COMPUTER

INTEGRATED
MANUFACTURING
MACHINE TOOLS
Submitted To:
Sir Zahid

Submitted By:
Tayyaba Noreen (BSIEM06-01)
Hurria Afzal (BSIEM06-30)
Asfa (BSIEM06-35)

Date of Submission:
14-09-2009

IQTM
 Q.1: Ans:

IMPORTANCE OF MACHINE TOOLS TO OUR SOCIETY:

The machine tools are of great strategic importance to economic growth and to nation’s
comparative international position both economically and militarily. Virtually every
manufactured product is produced on machine tool s or on machines built by machine
tools. Machine tools are crucial to a great variety of industrial processes and commercial
products. General economic growth depends closely upon the availability of machine
tools for the manufacture of new products. They have become important also because of
their durability and precision. They are so good at boosting the productivity that nearly
every manufacturer is forced to use them. They have contributed in the birth of product
engineering and mass production. With the machine tools many new technologies have
developed such as areas of electronics, optics and aero space etc.

Q.2: Ans:

DIFFERENCE BETWEEN TOOL AND MACHINE TOOL:

Common Tool:

A tool is a device or a piece of equipment which typically provides a mechanical

advantage in accomplishing a physical task, or provides an ability that is not naturally
available to the user of a tool. These tools are hand-held, portable powers, or manual
tools.

Machine Tool:

It is machining equipment that cuts, shears, punches, presses, drills, rolls, grinds, sands,
or forms metal, plastic, or wood stock. It may be automatic or semi-automatic. Machine
tools are generally power- driven metal cutting or forming machines used to shape metals
by:
• The removal of chips
• Pressing drawing or shearing
• Controlled electrical machining process
• Any machine tool has generally has capability of
• Holding and supporting the work piece
• Holding and supporting a cutting tool
• Imparting a suitable movement (rotating or reciprocating) to the cutting tool or the work
• Feeding the cutting tool so that the desired cutting action and accuracy will be achieved
• The performance of any machine too is generally stated in terms of its metal removal rate,
accuracy and repeatability.

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Q.3: Ans:

SIZE DESIGNATION OF VARIOUS MACHINE TOOLS:

The Lathe:

Lathe size is determined by the swing and length of bed. Swing indicates the largest
diameter that can be turned over the ways (flat or v-shaped bearing surface that aligns
and guides moveable parts of machines). Bed length is entire length of the ways.
Bed length must not be mistaken for the maximum length of the work that can be turned
between centers. The longest piece that can be turned is equal to the length of the bed
minus the distance taken up by the headstock and tailstock.

Milling Machine:

The size of a milling machine is based on the longitudinal (from left to right) table travel,
in inches. Vertical, cross, and longitudinal travel are all closely related as far as the
overall capacity. However, for size designation, only the longitudinal travel is used.

The Shaper:

The size of a shaper is designated by the maximum length of stroke or cut it can take.

Drill Press:

The size may be designated in different ways by different companies. Some companies
state the size as distance from the centre of spindle to column of machine; others specify
size by diameter of largest circular piece that can be drilled in the center.

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 Q.5: Ans:

VARIOUS OPERATIONS PERFORMED ON MACHINE

TOOLS:
The Lathe:

• Turning: Produces straight, conical, curved, or grooved work pieces

• Facing: Produces a flat surface at the end of the part
• Boring: To enlarge a hole
• Drilling: To produce a hole
• Cutting off: To cut off a work piece
• Threading: To produce threads
• Knurling: Produces a regularly shaped roughness
• Profiling: To turn cylindrical work pieces with rough and finished cuts
• Grooving: To make furrows or channels

Milling Machine:

• Peripheral milling: It is done when the surface being machined is PARALLEL with the
PERIPHERY of the cutter.
• Face milling: Face milling is the process of producing a flat vertical surface at right angle to
the cutter axis

