CONTENTS

 Drilling
 Boring
 Milling
 Grinding
 Finishing Operations
 Drilling
• Drilling is the operation of producing circular hole in
the work-piece by using a rotating cutter called
DRILL.

• The machine used for drilling is called drilling

machine.

• The drilling operation can also be accomplished in

lathe, in which the drill is held in tailstock and the
work is held by the chuck.

• The most common drill used is the twist drill.

 Drilling Machine
 It is the simplest and accurate machine used in
production shop.
 The work piece is held stationary ie. Clamped in
position and the drill rotates to make a hole.

 Types :-
a) Based on construction:
Portable, Sensitive,Radial, up-right,
Gang, Multi-spindle
b)Based on Feed:
Hand and Power driven
 Sensitive Drilling Machine
 Drill holes from 1.5 to
15mm

 Operator senses the

cutting action so
sensitive drilling
machine
 Radial Drilling Machine
 It the largest and
most versatile
used fro drilling
medium to large
and heavy work
pieces.
 Up-Right Drilling Machine
 Drill holes upto
50mm

 Table can move

vertically and
radially
 Gang type drilling machine
 In gang drilling machine, a number of
single spindle drilling machine columns
are placed side by side on a common
base and have a common worktable.
 A series of operation may be
performed on the job by shifting the
work from one position to the other
on the worktable.
 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
 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
Tool Nomenclature
 Drilling operations…

 Operations that can be performed in a drillin g machine are

 Drilling
 Reaming
 Boring
 Counter boring
 Countersinking
 Tapping
Operations in drilling machine
 BORING
 Boring is a process of producing circular internal
profiles on a hole made by drilling or another
process.
 It uses single point cutting tool called a boring bar.
 The boring bar can be rotated, or the work part can
be rotated.
 Machine tools which rotate the boring bar against a
stationary work piece are called boring machines
(also boring mills).
 Boring Machines
1.Horizontal boring machine :-


A horizontal boring machine or horizontal

boring mill is a machine tool which bores
holes
 in a horizontal direction.
There are three main types — table, planer and
floor.

The table type is the most common and, as it
is the most versatile, it is also known as the
universal
 type.
Used for drilling ,boring, and milling operations.
 Vertical boring machine
A large type of boring
machine in which a rotating
work piece is fastened to a
horizontal table, which
resembles a four-jaw
independent chuck with
extra radial T slots, and the
tool
 has a traverse motion.

Cutting tools are stationary

except for feed
movements.
 MILLING
 Milling is the machining process of
using rotary cutters to remove
material from a workpiece advancing
(or feeding) in a direction at an angle
with the axis of the tool. It covers a
wide variety of different operations
and machines,on scales from small
individual parts to large,heavy-duty
gang milling operations.
 It is one of the most commonly used
processes in industry and machine
shops today for machining partsto
precise sizes and shapes.
 PRINCIPLE OF MILLING
MACHINE
 Milling operates on the
principle of rotary
motion. A milling cutter is spun
about an axis
while a workpiece is advanced
through it in
such a way that the blades of
the cutter are able to shave
chips of material with each
pass.
 Variety of Operations
 Face milling
 End milling
 Keyway cutting
 Dovetail cutting
 T-slot and
 circular slot
 cutting
 Gear cutting
 Drilling
 Boring
 Jig boring
HORIZONTAL MILLING MACHINE
 Horizontal milling machine. 1: base 2:
column 3: knee 4 & 5: table (x-axis slide is
integral) 6: overarm 7: arbor (attached to
spindle)
 A horizontal mill has the same sort of x–y
table, but the cutters are mounted on a
horizontal arbor across the table. Many
horizontal mills also feature a built-in
rotary table that allows milling at various
angles; this feature is called a universal
table.
 VERTICAL MILLING MACHINE
 Vertical milling machine. 1: milling cutter
2:spindle 3: top slide or overarm 4:
column 5:table 6: Y-axis slide 7: knee 8:
base
 In the vertical mill the spindle axis is
vertically oriented. Milling cutters are
held in the spindle and rotate on its axis.
The spindle can generally be extended (or
the table can be raised/lowered, giving
the same effect), allowing plunge cuts
and drilling. There are two subcategories
of vertical mills: the bed mill and the
turret mill.
 GRINDING

