1. Reaming is a machining process that removes a small amount of material from the surface of holes to bring them to a more exact size and improve surface finish. It uses multi-flute cutting tools with straight or helical flutes.
2. There are different types of reamers including hand, machine, shell, expansion, and adjustable reamers. Rose reamers cut only on the beveled ends of teeth while chucking reamers can cut on all portions of teeth.
3. Boring is used to enlarge existing holes and make them concentric to the axis of rotation. It is essentially internal turning where the tool feeds parallel to the workpiece rotation axis. Boring
A reamer is a rotary cutting tool used to enlarge a previously drilled or bored hole to a high degree of accuracy and smooth finish. Reamers are made from heat treated steels or hard materials like tungsten carbide and diamond. There are various types of reamers including straight, hand, machine, rose, shell, tapered, and combination reamers. Reaming is performed on a lathe by mounting the workpiece and drilling or boring the hole slightly undersized, then mounting the reamer and slowly feeding it into the hole while applying cutting fluid to enlarge the hole to the final size.
This document discusses various gear manufacturing methods including forming processes like extrusion, stamping, and powder metallurgy as well as machining processes like gear shaping, hobbing, and other gear cutting methods. Extrusion can produce gears of any tooth shape in high volumes but is generally used for smaller non-ferrous gears. Stamping is best for low cost, low precision production while powder metallurgy allows for customizable material properties and reduces machining. Gear shaping and hobbing are true generating processes that cut gear teeth through the motion of cutting tools. Hobbing produces the most accurate gears due to averaging of errors across multiple teeth cuts.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Tool life is measured by the time period from when a tool starts cutting until failure or until it needs resharpening. Tool life can be measured in units of time, number of pieces cut, volume of material removed, or length of cut. Tools typically fail due to high temperatures, mechanical impacts, or gradual wear. Wear occurs on the flank and crater faces of tools and is caused by abrasion, diffusion, electrochemical reactions, and other mechanisms. Factors like cutting speed, workpiece properties, tool geometry, and cooling influence tool life.
This document provides information about milling machines and milling operations. It describes the major parts and differences between horizontal and vertical milling machines. Various milling operations like face milling, end milling and slot milling are explained along with principles of up and down milling. Different types of milling cutters are classified and their applications discussed. Specifications of milling machines like worktable size, movements in X, Y and Z directions and motor power are also covered.
Drilling is a machining process that uses a drill bit to cut a round hole through metal or non-metal materials. The drill bit is held by a drilling machine and rotated at high speeds while pressed against the workpiece. Key aspects of drilling include cutting speed and feed rate, which determine factors like material removal rate and machining time. There are various types of drilling machines suited for different applications, such as portable drills, bench drills, radial drills, and gang drilling machines. Common drilling operations include center drilling, reaming, countersinking, counterboring, and tapping.
A reamer is a rotary cutting tool used to enlarge a previously drilled or bored hole to a high degree of accuracy and smooth finish. Reamers are made from heat treated steels or hard materials like tungsten carbide and diamond. There are various types of reamers including straight, hand, machine, rose, shell, tapered, and combination reamers. Reaming is performed on a lathe by mounting the workpiece and drilling or boring the hole slightly undersized, then mounting the reamer and slowly feeding it into the hole while applying cutting fluid to enlarge the hole to the final size.
This document discusses various gear manufacturing methods including forming processes like extrusion, stamping, and powder metallurgy as well as machining processes like gear shaping, hobbing, and other gear cutting methods. Extrusion can produce gears of any tooth shape in high volumes but is generally used for smaller non-ferrous gears. Stamping is best for low cost, low precision production while powder metallurgy allows for customizable material properties and reduces machining. Gear shaping and hobbing are true generating processes that cut gear teeth through the motion of cutting tools. Hobbing produces the most accurate gears due to averaging of errors across multiple teeth cuts.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Tool life is measured by the time period from when a tool starts cutting until failure or until it needs resharpening. Tool life can be measured in units of time, number of pieces cut, volume of material removed, or length of cut. Tools typically fail due to high temperatures, mechanical impacts, or gradual wear. Wear occurs on the flank and crater faces of tools and is caused by abrasion, diffusion, electrochemical reactions, and other mechanisms. Factors like cutting speed, workpiece properties, tool geometry, and cooling influence tool life.
This document provides information about milling machines and milling operations. It describes the major parts and differences between horizontal and vertical milling machines. Various milling operations like face milling, end milling and slot milling are explained along with principles of up and down milling. Different types of milling cutters are classified and their applications discussed. Specifications of milling machines like worktable size, movements in X, Y and Z directions and motor power are also covered.
Drilling is a machining process that uses a drill bit to cut a round hole through metal or non-metal materials. The drill bit is held by a drilling machine and rotated at high speeds while pressed against the workpiece. Key aspects of drilling include cutting speed and feed rate, which determine factors like material removal rate and machining time. There are various types of drilling machines suited for different applications, such as portable drills, bench drills, radial drills, and gang drilling machines. Common drilling operations include center drilling, reaming, countersinking, counterboring, and tapping.
This document discusses different types of cutting tool materials and their properties. It covers seven main types of toolbit materials including high-speed steel, cast alloys, cemented carbides, ceramics, cermets, cubic boron nitride and polycrystalline diamond. The key properties for cutting tools are hardness, wear resistance, shock resistance, shape/configuration. Cemented carbides are widely used and offer high hardness, wear resistance and can operate at high speeds without losing sharpness. Coatings like titanium carbide and nitride and aluminum oxide are used to improve wear resistance at different speeds. Tool geometry including side relief, side clearance, rake angles and nose radius are also covered.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
The document discusses various aspects of drilling operations including:
- Types of drill presses like vertical, radial arm, gang, multi-spindle, and numerical control drills.
- Drill geometry parameters like point angle, helix angle, rake angle which vary along the drill.
- Cutting speed, feed rate, and formulas to calculate drilling time and material removal rate.
- Factors that affect drilling like workpiece material hardness, drill material, and geometry.
Dr. Rania Mostafa gave a lecture on drilling machines and techniques. The lecture covered the definition of drilling, types of drills and drilling machines, including drill presses, radial drilling machines and more. It discussed drill construction and nomenclature. The lecture also explained drilling operations, work holding, speed and feed calculations, troubleshooting, and safety precautions for drilling.
This document provides an overview of lathe machine operations, including the principle of how lathe machines work, different types of lathe machines, and various operations that can be performed on a lathe such as turning, taper turning, facing, knurling, thread cutting, and drilling. It explains that in a lathe machine, the workpiece is held by a chuck and rotated while a tool is fed against the workpiece. The document also describes different types of lathe machines such as engine lathes, turret lathes, single and multiple spindle automatic lathes, tracer lathes, and computerized numerically controlled lathes.
THIS PRESENTATION ON CENTRELESS GRINDING REGARDING THE MANUFACTURING SUBJECT, THIS PPT PRESENTED AT B&B INSTITUTE OF TECHNOLOGY.
HOPE IT WILL HELPED THE ENGINEERING STUDENT.
