INDUSTRIAL TRAINING INSTITUTE MAHESANA GUJARAT

CENTRE OF EXCELLANCE ( MECHANICAL SECTOR )

MODULE : 4

BASIC TURNING AND GRINDING

INSTRUCTOR SHRI.R.B.PATEL DURATION 8 WEEKS

BASIC TURNING AND GRINDING

SPLIT-UP OF SYLLABUS (THEORY)

Week Lesson No. No. 1. 1. 2. 2. 3. 4.

Name of the Lesson. (Turning) Introduction of ITI & Manufacturing process. Lathe machine types specification. Lathe Machine parts-Construction-Function. Lathe Operations.

5.
3. 6.

Work Holding devices and Accessories.

Lathe Tools and their Angle.

7.
8. 4. 9. 10.

Taper Method Uses Calculation.

Thread Types uses Calculation. Speeds , Feed & depth of cut of Lathe Machine. Coolants - Types Application.

Week No. 5. 6.

Lesson No. 11.

Name of the Lesson. (Grinding) Grinding Principle Process Safety.

12. 13.
14.

7. 8.

15. 16. 17. 18.

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.

LATHE M/C INTRODUCTION & SPECIFICATION

The length of bed. The maximum diameter(swing)of the work that can be turned. The length between centers and the pitch of the lead screw.

TYPES OF LATHES
Speed lathes engine lathes Bench lathes Tool room lathes Capstan and turret lathes Special purpose lathes Automatic lathes

PARTS OF LATHE M/C

Headstock bed Cross slide Compound rest Tail stock Feed shaft Carriage Lead screw Leg Quick change gear box

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

THREE JAW CHUCK

Backplate Body Jaws Crown wheel Pinion

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

FOUR JAW CHUCK

Backplate Body Jaws Square threaded screw shaft

DIFFERENCE BETWEEN 3 & 4 JAW CHUCK

Setting up of work is easy Has less gripping power Depth of cut is comparatively less Heavier jobs cannot be turned Workpieces cannot be set for eccentric turning Setting up of work is difficult More gripping power More depth of cut can be given Heavier jobs can be turned Workpieces can be set for eccentric turning

TYPES OF LATHE CENTERS

Ordinary centre Half centre Tipped centre Ball centre Pipe centre Revolving centre Insert type centre Self-driving centre Female centre Swivel `v` centre

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

FIXED STEADY REST

Top portion Lock screw top portion Adjustable pads Work Hinge Bearing pads locking screw Base Lathe bed clamp

FOLLOWER STEADY REST

Locking screw Bearing pads Adjusting screws Frame

LATHE MACHINE OPERATION - FACING

This is an operation of removing metal from the work-face by feeding the tool at right angles to the axis of the work.

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

DRILLING AND BORING

Drilling is the operation of originating circular holes. The tool employed for this purpose is a drill. Two different method are employed in a lathe for this operation. Work is clamped in the headstock in a chuck or on the faceplate. The drill is held in the tailstock and fed.

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

TAPER TURNING METHOD

Form tool method Compound slide method Tailstock offset method Taper turning method Taper turning attachment method

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.

USE OF SCREW THREAD

As fasteners to hold together and dismantle.components when needed To transmit motion on machine from one unit to another To make accurate measurements To apply pressure

PART OF SCREW THREAD

Crest Root Flank Thread angle Depth Major diameter Minor diameter Pitch diameter Lead Helix angle

FORM OF SCREW THREAD

Vee threads Square threads Trapezoidal threads

CUTTING TOOLS CLASSIFICATION

Single point cutting tools Multi point cutting tools Form tools

TYPES OF LATHE CUTIING TOOL

Solid type tools Brazed type tools Inserted bits with holders Throw away type tools

CUTTTING TOOLS ANGLE

Side cutting edge angle End cutting edge angle Top rake angle Side rake angle Front clearance angle Side clearance angle

EFFECT TOOL SETTING AND TOOL ANGLES

When tools are set above or below the centre line of the work piece, the clearance angles and rake angle will change.

CUTTING TOOL MATERIALS

Ferrous tool materials Non-ferrous tool materials Carbides Non-metallic materials

TYPE OF BORING TOOL

Solid forged tools Boring bars with inserted bits

CUTTING SPEED OF LATHE MCHINE

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

CUTTING SPEEDS AND FEEDS FOR H.S.S TOOL

Material being turned

Aluminium Brass (alpha)-ductile Brass (free cutting) Bronze (phosphor) Cast iron (grey) Copper Steel (mild) Steel (medium carbon) Steel (alloy-high tensile) Thermosetting plastics

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.

ADVANTAGE OF CUTTING FLUIDS

It removes the heat general. It improves the surface finish of the workpiece. It maintains the hardness of the heat-treated works. It removes burn marks on the ground surface. It keeps the grinding wheel face clean.

IMPORTANT POINTS TO BE NOTED WHILE USING CUTTING FLUIDS

Always add pure water to soluble oils. Do not allow soluble oil to mix with other oils. Always mix water to the oil in correct proportion and not oil to the water. It should be kept cool under normal temperature.