 Grinding is a process of removing material by

abrasive action of a revolving wheel on the surface of
a work-piece in order to bring it to required shape and
size.
 The wheel used for performing the grinding operation is
known as grinding wheel
 It consists of sharp crystal called abrasive held together by
a binding material or bond
 The wheel may be a single piece or solid type or may
be composed of several segments of abrasive blocks
joined together.
DIFFERENT METHODS OF GRINDING…

SURFACE GRINDING
Surface grinding uses a rotating abrasive wheel to remove
material, creating a flat surface.
 The surface grinder is composed of an abrasive wheel, a
work holding device known as a chuck, either
electromagnetic or vacuum, and a reciprocating table.
Grinding is commonly used on cast iron and various types of
steel.
These materials lend themselves to grinding because they
can be held by the magnetic chuck commonly used on
grinding machines, and they do not melt into the wheel,
clogging it and preventing it from cutting.
 CYLINDRICAL GRINDING
 Cylindrical grinding (also called centre-type grinding) is used to
grind the cylindrical surfaces and shoulders of the work piece.
 The work piece is mounted on centres and rotated by a device
known as a drive dog or centre driver.
 The abrasive wheel and the work piece are rotated by separate
motors and at different speeds.
 The table can be adjusted to produce tapers. The wheel head can
be swivelled.
 The five types of cylindrical grinding are: outside diameter (OD)
grinding, inside diameter (ID) grinding, plunge grinding, creep feed
grinding, and centre-less grinding.
ELECTROCHEMICAL GRINDING…
 Electrochemical grinding is a type of grinding in which
a positively charged work piece in a conductive fluid is
eroded by a negatively charged grinding wheel.
 Electrolytic in-process dressing (ELID) grinding is one
of the most accurate grinding methods.
 The grinding wheel is dressed electrochemically and
in-process to maintain the accuracy of the grinding.
 During the grinding operation one side of the wheel
takes part in the grinding operation whereas the
other side of the wheel is being dressed by
electrochemical reaction.
 GRINDING WHEEL…
 A grinding wheel is an expendable wheel used for various
grinding and abrasive machining operations.
 It is generally made from a matrix of coarse abrasive
particles pressed and bonded together to form a solid,
circular shape, various profiles and cross sections are
available depending on the intended usage for the wheel.
 To maintain uniformity throughout the country in the
system of making grinding wheel, the Bureau of Indian
Standard has devised a standard system to be followed by
all manufacturer.
 To maintain uniformity throughout the country in the
system of making grinding wheel, the Bureau of Indian
Standard has devised a standard system to be followed by
all manufacturer-
1. Abrasive 2. Grain size 3. Grade 4. Structure 5. Bond
DIFFERENT SHAPES OF GRINDING
WHEELS
 Finishing Operation
 To ensure reliable performance and prolonged service life of
modern machinery, its components require to be
manufactured not only with high dimensional and
geometrical accuracy but also with high surface finish.
 The surface finish has a vital role in influencing functional
characteristics like wear resistance, fatigue strength,
corrosion resistance and power loss due to friction.
 The finishing operations are assigned as the last operations
in the single part production cycle usually after the
conventional or abrasive machining operations, but also
after net shape processes such as powder metallurgy, cold
flash less forging, etc.
 Finishing Operations
 Lapping
 Buffing
 Honing
 Super finishing
 Wire brushing
 Polishing
 Electro polishing
 Magnetic-field-assisted polishing
 Lapping
 In lapping, instead of a bonded abrasive tool, oil-based fluid
suspension of very small free abrasive grains (aluminum oxide
and silicon carbide, with typical grit sizes between 300 and 600)
called a lapping compound is applied between the work piece and
the lapping tool.
 The lapping tool is called a lap, which is made of soft materials
like copper, lead or wood. The lap has the reverse of the desired
shape of the work part.
 To accomplish the process, the lap is pressed against the work
and moved back and forth over the surface.
 Lapping is sometimes performed by hand, but lapping machines
accomplish the process with greater consistency and efficiency.
Polishing
Polishing is a finishing operation to improve the surface finish
by means of a polishing wheel made of fabrics or leather and
rotating at high speed. The abrasive grains are glued to the
outside periphery of the polishing wheel. Polishing operations
are often accomplished manually.
Buffing
Buffing is a finishing operation similar to polishing, in which
abrasive grains are not glued to the wheel but are contained in
a buffing compound that is pressed into the outside surface of
the buffing wheel while it rotates. As in polishing, the abrasive
particles must be periodically replenished.
As in polishing, buffing is usually done manually, although
machines have been designed to perform the process
automatically.
Buffing wheels are made of discs of linen, cotton, broad cloth
and canvas
 Honing
 Honing is a finishing process, in which a tool called hone
carries out a combined rotary and reciprocating motion
while the work piece does not perform any working motion.
Most honing is done on internal cylindrical surface, such as
automobile cylindrical walls.
 The honing stones are held against the work piece with
controlled light pressure. The honing head is not guided
externally but, instead, floats in the hole, being guided by
the work surface
 It is desired that honing stones should not leave the work
surface stroke length must cover the entire work length.
Honing is a finishing process performed by a honing tool,
which contains a set of three to a dozen and more bonded
abrasive sticks. The sticks are equally spaced about the
periphery of the honing tool. They are held against the work
surface with controlled light pressure, usually exercised by
small springs.
HONING
 WELDING
 Welding is a fabrication or sculptural process that joins
materials, usually metals or thermoplastics, by
causing fusion, which is distinct from lower temperature
metal-joining techniques such as brazing and soldering,
which do not melt the base metal. In addition to melting
the base metal, a filler material is typically added to the
joint to form a pool of molten material (the weld pool) that
cools to form a joint that is usually stronger than the base
material. Pressure may also be used in conjunction
with heat, or by itself, to produce a weld. Welding also
requires a form of shield to protect the filler metals or
melted metals from being contaminated or oxidized.
 Some of the best known welding methods include:
• Oxy-fuel welding – also known as oxyacetylene welding or oxy welding, uses
fuel gases and oxygen to weld and cut metals.
• Shielded metal arc welding (SMAW) – also known as "stick welding" or
"electric welding", uses an electrode that has flux around it to protect the
weld puddle. The electrode holder holds the electrode as it slowly melts
away. Slag protects the weld puddle from atmospheric contamination.
• Gas tungsten arc welding (GTAW) – also known as TIG (tungsten, inert gas),
uses a non-consumable tungsten electrode to produce the weld. The weld
area is protected from atmospheric contamination by an inert shielding gas
such as argon or helium.
• Gas metal arc welding (GMAW) – commonly termed MIG (metal, inert gas),
uses a wire feeding gun that feeds wire at an adjustable speed and flows an
argon-based shielding gas or a mix of argon and carbon dioxide (CO2) over
the weld puddle to protect it from atmospheric contamination.
• Flux-cored arc welding (FCAW) – almost identical to MIG welding except it
uses a special tubular wire filled with flux; it can be used with or without
shielding gas, depending on the filler.
• Submerged arc welding (SAW) – uses an automatically fed
consumable electrode and a blanket of granular fusible flux.
The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under the
flux blanket.
• Electro slag welding (ESW) – a highly productive, single pass
welding process for thicker materials between 1 inch (25 mm)
and 12 inches (300 mm) in a vertical or close to vertical
position.
• Electric resistance welding (ERW) – a welding process that
produces coalescence of laying surfaces where heat to form
the weld is generated by the electrical resistance of the
material. In general, an efficient method, but limited to
relatively thin material.
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