The intern summarized key details from an internship document at LMTG:
1. The intern conducted two projects - developing a specialized tool for back spot facing an ash lock, and analyzing surface finish obtained from a wiper cutter on a horizontal boring machine.
2. For the first project, the intern proposed and tested solutions to challenges like tool length and vibrations. This included a stepped shaft design.
3. For the second project, the intern conducted trials varying machine, cutter, and parameters, finding spindle runout caused back cutting on one machine.
This document discusses machining and metal cutting. It defines machining as a process that converts raw materials into finished products with specific dimensions, shapes, and surfaces. It describes cutting speed, feed rate, depth of cut, and different types of chips formed during machining. It also covers tool geometry including rake angle, cutting edge angles, and tool signature. Mechanisms of chip formation and sources of heat generation during machining are explained. Different types of single point cutting tools and their nomenclature are discussed in detail.
Machining processes involve cutting a workpiece into a desired shape and size through controlled material removal. The three main machining processes are turning, drilling, and milling. Turning involves rotating the workpiece and feeding a single-point cutting tool parallel to the axis of rotation to cut external or internal features. Drilling produces round holes using a rotating drill bit. Milling uses a multi-toothed cutting tool to cut flat and complex shapes by rotating the tool perpendicular to the workpiece feed direction. Other machining processes include grinding, broaching, and advanced processes like water jet machining or electrical discharge machining.
The document summarizes various metal sawing manufacturing processes. It describes the characteristics of metal cutting saw blades including material, tooth form, tooth set, tooth spacing, and size. It also discusses sawing speeds and feeds. The document classifies different sawing operations and machines, specifically covering reciprocating/power hack sawing, circular sawing, band sawing, and friction sawing. It provides details on each process including equipment used and advantages.
1) Grinding is an abrasive machining process that uses abrasive particles held together by a bonding material to shape and finish workpieces.
2) Key factors in grinding include the abrasive material, grit size, bond type and strength, and wheel structure. Coarser grits and more open structures are used for stock removal while finer grits and denser structures provide better surface finishes.
3) Vitrified bonds are strong but brittle while resin and metal bonds offer more flexibility and toughness. Bond selection depends on factors like wheel speed and fluid compatibility.
* 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.
This document discusses super finishing processes used to achieve very smooth surfaces that improve functional properties like wear resistance. It describes honing, lapping, and superfinishing processes. Honing uses an abrasive tool with rotary and reciprocating motion to remove grinding marks. Lapping uses loose abrasives to produce geometrically true surfaces and close fits. Superfinishing scrubs a fine grit stone against a workpiece to produce a very smooth metal finish.
This document discusses machining and metal cutting. It defines machining as a process that converts raw materials into finished products with specific dimensions, shapes, and surfaces. It describes cutting speed, feed rate, depth of cut, and different types of chips formed during machining. It also covers tool geometry including rake angle, cutting edge angles, and tool signature. Mechanisms of chip formation and sources of heat generation during machining are explained. Different types of single point cutting tools and their nomenclature are discussed in detail.
Machining processes involve cutting a workpiece into a desired shape and size through controlled material removal. The three main machining processes are turning, drilling, and milling. Turning involves rotating the workpiece and feeding a single-point cutting tool parallel to the axis of rotation to cut external or internal features. Drilling produces round holes using a rotating drill bit. Milling uses a multi-toothed cutting tool to cut flat and complex shapes by rotating the tool perpendicular to the workpiece feed direction. Other machining processes include grinding, broaching, and advanced processes like water jet machining or electrical discharge machining.
The document summarizes various metal sawing manufacturing processes. It describes the characteristics of metal cutting saw blades including material, tooth form, tooth set, tooth spacing, and size. It also discusses sawing speeds and feeds. The document classifies different sawing operations and machines, specifically covering reciprocating/power hack sawing, circular sawing, band sawing, and friction sawing. It provides details on each process including equipment used and advantages.
1) Grinding is an abrasive machining process that uses abrasive particles held together by a bonding material to shape and finish workpieces.
2) Key factors in grinding include the abrasive material, grit size, bond type and strength, and wheel structure. Coarser grits and more open structures are used for stock removal while finer grits and denser structures provide better surface finishes.
3) Vitrified bonds are strong but brittle while resin and metal bonds offer more flexibility and toughness. Bond selection depends on factors like wheel speed and fluid compatibility.
* 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.
This document discusses super finishing processes used to achieve very smooth surfaces that improve functional properties like wear resistance. It describes honing, lapping, and superfinishing processes. Honing uses an abrasive tool with rotary and reciprocating motion to remove grinding marks. Lapping uses loose abrasives to produce geometrically true surfaces and close fits. Superfinishing scrubs a fine grit stone against a workpiece to produce a very smooth metal finish.
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.