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• Side milling: Side milling is used to machine a vertical surface on the sides or the ends of a
work piece
• Plane Milling or Surface Milling: This is the machining of plain, flat, horizontal surfaces by
means of cylindrical mills whose length is usually much greater than their diameters, the
larger kinds being constructed with inserted blades or teeth.
• Angle Milling: As the name suggests, this is the machining of a surface at some other than a
right angle to the axis of the milling cutter.
• Form Milling: The machining of some special cross-section generally composed of straight
lines and curves, or wholly of curves, is called form milling.
• Profiling: This operation is usually considered as machining the vertical edges of pieces of
irregular contour, and is generally done with an end mill mounted in a vertical spindle. The
exact form is generally determined by a templet or profile attached to the piece or to
the fixture supporting it.
• Slab milling: Machining flat surfaces which are parallel to the axis of the cutter.
• Special Operations:
o Routing is a term applied to milling an irregular outline while controlling the work
piece movement by hand feed.
o Grooving reamers and taps is called fluting.
o Gang milling is the term applied to an operation in which two or more milling cutters
are used together on one arbor.
o Straddle milling is the term given to an operation in which two milling cutters are
used to straddle the work piece and mill both sides at the same time

The Shaper:

The shaper operations are almost the same as those performed on milling machine the
reason why the shaper is used is that milling cutters of the correct size and angle are not
always readily available and to obtain them especially for occasional use would not be in
the interest of economy. For the shaper, however, a tool for any special shape can be
prepared in a short time, often by grinding the form on to a standard tool which is
already near to the form required.

Drilling Machine:

• Drilling: Producing cylindrical hole with tool called drill. It is simplest method of making
hole. Drilled hole always has rough surface and is oversized.
• Reaming: It is an accurate way of sizing and finishing a hole which has been drilled
previously. Hole has to be drilled undersized to be reamed. Reamer cannot originate hole and
is rotated at half the speed of drilling. Reamer cannot correct hole location. The material
removed is in the range 0.125 to 0.375mm.
• Boring: Enlarge the hole with adjustable tool. It is suitable for making odd size hole and is
used as finishing operation. It is used to machine surfaces of casted holes. It can be used to
correct out-off roundness of hole and to correct location of hole. Its accuracy is as high as
±0.00125mm and requires several passes of tool.

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• Counter-boring: Enlarging end of the hole. The enlarged hole forms square shoulder. It is
used to accommodate bolts, nuts, etc. counter-boring tool has straight or taper shank. Pilot
guides the tool. Accuracy of operation is ±0.05mm.
• Counter-sinking: Making cone-shaped end enlargement. There is a seat for screw or rivet
head (conical shaped).
• Spot facing: Smoothing and squaring surface around hole for nut or screw head
• Tapping: Operation of cutting internal thread by a tool called tap. Tapping can be performed
manually or by machine. Tap is a bolt with threads on it. Threads of tap act as cutting edges
and remove metal and cuts internal threads. Tapping is done on hole having smaller
diameters than outside diameter of thread.
• Trepanning: It is the operation of producing hole by removing metal along the
circumference of a hollow cutting tool and is used for producing large holes. Tool is in the
form of a hollow tube with cutting edges at one end and solid shank at other end to fit in drill
spindle. There is saving of material while drilling the hole.
• Lapping: Using lap, holes can be accurately finished/polished.
• Grinding: With grinding wheel mounted on spindle, made to feed up and down

Q.6: Ans:

CUTTING FEED AND SPEED OF VARIOUS MACHINE

TOOLS:
Cutting Speed:

The speed in surface feet per minute or meters per minute at which the metal may be
machined efficiently

Lathe Cutting Speed:

It may be defined as the rate at which a point on the work circumferences travels past the
cutting tool. When work is machined in a lathe, it must be turned at a specific number of
revolutions per minute(r/mint), depending on its diameter, to achieve the proper cutting
speed.
Cutting speed is always expressed in feet per minute (ft/mint) or in meters per
minute (m/mint).