Frictional welding is a solid-state welding process that uses relative motion and high force between two contacting workpieces to generate heat through friction and form a joint. There are different types of frictional welding processes defined by the motion used - linear, rotary, stir, radial, and orbital friction welding. Frictional welding produces joints with low surface impurities and narrow heat-affected zones. It can join similar and dissimilar metals for applications in automotive, aerospace, consumer products, medical, and other industries.
The document discusses measurement and metrology of screw threads. It begins with definitions of screw thread terminology such as major diameter, minor diameter, pitch, angle, and forms of threads. It then describes methods for measuring the major diameter, minor diameter, effective diameter, and pitch of screw threads. The key measurement methods discussed are using micrometers, pitch gauges, and a tool maker's microscope. The goal is to understand principles and techniques for measuring characteristics of screw threads.
The document discusses milling fixtures and their components. Milling fixtures securely hold workpieces for milling operations. They have locating elements to precisely position workpieces and clamping elements to securely hold them against cutting forces. Key components of milling fixtures include a base, tenons to locate the fixture on the machine table, setting blocks to position cutters, and clamps or vices to hold workpieces in place. Different types of milling fixtures are used for operations like face milling or gang milling and can have mechanical, hydraulic or pneumatic clamping systems.
Advanced Manufacturing Processes PDF Full book by badebhauEr. Bade Bhausaheb
This document provides a syllabus for an advanced manufacturing processes course. The syllabus covers 6 units: 1) metal forming processes, 2) advanced welding, casting and forging, 3) advanced material processing techniques, 4) micro machining processes, 5) additive manufacturing processes, and 6) measurement techniques for micro machining. Some key processes discussed include roll forming, hydroforming, electromagnetic forming, friction stir welding, vacuum die casting, and additive manufacturing methods like powder bed fusion. Contact information is also provided.
This document discusses different types of screw threads including external and internal threads, right and left hand threads, single and multi-start threads. It provides details on thread specifications such as shape, pitch, diameter, length, number of starts, material, and direction. It then describes various forms of threads including British Standard Fine (BSF), British Standard Pipe (BSP), British Standard Whitworth (BSW), square, acme, knuckle, and buttress threads. It discusses the applications of each thread type and concludes with references used.
The document discusses theories of metal machining and chip formation. It describes how early theories like the theory of tear and theory of compression were later disproven. The generally accepted theory today is the theory of shear, which proposes that metal cutting occurs through shear along a plane at an angle to the cutting direction. The document also outlines the difficulties in studying metal cutting processes and how orthogonal cutting experiments were developed to simplify the analysis.
Rotary forging is a combination of two actions, rotational and an axial compression movement, for precise component forming that can be carried out cold or hot
Machine tool iii grinding superfinishing limit fit tolerance & surface f...iukashyap
This document provides an overview of grinding and superfinishing processes. It discusses grinding wheels, their components like abrasives, bonds and specifications. It describes grinding wheel wear mechanisms and different types of grinding machines. Centerless grinding advantages are outlined. Honing, lapping and polishing are introduced as superfinishing processes to achieve very high surface finishes for critical machine components.
Milling is a machining process that uses a rotating cutting tool called a milling cutter to remove material from a workpiece. Milling cutters come in various types for different purposes like flat surfaces, slots, threads, gears, etc. There are two types of milling: up milling where the cutter moves against the workpiece feed and down milling where they move together. Down milling provides better surface finish and tool life. Milling machines are classified based on their purpose, configuration, orientation, and level of automation. Milling cutters are also classified based on their geometry and how they machine specific features. Key parameters like cutting speed, feed rate, and depth of cut determine the material removal rate
Reamers are metalworking tools used to create accurately sized holes. There are several types of reamers classified by their shank and cutting geometry. Straight and tapered reamers are used for precision holes, while ross and fluted reamers are used for roughing and finishing holes respectively. Other reamer types include shell, expansion, and adjustable reamers designed for specialized applications. Proper speeds and stock allowances are required when reaming to achieve the desired hole size and surface finish.
This document provides an overview of mechanical energy based unconventional machining processes. It discusses abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). For each process, it describes the basic working principles, key components, process parameters that influence material removal rate, advantages, disadvantages, and applications. It also compares different types of transducers used in USM and discusses factors affecting the machining performance of USM.
MILLING – Cutting parameters, machine time calculation
Milling operation – Plain milling, side & face milling, form milling, gang milling, end milling, face milling, T slot milling, slitting
GEAR CUTTING – Gear cutting on milling machine – dividing head and indexing method, gear hobbing, principle of operation, advantages & limitation, hobbing tech, gear shaping, gear finishing process
This document discusses drilling operations. It describes different types of drill presses used for drilling including vertical, radial arm, gang, multi-spindle, and numerical control drills. It explains that twist drills cut cylindrical holes with flutes that carry chips up and out of the hole. Key drill features like point angle, helix angle, rake angle, and their effects on drilling different materials are covered. Formulas for calculating drilling time, material removal rate, and chip geometry are provided. Examples of drilling calculations are included.
This document provides an overview of drilling, reaming and grinding processes. It describes how drilling uses a rotating multi-point drill bit to cut circular holes. Reaming enlarges and finishes previously drilled holes to tight tolerances. Grinding uses an abrasive wheel to remove small amounts of material from a workpiece. The document discusses various drill bits and reamer types, factors that influence accuracy and surface finish, and considerations for production economics with each process.
This document discusses different types of cutting tool materials and their properties. It covers seven main types of toolbit materials including high-speed steel, cast alloys, cemented carbides, ceramics, cermets, cubic boron nitride and polycrystalline diamond. The key properties for cutting tools are hardness, wear resistance, shock resistance, shape/configuration. Cemented carbides are widely used and offer high hardness, wear resistance and can operate at high speeds without losing sharpness. Coatings like titanium carbide and nitride and aluminum oxide are used to improve wear resistance at different speeds. Tool geometry including side relief, side clearance, rake angles and nose radius are also covered.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
The document discusses various aspects of drilling operations including:
- Types of drill presses like vertical, radial arm, gang, multi-spindle, and numerical control drills.
- Drill geometry parameters like point angle, helix angle, rake angle which vary along the drill.
- Cutting speed, feed rate, and formulas to calculate drilling time and material removal rate.
- Factors that affect drilling like workpiece material hardness, drill material, and geometry.
Dr. Rania Mostafa gave a lecture on drilling machines and techniques. The lecture covered the definition of drilling, types of drills and drilling machines, including drill presses, radial drilling machines and more. It discussed drill construction and nomenclature. The lecture also explained drilling operations, work holding, speed and feed calculations, troubleshooting, and safety precautions for drilling.
This document provides an overview of lathe machine operations, including the principle of how lathe machines work, different types of lathe machines, and various operations that can be performed on a lathe such as turning, taper turning, facing, knurling, thread cutting, and drilling. It explains that in a lathe machine, the workpiece is held by a chuck and rotated while a tool is fed against the workpiece. The document also describes different types of lathe machines such as engine lathes, turret lathes, single and multiple spindle automatic lathes, tracer lathes, and computerized numerically controlled lathes.