INTRODUCTION TO GRINDING PROCESS

It is the only economical method of cutting hard material like hardened steel. It produces very smooth surface up to N4, suitable for bearing surface. Surface pressure is minimum in grinding. It is suitable for light work,which will spring away from the cutting tool in the other machining processes.

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.

CONSTRUCTION OF A GRINDING WHEEL

In order make the grinding wheel suitable for different work situations,the features such as abrasive, grain size, grade, structure and bonding materials can be varied. A grinding wheel consists of an abrasive that does the cutting, and a bond that holds the abrasive particles together.

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)

STANDARD SHAPES OF GRINDING WHEELS

Straight wheel Cylinder Tapered Recessed one side Straight cup Recessed both sides Flaring cup Dish Saucer Mounted wheels

SPECIFICATION OF GRINDING WHEELS

Standard wheel markings Diameter of the wheel Bore diameter of the wheel Thickness of the wheel Type of the wheel

SELECTION OF GRINDING WHEEL

For grinding a job the right grinding wheel is to be selected. The selection of a grinding wheel will depend on the following factors. Material to be ground Amount of stock to be removed Finish required Area of contact Wheel speed Work speed Personal factor Method of cooling

GRINDING WHEEL DRESSING &TRUING

Dressing refers to the removing of clogs and blunt abrasive grains from the surface of the grinding wheel. Dressing exposes the cutting edges which restore the correct cutting action of the wheel. Dressing is done on a glazed or loaded wheel to recondition it. Truing refers to the shaping of the wheel to make it run concentric with the axis. When a new grinding wheel is mounted, it must be trued before use to remove the run out.

GLAZING & LOADING

When the surface of a grinding wheel develops a smooth and shining appearance, it is said to be glazed. This indicate the abrasive particles on the wheel face are not sharp. These are worked down to bond level. When soft materials like aluminium, copper, lead, etc. are ground the metal particles get clogged between the abrasive particles. This condition is called loading.

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

FINISH GRIND m/min.

20-25 30-40 45-65 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

SURFACE GRINDING MACHINE

It is precision grinding machine to produce flat surface on a workpiece. It is a more economical and more practical method of accurately finishing flat surface than filling and scraping.

PRECISION SURFACE GRINDER

SPECIFICATION OF A SURFACE GRINDER

Maximum dia. of the wheel that can be held on the spindle. Maximum size of the job that can be ground.(length*width*height)(150*150*400). The type of drive of the work table:hydraulic/electrical.

TYPES OF SURFACE GRINDERS

Horizonal spindle reciprocating table Horizontal spindle rotary table Vertical spindle reciprocating table Vertical spindle rotary table

HORIZONTAL TYPE GRINDER

Base Saddle Table Wheel head

WORK HOLDING DEVICES

The work holding devices used in grinding are: Magnetic chuck Vice Angle plates `V`blocks clamps

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.

TILTING TYPE VICE

A tilting vice is used to hold the workpiece while grinding angular surfaces. If required the tilting base can be removed and it can be mounted on the magnetic chuck as a plain vice.

SURFACE GRINDING OPERATIONS

Grinding flat surface Grinding vertical surface Grinding slot Grinding angular surface Grinding a radius Cutting off

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).

TYPES OF CYLINDRICAL GRINDERS

External cylindrical grinders Internal cylindrical grinders Universal cylindrical grinders Centreless grinders

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.

IMPORTANT FACTORE OF GRINDING ALLOWANCE

Harness of material to be ground Whether the part has to be heat treated Case depth of case hardened workpiece Grint and grade of grinding wheel Whether grinding is done wet or dry grinding

HEAT TREATMENT PURPOSE

The properties of steel depend upon its composition and its structure. These properties can be changed to a considerable extent, by changing either its composition or its structure. The structure of steel can be changed by heating it to a particular temperature, and then, allowing it to cool at a definite rate. The process of changing the structure and thus changing the properties of steel, by heating and cooling, is called `heat treatment of steel`.

TYPES OF STRUCTURE OF STEEL

The structure of steel become visible when a piece of the metals broken. The exact grain size and structure can be seen through a microscope. Steel is classified according to its structure.

HEAT TREATMENT PROCESS & PURPOSE

Hardening :- To add cutting ability Tempering :- To induce toughness and shock resistance. Annealing :- To relive toughness and stress. Normalizing:- To refine the grain structure of the steel. Steel is an alloy of iron and carbon. But the carbon content in steel does not exceed 1.7%.

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.

SURFACE HARDENING OF STEEL

Most of the components must have a hard, wear resisting surface supported by a tough, shock resisting core for better service condition and longer life. This combination of different properties can be obtained in a single piece of steel by surface hardening.

TYPES OF SURFACE HARDENING

Case hardening Nitriding Flame hardening Induction hardening

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.

ADVENTAGE OF FLAM HARDNING

The hardening devices are brought to the work piece. Short hardening time. Great depth of hardening. Easily controlled. Small Distortion. Low fuel consumption.

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.