Traditional machining processes use machine tools like lathes, mills, and drill presses with sharp cutting tools to remove material from a workpiece. Positive rake angles on cutting tools reduce cutting forces but weaken the tool, while negative rake angles strengthen the tool but increase forces. Common machining operations include turning, drilling, milling, grinding, planing, sawing, and stamping/pressing, each using different types of tools and machines to cut or form various geometries in materials. Gear cutting involves using a specialized cutter and dividing head to mill gear teeth according to the involute profile.
The document discusses abrasive processes and broaching. It describes various abrasive machining processes including grinding, honing and lapping. It details different types of grinding processes such as cylindrical grinding and centerless grinding. It also discusses broaching machines and broaching processes. Broaching involves using a multi-tooth tool to remove material in one pass to produce internal and external features with high tolerances and production rates.
Broaching is a machining process that uses a broach tool to remove material. There are different types of broaches and broaching methods depending on the operation. Broaching provides high production rates and accuracy for machining holes, slots and surfaces. It is well-suited for mass production but requires expensive broach tools and fixtures.
The document discusses forming solutions for increasing efficiency in manufacturing operations. It provides an overview of why forming is useful, examples of how it can replace or improve upon other processes like punching, and basics of forming like considerations for setup and maximum form heights. Key advantages of forming include increased efficiency, expanded capabilities, and elimination of secondary operations.
Machining is a subtractive process that removes excess material from a workpiece using a cutting tool. It involves gradually removing material in the form of chips using single-point or multi-point cutting tools, or abrasives, to achieve the desired shape, size, and surface finish. Various machining processes include turning, milling, drilling, grinding, and others. Machine tools are used to securely hold the workpiece and cutting tool and provide controlled motion and power for material removal during machining operations.
1. Grinding is a finishing operation that involves slowly wearing away material using an abrasive that is harder than the material being ground. Heat generated during grinding can damage the grinding wheel.
2. There are several types of grinding machines including surface grinders, cylindrical grinders, and universal tool and cutter grinders. Surface grinding is commonly used to grind flat surfaces while cylindrical grinding is used to grind external and internal diameters.
3. Grinding wheels come in different materials, shapes, grains, bonds, grades, and structures suited for different grinding applications and material removal needs. Proper wheel selection is important for achieving the desired surface finish.
This document discusses machine tools and machining processes. It covers topics such as cutting tools, tool selection factors, tool design and terminology, forces in metal cutting, tool life, cutting speeds and feeds, tool failure modes, machinability, cutting inserts, and cutting fluids. The document is presented by Vikrant Sharma of the Mechanical Engineering department and contains diagrams to illustrate machining concepts.
The document discusses the value of owning a tool sharpening system rather than sending tools out for sharpening. It provides 3 key benefits:
1) Sharpening tools on-site ensures they are sharpened correctly every time, extending tool life and improving product quality.
2) On-site sharpening allows tools to be sharpened as needed for convenience and to avoid downtime waiting for tools to be sharpened off-site.
3) Correct and frequent sharpening can more than double a tool's life, significantly lowering the cost per hole.
This document discusses the geometry of plain milling cutters and twist drills. It describes the key features of milling cutters such as radial rake angle, radial relief angle, land, and lip angle. It also explains different types of milling operations including up milling, down milling, string milling, and gang milling. For twist drills, it outlines the drill point, twist drill nomenclature, and recommended drill geometries for different materials. Equations are provided for estimating drilling forces based on drill diameter and feed rate.
Broaching is a machining process that uses a broach tool to remove material from a workpiece. The broach tool has a series of cutting teeth arranged in a row with each tooth slightly higher than the previous one. The broach is moved linearly through the workpiece, with each successive tooth removing more material. Broaching can produce finished surfaces and tight tolerances with a single pass of the broach tool. It is well-suited for mass production applications due to its high material removal rate and long tool life.
The document discusses various specialized tools from Mate Precision Tooling for punching and forming sheet metal parts. It describes tools that eliminate burrs during punching, create bend lines for easy bending, provide fastening methods to replace welding, and reduce sheet marking on delicate materials. It also provides information on tools for precision hole punching, sequential numbering, and tool maintenance.
The document provides information on Ultra Tooling lines including specifications for different station sizes and their features. Key details include lubricated guides to protect turrets from wear, quick tool adjustment without disassembly, compatibility with other brands, and strippers relieved for longer grind life. Larger C-D-E stations also offer quick length adjustment, while fully guided tooling provides rigidity and accuracy for small holes and thick material.
This document provides an introduction to manufacturing processes and machine tools. It defines key terms in manufacturing like speed, feed, depth of cut, and metal removal rate. It describes orthogonal and oblique cutting and different types of chips that can be produced. Factors that influence each chip type are outlined. Common tool angles used in machining are defined including back rake angle, side rake angle, end relief angle, and side relief angle. Key aspects of manufacturing like interchangeability, mass production, and higher living standards are noted.
