines (4M123) Last date of submission: 22.3.2012

Q.1. (i) What is the difference between machine and machine tool? (ii) Write difference between shaper, planer & slotter. (iii)What is the difference between single purpose and special purpose machines? (iv) What is difference between generating and forming? (v) What are major differences between CNC lathe and conventional lathe? Q.2. (a) Explain the different cutting tool materials? Write applications of each. (b) With neat sketch explain single point cutting tool geometry. Q.3. (a )What do you mean by taper turning? Explain the different taper turning methods used on lathe? Anil Dahiya 3/22/2012 3:30 AM (b) Explain the major work holding devices used on lathe.

Drilling
Drilling machines are generally or mainly used to

originate through or blind straight cylindrical holes in solid rigid bodies and/or enlarge (coaxially) existing (premachined) holes.
Holes of different diameter ranging from about 1 mm

to 40 mm
Holes of varying length depending upon the

requirement and the diameter of the drill

In different materials excepting very hard or very soft
Anil Dahiya

materials like rubber, polythene etc.

3/22/2012 3:30 AM

DRILLING M/C TOOL

Anil Dahiya

3/22/2012 3:30 AM

Anil Dahiya

3/22/2012 3:30 AM

Machining Video
Machining Video

Anil Dahiya

3/22/2012 3:30 AM

Classification of drilling machines

1.

General purpose drilling machines of common use

Table top small sensitive drilling machine

These small capacity ( 0.5 kW) upright (vertical)

single spindle drilling machines are mounted (bolted) on rigid table and manually operated using usually small size ( 10 mm) drills.
Anil Dahiya 3/22/2012 3:30 AM

Table top small sensitive drilling machine

Anil Dahiya

3/22/2012 3:30 AM

Sensitive Drill Press Parts

Hand feed lever Controls down feed pressure Feel the pressure Manufactured in

bench and floor model Four main parts

Base, column, table

and drilling head

Anil Kumar Dahiya

Sensitive Drill Press Parts

Base
Provides stability for machine Cast iron with holes to be bolted to table or bench Slots or ribs in base allow work-holding device or

work piece to be fastened

Column
Accurate cylindrical post that fits in base Table may be adjusted any point (base to head) Drill press head mounted near top

Anil Kumar Dahiya

Sensitive Drill Press Parts

Table
Round or rectangle shaped Used to support work piece to be machined Surface 90 to column (move around)

Drilling Head
Mechanism used to revolve cutting tool Spindle: round shaft holds cutting tool Quill: houses spindle

Anil Kumar Dahiya

Sensitive Drill

Anil Kumar Dahiya

Pillar drilling machine

These drilling machines, usually called pillar

drills, are quite similar to the table top drilling machines but of little larger size and higher capacity (0.55 ~ 1.1 kW) and are grouted on the floor (foundation).
Here also, the drill-feed and the work table

movement are done manually.

These low cost drilling machines have tall

tubular columns and are generally used for Anil Dahiya jobs and light drilling. 3/22/2012 3:30 AM small

Pillar drilling machine

Anil Dahiya

3/22/2012 3:30 AM

Anil Dahiya

3/22/2012 3:30 AM

Column drilling machine

These box shaped column type drilling machines

are much more strong, rigid and powerful than the pillar drills. In column drills the feed gear box enables automatic and power feed of the rotating drill at different feed rates as desired. Blanks of various size and shape are rigidly clamped on the bed or table or in the vice fitted on that. Such drilling machines are most widely used and Anil Dahiya over wide range ( light to heavy) work. 3/22/2012 3:30 AM

Column drilling machine

Anil Dahiya

3/22/2012 3:30 AM

Radial drilling machine

This usually large drilling machine possesses a

radial arm which along with the drilling head can swing and move vertically up and down.
The radial, vertical and swing movement of the

drilling head enables locating the drill spindle at any point within a very large space required by large and odd shaped jobs.
There are some more versatile radial drilling

machines where the drill spindle can be Anil Dahiya 3/22/2012 3:30 AM additionally swivelled and / or tilted.

Radial drilling machine

Anil Dahiya

3/22/2012 3:30 AM

Radial Drill
Sometimes called radial-arm drill
Advantages of this machine
Larger and heavier work may be machined Drilling head raised or lowered Drilling head moves rapidly to any desired location

while work piece remains clamped More power Head may swivel so holes can be drilled on angle

Anil Kumar Dahiya

Radial Drill

Anil Kumar Dahiya

Radial Drill

Anil Kumar Dahiya

Radial Drill Parts

Base
Heavy, box-type, ribbed cast iron or welded steel
Used to bolt machine to floor and provide coolant

reservoir Table may be bolted to base for small work

Column
Upright cylindrical member fitter to base Supports radial arm at right angles

Anil Kumar Dahiya

Radial Drill Parts

Radial arm
Attached to column May be raised and lowered by means of power-driven

elevating screw Supports drive motor and drilling head

Drilling head
Mounted on arm and moved along length of arm by

traverse hand wheel Drill spindle may be raised or lowered

Anil Kumar Dahiya

Radial Drill

Anil Kumar Dahiya

Radial Drill

Anil Kumar Dahiya

Radial Drill

Anil Kumar Dahiya

Radial Drill

Anil Kumar Dahiya

2. General purpose drilling machines with more specific use.

Hand drills Unlike the grouted stationary drilling machines, the hand drill is a portable drilling device which is mostly held in hand and used at the locations where holes have to be drilled.

