Mysore University School of Engineering

8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006

Elements of Mechanical Engineering

(21EME15-25)

MODULE 04 NOTES

Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006

Module 04: Course Content

4.0 Introduction to Machine Tools
4.1 Lathe: Working Principle of engine lathe,
4.2 Main parts of lathe,
4.3 Operations on lathe:
a) Turning Operations,
b) Facing Operations,
c) Knurling Operations,
d) Thread cutting Operations,
e) Taper turning Operations
f) Drilling Operations
4.4 Drilling Machine: Working Principle,
4.5 Operations of drilling machines,
a) drilling,
b) reaming,
c) lapping,
d) boring,
e) counter-boring,
f) counter-sinking,
g) Spot facing,
h) tapping
4.6 Grinding machine: working principle of cylindrical and surface grinding machines.
4.7 Metal Joining Processes: Definitions and methods
a) Soldering
b) Brazing
c) Welding

Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
4.0 Introduction to Machine Tools
Machine tools are mechanical devices that are used to shape or form parts by cutting, grinding, shearing, or
other processes. They are crucial for producing parts with precision and accuracy. Machine tools are typically
powered and designed to perform specific operations such as drilling, turning, milling, grinding, and others.
4.1 Lathe: Working Principle of Engine Lathe
The lathe is one of the oldest and most versatile machine tools used in
manufacturing processes. It is primarily used for shaping or machining
cylindrical parts. The engine lathe works on the principle of rotating a
workpiece against a cutting tool to remove material and shape the object.
The workpiece is mounted on a spindle, which rotates it, while the cutting tool is fed against the surface to
remove material. By controlling the movement of the tool and the workpiece, various shapes and forms can
be achieved.
4.2 Main Parts of Lathe

The main parts of a lathe machine are:

1. Bed: The base structure of the lathe that supports all other parts. It provides stability and rigidity to the
machine.
2. Headstock: Located at the left end of the lathe, the headstock houses the spindle and the motor, which
rotates the workpiece.
3. Tailstock: Positioned opposite the headstock, the tailstock supports the free end of the workpiece and
allows tools like drills to be held.
4. Carriage: This is the moving part that holds the tool post and cutting tools. It moves along the bed
and controls the positioning of the cutting tool.
5. Cross Slide: Part of the carriage that provides the lateral movement of the cutting tool.
6. Tool Post: The holder for the cutting tool. It allows the tool to be adjusted.
7. Saddle: The part that supports the carriage and can move along the bed.
8. Lead Screw: A screw that drives the carriage and is essential for operations like thread cutting.

Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
4.3 Operations on Lathe
Lathe machines can perform a variety of operations to shape, cut, and finish workpieces. Some of the key
operations are:
a) Turning Operations
Purpose: To remove material from the surface of a rotating workpiece to create cylindrical or other
symmetrical shapes.
• Cutting Tool: A single-point cutting tool is commonly used.
• Movement: The workpiece rotates, and the cutting tool moves along the length or radially.
• Common Types: Straight turning, form turning, shoulder turning, and rough turning.
• Surface Finish: Produces smooth, even surfaces with controlled diameters.
• Application: Used for producing shafts, rods, and cylindrical parts.

Straight Turning Form Turning

b) Facing Operations
Purpose: To machine the flat face (end) of a rotating workpiece.
• Cutting Tool: A cutting tool moves radially to the center of the workpiece.
• Movement: The tool moves perpendicular to the axis of the workpiece.
• Result: Produces a flat, smooth, and perpendicular surface at the end of the workpiece.
• Application: Used to prepare the end surfaces of parts for further operations or assembly.
c) Knurling Operations
Purpose: To create a textured pattern on the surface of the workpiece.
• Tool: A knurling tool with a set of hardened, textured wheels presses into the surface.
• Result: Forms a pattern, typically diamond or straight, on the workpiece.
• Uses: Provides a gripping surface on parts like handles, bolts, and knobs.
• Advantages: Increases grip and improves aesthetics for functional parts.