THIS PRESENTATION ON CENTRELESS GRINDING REGARDING THE MANUFACTURING SUBJECT, THIS PPT PRESENTED AT B&B INSTITUTE OF TECHNOLOGY.
HOPE IT WILL HELPED THE ENGINEERING STUDENT.
Frictional welding is a solid-state welding process that uses relative motion and high force between two contacting workpieces to generate heat through friction and form a joint. There are different types of frictional welding processes defined by the motion used - linear, rotary, stir, radial, and orbital friction welding. Frictional welding produces joints with low surface impurities and narrow heat-affected zones. It can join similar and dissimilar metals for applications in automotive, aerospace, consumer products, medical, and other industries.
The document discusses measurement and metrology of screw threads. It begins with definitions of screw thread terminology such as major diameter, minor diameter, pitch, angle, and forms of threads. It then describes methods for measuring the major diameter, minor diameter, effective diameter, and pitch of screw threads. The key measurement methods discussed are using micrometers, pitch gauges, and a tool maker's microscope. The goal is to understand principles and techniques for measuring characteristics of screw threads.
The document discusses milling fixtures and their components. Milling fixtures securely hold workpieces for milling operations. They have locating elements to precisely position workpieces and clamping elements to securely hold them against cutting forces. Key components of milling fixtures include a base, tenons to locate the fixture on the machine table, setting blocks to position cutters, and clamps or vices to hold workpieces in place. Different types of milling fixtures are used for operations like face milling or gang milling and can have mechanical, hydraulic or pneumatic clamping systems.
Advanced Manufacturing Processes PDF Full book by badebhauEr. Bade Bhausaheb
This document provides a syllabus for an advanced manufacturing processes course. The syllabus covers 6 units: 1) metal forming processes, 2) advanced welding, casting and forging, 3) advanced material processing techniques, 4) micro machining processes, 5) additive manufacturing processes, and 6) measurement techniques for micro machining. Some key processes discussed include roll forming, hydroforming, electromagnetic forming, friction stir welding, vacuum die casting, and additive manufacturing methods like powder bed fusion. Contact information is also provided.
This document discusses different types of screw threads including external and internal threads, right and left hand threads, single and multi-start threads. It provides details on thread specifications such as shape, pitch, diameter, length, number of starts, material, and direction. It then describes various forms of threads including British Standard Fine (BSF), British Standard Pipe (BSP), British Standard Whitworth (BSW), square, acme, knuckle, and buttress threads. It discusses the applications of each thread type and concludes with references used.
The document discusses theories of metal machining and chip formation. It describes how early theories like the theory of tear and theory of compression were later disproven. The generally accepted theory today is the theory of shear, which proposes that metal cutting occurs through shear along a plane at an angle to the cutting direction. The document also outlines the difficulties in studying metal cutting processes and how orthogonal cutting experiments were developed to simplify the analysis.
Rotary forging is a combination of two actions, rotational and an axial compression movement, for precise component forming that can be carried out cold or hot
Machine tool iii grinding superfinishing limit fit tolerance & surface f...iukashyap
This document provides an overview of grinding and superfinishing processes. It discusses grinding wheels, their components like abrasives, bonds and specifications. It describes grinding wheel wear mechanisms and different types of grinding machines. Centerless grinding advantages are outlined. Honing, lapping and polishing are introduced as superfinishing processes to achieve very high surface finishes for critical machine components.
Milling is a machining process that uses a rotating cutting tool called a milling cutter to remove material from a workpiece. Milling cutters come in various types for different purposes like flat surfaces, slots, threads, gears, etc. There are two types of milling: up milling where the cutter moves against the workpiece feed and down milling where they move together. Down milling provides better surface finish and tool life. Milling machines are classified based on their purpose, configuration, orientation, and level of automation. Milling cutters are also classified based on their geometry and how they machine specific features. Key parameters like cutting speed, feed rate, and depth of cut determine the material removal rate
Reamers are metalworking tools used to create accurately sized holes. There are several types of reamers classified by their shank and cutting geometry. Straight and tapered reamers are used for precision holes, while ross and fluted reamers are used for roughing and finishing holes respectively. Other reamer types include shell, expansion, and adjustable reamers designed for specialized applications. Proper speeds and stock allowances are required when reaming to achieve the desired hole size and surface finish.
This document provides an overview of mechanical energy based unconventional machining processes. It discusses abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). For each process, it describes the basic working principles, key components, process parameters that influence material removal rate, advantages, disadvantages, and applications. It also compares different types of transducers used in USM and discusses factors affecting the machining performance of USM.
MILLING – Cutting parameters, machine time calculation
Milling operation – Plain milling, side & face milling, form milling, gang milling, end milling, face milling, T slot milling, slitting
GEAR CUTTING – Gear cutting on milling machine – dividing head and indexing method, gear hobbing, principle of operation, advantages & limitation, hobbing tech, gear shaping, gear finishing process
This document discusses drilling operations. It describes different types of drill presses used for drilling including vertical, radial arm, gang, multi-spindle, and numerical control drills. It explains that twist drills cut cylindrical holes with flutes that carry chips up and out of the hole. Key drill features like point angle, helix angle, rake angle, and their effects on drilling different materials are covered. Formulas for calculating drilling time, material removal rate, and chip geometry are provided. Examples of drilling calculations are included.
This document provides an overview of drilling, reaming and grinding processes. It describes how drilling uses a rotating multi-point drill bit to cut circular holes. Reaming enlarges and finishes previously drilled holes to tight tolerances. Grinding uses an abrasive wheel to remove small amounts of material from a workpiece. The document discusses various drill bits and reamer types, factors that influence accuracy and surface finish, and considerations for production economics with each process.
This document provides information on different types of drills, their components and how they are used. It discusses stepped drills, gun drills, center hole drills, burnishing drills, twist drills and throwaway drills. The key components of drills are identified as the point angle, margin, drill diameter, web, chisel edge, back taper, tang, thinning and cutting edge. Challenges of drilling like friction with the hole wall and difficulty seeing the point are also summarized.
IDENTIFICATION AND APPLICATION OF CUTTING TOOLS FOR MILLING.pptxravulakollusainath
This document discusses the identification and application of common cutting tools used in milling operations. It identifies the main types of milling tools like end mills, ball end mills, face mills, indexable end mills, drills, taps, and reamers. For each tool, it describes the purpose, materials, coatings, and applications. The goal is to teach how to visually identify these tools and understand their uses in milling processes.
Introduction machining processes.
General Design rules for machining.
Dimensional Tolerances and surface roughness.
Design For machining.
Ease –redesigning of components for machining ease with suitable examples.
General design recommendations for machined parts
A lathe rotates a workpiece about an axis to perform various operations such as cutting, sanding, knurling with tools. It consists of a headstock, bed, carriage, tailstock. The headstock powers the spindle and workpiece. The carriage moves the tool parallel to the axis of rotation. Turret and capstan lathes allow quick tool changes. Automatic lathes can produce identical pieces without operator attention after initial setup.