The small and reasonably light hand drills are run by a

high speed electric motor. In fire hazardous areas the drill is often rotated by compressed air.
Anil Dahiya 3/22/2012 3:30 AM

Hand drills

Anil Dahiya

3/22/2012 3:30 AM

Gang drilling machine

In this almost single purpose and more productive

machine a number (2 to 6) of spindles with drills (of same or different size) in a row are made to produce number of holes progressively or simultaneously through the jig.

Anil Dahiya

3/22/2012 3:30 AM

Turret (type) drilling machine

Turret drilling machines are structurally rigid

column type but are more productive like gang drill by having a pentagon or hexagon turret.
The turret bearing a number of drills and similar

tools is indexed and moved up and down to perform quickly the desired series of operations progressively.
These drilling machines are available with

varying degree of automation both fixed and flexible type. Anil Dahiya 3/22/2012 3:30 AM

Turret (type) drilling machine

Anil Dahiya

3/22/2012 3:30 AM

Multi-spindle drilling machine

In these high production machine tools a large

number of drills work simultaneously on a blank through a jig specially made for the particular job.
The entire drilling head works repeatedly using

the same jig for batch or lot production of a particular job.

The rotation of the drills are derived from the

main spindle and the central gear through a number of planetary gears in mesh with the Anil Dahiya 3/22/2012 central gear and the corresponding flexible 3:30 AM

Multi-spindle drilling machine

The positions of those parallel shafts holding the

drills are adjusted depending upon the locations of the holes to be made on the job.
Each shaft possesses a telescopic part and two

universal joints at its ends to allow its change in length and orientation respectively for adjustment of location of the drills of varying size and length.
In some heavy duty multispindle drilling machines,

the work-table is raised to give feed motion instead of moving the heavy drilling head.
Anil Dahiya 3/22/2012 3:30 AM

Multi-spindle drilling machine

Anil Dahiya

3/22/2012 3:30 AM

Micro (or mini) drilling machine

This type of tiny drilling machine of

height within around 200 mm is placed or clamped on a table, and operated manually for drilling small holes of around 1 to 3 mm diameter in small work pieces.

Deep hole drilling machine

Very deep holes of L/D ratio 6 to even 30, required for

rifle barrels, long spindles, oil holes in shafts, bearings, connecting rods etc, are very difficult to make for slenderness of the drills and difficulties in cutting fluid application and chip removal. It needs machines like deep hole drilling machine such as gun drilling machines with horizontal axis which are provided with high spindle speed high rigidity tool guide pressurised cutting oil for effective cooling, chip removal and lubrication at the drill tip. Deep hole drilling machines are available with both

PARTS OF DRILLING M/C TOOL

Column with base: it is the basic structure to hold

the other parts Drilling head: this box type structure accommodates the power drive and the speed and feed gear boxes.
Spindle: holds the drill and transmits rotation and

axial translation to the tool for providing cutting motion and feed motion both to the drill.
Drilling machines are available in varying size and

configuration such as pillar drill, column drill, radial drill, micro-drill etc. but in working principle all are Anil Dahiya 3/22/2012 3:30 AM more or less the same.

Twist Drill

Classification of drill
According to type of shank they carry
Parallel shank Tapper shank According to type of flutes

flat drill twist drill According to length short series: 0.2mm-16mm stub series: 0.5mm-40mm long series: 1.5mm-26mm

Anil Dahiya 3/22/2012 3:30 AM

 According to application:
Core drill: carry 3 parallel flutes ,used for

enlarging drilled holes Drill for long hole drilling: heavy duty drill and larger helix angle Centre drill: Masonry drill :4mm-20mm, cutting anle:115used for drilling centre holes According to the tool material: High speed steel drill Carbide tipped drill

Anil Dahiya

3/22/2012 3:30 AM

Parts of Twist drill

1: point: The point is the cone shaped end and it

does the cutting. It consists of the following: (A) dead centre: It is the sharp edge at the extreme tip of the drill. This should always be the exact centre of the drill. (B) Lips: these are the cutting edges of the drill. (C) Heel : It is the portion of the point back from the cutting edge. 2: Shank : It is the portion of the drill by which it is clamped in the spindle. The shank may be either straight or tapered. Straight shank drills are used with a chuck. Tapered shank drills have self-holding tapes that fit directly into the drill press spindle. On the taper shank is the another term is used which