Drill Press Cutting Speed:

The speed of a drill is generally referred to as a cutting speed, surface speed or peripheral
speed.
It is the distance that a point on the circumference of a drill will travel in 1 minute.

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 Milling Machine Cutting Speed:

When work is machined in a milling machine, the cutter must be revolved at a specific
number of revolutions per minute(r/mint), depending on its diameter, to achieve the
proper cutting speed.

Formula:

Cutting speed of lathe drill press and milling machine can be find out from this formula
In Inches: r/mint=CS*12/πD
In Metric: r/mint=CS*320/D

Milling Machine Feed:

The milling feed is determined by multiplying the chip size (chip per tooth) desired, the
number of teeth in the cutter, and the r/mint of the cutter.
Drill Press Feed: Feed is the distance that a drill advances into the work for each
revolution. Drill feed may be expressed in decimals, fractions of an inch, or millimeters.

Lathe Feed:

The feed of a lathe may be defined as the distance the cutting tool advances along the
length of work for every revolution of spindle.
Feed of the lathe is dependent on the speed of the lead screw or feed rod. Speed is
controlled by the change gears in the quick – change gear box.

Q.7: Ans:

COMMON PARTS AND FEATURES OF BASIC MACHINE

TOOLS:
Common Parts:

• Electric motor
• Transmission mechanism
• Spindle
• Base or bed
• Slides or ways
• Cutting tool
• Mechanisms for different movements
• Different levers, hand wheels and gauges
• Work piece holding device
• Accessories

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 Common Features: (Specify material removal rate)

• Cutting speed
• Feed rate

Q.8: Ans:

BASE OF CAST IRON OF MACHINE TOOLS:

Cast iron is still one of the basic structural materials in machine tools, for two main
reasons: its operational and technological properties are excellent; and its potential is far
from exhausted.

ADVANTAGES OF CAST IRON:

• Good strength to weight ratio
• Typically lower cost than competing materials and relatively low cost per unit of strength
than other materials.
• Lower density and higher thermal conductivity than steels at comparable tensile strength
levels.
• Excellent machinability, allowing for high speeds and feeds and reduced (minimal) energy
due to the presence o f free graphite.
• Greater Tensile strength, Compressive Strength, Shear Modulus of Rupture and Endurance
Limit.

Q.9: Ans:

USE OF HOLES IN BASE OF MACHINE TOOLS:

After casting and cleaning operations, the bottom surface are machined in a shaping
machine and two holes drilled to set screws to clamp the guide strip. The jaw bearings are
taken up next. Holes are first drilled of diameter suitable for the screws which are used to
facilitate the jaw adjustment. Later these holes are enlarged on the inner end to suit the
size of jaws. Subsequently the smaller diameter ends of the holes are suitably tapped.
After the spot facing the required location, holes are drilled and tapped for set screws
which will clamp the jaw in position.

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 Q.10: Ans:

USE OF SLOTS WITH TABLES:

Slots are used to permit clamping of the work. They are used for locating the work piece
itself or for mounting various holding devices and attachments. They prevent work piece
from vibrations during machining. They can also provide the means for lining up a
surface parallel or perpendicular to important axes (e.g. spindle) on the machine.

Q.11: Ans:

LIST OF DIFFERENT TAPER SHANK TOOLS:

• Lathe centers
• Collect chucks
• End mills
• T-slot cutter
• Dove tail cutter
• Key less drill chucks
• Light boring tool with bent shank
• Arbor for shell reamer
• Flute chucking reamer
• Taper pin reamer
• Arbor (mandrel)
• Spiral end mill
• Woodruff key-seat cutter
• Spiral double-end mill
• Extra long spiral-end mill
• Drill for molded plastics
• Four-fluted drill
• Three-fluted drill
• High helix drill
• Fluted tipped shell expansion reamer
• Taper shank oil drill hole

ADVANTAGE OF USING TAPER SHANK TOOLS:

It makes contact with the grub screw (a place to hold the other tool within it) and makes
contact to increase the torque of the tool without the tool slipping. The diameter of the
shank can differ with the reference to the tool. The taper is used to make the tool hold

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 firmly and for faster operations. The taper shank doesn’t need any threading on it as its
shape is the main advantage which reduces into angle and diameter.