Nota berkaitan dengan kaedah drilling untuk sem 1qhairulshafiq
The document discusses drilling operations and drill bits. It defines the parts of a drill bit including the point, shank, body, flutes, and angles. It explains how drill sizes are stated based on factors like shank type, flute type, length, and application. The document also covers how to mark out for drilling, methods of holding drill bits, calculating spindle speed and feed rate, types of coolants, and safety procedures. It discusses work holding devices for drilling like v-blocks and different types of drilling jigs.
* Length of tapered portion (L) = 300 mm
* Large diameter (D1) = 50 mm
* Small diameter (D2) = 38 mm
* Half taper angle (α/2) = Tan-1[(D1-D2)/2L]
= Tan-1[(50-38)/2*300] = 5.71°
* Tailstock offset (h) = (D1-D2)Tan(α/2)/2
= (50-38)Tan(5.71°)/2 = 6 mm
The amount of offset of tailstock is 6 mm.
Broaching is a machining process that uses a broach tool to remove metal. A broach tool has a series of cutting teeth arranged from rough to fine. Each tooth removes a small amount of material. Broaching can machine internal or external surfaces in a single pass. Common applications include cutting keyways, splines or holes. Broaching is well-suited for mass production due to its high accuracy, surface finish and efficiency at removing metal in one pass of the broach tool. However, broaching is limited to machining through-holes and surfaces, and designing and manufacturing broach tools can be complex.
This document provides lecture notes on workshop practice II, covering drilling operations and welding processes. It discusses drilling machine types, drilling geometry, cutting conditions, feed and speed, operations like drilling and reaming. It also covers welding principles like fusion and pressure welding, classification into oxy-acetylene, shielded metal arc, MIG and TIG welding. Key details are provided on welding processes, inert gas shielding, and consumable electrodes.
Drilling, boring reaming operation on latheAliRaza1767
The document discusses drilling, boring, and reaming machine tools and processes. It describes how drilling uses a drill bit to cut a circular hole through rotation, with the material removed via shearing and extrusion. Different materials are used for drill bits depending on the workpiece material. Boring enlarges existing holes, while reaming finishes holes by making the surface smooth. Potential troubleshooting issues for drilling include insufficient torque/power, hole asymmetry, tool wear, and vibrations.
This document provides information on drilling basics and drill components. It discusses the history and evolution of drills from primitive drills used by Native Americans to modern twist and indexable drills. Key components of drills are described such as the point, helix, lip clearance, web thickness, chisel edge, land, and margins. Factors that influence drill selection and performance are also covered like drill point geometry, helix angle, clearance, speeds, feeds, forces, coolant delivery, and failure modes.
IRJET- Design and Fabrication of Drill Bit Grinding Attachment MachineIRJET Journal
This document describes the design and fabrication of a drill bit grinding attachment machine. It aims to develop a fixture to hold drill bits firmly against a grinding wheel during resharpening, making the process less prone to errors and allowing less skilled operators. The fixture design is presented, along with its working principle and advantages such as reducing tool failure, being economical, and ensuring operator safety. Applications are for small manufacturing industries to efficiently resharpen drill bits.
IRJET- Design and Fabrication of Drill Bit Grinding Attachment MachineIRJET Journal
This document describes the design and fabrication of a drill bit grinding attachment machine. It aims to develop a fixture to hold drill bits firmly against a grinding wheel during resharpening, making the process less prone to errors and able to be performed by less skilled operators. The fixture design is intended to eliminate the need for inspection and reduce waste from improperly resharpened bits. It will also help prolong the lifespan of drill bits and reduce costs by enabling repeated resharpening. The document provides details on the working principle, advantages, applications and conclusions of the designed fixture.
1. There are several types of lathes used in manufacturing including speed lathes, turret lathes, and numerical control turning centers.
2. Turret lathes have eleven tooling stations that allow for rough simultaneous cuts of metal and are economical for medium production lots.
3. Quick-change tool holders are used on lathes to reduce tool changing time which can constitute 50% of the total cycle time for jobs with repeated operations.
The document discusses common tools used in CNC milling, including end mills, face mills, drills, taps, and reamers. It describes the different types of each tool as well as factors to consider like material, coatings, flutes, and holders. End mills are the most versatile cutting tools and come in various styles for different milling applications. Tool coatings can increase hardness and wear resistance for better performance. Proper tool holders are also important for secure and accurate mounting of cutters.
This document discusses the drilling process as a manufacturing technique. It begins with definitions of manufacturing and manufacturing processes in general. It then describes drilling as a process that makes circular holes using a rotating cutting tool called a drill bit. Various types of drilling processes are outlined, including spot drilling, center drilling, deep hole drilling, gun drilling, trepanning, microdrilling, vibration drilling and orbital drilling. The document also discusses drilling in different materials like metals and wood, outlining techniques and challenges for each.
Presentation on steel, fabrication & erection Munger Ganga BridgeAshish Kumar Yadav
Presentation on Steel Fabrication work and Erection of girder by Cantilever erection method.
One of the largest bridge in India (Bridge Length 3.690 Km)
Similar Bridge 1. Patna- Sonpur (Digha Bridge) across the river Ganga, Bihar
2. Bogibeel across river Brahmaputra in Assam
A lathe is a machine that rotates a workpiece about an axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation. It uses a non-rotating cutting tool to cut material from the workpiece in the form of chips. The main components of a lathe include the headstock, ways, tailstock, bed, carriage, lead screw, and lead rod. Spindle speeds and feed rates are critical parameters. Lathes can perform operations like turning, threading, tapering, grooving, drilling, boring, knurling, and more. Workpieces are held using chucks, collets, faceplates, or between centers.
The document contains summaries of multiple past exam questions related to mechanical engineering topics like machining processes, material handling equipment, welding, and metallurgy. The questions are from exams administered by different organizations in India and cover topics such as coolants used for machining aluminum, purposes of trepanning, causes of bead weld failure between steel sections, and characteristics of killed steels.
A is true, R is false. Electric arc furnace can be used for both acid and basic steel making. However, impurities are not eliminated extensively in acid method using electric arc furnace. Impurities are eliminated extensively in basic oxygen furnace process, not in acid method.
Hence, A is true but R is false.
Ch 27.12 common applications of various materialsNandan Choudhary
Duralumin is an aluminum alloy containing 3.5-4.5% copper, 0.4-0.7% manganese, and 0.4-0.7% magnesium. It has a maximum tensile strength of around 400 MPa after heat treatment and age hardening. Duralumin is widely used for forging, stamping, bars, sheets, tubes and rivets due to its strength and ability to be age hardened.
Hardness is a material property that describes resistance to indentation. It is influenced by factors like carbon content in steel. Common hardness tests include Brinell, Rockwell, Vickers, and microhardness Knoop testing. Brinell testing involves indenting a specimen with a hard ball under load and measuring the diameter. Rockwell uses an indenting cone to measure depth. Vickers and Knoop are for very hard materials and measure indention diagonal length. Hardness values correlate to other properties like tensile strength. Hardness testing is used to evaluate properties but is not the only factor in assessing mechanical behavior.
The document discusses various cutting tool materials used in metal cutting operations, including their compositions, properties, and applications. It covers traditional materials like high carbon steels, high-speed steels, and cast cobalt alloys. It also discusses modern powder metallurgy based materials like cemented carbides and ceramics, which allow for higher cutting speeds due to their high hardness and heat resistance. The document provides details on commonly used compositions and grades for different applications.