 3: Body : It is the portion between the point and the shank. The

body consists of the following parts: (A) Flutes : Two or more spiral grooves that run the length of the drill body are called flutes. The flutes do four thing. Help from the cutting edge of the drill point. Curl the chip tightly for easier removal. From channels through which chips can escape from the hole being drilled. Allow the coolant and lubricant to get down to the cutting edge. (B) Margin It is the narrow strip extending back the entire length of the flute. It is the full diameter of the drill. (C) Body Clearance: It is the part of the drill body that has been reduced in order to cut down friction between the drill and the wallAM Anil Dahiya 3/22/2012 3:30 of the hole

Angles of a drill:
Rake or helix angle: angle between a plane containing

the drill axis and leading edge of the land. It can have +ve, -ve or zero right hand flute have +ve, left hand flute have ve, parallel have zero. Angle varies 0-48 (16-32 is generally used). Higher angle for softer materials and lower for harder . Point angle (cutting angle) : angle between two opposite lips of the drill ( 80-140) ,118 for large variety of materials, smaller angle for brittle materials, larger for harder materials Lip clearance angle: angle between flank and plane normal to drill axis (8-15) ,12 is most common Chisel edge angle: angle formed between the cutting lip and chisel edge (120-135) greater this angle larger will be clearance.

Drill Materials
The two most common types are 1. HSS drill - Low cost 2. Carbide- tipped drills - high production and in CNC machines Other types are Solid Carbide drill, TiN coated drills, carbide coated masonry drills, parabolic drills, split point drill

Drilling And Drills

Types of drills Twist drill: most common drill Step drill: produces holes of two or more different diameters Core drill: used to make an existing hole bigger

Different type of drill tools

Anil Dahiya

3/22/2012 3:30 AM

Drill fixed to the spindle

Drilling operations
Drilling

Centre Hole

Drilling
Drilling

Deep Holes

Thin Material Pilot Hole

Drilling

Drilling operations
Operations that can be performed in a drilling

machine are

Drilling Reaming Boring Counter boring Countersinking Tapping

Operations in drilling machine

Counter Boring & Counter sinking

Anil Dahiya

3/22/2012 3:30 AM

Standard Operations
Reaming

Operation of sizing and producing

smooth, round hole from previously drilled or bored hole

Boring
Truing and enlarging hole by means of single-point cutting tool

Standard Operations
Spot-Facing
Smoothing and squaring surface around hole to

provide seat for head of cap screw or nut Boring bar fitted with double-edged cutting too

Standard Operations
Tapping Cutting internal threads in hole with cutting tool called tap

Counterboring
Enlarging top of previously drilled hole to given depth to provide square shoulder for head of bolt or capscrew

Operations in drilling machine

Types of cutters
Combined Countersinks and central drill :Special drilling tool to start the hole accurately. At the end it makes countersinks in the work piece. Gun drill :Machining of lengthy holes with less feed rates.

To overcome the heating and short life of the normal drill tool

Types of cutters
Tapping:-

For cutting internal thread

Multi cutting edge tool. Tapping is performed either by hand or by machine. Minor dia of the thread is drilled and then tapping is done.

Different Type of Reamers

Anil Dahiya

3/22/2012 3:30 AM

Mounting of job and tool in a drilling M/C

In general purpose drilling machines like column and radial arm type, the work-piece or blank is generally mounted:
By directly clamping on the drilling machine bed

particularly when the job is heavy and /or of odd shape and size.
In a vice which is clamped on the bed. In a suitable jig clamped on the bed. Anil Dahiya

3/22/2012 3:30 AM

Mounting of tool & Work Piece

Anil Dahiya

3/22/2012 3:30 AM

Work Holding Devices

Step Blocks
Clamps V-Blocks Angles Jigs T- Slots Bolt

Vices to hold Work pieces in Drilling

Anil Dahiya

3/22/2012 3:30 AM

Mounting of Job in a jig which is clamped on the drill-bed

Anil Dahiya

3/22/2012 3:30 AM

Drill socket for mounting drill chuck and taper shank drills in spindle

Anil Dahiya

3/22/2012 3:30 AM

Drill

Anil Dahiya

3/22/2012 3:30 AM

Drilling

Anil Dahiya

3/22/2012 3:30 AM

Use of drilling m/c

Mainly for drilling (originating or enlarging

cylindrical holes)
Occasionally for boring, counter boring,

counter sinking etc.

Also for cutting internal threads in parts like

nuts using suitable attachment.

Anil Dahiya 3/22/2012 3:30 AM

DRILLING MACHINE Specifications

Maximum drill size (diameter) that can be used Size and taper of the hole in the spindle Range of spindle speeds Range of feeds Power of the main drive Range of the axial travel of the spindle / bed Floor space occupied by the machine
Anil Dahiya 3/22/2012 3:30 AM