Q.12: Ans:

SLIDES OR WAYS USED IN MACHINE TOOLS:

Slide ways can be broadly classified in two categories:
• Closed Slide ways
• Open slide ways

The most commonly used shapes of guide ways or slide ways are:
• Vee-Ways
• Flat-Ways
• Dovetail-Ways
• Hardened way slide
• Linear guide slide
• Cylindrical-Ways
• Roller ways
• Box ways

Q.13: Ans:

FEATURES OF POWER TRANSMISSION MECHANISMS:

Gear Mechanism:

• A gear, or toothed wheel, when in operation, may actually be considered as a lever with the
additional feature that it can be rotated continuously, instead of rocking back and forth
through a short distance.
• The gear that is closer to the source of power is called the driver, and the gear that receives
power from the driver is called the driven gear. The driver gear meshes with driven gear and
it begins to turn as well.

• If a large gear turns a small gear the speed increases. On the other hand, if a small gear
turns a large gear the opposite happens and the speed decreases.

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• Rotational speed is proportional to a wheel's circumferential speed divided by its radius. The
larger the radius of a gear, the slower will be its rotational speed, when meshed with a gear of
given size and speed. The same conclusion can also be reached by a different analytical
process: counting teeth. Since the teeth of two meshing gears are locked in a one to one
correspondence, when all of the teeth of the smaller gear have passed the point where the
gears meet -- i.e., when the smaller gear has made one revolution -- not all of the teeth of the
larger gear will have passed that point -- the larger gear will have made less than one
revolution. The smaller gear makes more revolutions in a given period of time; it turns faster.
The speed ratio is simply the reciprocal ratio of the numbers of teeth on the two gears.
(Speed A * Number of teeth A) = (Speed B * Number of teeth B)
This ratio is known as the gear ratio.
• The pitch circle of a gear is very important as it is used by engineers to determine the shape
of the teeth and the ratio between gears. The pitch of a gear is the distance between any point
on one tooth and the same point on the next tooth. The pitch point is the point where gear
teeth actually make contact with each other as they rotate.
• A gear train may have several drivers and several driven gears.

When gear A turns once clockwise, gear B turns 4 times counter-clockwise and gear C
turns once clockwise. Hence gear B does not change the speed of C from what it would
have been if geared directly to gear A, but it changes its direction from counterclockwise
to clockwise. The velocity ratio of the first and last gears in a train of simple gears dose
not change by putting any number of gears between them.
• Backlash is the error in motion that occurs when gears change direction. It exists because
there is always some gap between the trailing face of the driving tooth and the leading face of
the tooth behind it on the driven gear, and that gap must be closed before force can be
transferred in the new direction. A pair of gears could be designed to have zero backlash, but
this would presuppose perfection in manufacturing, uniform thermal expansion
characteristics throughout the system, and no lubricant. Therefore, gear pairs are designed to
have some backlash.
• Gear mechanism has highest torque/force capability; steel gears with large teeth can transfer
tremendous torque. This mechanism requires high precision placement and alignment of
gears. Gears could be noisy at high speeds; small teeth may slip under load due to bearing
slop/play.

Belt and Pulley Mechanism:

• Pulleys are nothing but gears without teeth and instead of running together directly they are
made to drive one another by cords, ropes, cables, or belting of some kinds. By crossing the
belt the direction of drive can be changed.
• Drive can be transferred by friction of the belt on the pulley or, if required, buy using a
toothed belt. Pulley wheels are grooved so that the belt cannot slip off. Also, the belt is pulled

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 tight between the two pulley wheels (in tension). The friction caused by this means that when
the driver rotates the driven follows.
• If both pulleys have same diameter they will rotate at same speed. The velocities of pulleys
are inversely proportional to their diameters in case of different size pulleys. For every single
revolution of the larger driven pulley wheel, the smaller driver pulley wheel rotates twice.
This is due to velocity ratio which can be calculated as:
Velocity ratio = (Distance moved by driver pulley) / (Distance moved by driven
pulley)
The diagram shows a small driver pulley pulling round a larger driven pulley. The rpm
(revolutions per minute) of the larger driven pulley wheel will be less than the smaller
driver pulley wheel.