Gear finishing processes are necessary to produce accurate, smooth gear teeth after initial formation. The main gear finishing processes are gear shaving, burnishing, grinding, lapping, and honing. Gear shaving involves running a gear against a cutter to scrape off irregularities. Gear burnishing plastically moves excess material during rolling. Gear grinding is the most accurate but also the most expensive method. Lapping and honing use abrasives to remove burrs and irregularities from heat treated gears in a faster process than other methods.
The document contains multiple choice questions about rules of the road, traffic signs, and safe driving practices. It covers topics like right of way, stopping at intersections, traffic light behaviors, speed limits, parking rules, and hazard warnings. The questions test knowledge of when to yield, proper vehicle positioning, legal maneuvers, and safety procedures in various driving scenarios involving other vehicles, pedestrians, and infrastructure like traffic lights and signs.
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.
Traditional machining processes use machine tools like lathes, mills, and drill presses with sharp cutting tools to remove material from a workpiece. Positive rake angles on cutting tools reduce cutting forces but weaken the tool, while negative rake angles strengthen the tool but increase forces. Common machining operations include turning, drilling, milling, grinding, planing, sawing, and stamping/pressing, each using different types of tools and machines to cut or form various geometries in materials. Gear cutting involves using a specialized cutter and dividing head to mill gear teeth according to the involute profile.
The document discusses abrasive processes and broaching. It describes various abrasive machining processes including grinding, honing and lapping. It details different types of grinding processes such as cylindrical grinding and centerless grinding. It also discusses broaching machines and broaching processes. Broaching involves using a multi-tooth tool to remove material in one pass to produce internal and external features with high tolerances and production rates.
Broaching is a machining process that uses a broach tool to remove material. There are different types of broaches and broaching methods depending on the operation. Broaching provides high production rates and accuracy for machining holes, slots and surfaces. It is well-suited for mass production but requires expensive broach tools and fixtures.
The document discusses forming solutions for increasing efficiency in manufacturing operations. It provides an overview of why forming is useful, examples of how it can replace or improve upon other processes like punching, and basics of forming like considerations for setup and maximum form heights. Key advantages of forming include increased efficiency, expanded capabilities, and elimination of secondary operations.
Machining is a subtractive process that removes excess material from a workpiece using a cutting tool. It involves gradually removing material in the form of chips using single-point or multi-point cutting tools, or abrasives, to achieve the desired shape, size, and surface finish. Various machining processes include turning, milling, drilling, grinding, and others. Machine tools are used to securely hold the workpiece and cutting tool and provide controlled motion and power for material removal during machining operations.
1. Grinding is a finishing operation that involves slowly wearing away material using an abrasive that is harder than the material being ground. Heat generated during grinding can damage the grinding wheel.
2. There are several types of grinding machines including surface grinders, cylindrical grinders, and universal tool and cutter grinders. Surface grinding is commonly used to grind flat surfaces while cylindrical grinding is used to grind external and internal diameters.
3. Grinding wheels come in different materials, shapes, grains, bonds, grades, and structures suited for different grinding applications and material removal needs. Proper wheel selection is important for achieving the desired surface finish.
This document discusses machine tools and machining processes. It covers topics such as cutting tools, tool selection factors, tool design and terminology, forces in metal cutting, tool life, cutting speeds and feeds, tool failure modes, machinability, cutting inserts, and cutting fluids. The document is presented by Vikrant Sharma of the Mechanical Engineering department and contains diagrams to illustrate machining concepts.
The document discusses the value of owning a tool sharpening system rather than sending tools out for sharpening. It provides 3 key benefits:
1) Sharpening tools on-site ensures they are sharpened correctly every time, extending tool life and improving product quality.
2) On-site sharpening allows tools to be sharpened as needed for convenience and to avoid downtime waiting for tools to be sharpened off-site.
3) Correct and frequent sharpening can more than double a tool's life, significantly lowering the cost per hole.
This document discusses the geometry of plain milling cutters and twist drills. It describes the key features of milling cutters such as radial rake angle, radial relief angle, land, and lip angle. It also explains different types of milling operations including up milling, down milling, string milling, and gang milling. For twist drills, it outlines the drill point, twist drill nomenclature, and recommended drill geometries for different materials. Equations are provided for estimating drilling forces based on drill diameter and feed rate.
Broaching is a machining process that uses a broach tool to remove material from a workpiece. The broach tool has a series of cutting teeth arranged in a row with each tooth slightly higher than the previous one. The broach is moved linearly through the workpiece, with each successive tooth removing more material. Broaching can produce finished surfaces and tight tolerances with a single pass of the broach tool. It is well-suited for mass production applications due to its high material removal rate and long tool life.
The document discusses various specialized tools from Mate Precision Tooling for punching and forming sheet metal parts. It describes tools that eliminate burrs during punching, create bend lines for easy bending, provide fastening methods to replace welding, and reduce sheet marking on delicate materials. It also provides information on tools for precision hole punching, sequential numbering, and tool maintenance.
