PRODUCTION TECHNOLOGY Angular Velocity : Of a rotating body is the distance covered per second by a point lying at a distance of one

meter from the axis of rotation, along the periphery of circle of 1 meter radius and having its centre along the axis of rotation. = 2N !" rad sec # = r Ba ic o! "ac#ine tool : $achine tools produce the re%uired shape by performing some metal removing operation on the ra& material. 'or this the machine tools

(old support guide the &or) piece tools. *egulate the cutting speed and fee bet&een tool and &or) piece.

Part o! a "ac#ine Tool : 1. Machine Bed frame and Structure : +his houses and supports other parts. ,ome are in motion and others are fixed. this provides stability. 2. Slide ways and Slide - +hey are attached to the top of bed and guide the slides. +he movement of slides should be accurate. +he different types are flat, vee, dovetail, cylindrical and combined. .. Spindles and Bearings - ,pindles are provided to ensure that the position of axis or rotation is &ithin line. $embers that rotate the &or) piece and cutters are called spindles. +hese spindles are shaft mounted on bearings. +he spindles must be rigid and must have rotational accuracy. /. Machine tool drives - electric motor is the po&er unit and the po&er from motor reaches the &or) piece or cutter through belts, gears, chains and pulley. 0n machine tools there are t&o types of motion. +hey are

1rimary $otion - +his is higher that other speeds. 'eed motion - +his is less than primary motion.

Ele$ent o! "etal Cutting : Cutting speed : 0t is the distance traveled by &or) surface related to the cutting edge of +ool v = dN 1""" m min

Feed (s) : +he motion of cutting edge of tool &ith reference to one revolution of &or) piece. Depth of cut (t) : 0t is measured perpendicular to axis of &or) piece and in straight turning in one pass. +his can be estimated from the relation t = 2 3 4 d 5 2 mm Undeformed chip (Fc) : +he cross sectional area of chip before it is removed from &or) piece. it is e%ual to the product of feed and depth of cut. 'c = s x t mm2 6ll tools have a ma7or and minor cutting edge. +he ma7or cutting edge removes bul) of material. 8here as the minor cutting edge gives good surface finish. %orce on a ingle &oint cutting tool : 'ollo&ing are the three forces acting on a tool 1. 6xial force 2. +angential force and .. *adial force. 8attmeter is a indirect method for measuring cutting force. $ore exact method is the use of dynamometer. Of the total heat generated during machining process, given belo& is the rough heat distribution.

9hip carries :" ; of heat. 8or) piece carries 1< ; of heat and +ool carries the remaining 1< ; of heat generated.

Tool li!e : 0t could be defined from any of the belo& mentioned criteria.

#olume of material removed bet&een t&o successive tool grind. Number of &or) piece machined bet&een t&o successive tool grinds. time of actual cutting bet&een 2 successive tool grinds.

+ool failure occurs by chipping or brea)age or &ear 2 +a)es place by crater formation or by flan) &ear 5 or deformation.

"ac#ina'ility : 0t could be evaluated by using

+ool life mm. of stoc) removed 9utting force re%uired. +emperature of tool and chip

$achinability 0ndex 2 ; 5 = 2 9utting speed of &or) piece for 2" mm +ool life 5 2 9utting speed of ,6= 1112 steel for 2" mm min tool life 5 > 1"". "etal (a)ing : +his machine is used to produce &or) piece of desired length. 'ollo&ing are the different sa&ing machines. 1. *eciprocating ,a& 2 manual and po&er operated 5 2. ?and sa& 2 ?and filing, #ertical, (ori@ontal and friction 5 .. 9ircular sa& 2 9old sa&, ,teel friction dis) and 6brasive dis) 5 Lat#e : 'ollo&ing are the important parts in a lathe. 1. (ead stoc), 2. +ail stoc), .. live centre, /. dead centre, <. apron, !. cross slide :. top slide and A. +ool post. 6 lathe is specified by

Bength of bed, &idth of bed, No of spindle speeds and $aximum distance bet&een centers.

'ollo&ing are the different types of lathes.

,peed lathe, =ngine lathe, ,pecial lathe 6utomatic lathe, ?ench lathe, +ool room lathe and +urret lathe.

Machining time :

B 4 Bength of cut. f 4 feed in mm rev , 4 cutting speed in m min N 4 ,pindle speed and 3 4 3iameter of &or) piece. $achining time = B f x N 8here N = 1""" , 3.