• Pulley mechanism has lower torque capability; may slip under load. The belt will slip on a
very small pulley because it cannot wrap tightly around a small radius. The fabrication ease
level is of Medium difficulty. Pulleys must be held in tension. A flange on at least one side is
required to prevent belt from slipping off pulley. The belt may stretch over time.

Q.14: Ans:

LIST OF WORK PIECES AND CUTTING TOOL HOLDING

DEVICES:
Work and Cutting Tool Holding Devices for Lathes:

• A lathe dog
• Three Jaw chuck
• Four Jaw chuck
• Magnetic chuck
• Face plates
• Tool post
• Mandrels: There are 2 types: plain and expanding mandrels.
• Colet chuck
• Lathe center

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• Steady rest
• Follower Rest
• Vice
• V-Block
• Angle plates
• Parallels

Work and Cutting Tool Holding Devices for Shaper:

• Vise
• Adjustable screw stop
• Compressive clamp
• Inclined screw for T-slot

Work and Cutting Tool Holding Devices for Drilling Machines:

• Spindle hole
• Drill chuck: i) Key-type drill chucks ii) Keyless drill chucks
• Drill socket
• Drill sleeve
• Step Blocks
• Clamps
• V-Blocks
• Angles
• Jigs
• T- Slots Bolt
• Machine Table Vice
• Fixtures

Work and Cutting Tool Holding Devices for The milling Machine:

• Vice: i) Swivel base vise ii) Plain Vise iii) Universal vise
• Parallels
• End mill adaptors
• Fixtures
• Motorized over arm attachment
• Slotting attachment
• Circular table
• Rack milling attachment
• Arbors
• Collets
• Indexing or dividing head

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Q.15: Ans:

MECHANISMS USED FOR MOVEMENT OF

DIFFERENT PARTS OF MACHINE TOOLS:

Rack and Pinion Gear Mechanism:

The rack and pinion gear mechanism is used to convert between linear and rotary motion.
Often the pinion rotates in a fixed position and the rack is free to move. Alternatively, the
rack may be fixed and the pinion rotates moving up and down the rack. This latter
arrangement is used as the drive mechanism for portable lathe or end shaft turning
machine adapted for mounting on a work piece to be machined and includes a cutting
tool which is mounted on an axially driven turning bar. The turning bar is advanced by a
rack-and-pinion mechanism, the pinion being advanced by pivotal movement of a clutch
mechanism. The clutch mechanism is pivoted by the upward and downward movement of
push rods that engage a cam mechanism as the lathe body is rotated about a central
spindle.
The portable drill press has a rack bar with a brace attached at one end. A pinion slide
assembly is slid ably engaged with the rack bar such that the pinion is in rotational
engagement with a rack. The pinion slide assembly may be retained on the rack bar by a
bolt. The pinion may be attached to a pinion shaft that may be rotated by a rotation lever.
A mounting bracket may be attached to the pinion slide assembly for attachment of a
hand drill.

Quick Return Mechanism:

Quick return mechanism is used where there is a need to convert rotary motion into
reciprocating motion. As the disc rotates the black slide moves forwards and backwards.
The quick return mechanism is used in shaping machine is used to machine flat metal
surfaces especially where a large amount of metal has to be removed. As the disc rotates
the top of the machine moves forwards and backwards, pushing a cutting tool. The
cutting tool removes the metal from work which is carefully bolted down.
The quick return mechanism in milling is used to move crank shaft drive ram,
connecting rod and slider block that holds the work piece.
The quick and return mechanism in drill press is also used to move the drill head or cam.
Drill head and cam are moved by two electrical motors. Cam move opposite direction of
drill head when cam returned to is original position then clutch is disengaged.