The document provides information on Ultra Tooling lines including specifications for different station sizes and their features. Key details include lubricated guides to protect turrets from wear, quick tool adjustment without disassembly, compatibility with other brands, and strippers relieved for longer grind life. Larger C-D-E stations also offer quick length adjustment, while fully guided tooling provides rigidity and accuracy for small holes and thick material.
This document provides an introduction to manufacturing processes and machine tools. It defines key terms in manufacturing like speed, feed, depth of cut, and metal removal rate. It describes orthogonal and oblique cutting and different types of chips that can be produced. Factors that influence each chip type are outlined. Common tool angles used in machining are defined including back rake angle, side rake angle, end relief angle, and side relief angle. Key aspects of manufacturing like interchangeability, mass production, and higher living standards are noted.
Gear finishing processes are necessary to produce accurate, smooth gear teeth after initial formation. The main gear finishing processes are gear shaving, burnishing, grinding, lapping, and honing. Gear shaving involves running a gear against a cutter to scrape off irregularities. Gear burnishing plastically moves excess material during rolling. Gear grinding is the most accurate but also the most expensive method. Lapping and honing use abrasives to remove burrs and irregularities from heat treated gears in a faster process than other methods.
The document contains multiple choice questions about rules of the road, traffic signs, and safe driving practices. It covers topics like right of way, stopping at intersections, traffic light behaviors, speed limits, parking rules, and hazard warnings. The questions test knowledge of when to yield, proper vehicle positioning, legal maneuvers, and safety procedures in various driving scenarios involving other vehicles, pedestrians, and infrastructure like traffic lights and signs.
Trying to keep up with your competitors is hard enough. Trying keep up with your customers is even harder, and it’s going to become even harder in the coming years. If you could look into a crystal ball and know how your customers will buy in the future, you will come out a champion in your customers eyes. Are you willing to change what you’re doing today to succeed tomorrow? Learn what you need to know. I’ll bring the ball.
Search engines work by searching their databases for web pages, images, and other files that match the search terms provided by users. They use complex processes and methodologies to retrieve and rank results. The main search engines are Google, Bing, Yahoo, and Baidu, but there are over 30 search engines total that users can employ, with different search engines sometimes returning varying results.
The document describes the process of creating a movie poster for an ancillary task over several days in February. It details researching poster conventions, taking and editing a main photo to look scarier, adding effects in Photoshop like removing eyes and adding a bloody mouth and scar. Background images were also added and the poster was finalized with a font, character names, and critic ratings.
The document discusses the need for health system transformation in Ontario. It notes that over 50% of adults and 20% of youth are overweight, contributing to increased rates of diabetes and costs. It also discusses how people are making avoidable emergency department visits and being readmitted to hospitals shortly after discharge because they are not receiving proper follow-up care. The aging population is increasing health costs substantially. The document outlines plans to shift more procedures out of hospitals and into community clinics to improve health outcomes and reduce costs. TSH will re-evaluate its programs and services as part of this transformation while continuing to engage community partners.
The document is a user manual for Fluke Ti10, Ti25, TiR, and TiR1 Thermal Imagers. It provides instructions on using the imagers, including [1] charging the battery, [2] turning the imager on and off, [3] using the menu system to adjust settings and view stored images, and [4] capturing, saving, and adjusting thermal images. The manual also outlines safety information, unpacking instructions, and specifications for the imagers.
This document discusses techniques for unit testing code with external dependencies, including dependency injection, isolation frameworks, dummy classes, and mocking. It provides examples of using a dummy class to break the dependency on a real class, and using mocking to stub out method calls on dependencies to return fixed values. The key techniques are to identify dependencies, break dependencies through injection or isolation, and use mocking to isolate the code under test from uncontrollable dependencies.
The document is a quarterly balanced scorecard report for The Scarborough Hospital that evaluates performance on key strategic priorities and indicators for Q3 2010/11. It shows that while some targets were met or exceeded, such as the percentage of defined model of care positions transitioned and accountability agreement indicators achieved, other metrics like patient satisfaction scores, hand hygiene compliance rates, and project milestone completion fell below targets for the reporting period. The report identifies indicators as low, medium, or high risk depending on whether targets were missed without improvement from the previous period. Overall, the scorecard evaluates The Scarborough Hospital's progress on strategic goals related to patient experience, service excellence, employee engagement, clinical coordination, and organizational performance.
This document provides a summary of a partner update meeting held by the NewcastleGateshead Initiative. It introduces new leadership including Paul Callaghan as the new chair. It outlines the agenda which includes updates on inward investment, the Rugby World Cup 2015, research and intelligence, and networking. Specific areas of focus are noted including growing tourism, developing the city brand, and upcoming festivals and events in the region. Performance metrics on tourism in 2013 are also reviewed showing growth in visits, expenditure, and overnight stays.