(#a&ing o&eration : +here are three shaper diving mechanisms. +hey are 1. slotted lin) %uic) return mechanism, 2. 8hit&orth %uic) return mechanism and .. (ydraulic mechanism. ,haping operations can be used to cut splines and gears. Cutting speed : On a shaper may be defined as the average speed of tool during the cutting stro)e and primarily depends on number of stro)es min and length of stro)e. B 4 length of stro)e N 4 Number of stro)es min. 3istance moved per minute = BN. $achining is done during cutting stro)e and return stro)e is a idle stro)e.

9utting stro)e *eturn stro)e = . 2 9utting time +otal time = . <. +hus actual time to cut BN metres is . < min and not 1 minute. (ence in one minute the tool cuts < . BN metres. (lotting "ac#ine : +hese can be considered as a vertical shaper. +he difference bet&een a shaper and slotter is the direction of cutting action. +hey are sued to create splines, )ey &ays, 0nternal and =xternal gears. Planner : +hese are similar to shaping machines, but the tool is stationer and the &or) piece slides bac) and forth. +he follo&ing are the different types of planers.

3ouble housing planner. Open side planer, 1it type planner and 3ivided table planner. 'ollo&ing are the differences bet&een shaper and planner. (HAPER ,uitable for small 7obs. Bight duty machine Only one cutting tool is used Bess accuracy PLANNER ,uitable for large 7obs. (eavy duty machine $ultiple cutting tools. $ore accuracy because of high rigidity

Drilling "ac#ine : 'ollo&ing are the different types of drilling machines. 1. 2. .. /. <. !. 1ortable 3rilling $achine. ?ench type 3rilling $achine ,ensitive 3rilling $achine $ultiple 3rilling $achine 3eep hole 3rilling $achine and 6utomatic 3rilling $achine.

Di!!erent ty&e o! *rilling o&eration :

Drilling : 0s used to ma)e circular holes. 3rilling involves the creation of holes that are right circular cylinders. +his is accomplished most typically by using a t&ist drill, something most readers &ill have seen before. +he figure belo& illustrates a cross section of a hole being cut by a common t&ist drill. +he chips must exit through the flutes to the outside of the tool. 6s can be seen in the figure, the cutting front is embedded &ithin the &or) piece, ma)ing cooling difficult. +he cutting area can be flooded, coolant spray mist can be applied, or coolant can be delivered through the drill bit shaft.

+he characteristics of drilling that set it apart from other po&ered metal cutting operations are

+he chips must exit out of the hole created by the cutting. 9hip exit can cause problems &hen chips are large and or continuous. +he drill can &ander upon entrance and for deep holes. 'or deep holes in large &or) pieces, coolant may need to be delivered through the drill shaft to the cutting front. Of the po&ered metal cutting processes, drilling on a drill press is the most li)ely to be performed by someone &ho is not a machinist.

eaming - +his uses a multipoint cutting tool. 9annot produce holes but produces accurate si@e and good finish. *eaming is a process &hich slightly enlarges a pre4 existing hole to a tightly toleranced diameter. 6 reamer is similar to a mill bit in that it has several cutting edges arranged around a central shaft, as sho&n belo&. ?ecause of the delicate nature of the operation and since little material is removed, reaming can be done by hand. *eaming is most accurate for axially symmetric parts produced and reamed on a lathe.

*eamed holes should not intersect &ith drilled holes, so the configuration belo& should NO+ be implemented

Boring - +his operation, enlarges a existing hole and finishes it. Csed &hen a drill of a particular si@e is not available. 6d7ustable boring head eliminate the need for a complete inventory of expensive large si@e drills. Counter !oring - 8here as boring enlarges for a entire length of hole, counter boring does not. Counter sin"ing - ?evels the mouth of hole &ith a tool called counter sin).

#apping - Csed to cut threads in drilled holes.

#repanning - is used &hen a large hole has to be created on a thin metal sheet. Ty&e o! +or, #ol*ing *e-ice :

$achine vice, #4 ?loc), + bolts, ,trap clamps, ,tep bloc)s and 6ngle plate.

Broac#ing :

+his operation uses a tool called as broach. 6 tapered tool, &here there is a teeth of desired contour. 0t passes through the &or) piece and produces the contour in a single pass. Csed for mass production. 9an machine both internal and external surfaces 6 broach has . types of teeth. +hey are *oughing teeth, finishing teeth and semi4 finishing teeth.