Elastomers are polymers that can undergo large elastic deformations when force is applied and then quickly recover their original shape when the force is removed. Their molecular chains are coiled like springs. When force is applied, the chains uncoil and stretch the material. Upon release of force, the chains recoil back to the original shape. Crosslinking the chains restricts viscous flow under force and allows the material to retain its elastic properties after many stretch-release cycles. The elasticity of an elastomer can be controlled by the amount of crosslinking, with more crosslinks producing a harder, stiffer material.
Plastics or polymers are large molecules built from joining smaller molecules. They can be natural or synthetic resins. Key properties of plastics include being lightweight, resistant to corrosion, easy to fabricate into complex shapes, and having low thermal and electrical conductivity. Plastics can be classified as thermoplastics or thermosets based on their molecular structure and response to heat. Thermoplastics soften when heated and harden when cooled, allowing them to be recycled, while thermosets permanently set during heating and cannot be remelted or remolded. Common thermoplastics include polyethylene, polypropylene, and nylon, while common thermosets include epoxies, polyesters, and
Ch 27.7 alloying element of steel and alloy steelNandan Choudhary
Alloy steel is steel to which other elements have been added to achieve particular properties. Nickel increases strength and toughness. Invar, containing 36% nickel, has nearly zero coefficient of expansion. Austenitic stainless steel contains 18% chromium and 8% nickel which stabilizes the austenitic structure. It is non-magnetic, corrosion resistant and cannot be hardened by heat treatment. Chromium provides corrosion resistance in stainless steel by forming a protective oxide layer.
Cast iron is an alloy of iron and carbon. It typically contains 2-4% carbon but can vary from 2-6.5% carbon. The properties of cast iron make it valuable for engineering purposes due to its low cost, good casting characteristics, high compressive strength, wear resistance, and machinability. Cast iron has a higher compressive strength than tensile strength. Common types of cast iron include grey cast iron, which contains free graphite flakes; white cast iron, which contains cementite carbides; and nodular or spheroidal graphite cast iron, which contains graphite in nodules/spheroids. Nodular cast iron has improved ductility and strength over other types. Cast iron
Cast iron is an alloy of iron and carbon. It exists in several forms depending on the carbon content and microstructure:
- Gray cast iron has 2-4% carbon present as graphite flakes, giving it a gray color. It has high compressive strength but is brittle. Widely used in machine bases.
- White cast iron has 1.75-2.3% carbon present as cementite, making it very hard and strong but brittle. Used for wear-resistant parts.
- Nodular or spheroidal graphite cast iron has graphite in spherical nodules, making it more ductile. Commonly used for pipes and fittings.
1. The document discusses the iron-carbon equilibrium diagram, which shows the different phases of iron as carbon content and temperature vary.
2. It describes the different phases of iron - ferrite, austenite, cementite - and how their crystal structures and carbon solubility change with temperature.
3. Pearlite, an important microstructure in steel, is a lamellar structure composed of alternating layers of ferrite and cementite that forms during a eutectoid reaction when austenite cools below 723°C.
- Plain-carbon steel is an alloy of iron and carbon, with a maximum carbon content of around 6.67%.
- The strength and hardness of steel increases with higher carbon content, up to around 2% carbon when it becomes classified as steel rather than iron.
- Steel is commonly classified based on carbon content as low-carbon (<0.3%C), medium-carbon (0.3-0.8%C), or high-carbon (>0.8%C) steel, with each type having different properties and applications.
Heat treatment involves heating metals or alloys to specific temperatures, holding for durations, and cooling at controlled rates. This controls microstructure and properties. Key processes include annealing, stress relieving, hardening, tempering, and carburizing. Annealing relieves stresses and strains, improves machinability and ductility. Normalizing refines grains and relieves stresses. Stress relieving reduces stresses without changing microstructure.
Ch 27.2 crystalline materials & detects in crystalline materialsNandan Choudhary
Crystalline materials have atoms arranged in a specific, repeating pattern called a crystal structure. There are several common crystal structures including face-centered cubic, body-centered cubic, and hexagonal close packed.
A crystal structure is built from a repeating three-dimensional pattern called a unit cell, which contains one or more atoms. The unit cell is characterized by the types and positions of atoms within it, the cell dimensions and angles, and the number of atoms per cell. Common unit cells include simple cubic, body-centered cubic, and face-centered cubic.
Miller indices are used to describe directions and planes in a crystal structure. They are represented by sets of integers that indicate the intercepts of a plane or
The document discusses jigs and fixtures, which are devices used to precisely locate and secure workpieces for machining. It describes the key functions of jigs and fixtures as locating, clamping, and supporting workpieces. The main difference between jigs and fixtures is that jigs also include provisions for guiding cutting tools. The document outlines principles for properly locating and securing workpieces, such as the 3-2-1 locating principle, and discusses various types of locators, clamps, and other elements used in jig and fixture design.
Shell moulding is a casting process where a thermosetting resin-sand mixture is allowed to adhere to a heated metal pattern, forming a shell. The shell is then removed from the pattern. Molten metal is poured into the shell mould to form the casting. Shell moulding can produce complex parts with good dimensional accuracy and surface finish, reducing machining needs. Common materials cast are iron, aluminum, and copper alloys. Advantages include close tolerances and smooth surfaces, while limitations include expensive patterns and size restrictions. Applications include engine parts like cylinders and heads.
Sand casting uses sand as the primary mould material mixed with other materials like clay and water. A pattern with the shape of the desired casting is packed in sand to form the mould cavity. Molten metal is poured through a sprue hole and gates into the mould. After solidification, the mould is broken and the casting is removed and further processed by cutting off ingates. The sequential steps involve packing sand in the drag and cope halves of a flask with the pattern, cutting runners and gates, and pouring molten metal. Key terms include flask, pattern, parting line, and gates. Core sands require higher strength and permeability than moulding sands.
Resistance welding uses both heat and pressure to join metal workpieces. Heat is generated by the electrical resistance between the workpieces when a current is passed through them. Pressure holds the workpieces together during welding. Some key advantages of resistance welding are that it is very fast, can be fully automated, and does not require filler metal, shielding gases, or flux. Common types of resistance welding include resistance spot welding, seam welding, and projection welding.
Ch 19 gas welding, gas cutting & arc weldingNandan Choudhary
Welding is a process that joins materials by causing coalescence through heating or pressure. It requires a heat source, protection of the metal from oxidation, and care to avoid harmful metallurgical effects. Oxy-fuel gas welding uses a flame from oxygen and fuel gas, typically acetylene, to heat and join metals. The ratio of gases determines the flame type, with neutral flame being most common for welding. While portable, gas welding exposes heated metal to contamination and causes more distortion than other processes.
The document discusses electrochemical machining (ECM). ECM is an unconventional machining process where material is removed from a workpiece made of an electrically conductive material via an electrochemical reaction. In ECM, the workpiece acts as an anode in an electrolyte solution, and a tool acts as a cathode. A direct current is passed between them, causing metal ions from the workpiece to dissolve into the electrolyte solution. ECM can machine complex shapes with high accuracy and no tool wear. It has the highest material removal rate of any unconventional machining process but requires expensive equipment and a conductive workpiece material.