The magazine front cover targets young girls, as shown by its bright pink colors, glittery masthead, and pictures of male celebrities asking "Who's the Fittest?". It advertises the latest fashion trends and has a low price of £2.99, suggesting it aims for a young female audience. Feminine fonts and pink/purple color scheme further reflect the intended audience.
The magazine front targets men in their mid-20s and older with articles about bands like The Stone Roses and The Strokes. A red, gold, and white color scheme along with block lettering communicate a masculine style.
The magazine aims for trend-conscious youth ages 15-25, with a sophisticated red
Graeme Mason, Planning and Corporate Affairs Director at Newcastle International Airport, gave a briefing to business leaders on April 9, 2014. He discussed how the airport is a public-private partnership and its connectivity helps drive the regional economy, supporting thousands of jobs and billions in revenue. He also covered the airport's plans to improve customer experience and facilities while supporting additional UK runway capacity and lower aviation taxes.
El documento presenta las diferentes profesiones existentes organizadas en categorías como policía, futbolista, panadero, bailarina, docente, cartero, obrero, administrador, médico, carpintero, músico, escritor, ebanista, torero, enfermera y fotógrafo. El lector puede seleccionar cada profesión para obtener más información sobre sus elementos y características.
Machining is an essential process for finishing workpieces to desired dimensions and surface finish. A lathe allows for gradually removing excess material from a workpiece through cutting tools. Common lathe operations include turning, grooving, chamfering, parting, facing, and knurling. Taper turning can be done through methods like using a form tool, swiveling the compound rest, or a taper attachment. Thread cutting follows a helical path and involves engaging a half-nut to advance the tool.
Machining is an essential process for finishing workpieces to desired dimensions and surface finish. A lathe allows precise machining of cylindrical workpieces through various operations like turning, grooving, chamfering, parting, and facing. Key parts of a lathe include the headstock, which holds the workpiece, and the carriage, which supports the cutting tool. Common lathe accessories include centers, chucks, and rests, which provide workpiece support during machining operations.
This document provides instructions for making a single piece pattern mould. It lists the required materials, tools, and steps to complete the process. The key steps are:
1. Preparing moulding sand and placing it in the drag flask.
2. Ramming the sand and creating a cavity for the pattern using a strike-off bar.
3. Adding the sprue and riser pins before placing the cope on top of the drag.
4. Repeating the ramming process for the cope. Then removing the sprue, riser, and pattern to create the mould cavity.
This document contains procedures for performing various machining operations on a lathe, including plain turning, step turning, taper turning, threading, and knurling. It also includes procedures for making a hexagonal block using a shaping machine and cutting a spur gear using a milling machine. The summaries are:
1. Procedures are provided for performing plain turning, step turning, taper turning, threading, and knurling operations on a lathe to manufacture various turned parts based on given sketches and specifications.
2. The document outlines the process for making a hexagonal block from a round stock using a shaping machine, including marking, securing the workpiece, and performing the shaping cuts.
3. Steps are
Centre lathe, constructional features, various operations and specifications, taper turning methods, thread cutting methods, special attachments, machining time and power estimation. Capstan and turret lathes – Automatic lathe: single spindle, swiss type, screw type, multi spindle - Turret Indexing mechanism - Bar feed mechanism
Centre lathe, constructional features, specification, operations – taper turning methods, thread cutting methods, special attachments, machining time and power estimation. Capstan and turret lathes- tool layout – automatic lathes: semi automatic – single spindle : Swiss type, automatic screw type – multi spindle:
Manufacturimg of comressor blade presentation 4 - copyanup sharma
The document discusses the manufacturing process of compressor blades. Compressor blades are used in aircraft propulsion systems and power stations. The process begins with selecting stainless steel as the raw material. The steel is cut to size and then milled and surface ground to shape. CNC machining is used to further refine the shape. Quality control checks the dimensions before polishing and packing. Compressor blades extract energy from high pressure gas and must withstand high stresses and loads during operation in propulsion and power generation systems.
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.
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 discusses drilling machines and drilling operations. It describes different types of drilling machines including bench drilling machines, radial drilling machines, and upright drilling machines. It also covers drilling tools and operations such as reaming, boring, counterboring, countersinking, spot facing and tapping. Safety precautions for operating drilling machines and definitions of cutting speed, feed rate, and depth of cut are provided.
The document discusses drilling operations and drilling machines. It describes how drilling is performed using a rotating cutter called a drill. Drilling machines hold the workpiece stationary and rotate the drill to make a hole. Common types of drilling machines include portable, sensitive, radial, upright, gang, and multi-spindle machines. Drilling operations can include center hole drilling, deep hole drilling, thin material drilling, and pilot hole drilling. Safety precautions are important when using drilling machines.
This document provides information on metal cutting processes and machining technology. It discusses:
- The purpose, principles, and definition of machining as a process to produce parts to desired dimensions and surface finish through chip removal.