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Belt and Pulley Mechanism:

Belt and Pulley Mechanism transfer rotating motion from one shaft to another.
A belt tensioning device is provided for an apparatus such as a lathe which includes a
centering member adapted to be attached to a work piece and is supported for rotation
about an axis. A motor is spaced from the centering member and is supported by a pivot
member. A drive pulley is attached to the motor and a driven pulley is attached to the
centering member. A belt is engaged between the drive pulley and the driven pulley for
transmitting driving torque from the motor to the centering member. A belt tensioning
device is provided for moving the pivot member between a first position wherein the belt
is tensioned between the drive and driven pulleys and a second position wherein the belt
is loosened between the drive and driven pulleys
In milling machine if both pulleys have the same speed then they will move in same
speed. If one pulley is larger then the other, than mechanical advantage and pulley ratio
are gained. .
A speed adjusting device for a drill press includes a first variable pulley mounted to the
motor shaft and a second variable pulley mounted to the output shaft with a belt
connected between the two variable pulleys. A pressing member is mounted to the second
variable pulley and the first end of the pressing member is pivotally connected to a fixed
member and the second end of the pressing member is connected to a control device. The
control device has a connecting member connected to the second end of the pressing
member so that the pressing member exerts a force to the second variable pulley by
operating the control device to adjust the effective diameter of the belt in the first and the
second variable pulley.

Quick Tool Release Mechanism:

Tool/collets alignment and secure arrangement for a vertical milling machine having a J-
head and a manually adjustable spindle for the secure and rapid change of a tool held in a
collet in a lower end of the spindle. Arrangements of receiving bores are spaced annularly
around the lower end of the spindle. An arrangement of locating pins are correspondingly
arranged about the tool/collet so as to mate with the receiving bores in the spindle, to
provide secure and efficient engagement of the collet/tool with the spindle in the vertical
milling machine.

Carriage Feed mechanism:

This operation is also performed in lathe. Carriage holds the tool bit and moves it
longitudinally (turning) or perpendicularly (facing) under the control of the operator. The
operator moves the carriage manually via the hand wheel or automatically by engaging
the feed screw with the carriage feed mechanism.

Multiple Gear Mechanism:

Multiple gears can be connected together to form a gear train. If there are an odd number
of gears, the output rotation will be the same direction as the input. If there are even

15
numbers, the output will rotate in the opposite direction to the input. Note that for the
simple type of gear train shown, the number of teeth on the intermediate gears does not
affect the overall velocity ratio which is governed purely by the number of teeth on the
first and last cog. The lathe must be stopped before speed change by means of manually
operating a gear lever. It is a primary object of the present invention to provide an
improved speed change gear mechanism that includes various sets of gears to provide
various speeds and to allow speed change without stopping the lathe. It can also be used
in milling machines.

Drive Mechanism:

It is the object of this invention to provide a drive mechanism for producing angular
movement of a work spindle on a lathe in a convenient and efficient form. A drive
mechanism for producing angular movement of a work spindle on a multi spindle lathe
comprises an electrical stepping motor connected to the spindle through dis-connectible
drive means, the spindle also having an associated brake.

Q.16: Ans:

CUTTING TOOL MATERIALS AND PROPERTIES

IMPARTED BY THESE MATERIALS ON CUTTING TOOL:
High Carbon Steel:

This material is one of the earliest cutting materials used in machining. It is however
now virtually superseded by other materials used in engineering because it starts to
temper at about 220oC. This softening process continues as the temperature rises. As a
result cutting using this material for tools is limited to speeds up to 0.15 m/s for
machining mild steel with lots of coolant.