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
Software Engineering and Project Management - Introduction, Modeling Concepts...Prakhyath Rai
Introduction, Modeling Concepts and Class Modeling: What is Object orientation? What is OO development? OO Themes; Evidence for usefulness of OO development; OO modeling history. Modeling
as Design technique: Modeling, abstraction, The Three models. Class Modeling: Object and Class Concept, Link and associations concepts, Generalization and Inheritance, A sample class model, Navigation of class models, and UML diagrams
Building the Analysis Models: Requirement Analysis, Analysis Model Approaches, Data modeling Concepts, Object Oriented Analysis, Scenario-Based Modeling, Flow-Oriented Modeling, class Based Modeling, Creating a Behavioral Model.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
The CBC machine is a common diagnostic tool used by doctors to measure a patient's red blood cell count, white blood cell count and platelet count. The machine uses a small sample of the patient's blood, which is then placed into special tubes and analyzed. The results of the analysis are then displayed on a screen for the doctor to review. The CBC machine is an important tool for diagnosing various conditions, such as anemia, infection and leukemia. It can also help to monitor a patient's response to treatment.
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
The aquaponic system of planting is a method that does not require soil usage. It is a method that only needs water, fish, lava rocks (a substitute for soil), and plants. Aquaponic systems are sustainable and environmentally friendly. Its use not only helps to plant in small spaces but also helps reduce artificial chemical use and minimizes excess water use, as aquaponics consumes 90% less water than soil-based gardening. The study applied a descriptive and experimental design to assess and compare conventional and reconstructed aquaponic methods for reproducing tomatoes. The researchers created an observation checklist to determine the significant factors of the study. The study aims to determine the significant difference between traditional aquaponics and reconstructed aquaponics systems propagating tomatoes in terms of height, weight, girth, and number of fruits. The reconstructed aquaponics system’s higher growth yield results in a much more nourished crop than the traditional aquaponics system. It is superior in its number of fruits, height, weight, and girth measurement. Moreover, the reconstructed aquaponics system is proven to eliminate all the hindrances present in the traditional aquaponics system, which are overcrowding of fish, algae growth, pest problems, contaminated water, and dead fish.
Discover the latest insights on Data Driven Maintenance with our comprehensive webinar presentation. Learn about traditional maintenance challenges, the right approach to utilizing data, and the benefits of adopting a Data Driven Maintenance strategy. Explore real-world examples, industry best practices, and innovative solutions like FMECA and the D3M model. This presentation, led by expert Jules Oudmans, is essential for asset owners looking to optimize their maintenance processes and leverage digital technologies for improved efficiency and performance. Download now to stay ahead in the evolving maintenance landscape.
3. Reaming
Reaming removes a small amount of material from the
surface of holes.
It is done for two purposes: to bring holes to a more exact
size and to improve the finish of an existing hole.
Multiage cutting tools that has many flutes, which may be
straight or in a helix are used.
No special machines are built for reaming. The same
machine that was employed for drilling the hole can be used
for reaming by changing the cutting tool.
Only a minimum amount of materials should be left for
removal by reaming. As little as 0.1 mm is desirable, and in
no case should the amount exceed 0.4 mm.
A properly reamed hole will be within 0.025 mm of the
correct size and have a fine finish.
6. Reamer Flutes
The reamer flutes are either straight or helical.
The helical flutes promote smoother cutting and should be
used specifically for holes that are not continuous, such as
those with keyways parallel to the axis of the hole.
The cutting action of the helical flutes is smoother and helps
in preventing chatter.
The reamers are termed as left hand or right hand,
depending upon the direction in which they are moved,
looking from the shank to the cutting portion.
The right-hand reamer with right-hand helix is used for
roughing cuts, since the tool tends to go into the workpiece
more efficiently and thereby promotes the material removal.
A right-hand reamer with left-hand flutes is used for
finishing cuts.
7. Types of Reamers
The principal types of reamers are:
1. Hand reamers
a. Straight
b. Taper
2. Machine or chucking reamers
a. Rose
b. Fluted
3. Shell reamers
4. Expansion reamers
5. Adjustable reamers
8. Reaming
To meet quality requirements, including both finish and
accuracy (tolerances on diameter, roundness,
straightness, and absence of bell-mouth at ends of
holes). Reamers must have adequate support for the
cutting edges, and reamer deflection must be minimal.
Reaming speed is usually two-thirds the speed for
drilling the same materials. However, for close tolerances
and fine finish, speeds should be slower.
Feeds are usually much higher than those for drilling
and depend upon material.
Recommended cutting fluids are the same as those for
drilling.
9. Reaming
Reamers, like drills, should not be allowed to become dull.
The chamfer must be reground long before it exhibits
excessive wear. Sharpening is usually restricted to the
starting taper or chamfer. Each flute must be ground exactly
evenly or the tool will cut oversize.
Reamers tend to chatter when not held securely, when the
work or work holder is loose, or when the reamer is not
properly ground.
Irregularly spaced teeth may help reduce chatter. Other cures
for chatter in reaming are to reduce the speed, vary the feed
rate, chamfer the hole opening, use a piloted reamer, reduce
the relief angle on the chamfer, or change the cutting fluid.
Any misalignment between the work piece and the reamer
will cause chatter and improper reaming.
10. Rose Reamer
Rose chucking reamers
are ground cylindrical
and have no relief
behind the outer edges
of the teeth. All cutting
is done on the beveled
ends of the teeth
11. Chucking Reamer
Fluted chucking
reamers have relief
behind the edges of the
teeth as well as beveled
ends. They can cut on
all portions of the teeth.
Their flutes are
relatively short and they
are intended for light
finishing cuts.
12. Shell Reamer
Shell reamers often are
used for sizes over 20
mm to save cutting-tool
material. The shell,
made of HSS for smaller
sizes and with carbide
edges for larger sizes or
for mass-production
work.
13. IFS-2011
What is the main difference between rose reamer
and chucking reamer ? Write in short about shell
reamer.
[5-marks]
14. Trepanning
Trepanning is a annular groove producing operation
which leaves a solid cylindrical core in the centre. In
trepanning a cutter consisting of one or more cutting
edges placed along the circumference of a circle is used
to produce the annular groove.
Trepanning Tool
15. IES - 1999
Which one of the following processes results in the
best accuracy of the hole made?
(a) Drilling (b) Reaming
(c) Broaching (d) Boring
16. IES - 1999
Consider the following statements regarding
reaming process:
1. Reaming generally produces a hole larger than its
own diameter
2. Generally rake angles are not provided on reamers.
3. Even numbers of teeth are preferred in reamer
design.
Which of these statements are correct?