- Classification of metal cutting processes as orthogonal or oblique cutting. It also discusses cutting tool angles like back rake angle and relief angles.
- Factors that affect cutting forces like rake angle, feed rate, and depth of cut.
- Tool designation systems like ASA and common tool materials like high-speed steel and cemented carbide.
- The mechanism of chip formation and different chip types like continuous, discontinuous, and chips with built-up edge
internship report on working & types of drilling machineprabhatkumarsamal
The document discusses different types of drilling machines and their uses. It describes portable drilling machines, bench drilling machines, upright drilling machines, and radial drilling machines. It provides details on the working principles, parts, specifications, operations, and applications of drilling machines. Drilling machines are used to drill holes in workpieces and can perform operations like drilling, boring, reaming, counterboring, countersinking, spot facing and tapping.
This document discusses the vertical milling machine. It begins by listing the objectives of describing the main parts of a ram-type vertical milling machine and explaining how to select cutting speeds, feeds, and depth of cut. It then explains the parts of a ram-type vertical milling machine and how to align the vertical head and vise. The document provides information on various milling operations and cutter types including end mills. It concludes by outlining the procedure for accurately machining a block square and parallel and drilling holes to location using a vertical milling machine.
Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip, cutting
tools– nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials, tool wear,
tool life, surface finish, cutting fluids and Machinability
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.
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.
Top mailing list providers in the USA.pptxJeremyPeirce1
Discover the top mailing list providers in the USA, offering targeted lists, segmentation, and analytics to optimize your marketing campaigns and drive engagement.
Navigating the world of forex trading can be challenging, especially for beginners. To help you make an informed decision, we have comprehensively compared the best forex brokers in India for 2024. This article, reviewed by Top Forex Brokers Review, will cover featured award winners, the best forex brokers, featured offers, the best copy trading platforms, the best forex brokers for beginners, the best MetaTrader brokers, and recently updated reviews. We will focus on FP Markets, Black Bull, EightCap, IC Markets, and Octa.
How MJ Global Leads the Packaging Industry.pdfMJ Global
MJ Global's success in staying ahead of the curve in the packaging industry is a testament to its dedication to innovation, sustainability, and customer-centricity. By embracing technological advancements, leading in eco-friendly solutions, collaborating with industry leaders, and adapting to evolving consumer preferences, MJ Global continues to set new standards in the packaging sector.
Recruiting in the Digital Age: A Social Media MasterclassLuanWise
In this masterclass, presented at the Global HR Summit on 5th June 2024, Luan Wise explored the essential features of social media platforms that support talent acquisition, including LinkedIn, Facebook, Instagram, X (formerly Twitter) and TikTok.
Taurus Zodiac Sign: Unveiling the Traits, Dates, and Horoscope Insights of th...my Pandit
Dive into the steadfast world of the Taurus Zodiac Sign. Discover the grounded, stable, and logical nature of Taurus individuals, and explore their key personality traits, important dates, and horoscope insights. Learn how the determination and patience of the Taurus sign make them the rock-steady achievers and anchors of the zodiac.
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Building Your Employer Brand with Social MediaLuanWise
Presented at The Global HR Summit, 6th June 2024
In this keynote, Luan Wise will provide invaluable insights to elevate your employer brand on social media platforms including LinkedIn, Facebook, Instagram, X (formerly Twitter) and TikTok. You'll learn how compelling content can authentically showcase your company culture, values, and employee experiences to support your talent acquisition and retention objectives. Additionally, you'll understand the power of employee advocacy to amplify reach and engagement – helping to position your organization as an employer of choice in today's competitive talent landscape.
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1. INTERNSHIP AT LMTG
Presented by:
Ashish Sethi
Indian Institute of Technology
(Banaras Hindu University),
Varanasi
(May-June 2013)
2. Steam Turbine
• Thermal energy from pressurized steam does mechanical
work on a rotating output shaft.
• Drives an electrical generator which produces power.
• Increase in thermodynamic efficiency by using multiple stages
in the expansion of steam.
3. Projects: Past and Present
Projects Undertaken
By LMTG
Power
Rating
APPDCL-1
800 MW
APPDCL-2
800 MW
JP-1
660 MW
MH-1
660 MW
Rajpura-1
700 MW
JP-2
660 MW
MH-2
660 MW
Rajpura-2
700 MW
MH-3
660 MW
USA
660 MW
Rabigh IWSPP
120 MW
RRVUNL-1
660 MW
RRVUNL-2
660 MW
• Supercritical range: 5001000 MW
• Refers to main steam
operating conditions
being above critical
pressure of water (221.5
bar)
• At a pressure of 242 bar,
main steam and reheat
steam temperatures are
565ºC and 593ºC
respectively.
6. Machine Shop T3
• Planomillers: Gen 6 and ST 13
Planing
Milling
Planomilling
Axes are X, Y, Z, W and C.
Bed moves, columns are stationary.
