Académique Documents
Professionnel Documents
Culture Documents
MODULE : 4
Name of the Lesson. (Turning) Introduction of ITI & Manufacturing process. Lathe machine types specification. Lathe Machine parts-Construction-Function. Lathe Operations.
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Week No. 5. 6.
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Grinding Wheels Types Selection. Grinding Wheels Mounting & Balancing Grinding Wheels Dressing & Turning. Surface Grinding Machine-Parts-Types-Uses Cylindrical Grinding Machine-Parts-Types-Uses. Grinding Diffect and Remindes. Heat Treatment Process Anealing Normalizing Case Hardening. Steel Classification Alloings elements.
TYPES OF SAFETY
General safety Personal safety Machine safety
PERSONAL SAFETY
Wear a one piece overall or boiler suit. Keep the over all buttons fastened. Dont use ties and scarves. Cut the hair short. Dont wear a ring,watch or chain.
MACHINE SAFETY
Switch off the machine immediately if something goes wrong. Keep the machine clean. Stop the machine before changing the speed. Check the oil level before starting the machine.
TYPES OF LATHES
Speed lathes engine lathes Bench lathes Tool room lathes Capstan and turret lathes Special purpose lathes Automatic lathes
HEAD STOCK
All Geared Headstock Cone Pulley Drive Headstock
CARRAIGE
Tool post Cross slide Top slide Saddle Saddle lock Compound rest Apron
BED
Vee slides Heavily ribbed Machined ways Heavy construction fine grain cast iron
TAIL STOCK
Base Body Spindle spindle locking lever Operating screw rod Operating nut Tailstock hand wheel Key Clamping unit
FEED MECHANISM
Spindle gear Tumbler gear unit Fixed stud gear Change gear unit Quick change gearbox Feed shaft/lead screw Apron mechanism
TOOL POST
American type tool post Indexing type tool post Quick change tool post
SPECIFICATION OF A CHUCK
Type of chuck Capacity of the chuck Diameter of the body Width of the body Method of mounting to the spindle nose
TYPE OF CARRIERS
Straight tail carrier Bent carrier Clamp type carrier
DRIVING PLATE
Catch plates Driving plates Safety driving plates
FACE PLATE
Face-plates with only elongated radial slots Face-plates with elongated slots and `T`slots Face-plates with elongated radial slots and additional parallel slots.
STEADY REST
Fixed steady rest Follower steady rest
PURPOSE OF FACING
To have a reference plane to mark and measure the step lengths of work. To have a face at right angle to the axis of the work. To remove the rough surface on the faces of the work and have finished faces instead. To maintain the total length of the work.
PLAIN TURNING
Rough turning, using roughing tool or knife tool. Finish turning using a finishing tool.
GROOVING
Grooving is the process of turning a grooved form or channel on a cylindrically turned work piece. The shape of the cutting tool and depth to which it is fed determine the shape of the groove.
TYPE OF GROOVES
Square grooves Round groove `V`shaped groove
CHAMFERING
To remove burrs and sharp edges from the turned components to make their handling safe. To permit for easy assembly of mating components. To provide better appearance.
MATHOD OF CHEFERING
Form tool method Filling method Compound slide method
TYPE OF KNURLING
Diamond knurling Straight knurling Cross knurling Concave knurling Convex knurling
TYPES OF MANDRELS
Expansion mandrel Gang mandrel Stepped mandrel Screw or threaded mandrel Taper shank mandrel Cone mandrel
TAPER
A Taper is uniform increase or decrease in diameter along the length of a cylinder.
TYPES OF TAPER
Self-holding tapers Quick releasing tapers Morse taper Brown and sharpe taper Jarno taper Metric taper Pin taper
SCREW THREAD
A screw thread is a ridge of uniform section formed helically on the surface of a cylindrical body. An external screw thread is formed on the outer surface of a cylindrical part.
The finished required Depth of cut Tool geometry Properties and rigidity of the cutting tool and its mounting Properties of the workpiece material Rigidity of the workpiece The type of cutting fluid used Rigidity of the machine tool
FEED
Tool geometry Surface finish required on work Rigidity of the tool Coolant used
Feed mm/rev
0.2-1.00 0.2-1.00 0.2-1.5 0.2-1.00 0.15-0.7 0.2-1.00 0.2-1.00 0.15-0.7 0.08-0.3 0.2-1.00
Cutting speed m/min. 70/100 50-80 70-100 35-70 25-40 35-70 35-50 30-35 5-10 35-50
CUTTTING FLUIDS
Application of the cutting fluid is very important in a grinding operation. The cutting fluid should be applied in adequate quantity and at very low pressure. The cutting fluid should be directed on the work just above the point where it make contact with the wheel ie.contact zone.
GENERAL SAFETY
Keep the floor and gangways clean and clear. Dont touch or handle any equipment/machine unless authorized to do so. Dont walk under suspended . Use the correct tools for the job. Keep the tools at their proper palace. Wipe out split oil immediately. Ensure adequate light in the workshop.