(a) 1 and 2 (b) 2 and 3
(c) 1 and 3 (d) 1, 2 and 3
17. IES - 1998
Match List-I with List-II and select the correct answer
using the codes given below the lists:
List-I List-II
A. Reaming 1. Smoothing and squaring surface
around the hole for proper seating
B. Counter-boring 2.Sizing and finishing the hole
C. Counter-sinking 3. Enlarging the end of the hole
D. Spot facing 4. Making a conical enlargement at the
end of the hole
Code:A B C D A B C D
(a) 3 2 4 1 (b) 2 3 1 4
(c) 3 2 1 4 (d) 2 3 4 1
18. IES - 1994
In reaming process
(a) Metal removal rate is high
(b) High surface finish is obtained.
(c) High form accuracy is obtained
(d) High dimensional accuracy is obtained.
19. GATE – 2007 (PI)
Reaming is primarily used for achieving
(a) Higher MRR
(b) Improved dimensional tolerance
(c) Fine surface finish
(d) Improved positional tolerance
20. GATE – 2014 (PI)
Reaming is a process used for
(a) creating a circular hole in metals
(b) cutting a slot on the existing hole surface
(c) finishing an existing hole surface
(d) making non-circular holes in metals
21. IES - 1993
A hole of 30 mm diameter is to be produced by reaming.
The minimum diameter permissible is 30.00 mm while
the maximum diameter permissible is 30.05 mm. In this
regard, consider the following statements about the
reamer size:
1. The minimum diameter of the reamer can be less than 30 mm.
2.The minimum diameter of the reamer cannot be less than 30 mm.
3. The maximum diameter of the reamer can be more than 30.05 mm.
4.The maximum diameter of the reamer must be less than 30.05 mm.
Of these statements
(a) 1 and 4 are correct (b) 1 and 3 are correct
(c) 2 and 3 are correct (d) 2 and 4 are correct
22. IES - 1998
A component requires a hole which must be within
the two limits of 25.03 and 25.04 mm diameter.
Which of the following statements about the
reamer size are correct?
1. Reamer size cannot be below 25.03 mm.
2. Reamer size cannot be above 25.04 mm.
3. Reamer size can be 25.04 mm.
4. Reamer size can be 25.03 mm.
Select the correct answer using the codes given below:
(a) 1 and 3 (b) 1 and 2
(c) 3 and 4 (d) 2 and 4
23. IAS - 1999
For reaming operation of blind hole, the type of
reamer required is
(a) Straight flute reamer
(b) Right hand spiral fluted reamer
(c) Left hand spiral fluted reamer
(d) None of the above
24. IAS - 2003
Match List I (Operation) with List II (Application) and select
the correct answer using the codes given below the lists:
List-I List-II
(Operation) (Application)
(A) Reaming 1. Used for enlarging the end of a hole to give it a
conical shape for a short distance
(B) Boring 2. Used for enlarging only a limited portion of the
hole
(C) Counter boring 3. Used for finishing a hole
(D) Counter sinking 4. Used for enlarging a hole
Codes:A B C D A B C D
(a) 3 2 4 1 (b) 1 4 2 3
(c) 3 4 2 1 (d) 1 2 4 3
25. IES - 1992
Shell reamers are mounted on
(a) Tool holders (b) Amour plates
(c) Arbor (d) Shanks
28. Boring
Boring always involves the enlarging of an existing hole,
which may have been made by a drill or may be the result of a
core in a casting.
An equally important and concurrent purpose of boring may
be to make the hole concentric with the axis of rotation of
the workpiece and thus correct any eccentricity that may
have resulted from the drill drifting off the centerline.
Concentricity is an important attribute of bored holes.
When boring is done in a lathe, the work usually is held in a
chuck or on a faceplate. Holes may be bored straight,
tapered, or to irregular contours.
Boring is essentially internal turning while feeding the tool
parallel to the rotation axis of the workpiece.
29.
30. Boring
The same principles are used for boring as for turning.
The tool should be set exactly at the same height as the
axis of rotation. Slightly larger end clearance angles
sometimes have to be used to prevent the heel of the tool
from rubbing on the inner surface of the hole.
31. Boring
Because the tool overhang will be greater, feeds and
depths of cut may be somewhat less than for turning to
prevent tool vibration and chatter.
In some cases, the boring bar may be made of tungsten
carbide because of this material's greater stiffness.
The boring tool is a single-point cutting tool.
Hole quality, finish boring can typically achieve holes
within tolerances of IT9.
Surface finishes better than Ra 1 micron can be achieved.
33. Formula for Boring
Average diameter of workpiece
Cutting Time,
Metal Removal Rate
1 2
avg
D D
D mm
2
L A O
CT
fN
2 2
1 2
avg
D D
MRR D dfN
4 / fN
34. IES - 1993
The main purpose of boring operation, as compared
to drilling is to:
(a) Drill a hole
(b) Finish the drilled hole
(c) Correct the hole
(d) Enlarge the existing hole
35. IES – 1994, ISRO-2008
Enlarging an existing circular hole with a rotating
single point tool is called
(a) Boring (b) Drilling
(c) Reaming (d) Internal turning.
36. IES – 1992, ISRO-2010
Which of the machine tools can be used for boring
1. Lathe
2. Drilling machine
3. Vertical milling machine
4. Horizontal milling machine
(a) 1, 2, 3 (b) 1, 3, 4
(c) 2 and 4 (d) 1, 2, 3, 4
37. IES - 2000
Which one of the following sets of tools or tools and
processes are normally employed for making large
diameter holes?
(a) Boring tool
(b) BTA tools (Boring and trepanning association) and
gun drill
(c) Gun drill and boring tool
(d) Boring tools and trepanning
38. IES - 1996
Which of the following statements are correct?
1. A boring machine is suitable for a job shop.
2. A jig boring machine is designed specially for doing
more accurate work when compared to a vertical
milling machine.
3. A vertical precision boring machine is suitable for
boring holes in cylinder blocks and liners.
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3.
39. IES - 1995
The effects of setting a boring tool above centre
height leads to a/an.
(a) Increase in the effective rake angle and a decrease in
the effective clearance angle.
(b) Increase in both effective rake angle and effective
clearance angle.
(c) Decrease in the effective rake angle and an increase
in the effective clearance angle.
(d) Decrease in both effective rank angle and effective
clearance angle.
40. JWM 2010
Consider the following operations regarding boring
machines :
1. Counterboring
2. Countersinking
3. Trepanning
Which of the above operations is/are correct ?
(a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 only
42. Broaching
Broaching is a multiple-tooth cutting operation with the
tool reciprocating.
Since in broaching the machining operation is
completed in a single-stroke as the teeth on the cutting
tool, called broach, are at gradually increasing height
corresponding to the feed per tooth of a milling cutter.
The shape of the broach determines the shape of the
machined part.
Broaching was originally developed for machining
internal keyways, but looking at the advantages, it has
been extensively used in the mass production of
automobile component manufacture for various other
surfaces as well.
43. Broaching
The material removal using the broach teeth is shown
schematically in Fig. shown in below. The dotted line in
the figure indicates the amount of material being
removed by successive individual teeth.
45. Broach Construction
The broach is composed of a series of teeth, each tooth
standing slightly higher than the previous one. This rise
per tooth is the feed per tooth and determines the
material removed by the tooth.
There are basically three sets of teeth present in a broach
as shown in Fig. shown above.
The roughing teeth that have the highest rise per tooth
remove bulk of the material.