Attachments include right angle, universal, extension and surfacing.
• Horizontal Boring Machines (HBMs): UDM 1, UDM 2, UDM 5, ST 15
Operations such as drilling, boring, facing, back spot facing, turning,
etc. can be performed.
Possible axes include X, Y, Z, W, V, B.
Attachments include right angle, universal, facing and profiling,
offset.
7. Machine Shop T3 (contd.)
• Vertical Turning Lathes (VTLs): Gen 7 and ST 9
Facing, ID turning, OD turning, chamfering etc. performed using a
single point tool.
Axes are X, Z and W.
• Electric Discharge Machine:
Used for machining thin slits in blades and grooves for caulking.
Used for machining hard materials like HSS.
Copper electrode is used.
Job is completely submerged in dielectric oil, which acts as a
capacitive medium.
When voltage is sufficiently high, electric arc is generated which
jumps across dielectric medium and erodes metal.
8. Machining Tools and Operations
Operation
Purpose
Tool
Facing
Generation of a flat
surface
Face mill, Shoulder
mill
Turning
Generation of a
cylindrical surface
Single point
cutting tool
Drilling
Making holes
Drills
Boring
Enlarging holes, ID
machining
Boring tool
Tapping
Making internal
threads
Taps
Reaming
Finishing of holes
Reamer
Chamfering
Generation of
Chamfering tool
angled surfaces to
remove sharp edges
Slot Milling
Machining of slots
End mills
9. Cutting Parameters
•
where,
V is the cutting velocity
N is the required rpm
D, for turning – diameter of job
for facing – diameter of cutter
for drilling – diameter of drill bit
For tools with multiple inserts,
where,
Feed rate is in mm/min
fz is the feed/revolution/tooth
10. PROJECT I: TOOL DEVELOPMENT
Objective: Developing tool for back spot facing of
diameter 46 mm for “D4” detail in ash lock
11. Challenging Aspects of Ash
Lock Machining
• Ash lock has two openings (A1 and A2). The machine ram
cannot enter A2.
• Large spindle overhang makes it difficult to maintain
concentricity of various IDs.
• Vibrations arise as machining operations take place at very
large distances from the ram.
• Not possible to mount the ash lock at the centre of the table.
On rotating the rotary table, the centre of various IDs gets
displaced.
12. Common Back Spot Facing Tools
• Centric Tool:
Rotates about its centre.
Has a removable head.
Suitable in situations where back spot diameter is much more than passing
diameter.
• Eccentric Tool:
Insert is offset from the central axis of tool.
Efficient as no manual intervention is required.
Suitable when difference between spot face diameter and passing diameter
is less.
• Tool with HSS Bit:
Boring bar with slot at its end to hold the HSS bit.
Similar to centric tool, as bar is first passed through the bore and then the bit
is inserted.
• Butterfly Tool:
Has a foldable wing.
No manual interruption.
14. Problems Faced and Possible Solutions
• Unavailability of tool of sufficient length and required passing
diameter. Length of the tool should be more than
(1350 + 50 + 50 – 1000) = 450 mm
Maximum spindle travel
Clearance between ram and A2
Minimum thickness of the flange
Distance between A2 and D4
• Vibrations in the tool because:
Spindle would be at close to its maximum extension.
The length of the tool is large.
The diameter of the bar is small.
15. Problems Faced and Possible Solutions (contd.)
Suggested solution:
• The bar of the tool to be in the form of a stepped shaft.
• The bar of the centric tool is internally threaded at its end, for
attaching the removable head.
• A short tool of this type with a large passing diameter could be
attached to another with a passing diameter less than 27 mm,
creating a stepped bar.
• External threads would have to be machined on the tool with
smaller diameter, to mesh with the internal threads present in
the first tool.
16. Problems Faced and Possible Solutions (contd.)
• Problem of chip evacuation because of large depth of back
spot.
Suggested solution:
Using a tool with HSS bit. Proper angles can be provided to guide
chip flow.
Machining of a helical path in the removable head of centric tool.
• If we use a tool with HSS bit, setting the bit to make the
required back spot diameter is time consuming.
Suggested solution:
Step to be created on the bit at a pre-determined distance from
the cutting tip.
Stepped part will not enter the slot.
17. Problems Faced and Possible Solutions (contd.)
Cutting
Force
• Large spindle overhang results in drooping
of machine spindle.
• Cutting forces on the bit tend to reduce the
diameter of the back spot.
• Difficult to accurately predict the diameter
formed for a particular length of tool bit
cutting edge.
Suggested solution:
Preparation of tool bit for a slightly larger
diameter.
Modification to length of cutting edge
depending on outcome of trials.
18. The Final Tool
• Boring bar of length 450 mm and passing
diameter 26 mm used.
• Longer adaptor not originally meant for
this boring bar used.
• Slot of 9.5 x 9.5 mm for housing HSS bit.