d) Thread Cutting Operations

Purpose: To create threads (internal or external) on a rotating workpiece.
• Cutting Tool: A single-point tool or die is used to cut the threads.
• Movement: The cutting tool moves along the workpiece to cut the helical threads.
• Types of Threads: External threads (on bolts) or internal threads (on nuts).
• Precision: Produces highly precise threads based on pitch and depth specifications.
• Applications: Used for fasteners, screws, bolts, nuts, and pipe threads.
Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006

External Thread Cutting Internal Thread Cutting

e) Taper Turning Operations
Purpose: To create a conical shape by reducing the diameter of the workpiece along its length.
• Method: Achieved by tilting the tool, using a taper attachment, or offsetting the tailstock.
• Result: Produces a tapered, conical shape on the workpiece.
• Application: Used for making parts like shafts, axles, and spindles with taper features.
• Precision: Offers control over the taper angle and dimensions for accurate conical shapes.

f) Drilling Operations
Purpose: To create holes in a workpiece.
• Cutting Tool: A rotating drill bit or similar tool is used to cut into the workpiece.
• Movement: The drill is fed into the stationary or rotating workpiece.
• Types: Drilling, reaming, boring, tapping, counterboring, countersinking.
• Result: Produces holes with controlled depth, diameter, and surface finish.
• Application: Used for making holes for fasteners, bearings, and components in various industries.

4.4 Drilling Machine: Working Principle

The Drilling machine works on the basic principle of removing material from a stationary workpiece using
a rotating drill bit. The cutting tool (drill bit) is typically a cylindrical tool with a pointed tip that rotates at
high speeds to create a hole by cutting into the material. The workpiece is held securely in place, and the drill
bit is fed into the material, usually under a controlled feed rate, until the desired hole depth and diameter are
achieved.
Main Parts of a Drilling Machine
The main parts of a drilling machine are designed to support the drilling operation and ensure precision and
safety. These parts typically include:

Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
1. Base: Provides stability and support to the entire drilling
machine and for strength and vibration damping.
2. Column: Serves as the vertical support structure that holds
the other parts of the machine. The column extends from
the base and supports the arm, head, and other components.
3. Arm: Holds the drilling head and allows it to move
vertically along the column. The arm can be adjusted in
height to position the drill bit at different levels depending
on the workpiece's size.
4. Table: Provides a platform to hold the workpiece securely
during drilling operations.
5. Spindle: Holds the drill bit and drives it in rotation. The spindle is connected to the motor via belts or
gears, and it rotates the drill bit during operation.
6. Drill Head: Houses the spindle, motor, and gearing mechanisms that control the rotation of the spindle
and drill bit.
7. Chuck: Holds and secures the drill bit in place. The chuck is mounted on the spindle and grips the drill
bit firmly, allowing it to rotate without slipping.
8. Depth Stop: Limits the depth of the hole being drilled. The depth stop ensures that the drill bit does
not penetrate too deeply into the workpiece, maintaining uniform hole depth.
4.5 Operations of drilling machines
a) Drilling
Purpose: To create round holes in a workpiece using a rotating drill bit.
• Cutting Tool: Drill bit (usually cylindrical with a pointed tip).
• Movement: The workpiece is stationary, and the drill bit moves vertically (feeds
into the material).
• Application: Used for making holes of various sizes and depths in metals, plastics,
wood, and other materials.
• Feed Mechanism: The drill bit is fed into the material manually or automatically.
• Precision: Suitable for producing holes with specific diameter and depth tolerances.
b) Reaming
Purpose: To improve the surface finish and dimensional accuracy of an existing hole.
• Cutting Tool: Reamer (a tool with multiple cutting edges that re-shapes the hole).
• Movement: The reamer is rotated and fed into the hole after the drilling operation.
• Result: Provides smoother surfaces and more accurate diameters, eliminating burrs and
imperfections.
• Application: Often used after drilling to ensure holes are precise for fitting parts or fasteners.
Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
c) Lapping
Purpose: To produce a fine finish on the surface of a workpiece or
refine the dimensions of a hole.
• Cutting Tool: Lapping tool (abrasive slurry or paste with a
rotating lap surface).
• Movement: The workpiece is moved against the abrasive surface under controlled pressure, with
abrasive particles grinding the surface.
• Result: Achieves high levels of surface finish and can correct minute errors in hole dimensions.
• Application: Common in high-precision engineering and for parts that require an smooth finish.
d) Boring
Purpose: To enlarge or finish a previously drilled hole to precise dimensions and improve
accuracy.
• Cutting Tool: Boring tool (single-point tool or boring head with multiple cutters).
• Movement: The boring tool is fed radially into an existing hole, removing small amounts of material
to enlarge it.
• Result: Achieves a precise hole diameter and superior finish compared to drilling.
• Application: Typically used when a larger or more accurate hole is required, such as for engine blocks,
housings, and flanges.
e) Counter-boring
Purpose: To create a flat-bottomed hole with a larger diameter at the top, accommodating a
bolt or screw head.
• Cutting Tool: similar to a drill bit but with a flat end and a larger diameter).
• Movement: The counterbore tool is fed into an existing hole to create a flat-bottomed
recess.
• Result: Produces a hole that allows the fastener head to sit below the work surface, preventing
protrusion.
• Application: Common in assembly operations, particularly for counterbored holes for bolts and
screws.
f) Counter-sinking
Purpose: To create a conical recess around a hole, allowing a countersunk screw or bolt head
to sit flush with or below the surface.
• Cutting Tool: Countersink tool (a drill bit with a conical tip).
• Movement: The countersink tool is inserted into the hole to cut a conical shape
around the hole’s top.
• Result: A smooth, conical hole is formed, allowing for flush-fitting fasteners.
• Application: Typically used for countersinking holes for flat-head screws, bolts, or rivets.
Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
g) Spot Facing
Purpose: To create a flat surface around a hole for the seating of a fastener, washer, or nut.
• Cutting Tool: Spot facing tool (similar to a small milling cutter).
• Movement: The tool is positioned above a hole, and a small circular face is machined
around it.
• Result: Provides a smooth, flat surface at the hole’s top, ensuring that fasteners sit securely and evenly.
• Application: Used when precision is required in mounting or assembly, often for bolt heads or nuts.
h) Tapping
• Purpose: To cut internal threads inside a hole, allowing the workpiece to accept
bolts, screws, or other threaded fasteners.
• Cutting Tool: Tap (a tool with cutting edges that forms internal threads).
• Movement: The tap is rotated and fed into the hole to cut threads.
• Result: Creates internal threads that fit corresponding external threads (e.g., on bolts or screws).
• Application: Common in manufacturing applications requiring threaded holes for fastening parts
together, such as in metalworking and plastic components.

4.6 Grinding machine: working principle of cylindrical and surface grinding machines.
A grinding machine is a tool used for fine finishing of workpieces by abrasion. It uses a rotating abrasive
wheel to remove material from the surface of the workpiece, typically to achieve a smooth, high-precision
surface finish. Grinding machines are essential in industries like manufacturing, automotive, aerospace, and
toolmaking, where high accuracy and smooth finishes are required.
Grinding machines are classified based on the workpiece shape and grinding process, with two of the most
common types being cylindrical grinding machines and surface grinding machines.
Working Principle of Cylindrical Grinding Machine
Cylindrical grinding is a type of grinding machine used
for producing cylindrical shapes. The workpiece rotates
between a fixed wheel and a moving wheel. The process
is often used for parts like shafts, spindles, and rods that
require a high level of surface finish and dimensional
accuracy.
Key Features of Cylindrical Grinding:
• Workpiece Movement: The workpiece is mounted on a rotating spindle, which is held between two
centers (or a chuck) in the machine.
• Grinding Wheel: The grinding wheel is mounted on a spindle and is also rotating, but it is positioned
to grind the surface of the workpiece.

Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
• Grinding Action: The grinding wheel removes small amounts of material from the
workpiece as it rotates, creating a smooth cylindrical surface.
• Feed Mechanism: The workpiece is fed longitudinally or laterally across the grinding wheel,
depending on the type of cylindrical grinding (e.g., external, internal, or plunge grinding).

Types of Cylindrical Grinding:

1. External Cylindrical Grinding: This involves grinding the external surfaces of a cylindrical
workpiece.

2. Internal Cylindrical Grinding: Involves grinding the inside diameter of a workpiece, such as a bore
or hole.

3. Centerless Grinding: The workpiece is supported by two rotary wheels but does not require centers
(chucks), commonly used for high-volume production.

Working Principle of Surface Grinding Machine

Surface grinding is a process used to create a flat, smooth
surface by grinding the workpiece with a rotating grinding
wheel. The workpiece is typically held on a flat surface or
magnetic chuck while the wheel moves in a precise direction.
Key Features of Surface Grinding:
• Workpiece Setup: The workpiece is mounted on a
magnetic chuck, clamped, or held on a surface plate.
It may also be manually fed or moved by a mechanical or automatic system.
• Grinding Wheel: A rotating abrasive wheel is used to grind the surface of the workpiece.

Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
• Grinding Action: The grinding wheel is moved across the workpiece’s surface in a linear
or rotary motion, depending on the specific design of the surface grinder.
• Feed Mechanism: The workpiece is usually moved in a horizontal or vertical direction relative to the
grinding wheel, allowing for even material removal.

Types of Surface Grinding:

1. Horizontal Spindle Surface Grinding: In this type of grinder, the grinding wheel is oriented
horizontally, and the workpiece is fed back and forth beneath it.
2. Vertical Spindle Surface Grinding: Here, the grinding wheel is mounted vertically, and the
workpiece is either moved vertically or horizontally to ensure precise material removal.
3. Reciprocating Surface Grinding: The grinding wheel reciprocates (moves back and forth) across the
workpiece, often used for larger workpieces.
4. Rotary Surface Grinding: The workpiece rotates on a rotary table while the grinding wheel moves
in a radial direction.

Difference between Cylindrical and Surface Grinding Operation

Feature Cylindrical Grinding Surface Grinding
Workpiece Shape Cylindrical or tubular Flat, rectangular, or irregular shapes
Wheel Position Wheel rotates against cylindrical surface Wheel rotates flatly against the surface
Types of Grinding External, internal, centerless grinding Horizontal and vertical surface grinding
Applications Shafts, spindles, rods, internal bores Flat surfaces, finishing surfaces of parts

4.7 Metal Joining Processes: Definitions and methods

Metal joining processes refer to the various methods used to permanently bond two or more metal parts
together.
Permanent joint is one that does not allow disassembly of
joined components without rupturing them. It can provide a
sound, reliable, leak-proof and sufficiently strong joint and
thus can be safely used for heavy Loa applications. Examples
are Soldering, Brazing and Welding

Temporary joining processes are all those joining processes

that allow easy dismantling of joined components without
rupturing them. It facilitates assembly and disassembly of solid structures as and when required without
harming them. All fasteners basically provide temporary joints. Examples are Fastening, Press Fit, Seam
Joints, key Joints, nut-bolt, zipper, button, nail hook, etc.
Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
a) Soldering
Soldering is a metal joining process in which two or more metals are joined together by melting a filler metal
(solder) that has a lower melting point than the workpieces. The process occurs at relatively low temperatures
(below 450°C), which prevents the workpieces from being affected by heat, making it ideal for delicate parts
like electronics.
Principle:
The principle behind soldering is the use of a molten filler metal
(solder) that flows between the surfaces to be joined. The solder
cools and solidifies, forming a strong bond without the need for the
workpieces to melt.
Steps in Soldering:
1. Preparation of Surfaces: Clean the surfaces to be joined to
remove any dirt, oil, or oxide layers, ensuring a good bond.
2. Flux Application: Apply flux to the joint area to prevent oxidation during heating and to facilitate the
flow of solder.
3. Heating: Heat the workpieces and the filler metal (solder) using a soldering iron or torch until the
solder reaches its melting point.
4. Soldering: Once the solder melts, it flows into the joint by capillary action, forming a bond between
the metal surfaces.
5. Cooling: Allow the joint to cool, solidifying the solder and creating a strong bond.
Applications:
• Electronics: Joining components like resistors, capacitors, and integrated circuits to circuit boards.
• Plumbing: Connecting pipes.
• Jewelry: Joining small metal parts.