0t is very similar to shaper but uses a multipoint cutting tool, as it has many teeth. =ach successive tooth has a greater cutting edge. =ach tooth removes a predetermined %uantity of material. (ur!ace %ini # Proce

(oning - 0t is &ell cutting process &hich removes metal by means of a revolving honing tool. +his tool moves up and o&n inside the &or) piece. Bapping and ,uper finishing.

+el*ing : 0t is the process of 7oining different metals. #arious &elding and allied process are classified belo&. 1. Das 8elding

6ir acetylene Oxy acetylene Oxy hydrogen 1ressure gas &elding.

2. 6rc &elding

9arbon arc &elding and ,hielded metal arc &elding.

O.y/Acetylene +el*ing : 0n this acetylene is mixed &ith oxygen in proper proportions. 1roduces a temperature of .2"" 9. +here are three types of flames produced. +hey are 1. Neutral flame - 1roduces no chemical change on molten metal. (ence no cambering or oxidi@ing. 2. Oxidi@ing flame - 1roduces a loud roar. (igh temperature is reached. +he ratio of oxygen to acetylene is 1.< - 1. .. 9arburi@ing flame. "etal Arc )el*ing : 0t is a arc &elding process done by heating the &or) piece by stri)ing a arc bet&een the electrode and &or) piece. +he arc melts the electrode and 7ob and molten metal is transferred from electrode to &or) piece. +he flux coating melts and forms a gaseous shield and slag to prevent atmospheric contamination of molten metal. (u'$erge* Arc +el*ing : 0n this instead of a flux coated electrode, granular flux and base electrode is used. +he 7ob remain submerged under the flux. +he flux serves a shield and protects the molten metals from contamination. Tung ten Inert Ga +el*ing : 0t is a arc &elding process done by heating the 7ob &ithin a electric act struc) bet&een tungsten electrode and 7ob. 6 gas shield namely helium or 6rgon is used to avoid atmospheric contamination of &elding pool. "etal Arc +el*ing : 0t is done by stri)ing a arc bet&een a continuously fed metal electrode and the 7ob. No flux is used by t he act and molten metal is protected by helium or 6rgon. Pla $a Arc +el*ing : 0n this arc is circulated bet&een tungsten electrode and &ater cooled no@@le. +&o inert gases are used. One of them produces the plasma arc and the second acts as a shield. 0n this there are t&o types. 1. Non4transfer arc process- 0n this arc is produced bet&een no@@le and tungsten electrode. 8or) piece does not form part of electrical circuit.

2. +ransfer arc process - +his is a arc bet&een tungsten electrode and &or) piece. Re i tance +el*ing : 0n this the 7oin is produced b using the resistance of the &or) piece for the flo& of current and by application of pressure. No filler metal is re%uired. (&ot )el*ing : 0t is a type of resistance &elding process, in &hich t&o overlapping sheets of metal are 7oined by local fusion at one or more spots by the heat produced by resistance to the flo& of current, that are held together by the forces or electrodes. Col* +el*ing : 0t is a solid state &elding carried out at room temperature and no heat is produced. +he condition is that one of the material must be ductile. Only mechanical pressure is applied. Ultra onic +el*ing : 0n this a high fre%uency vibratory energy is applied on &or) piece. +he &or) piece is held in a interface. +he combine effect of pressure and vibration causes movement of metal molecules and this creates a sound bonding. +his completed in ".< 4 1.< seconds. %riction an* Inertial +el*ing : +he &or) piece are rotated and suddenly pressure is applied and both pieces get &elded, ?ecause of the high heat generated. Ato$ic/Hy*rogen +el*ing : 0n this the 7oint is produced by an act bet&een 2 electrodes in a atmosphere of hydrogen, &hich acts as shielding gas. Eob does not become a part of electrical circuit. Electron Bea$ )el*ing : 0n this 7oint is produced by heat obtained by concentrated electron beam &hich contains high speed electrons. Bra0ing : 0n this 7oint is produced by heating to a suitable temperature and by using a filler material having li%uidus belo& the solidus of base metal. Csed for non ferrous metals.

(ol*ering : +he melting point of the filler material is belo& /2:o 9. +he melting point of filler material used in bra@ing is above /2:o 9. Bast updated on ,