1. Manufacturing process-1 (2131903) General Purpose Machine Tools

2. Manufacturing process-1 (2131903)
General Purpose Machine Tools
Prepared By: Guided By:
Prof. Stany R. Ghadiyali

3. General Purpose Machine Tools
General classification of machine tools
Conventional or traditional machine tools like Lathes, Milling machines, etc. are used more widely for faster material removal by shearing or brittle fracturing.
Non-conventional or non-traditional machine tools: like EDM, ECM, USM, etc. which remove material from exotic materials slowly by electro-physical, electro-chemical processes.
Modern numerical and computer controlled machine tools: Like CNC lathe, CNC milling

4. General Purpose Machine Tools
The basic machine tools which are commonly used for general purposes are:
Lathes
Drilling machines
Shaping machines
Planning machines
Slotting machines
Milling machines
Boring machines
Hobbing machines
Gear shaping machines
Broaching machines
Grinding machine

5. Classification Of Lathes
(a) According to configuration
• Horizontal -Most common for ergonomic conveniences
• Vertical - Occupies less floor space, only some large lathes are of this type.
(b) According to purpose of use
• General purpose
Very versatile where almost all possible types of operations are carried out on wide ranges of size, shape and materials of jobs; example: centre lathes
Single purpose: Only one (occasionally two) type of operation is done on limited ranges of size and material of jobs; example – facing lathe, roll turning lathe etc.
• Special purpose - Where a definite number and type of operations are done repeatedly over long time on a specific type of blank; example: gear blank machining lathe etc.

6. Classification Of Lathes
(c) According to size or capacity
• Small (low duty) - In such light duty lathes (upto 1.1 kW), only small and medium size jobs of generally soft and easily machinable materials are machined
• Medium (medium duty) - These lathes of power nearly upto 11 kW are most versatile and commonly used
• Large (heavy duty)
• Mini or micro lathe - These are tiny table-top lathes used for extremely small size jobs and precision work; example : swiss type automatic lathe

7. Classification Of Lathes
(d) According to degree of automation
• Non-automatic - Almost all the handling operations are done manually; example: centre lathes
• Semi-automatic - Nearly half of the handling operations, irrespective of the processing operations, are done automatically and rest manually; example: capstan lathe, turret lathe, copying lathe relieving lathe etc.
• Automatic - Almost all the handling operations (and obviously all the processing operations) are done automatically; example – single spindle automat (automatic lathe), swiss type automatic lathe, etc.
e) According to type of automation
• Fixed automation - Conventional; example – single spindle automat, swiss type automatic lathe etc.
• Flexible automation - Modern; example CNC lathe, turning centre etc.

8. Classification Of Lathes
(f) According to configuration of the jobs being handled
• Bar type - Slender rod like jobs being held in collets
• Chucking type - Disc type jobs being held in chucks
(g) According to precision
• Ordinary
• Precision (lathes) - These sophisticated lathes meant for high accuracy and finish and are relatively more expensive.
(h) According to number of spindles
• Single spindle -Common
• Multispindle (2, 4, 6 or 8 spindles)
Such uncommon lathes are suitably used for fast and mass production of small size and simple shaped jobs.

10. Kinematics System And Working Principle Of Lathes

11. Machining Operations Usually Done In Centre Lathes
Facing
Centering
Rough and finish turning
Chamfering, grooving, etc
Axial drilling and reaming by holding the cutting tool in the tailstock barrel
Taper turning by
offsetting the tailstock
swivelling the compound slide
using form tool with taper over short length
using taper turning attachment if available
combining longitudinal feed and cross feed, if feasible.
Boring (internal turning); straight and taper
Forming; external and internal
Cutting helical threads; external and internal
Parting off
Knurling

12. Machining Operations Usually Done In Centre Lathes
Turning
Facing

13. Machining Operations Usually Done In Centre Lathes
Grooving
Parting

14. Machining Operations Usually Done In Centre Lathes
Threading
Drilling

15. Machining Operations Usually Done In Centre Lathes
Boring
Reaming
Tapping

16. Basic purposes of use of drilling machines
Drilling machines are generally or mainly used to originate through or blind straight cylindrical holes in solid rigid bodies and/or enlarge (coaxially) existing (pre-machined) holes :
of different diameter
of varying length depending upon the requirement and the diameter of the drill
in different materials excepting very hard or very soft materials like rubber, polythene etc.

17. Classification of drilling machines
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 (φ≤ 10 mm) drills.

18. Classification of drilling machines
General purpose drilling machines
Pillar drilling machine :These drilling machines 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).

19. Classification of drilling machines
General purpose drilling machines
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.

20. Classification of drilling machines
General purpose drilling machines
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.

21. Classification of drilling machines
General purpose drilling machines
CNC column drilling machine: In these versatile and flexibly automatic drilling machine having box-column type rigid structure the work table movements and spindle rotation are programmed and accomplished by Computer Numerical Control (CNC).
Hand drills: hand drill is a portable drilling device which is mostly held in hand and used at the locations where holes have to be drilled.

22. Classification of drilling machines
B) General purpose drilling machines with more specific use
Gang drilling machine: This is 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

23. Classification of drilling machines
B) General purpose drilling machines with more specific use
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.

24. Classification of drilling machines
B) General purpose drilling machines with more specific use
Multispindle 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.

25. Classification of drilling machines
B) General purpose drilling machines with more specific use
Deep hole drilling machine : Very deep holes of L/D ratio 6 to even 30
Machining Parameters:
Cutting motion
Feed motion
In drilling machines, generally both the cutting motion and feed motion are imparted to the drill.

26. Milling machines

27. Classification of Milling machines
According to configuration and motion of the work-holding table
Knee type: small and medium duty machines the table with the job/work travels over the bed (guides) in horizontal (X) and transverse (Y) directions and the bed with the table and job on it moves vertically (Z) up and down.

28. Classification of Milling machines
According to configuration and motion of the work-holding table
Bed type : Usually of larger size and capacity; the vertical feed is given to the milling head instead of the knee type bed

29. Classification of Milling machines
According to configuration and motion of the work-holding table
Planer type : These heavy duty large machines, called plano-miller, look like planing machine where the single point tools are replaced by one or a number of milling heads; generally used for machining a number of longitudinal flat surfaces simultaneously.

30. Milling machines Rotary table type : This
high production milling machines possess one large rotary work-table and one or two vertical spindles.
the positions of the job(s) and the milling head are adjusted according to the size and shape of the job.

31. Classification of Milling machines
According to the orientation of the spindle(s).
Horizontal spindle type:

32. Classification of Milling machines
According to the orientation of the spindle(s).
Vertical spindle type:

33. Classification of Milling machines
According to the orientation of the spindle(s).
Universal head milling machine: