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1 Institute of Applied Technology Year 12 Machining Semester 1 September
2 Machining 2
3 Lets Warm Up Think, Pair, Share Minds On Activity Video 1 The Lathe
4 Objectives After the completion of this unit, you will be able to: 1. Recognize the function and importance of machine tools. 2. Differentiate between the basic categories of machine tools. 3. Read and understand the main technical drawings symbols. 4. Take precise measurement using Vernier Caliper and Micrometer. 4
5 1.0 Introduction How much a nation produces determines how well its people live. Today, every known Product from a paper clip to a space vehicle is a product of machine tools. If machine tools are not used directly in the manufacture of the product itself, machine tools are required to produce the machinery and the equipment necessary for its processing. Without machine tools, modern civilization could not exist. Think of what would the world be without the automobile, electric power generators, aircrafts etc. Fig Fig
6 1.1 What is Machine Tool? A machine tool is a power-driven machine not portable by hand, used to shape or form metals or materials by cutting, impacting, forming, eroding, or a combination of these processes. Example of machine tools is shown in Fig. 1.2 Fig. 1.2: CNC milling is one of the machine tools 6
7 2.0 Basic Machine Tools There are three main categories of machine tools: 1. Non-chip producing machine tools. 2. Conventional chip producing machine tools. 3. New Generation of machine tools. 2.1 Non-chip producing machine tools This type of machines shapes metals by shearing, pressing, and drawing to a desired shape. Fig. 1.3 Non-chip producing machine tool 7
8 2.0 Basic Machine Tools 2.2 Conventional chip producing machine tools Machines of this type shape metal to a size and contour by cutting away the unwanted portions in form of metal chips. Fig. 1.4 The collection of material-working processes in which conventional machine tools are used is called conventional machining. Process of Chip removal This is the type of machine tools that we are going to cover in this course. 8
9 2.0 Basic Machine Tools Fig. 1.5 shows many parts of different shape that made by this type of machine tools. These parts could be used in the production of engines, machines or any industrial product. With conventional machine tools, the operator uses machine hand-wheels to manually control the table or spindle movements to produce the part. Fig. 1.6 Machine tools products The accuracy of the part produced depends upon the skills of the operator or machinist. Hand wheels of conventional machine tool 9
10 2.0 Basic Machine Tools Lathe and Milling machines are examples of this type of machine tools. Fig 1.7 (a) shows lathe machine. Fig. 1.7 (b) shows milling machine. Conventional lathe machine Conventional milling machine 10
11 2.0 Basic Machine Tools 2.3 New Generation of machine tools To increase the rate of production as well as preciseness of machined parts, automatic programming has also been added to conventional machines and called NC or CNC (Computer Numerical Control) machines. With Computerized Numerical Control machine tools (example, CNC lathe and CNC milling), the programmer programs the machine control unit (MCU), through the use of symbols, letters, and numbers (coded instructions) which automatically control the machine tool movements to produce the desired part. Fig 1.8 Computerized Numerical Control machine tool 11
12 2.0 Basic Machine Tools The cutting action of CNC machine tools is similar to conventional machining. Fig 1.9 (a) and 1.9 (b) show a CNC milling machine and CNC lathe machine respectively. Fig. 1.9 (a) : CNC milling machine Electric discharge machines (EDM) and electrochemical machines are also examples of new generation machine tools but are completely different in construction and in the way they shape metals so they will not be part of this course. (b) CNC lathe machine 12
13 Lets increase our knowledge! Video 2 Thread Cutting
14 3.0 Skills required to use Conventional Machine Tools In order to machine any part using the chip removal machine tools, you need to: 1. Acquire certain skills, ex: for the part shown in Fig. 1: Have the skills of drafting, read drawings and taking precise measurements. Machined Part Drilling bit 14
15 Show and Tell WHOEVER PARTICIPATES & WINS, PLENTY OF BONUS MARKS! Think Fast
16 3.1 Engineering Drawing Engineering drawing is a common language by which drafts persons, tool designers, and engineers indicate to the machinist and toolmaker the physical requirements of a part. Drawings are made up of a variety of lines, which represent surfaces, edges, and contours of a workpiece. By adding symbols, dimension lines and sizes, and word notes, the draftsperson can indicate the exact specifications of each individual part. Fig Technical Drawing 16
17 Recap from AutoCAD
18 3.1 Engineering Drawing Orthographic Projection: Orthographic Projection is a way of drawing a 3D object from different directions. Usually a front, side and top view (Three standard views) are drawn so that a person looking at the drawing can see all the important sides. Orthographic drawings are useful especially when a design has been developed to a stage whereby it is almost ready to manufacture. Fig Three standard views in orthographic drawings 18
19 Recap from AutoCAD
20 3.1 Engineering Drawing Sectional Views: Sectional views are used to clarify interior or hidden details on a multiview drawing of an object. Fig Sectional views are located by creating a Cutting Plane Line in one view. "Section Lining" or "Hatching" is added to the Section view mainly to distinguish the solid portions from the hollow areas of an object. Sectional View 20
21 Recap from AutoCAD
22 3.1 Engineering Drawing Isometric drawing: Isometric drawings consist of twodimensional drawings that are tilted at some angle to expose other views and give the viewer the feeling that what he or she is viewing is a three-dimensional drawing. Fig Isometric Drawing 22
23 3.1 Engineering Drawing Tolerance: It is the permissible variation of specified size of a part. The basic dimensions plus or minus the variation allowed is given on a drawing. Example: From Fig.1.15 the following can be calculated: The largest permissible dimension = 70.1 mm ( = 70.1 mm) The smallest permissible dimension = 69.7 mm ( = 69.7 mm) The tolerance = = 0.4 mm 23
24 3.1 Engineering Drawing Allowance: Allowance (Fig. 1.16) is the intentional difference in the sizes of mating parts, such as the diameter of a shaft and the size of the hole. On a shop drawing, both the shaft and the hole would be indicated with maximum and minimum sizes to produce the best fit. There are two general classes of fits: 1. Clearance fits, whereby a part may revolve or move in relation to a mating part. 2. Interference fits, whereby two parts are forced together to act as a single piece. Fit is the range of tightness between two mating parts. Fig. 1.16: Largest and smallest dimensions of two mating parts 24
25 3.1 Engineering Drawing Common Symbols and abbreviations: R: Radius of a circle. Fig Ø: Dia. = Diameter. Fig TYP: Typical dimensions. Fig P: Pitch of the thread Fig mm: the unit of measurement is millimeter M: Metric Thread R: means radius Example: M10 X 1.5 M = metric thread (Screw) 10 = diameter, 1.5 = Thread pitch Pitch of a thread The diameter of the two similar holes is 5.5 mm 25
26 Students Presentation Each group of students teach/present the next few topics of module 1 followed by teacher s lesson/clarification. 26
27 3.2 Measurement There are two measuring systems: 1. International system of measurements (Abbreviated SI from Systeme Internationale the French version of the name). Meter (m) is the basic unit of length measurement. 1m=100 cm=1000 mm 1cm=10 mm Note: In machine shop, most dimensions are in millimeters (mm). Large dimensions are in meters (m) and millimeters (mm). Fig 1.20 shows a steel ruler with mm scale at the top and inch scale on the bottom. Steel ruler with two measuring systems 27
28 3.2 Measurement 2. Imperial system (Old system using Yard as basic unit of length) 1 yard = 36 inch I inch = 25.4 mm Note: Care must be taken when using measuring tools. Most of tools have very sharp edges that may result in severe injuries. (Fig. 1.21), Tools could be damaged easily if bended, twisted or screwed with extra force. When using the graduated measuring tools, you must look at 90 degrees for accurate measurement. Fig Sharp edges of tools may result in severe injuries 28
29 3.2 Measurement Steel Ruler: Metric steel rulers, are usually graduated in millimeters and half-millimeters, and used for making linear metric measurements that do not require great accuracy. Fig Metric steel ruler A: 12 mm B:31.5 mm 29
30 3.2 Measurement Metric Vernier: There are three basic types of Vernier caliper: 1. Standard, Fig a 2. Dial, Fig b 3. Digital, Fig c. GRP car frame 30
31 3.2 Measurement The Vernier caliper is used to measure outside, inside and depth measurement as shown in Fig below: Outside measurement Inside measurement Depth measurement 31
32 3.2 Measurement Reading Vernier Caliper The accuracy of a measurement system is the degree of closeness of measurements of a quantity to that quantity's actual (true) value. 1. The Vernier caliper with 10 divisions in Vernier scale (Vernier scale is the bottom scale on the Vernier) is accurate to (1/10) ±0.1 mm. Fig.1.25 (a) reading = 15.8 mm 32
33 Examples of measurements 2. The Vernier caliper with 20 divisions in Vernier scale is accurate to (1/20) ±0.05 mm. Fig (b). reading = mm 3. The Vernier caliper with 50 divisions in Vernier scale is accurate to (1/50) ±0.02 mm. Fig (c). reading = mm 33
34 Extra examples of vernier caliper reading Main scale = 28.0mm Vernier scale = 37 divisions (0.02) = 0.74mm Total reading = 28.0mm mm = 28.74mm 34
35 Extra examples of vernier caliper reading The reading is 7.5mm Main scale = 7.0mm Vernier scale = 5 divisions (0.1) = 0.5mm Total reading = 7.0mm + 0.5mm = 7.5mm 35
36 3.2 Measurement Metric Micrometer: A Micrometer is a device incorporating a calibrated screw used widely for precise measurement of small distances in mechanical engineering and machining as well as most mechanical trades. Outside Micrometer There are three basic types of micrometers: 1. Outside micrometer, used for external measurement. Fig (a) 2. Inside micrometer, used to measure the diameter of holes. Fig (b) 3. Depth micrometer, measures depths of slots and steps. Fig (c) Inside Micrometer Depth Micrometer 36
37 Zero Error > Not acceptable > False reading! 37
38 Lets check our knowledge!! Video Micrometer Reading 38
39 3.2 Measurement Reading the micrometer: Each division on the upper scale on the sleeve equal 1 mm. (Fig. 1.27) Each line appears after the upper scale reading is equal to 0.5 mm. The micrometer screw gauge also uses an auxiliary scale (measuring hundredths of a millimeter) which is marked on a rotary thimble. (Fig.1.27). The micrometers in our laboratory have a pitch of 0.50 mm i.e. the thimble must be rotated through two revolutions to open the jaws by 1 mm. The rotating thimble is subdivided into 50 equal divisions. This means each division on the thimble = 0.01 mm Fig sleeve and thimble of the micrometer 39
40 Ex 1: 3.2 Measurement Fig (a) shows example 1 of a micrometer reading. Steps of solution: = 5.78 mm Ex 2: Fig (b), shows example 2 of a micrometer reading. Fig (a) Steps of solution: = 5.28 mm Fig (b) 40
41 Extra examples of micrometer reading Sleeve reading up= 7 mm down=0.5 mm Thimble reading=22 x0.1=.22 mm Total reading= 7.72mm
42 Extra examples of micrometer reading Sleeve reading =7mm =0mm Thimble reading= 38x0.1=38mm Total reading=7+.38=7.38 mm
43 3.2 Measurement Digital micrometers: Digital micrometers are also available to give direct reading. Fig 1.29 Digital micrometers 43
44 In class activity Scavenger Hunts! In groups of 4, follow your path and do the following: a. Measure (in mm) the physical parts listed below with a (i) micrometer and (ii) vernier caliper. b. Provide your accurate reading and show all step calculations. 1. Brass round tip specimen (outer diameter) micrometer / vernier 2. Hand wheel on tail stock (inner diameter) vernier 3. Gear (thickness) micrometer 4. White Teflon specimen (height) micrometer / vernier 5. 3-jaw chuck (inner diameter across flat) vernier 44
45 4.0 Prepare the blank part Power hacksaw (Fig. 1.30) is used to cut the blank part from a long bar (stock bar). Cutting fluids must be used when cutting hard materials (steel). (For practical tasks, the teacher will provide each group of students with a ready blank part). Power hacksaw 45
46 For further reading, you can use the following links:
47 References 1. Technology of Machine Tools. Seventh Edition, McGraw-Hill Companies, 2. Machine shop operations and setups, 4th edition, Lascoe nelson Porter. 3. Machine tool and Manufacturing technology, Steve F. Krar, Mario Rapisarda, Albert F. Check., Delmar Publishers. 4. en.wikipedia.org/wiki/machining * Teacher s weebly site 47
48 IN CLASS WORKSHEET - 1 Finish in class worksheet - Share your answers and thoughts with your partner 48
49 IN CLASS WORKSHEET2 posted on weebly Work on questions - Share your answers and thoughts with your partner. 49
50 HOMEWORK M1 (worksheet back of module 1) Given to students on Wednesday Sept 11th, Homework Due date 2 nd week - Sunday Sept 13th,
51 Quiz Module 1 TBD 51
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