High Speed Steel (HSS):

This range of metal contains about 7% carbon, 4% chromium plus additions of tungsten,
vanadium, molybdenum and cobalt. These metals maintain their hardness at temperature
up to about 600, but soften rapidly at higher temperatures. These materials are suitable
for cutting mild steel at speeds up maximum rates of 0.8 m/s to 1.8 m/s.

Cast Alloys:

These cutting tools are made of various nonferrous metals in a cobalt base. They can
withstand cutting temperatures of up to 760oC and are capable of cutting speeds about
60% higher than HSS.

Stellite:

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This is a cast alloy of Co (40 to 50%), Cr (27 to 32%), W (14 to 19%) and C (2%).
Stellite is quite tough and more heat and wear resistive than the basic HSS (18 – 4 – 1)
But such stellite as cutting tool material became obsolete for its poor grindability and
especially after the arrival of cemented carbides.

Cemented carbides (cermet) (sintered carbide):

This material usually consists of tungsten carbide or a mixture of tungsten carbide,

titanium, or tantalum carbide in powder form, sintered in a matrix of cobalt or nickel. As
this material is expensive and has low rupture strength it is normally made in the form of
tips which are brazed or clamped on a steel shank. The clamped tips are generally used as
throw away inserts.

Coated Carbides:

The cutting system is based on providing a thin layer of high wear-resistant titanium
carbide fused to a conventional tough grade carbide insert, thus achieving a tool
combining the wear resistance of one material with the wear resistance of another. These
systems provide a longer wear resistance and a higher cutting speed compared to
conventional carbides.

Ceramics:

Ceramics are made by powder metallurgy from aluminium oxide with additions of
titanium oxide and magnesium oxide to improve cutting properties. These have a very
high hot resistance and wear resistance and can cut at very high speed. However they are
brittle and have little resistance to shock. Their use is therefore limited to tips used for
continuous high speed cutting on vibration-free machines.

Diamonds:

Diamonds have limited application due to the high cost and the small size of the stones.
They are used on very hard materials to produce a fine finish and on soft materials
especially those inclined to clog other cutting materials. They are generally used at very
high cutting speed with low feed and light cuts. Due to the brittleness of the diamonds the
machine has to be designed to be vibration free. The tools last for 10 (up to 400) times
longer than carbide based tools.

Q.17: Ans:

DIFFERENCE BETWEEN CONVENTIONAL MACHINE

TOOLS AND CNC MACHINE TOOLS:
CNC or "computer numerical controlled" machines are sophisticated metalworking
tools that can create complicated parts required by modern technology. Growing rapidly

17
with the advances in computers, CNCs can be found performing work as lathes, milling
machines, laser cutters, abrasive jet cutters, punch presses, press brakes, and other
industrial tools
CNC is 'computer numeric controls' meaning the dimensions are programmed into a
computer and it directs the equipment to perform specific functions. With the advent of
cheap computers, free operating systems such as Linux, and open source CNC software,
the entry price of CNC machines has plummeted. The CNC machines are often totally
enclosed, due in large part to Occupational health and safety (OH&S) issues. The
machine is controlled electronically via a computer menu style interface; the program
may be modified and displayed at the machine, along with a simulated view of the
process. The setter/operator needs a high level of skill to perform the process, however
the knowledge base is broader compared to the older production machines where intimate
knowledge of each machine was considered essential.

A drill press (also known as pedestal drill, pillar drill, or

bench drill) is a fixed style of drill that may be mounted on
a stand or bolted to the floor or workbench. A drill press
consists of a base, column (or pillar), table, spindle (or
quill), and drill head, usually driven by an induction motor.

Computer Numerical Control (CNC) Drilling is

commonly implemented for mass production. The
appropriate CNC drill press is brought into position
through movement of the turret, so that bits do not need
to be removed and replaced.
CNC drill presses are controlled by computers and
different software programs are used to control these
movements of machine. CNC drill press which, on
command, drills a hole of a set diameters and depth into a
part set up beneath it.
The largest time sink for CNC drilling is with tool
changes, so for speed, variation of hole diameters should
be minimized.