b) Brazing
Brazing is a metal joining process that involves joining two or more metals using a filler metal with a melting
point above 450°C but below the melting point of the workpieces. Unlike soldering, brazing generally involves
higher temperatures, and it results in stronger joints.
Principle:
In brazing, the filler metal is heated above its
melting point and flows into the joint by
capillary action, bonding the workpieces
together. The heat causes the filler metal to
melt and fuse with the surfaces of the base
metals, forming a strong bond upon cooling.
Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
Steps in Brazing:
1. Preparation of Surfaces: Clean the surfaces to remove oxides, dirt, and other contaminants that could
affect the bonding process.
2. Flux Application: Apply flux to prevent oxidation and to ensure the filler metal flows smoothly into
the joint.
3. Heating: Heat the workpieces and filler metal using a torch, furnace, or induction heating. The filler
metal is heated to a temperature above its melting point but below the melting point of the base metals.
4. Filler Metal Addition: Once the base metals and the filler metal are sufficiently heated, the filler metal
is added to the joint. It melts and flows into the gap between the parts.
5. Cooling: Allow the joint to cool, and solidify the filler metal to form a permanent bond.
Applications:
• Automotive: Joining parts like exhaust systems, radiators, or heat exchangers.
• Aerospace: Joining components in aircraft.
• Electronics: For connecting metal parts in circuit boards and connectors.

c) Welding
Welding is a metal joining process in which two or more metals are joined by applying heat and pressure,
often with the addition of a filler material. The workpieces are typically melted at the joining area, creating a
bond as they cool and solidify. Welding involves high temperatures and can be used for thick materials.
Principle:
The principle behind welding is the application of heat and
sometimes pressure to melt the workpieces at the joint. A
filler metal may be used to enhance the bond. Once the
molten metal cools, it solidifies and forms a permanent bond
between the workpieces.
Steps in Welding:
1. Preparation of Surfaces: Clean the metal surfaces to
remove contaminants, ensuring a good weld.
2. Positioning: Position the workpieces in the desired alignment and hold them securely using clamps or
fixtures.
3. Heating: Apply heat using an electric arc, gas flame, or laser to melt the edges of the workpieces (and
possibly the filler material) at the joint.
4. Filler Metal Addition (if necessary): Add filler metal to the molten pool of metal to create a stronger
bond.
5. Cooling: Allow the welded joint to cool and solidify, forming a strong, permanent bond between the
workpieces.
Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006
 Mysore University School of Engineering
8J99+QC7, Manasa Gangothiri, Mysuru, Karnataka 570006
Applications:
• Construction: Structural components for buildings, bridges, and infrastructure.
• Automotive: Joining car body panels and exhaust systems.
• Shipbuilding: Joining steel plates to construct ships.

Difference between Welding Soldering and Brazing

Feature Soldering Brazing Welding
Temperature Below 450°C Above 450°C Above 1000°C
Range
Workpiece No, only filler metal melts No, only filler metal melts Yes, base metals melt
Melting
Solder Filler metal Filler metal
Filler Material (low-melting point) (usually brass, silver, or (optional, depending on the
copper alloys) type of welding)
Relatively low (compared to Stronger than soldering, Very strong and durable
Bond Strength
brazing and welding) weaker than welding
Electronics, plumbing, Automotive, aerospace, Construction, automotive,
Applications
jewelry heat exchangers shipbuilding

Prepared by: Mr Thanmay J S, Assistant Professor, Bio-Medical & Robotics Engineering, UoM, SoE, Mysore 57006