The semi-finishing teeth, whose rise per tooth is smaller,
remove relatively smaller amounts of material compared
to the roughing teeth.
46. Broach Construction
The last set of teeth is called the finishing or sizing teeth.
Very little material will be removed by these teeth.
The necessary size will be achieved by these teeth and
hence all the teeth will be of the same size as that
required finally. With the progress of time, when the
first set of teeth wear out, the next set of teeth will be
able to provide the sizing function.
The pull end of the broach (Fig. shown in above) is
attached to the pulling mechanism of the broaching
machine with the front pilot aligning the broach
properly with respect to the workpiece axis before the
actual cutting starts.
47. Broach Construction
The rear pilot helps to keep the broach to remain square
with the workpiece as it leaves the workpiece after
broaching.
Broaching speeds are relatively low, of the order of 6 to 15
m/min. However, the production rate is high with the
cycle times being about 5 to 30 seconds, including the
workpiece and tool handling times. The low cutting
speeds are conducive to very high tool life with very
small tool wear rates.
48. Broach Construction
Broaches are generally made of high speed steel in view
of its high impact strength. Sometimes, the titanium
nitride coating helps to improve the tool life further.
Also, the carbide insert-type broaches are used more for
surface broaching of cast iron for very large volume
production to reduce the frequent resharpening of the
broach, which is a very difficult operation.
Standard broaches are available for common and more
often used forms, such as round and square holes,
keyways, etc.
49. Broach Construction
For smooth operation, it is essential that at least two or
three teeth be simultaneously engaged.
The thumb rule for tooth spacing,
The cut per tooth f is kept in the range 0.05 mm – 0.09
mm.
In the normal speed BUE may be a problem. To avoid
this a copious supply of the cutting fluid is provided.
1.75 ,s l mm
50. Advantages of broaching
1. It is the fastest way of finishing an operation with a single
stroke.
2. Since all the machining parameters are built into the
broach, very little skill is required from the operator.
3. Broaching machine is simple since only a single
reciprocating motion is required for cutting.
4. Final cost of the machining operation is one of the lowest
for mass production.
5. Any type of surface, internal or external, can be generated
with broaching.
6. Many surfaces, which are very difficult or impossible by
other means, can be done by broaching. For example, square
hole and internal splines.
7. Good surface finish and fine dimensional tolerances can be
achieved by broaching, often better than boring or reaming
51. Limitations of broaching
1. Custom made broaches are very expensive and can
therefore be justified only for very large volume
production.
2. A broach has to be designed for a specific application
and can be used only for that application. Hence, the
lead time for manufacture is more for custom designed
broaches.
3. Broaching, being a very heavy metal removal
operation, requires that the workpiece is rigid and
capable of withstanding the large forces.
4. Broaching can only be carried out on the workpiece
whose geometry is such that there is no interference for
the broach movement for the cutting.
52. IES - 2007
Among the following machining processes, which
can be used for machining flat surfaces?
1. Shaping 2. Milling 3. Broaching
Select the correct answer using the code given below:
(a) 1 and 2 only (b) 1 and 3 only
(c) 2 and 3 only (d) 1, 2 and 3
53. IES - 1993
Assertion (A): Soluble oils are employed with
broaching machine.
Reason (R): Soluble oils have excellent cooling
effect.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
54. IES – 1993, 2001
Assertion (A): No separate feed motion is required
during broaching.
Reason (R): The broaching machines are generally
hydraulically operated.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
55. IES - 2001
The screw and nut in a broaching machine are
changed from square thread to ACME thread. The
power requirement of the machine at the same
r.p.m. will
(a) Remain same
(b) Decrease
(c) Increase
(d) Depend on the operator
56. IAS - 2004
Which one of the following is true for the last few
teeth of a broach which are meant for fine
finishing?
(a) They have equal diameter
(b) They have increasing diameter
(c) They have decreasing diameter
(d) They have alternately increasing and decreasing
diameter.
57. IES - 2005
Match List I (Tool) with List II (Element of Tool) and
select the correct answer using the code given below the
Lists:
List I List II
A Broach 1. Tang
B. Reamer 2. Pilot
C. Drill 3. Front taper
D. Carbide insert face mill 4. Bond
5. Sweeper tooth
Codes:A B C D A B C D
(a) 2 5 1 3 (b) 1 3 4 5
(c) 2 3 1 5 (d) 1 5 4 3
58. IES - 2002
Match List I with List II and select the correct answer:
List I (Machine tool) List II (Features)
A. Lathe 1. Push or pull tool
B. Drilling machine 2. Rachet and pawl
mechanism
C. Shaper 3. Dividing head
D. Broaching machine 4. Hollow tapered spindle
5. Face plate
Codes:A B C D A B C D
(a) 2 4 5 1 (b) 5 3 2 4
(c) 2 3 5 4 (d) 5 4 2 1
Editor's Notes
Ans. (b)
Ans. (b)
Ans. (d)
Ans. (d) Reaming usually follows drilling or core drilling and its purpose is to remove all coarse traces of previous machining operations with the help of a multipoint cutting tool called "reamer".
Ans. (b) Reaming usually follows drilling or core drilling and its purpose is to remove all coarse traces of previous machining operations with the help of a multipoint cutting tool called "reamer".
Ans. (c)
Ans. (d) Since hole has to lie between 30.00 mm and 30.05 mm, the reamer size can be less than 30 mm and maximum diameter must be less than 30.05 mm.
Ans. (b)
Ans. (b)
Ans. (c)
Reaming usually follows drilling or core drilling and its purpose is to remove all coarse traces of previous machining operations with the help of a multipoint cutting tool called "reamer".
Counter boring consists in enlarging a portion of an existing hole to a larger diameter and making the surface at the bottom of the larger diameter flat and square.
Counter sinking is done after drilling a hole to chamfer the entrance to a hole or to make a conical recess or a seat for a flat headed screw or rivet so that the heads are flush or below the main surface.
Ans. (c) Shell reamers often are used for sizes over ¾ in to save cutting-tool material. The shell, made of tool steel for smaller sizes and with carbide edges for larger sizes or for mass-production work, is held on an arbor that is made of ordinary steel. One arbor may be used with any number of shells. Only the shell is subject to wear and need be replaced when worn. They may be ground as rose or fluted reamers.
Ans. (d) The main purpose of boring operation is to enlarge the existing hole.
Ans. (a) Enlarging an existing circular hole with a rotating single point tool is called boring.
Ans. (a)
Ans. (d)
Ans. (a)
Ans. (c)
Ans. (a) Trepanning is a annular groove producing operation which leaves a solid cylindrical core in the centre. In trepanning a cutter consisting of one or more cutting edges placed along the circumference of a circle is used to produce the annular groove.
In medical Trepanning or making a burr hole, is a surgical intervention in which a hole is drilled or scraped into the human skull, exposing the dura mater in order to treat health problems related to intracranial diseases.
S is the tooth spacing and l is the broached length in mm.
Ans. (d)
Ans. (a) Both A and R are true. Also R provides correct explanation for A.
Ans. (b)
Ans. (c) Efficiency of ACME thread is lower than square thread.