MANUFACTURING MACHINES
Module I: Introduction to Machine Tools
At the end of this lesson, the student would be able to :
(i) Identify the necessity of “manufacturing”
(ii) Define with examples the concept of “manufacturing”
(iii) List the main classifications of the manufacturing
processes with examples
(iv) State the main purposes of “machining”
(v) Define with examples the concept of “machining”
(vi) State with example the principles of “machining”
(vii) State with examples the main requirements for
“machining”
(viii) State with examples the main functions of “Machine
tools”
(ix) Define the concept of “machine tools”
INTRODUCTION
• The progress and the prosperity of human
civilization is judged by improvement in the
standard of living which depends directly
upon production of goods and services of
better quality with sufficient quantity, and the
production of goods and services depends
upon 3 factors:
• availability of natural resources
• exertion of human effort ; both physical and
mental
• development and use of power tools and
machines (Tools)
Production Engineering covers two
domains:
a) Manufacturing Processes
b) Production Management
a) Manufacturing Processes
This refers to manufacturing of products effectively,
efficiently, economically and environment-friendly
through :
• Application of any existing manufacturing process
and system
• Proper selection of input materials, tools,
machines and environments.
• Improvement of the existing materials and
processes
• Development of new materials, systems,
processes and techniques
(b) Production Management
This is also equally important and essential
in the manufacturing world. It mainly refers
to planning, coordination and control of the
entire manufacturing system in most
profitable way with maximum satisfaction
to the customers by best utilization of the
available resources like man, machine,
materials and money.
Classification Manufacturing
Processes.
• All manufacturing processes can be broadly
classified in four major groups as follows
• (a) Shaping or forming
• (b) Joining process
• (c) Material Removal process
• (d) Regenerative manufacturing
(a) Shaping or forming
• Manufacturing a solid product of definite size
and shape from a given material taken in three
possible states:
• • in solid state – e.g., forging rolling,
extrusion, drawing etc.
• • in liquid or semi-liquid state – e.g.,
casting, injection moulding etc.
• • in powder form – e.g., powder
metallurgical process.
(b) Joining process Welding, brazing, soldering etc.
• (c) Removal process: Machining (Traditional or Non-traditional),
Grinding etc.
• (d) Regenerative manufacturing Production of solid products in
layer by layer from raw materials in different form:
• • liquid – e.g., stereo lithography
• • powder – e.g., selective sintering
Purpose of Machining
• Machining to high accuracy and finish
essentially enables a product
– • fulfill its functional requirements
– • improve its performance
– • prolong its service
Principle of Machining
A metal rod of irregular shape, size and
surface is converted into a finished
rod of desired dimension and surface
by machining by proper relative
motions of the tool-work pair .
Definition of Machining
Machining is an essential process of
Manufacturing by which jobs (finished
work piece) are produced to the desired
dimensions and surface finish by
gradually removing the excess material
from the blank in the form of chips with
the help of cutting tool(s) moved past
the work surface(s).
Basic functions of Machine Tools
• Machine Tools basically produce geometrical
surfaces like flat, cylindrical or any contour on
the preformed blanks by machining work with
the help of cutting tools.
• The physical functions of a Machine Tool in
machining are:
• firmly holding the blank and the tool
• transmit motions to the tool and the blank
• provide power to the tool-work pair for the machining
action.
• control of the machining parameters, i.e., speed, feed and
depth of cut.
Quiz
• 1. Machining is a
– (a) shaping process
– (b) removal process
– (c) regenerative process
– (d) joining process.
• 2. An object is machined to
– (a) fulfill its functional requirement
– (b) provide desirably good performance
– (c) render longer service life
– (d) all of the above.
3. Feed rate is expressed in turning operation by
(a) mm/revolution
(b) mm/stroke
(c) mm per min
(d) none of the above.
4. Rapid prototyping is a
(a) joining process
(b) removal process
(c) regenerative manufacturing process
(d) finishing process.
Answers:
1. – (b)
2. – (d)
3. – (a)
4. – (c)