Conventional Lathe: The machine has been greatly

modified for various applications however a familiarity
with the basics shows the similarities between types. This
machine consist of, a headstock, bed, feed and lead
screws, carriage, cross slide, compound rest, tool post and tailstock. The better machines
are solidly constructed with broad bearing surfaces (slides or ways) for stability and

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 manufactured with great precision. This helps ensure the components manufactured on
the machines can meet the required tolerances and repeatability.
CNC lathes are rapidly replacing the older production lathes (multi spindle, etc) due to
their ease of setting and operation. They are designed to use modern carbide tooling and
fully utilize modern processes. The part may be designed and the tool paths programmed
by the CAD/CAM process, and the resulting file uploaded to the machine, and once set
and trialed the machine will continue to turn out parts under the occasional supervision of
an operator.
A milling machine is a machine tool used for the
shaping of metal and other solid materials. Milling
machines exist in two basic forms: horizontal and
vertical, which terms refer to the orientation of the
cutting tool spindle. Milling machine consist of base,
column, knee, table, overhanging arm, front brace
and arbor.
The parts of the manual mill are separated in
diagram. The knee moves up and down the column
on guide ways in the column. The table can move in
x and y on the knee and the milling head can move
up and down. Typically, conventional milling is used
for roughing the part to size, requiring less force.
CNC milling machines are traditionally programmed using a set of commands known as
G-codes. G-codes represent specific CNC functions in alphanumeric format.
Computer Numerical Control (CNC) Milling is the most common form of CNC. CNC
mills can perform the functions of drilling and often turning. CNC Mills are classified
according to the number of axes that they possess. Axes are labeled as x and y for
horizontal movement, and z for vertical movement, as shown in this view of a manual
mill table. Most CNC milling machines (also called machining centers) are computer
controlled vertical mills with the ability to move the spindle vertically along the Z-axis.
A standard manual light-duty mill (such as a Bridgeport) is typically assumed to have
four axes:
• Table x
• Table y
• Table z
• Milling Head z
The most advanced CNC milling-machines, the 5-axis machines, add
two more axes in addition to the three normal axes (XYZ). Horizontal
milling machines also have a C or Q axis, allowing the horizontally
mounted work piece to be rotated, essentially allowing asymmetric
and eccentric turning. The fifth axis (B axis) controls the tilt of the tool itself. When all of
these axes are used in conjunction with each other, extremely complicated geometries,
even organic geometries such as a human head can be made with relative ease with these
machines. But the skill to program such geometries is beyond that of most operators.
Therefore, 5-axis milling machines are practically always programmed with CAM.

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REFRENCES:
http://ase.tufts.edu/mechanical/shop/classes/me1/lathe.htm

http://opensourcemachine.org/wp-content/uploads/2008/10/us-army-machinist-course-
milling-machine-operations-od1644-ww.pdf

http://science.jrank.org/pages/4041/Machine-Tools-Shapers.html

http://www.roymech.co.uk/Useful_Tables/Manufacturing/CutMat.html

http://www.cs.cmu.edu/~rapidproto/mechanisms/chpt2.html

http://www.technologystudent.com/gears1/pulley4.htm

http://maelabs.ucsd.edu/mae_guides/machine_design/power_transmission/pros_cons.htm

http://books.google.com.pk
Holding device for milling machines - Patent 4930954

Machine Shop 3 - Basic Milling Types - Work Holding

workpiece and cutting tool holding devices of milling machine - Google Search

Tech Of Machine Tools (Sie) - Google Books

http://www.scribd.com/doc/11621489/15-Cutting-Tool-Materials-of-Common-Use

www.efunda.com

What does shank mean? definition, meaning and pronunciation (Free English Language
Dictionary)

http://www.icscuttingtools.com/catalog/page_095.pdf

Machine taper - Wikipedia, the free encyclopedia

ICS Cutting Tools - taper shank accessories

Technology of machine tools by J.F.Karar

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