ABRASIVES
There are two types of abrasives. Natural abrasives Artificial abrasives
GRAIN SIZE
The number indicating the size of the grit represents the number of openings in the sieve used to size the grain. The larger the grit size number , the finer the grit.
GRADE
Grade indicates the strength of the bond and, therefore, the `hardness` of the wheel. In a hard wheel the bond is strong and it securely anchor the grit in place, and therefore, reduces the rate of wear. In a soft wheel, the bond is weak and the grit is easily detached resulting in a high rate of wear.
STRUCTURE
This indicates the amount of bond present between the individual abrasive grains, and the closeness of the individual grain to each other. An open structured wheel will cut more freely. That is, it will remove more metal. In a given time and produce less heat.
BOND
Vitrified bond (V) Silicate bond (S) Shellac bond (E) Rubber bond (R) Resinoid bond (B)
GRINDING SPEED
TYPE OF GRINDING Rough grinding wheel with vitrified bond Rough grinding wheels with resinoid bond Surface grinding wheels with vitrified bond Internal grinding wheels with vitrified bond Centreless grinding wheels with vitrified bond Cylindrical grinding wheels with vitrified bond Cutting off wheels with resinoid bond Hand grinding of tools Automatic grinding of tools Hand grinding of carbide tools
WHEEL SPEED m/sec. 25 45 20-25 20-35 30-80 30-35 45-80 20-25 25-35 18-25
WORK SPEED
CLASS OF WORK ROUGH GRIND m/min.
10-20 25-30 35-55 50-65
Soft steel Hardened steel Cast iron Aluminium and fine brass
DEPTH OF CUT
It is the thickness of the material removed in surface grinding for one cut. Depth of cut in grinding depend on the: Cutting load Power of the machine Finish required
MAGNETIC CHUCK
Magnetic chucks are of two types Electromagnetic chuck Permanent magnetic chuck The magnetic power of the electro magnetic chuck can be varied according to the size of the work. But not so in the case of a permanent magnetic chuck.
CYLINDRICAL GRINDERS
Cylindrical grinders are used to grind the external of internal surface of a cylindrical workpiece. By cylindrical grinding the diameter of a workpiece can be maintained to a close tolerance (up to 0.0025 mm), and a high quality surface finish can be obtained (up to N4).
GRINDING ALLOWANCE
Machine parts are processed in different machine such as lathes, shaping machines, etc. in such a way that their final dimension have some stock left, which is finished during the grinding operation. The amount of this stock left is called the `grinding` allowance.
HARDENING
Hardening is a heat treatment process in which steel is heated to 30-50.C above the critical range. Soaking time is allowed to enable the steel to obtain a uniform temperature throughout its cross section. Then the steel is rapidly cooled through a cooling medium.
TEMPERING
Tempering is a heat-treatment process consisting of reheating the hardened steel to a temperature below 400.C, followed by cooling.
1. 2. 3.
Purpose of tempering the steel:To relieve the internal stresses To regulate the hardness and toughness To restore some ductility Process of tempering the steel:The tempering process consists of heating the hardened steel to the appropriate tempering temperature and soaking at this tempering, for a definite period.
ANNELING
Definition:- The annealing process is carried out by heating the steel above the critical range, soaking it for sufficient time to allow the necessary changes to occur, and cooling at a predetermined rate, usually very slowly witching the farness.
1. 2. 3. 4.
Purpose :To soften the steel. Ti improve the machinebility. To increase the ductility. To relieve the internal stresses.
Process:Annealing consists of heating of hypo eutectoid steels to 30t50c above the upper critical temperature and 50c above the lover critical temperature for hypereutectoid steels.
NORMALISING
Definition:-The process of removing the internal defecate or to refine the structure of steel components is cold normalizing. Purpose: To produce fine grain size in the metal. To reduce ductility. To prevent warping.
CASE HARDENING
Parts to be hardened by this process are made from a steel with a carbon contact of 0.15% so that they will not respond to direct hardening. The steel is subjected to treatment in which the carbon contact of the surface layer is increased to about o.9%.
CARBURISING
In this operation the steel is heated to a suitable temperature in a carbonaceous atmosphere, and kept at that temperature untill the carbon has penetrated to the depth required. The carbon can be supplied as a solid, liquid or gas.
NITRIDING
Gas nitriding Nitriding in salt bath Process Advantages
FLAME HARDENING
In This type of hardening, the heat is applied to the surface of the work piece by specially constructed burner.the heat is applied to the surface very rapidly and the work is quenched immediately by spraying it with water.
INTRODUCTION HARDNING
This a production method of surface hardening in which the part to be surface hardened is pleased within an inductor coil through which a high frequency current is passed. The depth of hardening for high frequency current o.7 to 1.0mm.the depth of hardening for medium frequency current is 1.5to2.0mm. Special steel and unalloyed steels with a carbon content of 0.35t00.75% are used.