• Outer part of the bar is ground to
smaller diameter.
19. The HSS Bit
Diameter of the boring bar = 26 mm
Radial distance between the bore and the bar = 0.5 mm
Difference between spot face diameter and bore diameter = 19 mm
So, Radial distance between bore and OD of spot face = 9.5 mm
Allowance for cutting force problem = 0.5 mm
So, distance from step to tip of tool = 26 + 0.5 + 9.5 + 0.5 = 36.5 mm
• Three relief angles – rake angle, clearance angle, end cutting
edge angle
• Step was removed one side and pushed inwards.
20. Machining of HSS Bit
Step was created on VMC in T6
Required angles were given on Tool
and Cutter Grinder in T6
Required length (including the step)
was cut off from the bar on EDM in T3
Step was pushed inward on required
side on Tool and Cutter Grinder in T6
21. Trials Conducted
Distance
from step Spindle
to cutting extension
tip (mm)
(mm)
Diameter of back
spot formed
Remarks
0.7 mm material was subsequently
ground off from the end of the bit.
0.1 mm material was subsequently
ground off from the end of the bit.
Very long chips were formed and good
surface finish was obtained with
coolant.
Surface finish without coolant was not
very good.
Repeatability of the bit was confirmed.
Long chips and good surface finish was
obtained with a feed rate of 1 mm/min.
Increasing the feed rate to 1.5 and 2
mm/min degraded the surface finish.
Repeatability of the second bit was
confirmed.
36.9
500
48.4
36.2
500
46.8
36.1
500
46.4
36.1
1100
46.2
Bit II
36.1
36.2
1100
800
46.2
46.8
(for
clockwise
spindle
rotation)
36.2
800
46.8
Bit I
(for counter
clockwise
spindle
rotation)
23. Wiper Cutter
• Used for finishing of plane surfaces.
• Not a single point cutting tool. Whole
cutting edge ‘wipes’ off the high points.
• Can be done using a single insert, or
more than one.
• If more than one insert is used, one
forms the roughing edge and the other
forms the finishing edge.
• The finishing edge is placed 10-20
microns below the roughing edge.
• The finishing edge is radially inward in
comparison to roughing edge.
• Mitsubishi wiper cutter can hold 2
inserts, Dijet can hold 4.
Operation of wiper cutters with single insert on UDM 1 is
generating extensive back cut marks on the surface.
24. Trials Conducted
Machine
Make of
Cutter
Cutting
Parameters
Back Cut
UDM 1
Mitsubishi
100 rpm
Clearly visible
back cut
A face out of 0.04 mm was
observed on the cutter.
Less back cut
A face out of 0.16 mm was
observed on the cutter.
Less back cut
Cutter was removed and set
again. A face out of 0.12 mm
was observed on the cutter.
Possible reasons for this face
out were discussed:
125 mm/min
feed
UDM 1
Dijet
100 rpm
125 mm/min
feed
UDM 1
Dijet
100 rpm
125 mm/min
feed
Remarks
•
Face out in the cutter itself
•
Face out in the cutter due
to run out of the spindle
25. Machine
Gen 6
Gen 6
Make of
Cutter
Mitsubishi
Cutting
Parameters
220 rpm
Mitsubishi
300 mm/min
feed
220 rpm
300 mm/min
feed
Gen 6
Mitsubishi
220 rpm
300 mm/min
feed
Gen 6
Mitsubishi
250 rpm
300 mm/min
feed
Back Cut
Remarks
Visible back
cut
Face out on the cutter observed.
Visible back
cut
A different Mitsubishi cutter was
used. Face out of 0.08 mm
observed. Insert was kept on the
lower end of the cutter.
Replaced insert. Other conditions
same as before.
Visible back
cut
Slightly less
back cut
Concluded that problem not with
the cutter.
Insert position changed from lower
end to upper end. Possible reason
for back cut could be spindle run
out.
•
Spindle run out of UDM 1 is 0.5
mm.
•
ST 13
Mitsubishi
300 rpm
350 mm/min
feed
No back cut
Spindle run out of Gen 6 is 0.25
mm.
No spindle run out on ST 13.
Reason for back cut found to be
spindle run out.
26. Suggestions for Improvement in Shop
Reasons for formation of such an irregularly shaped pit
were discussed:
• If the table of EDM is not locked, it can deviate
slightly if a jerk is encountered for any reason.
• There may be an error in initial setting of the
electrode by the operator.
Suggestion:
Job could be covered with an insulating material in
areas where no cutting is to take place.
27. Suggestions for Improvement
in Shop (contd.)
• Using ATC (Automatic Tool Change) in Gen 6 Planomiller
machine.
Offset of tools needed for the next planned job can be taken and
their values stored in the ATC beforehand.
Tools can be stored in the ATC.
Time required for completion of job can be reduced.
• Leakage from the roof over Machine Shop T6.
Machines such as Tool and Cutter Grinder can not be used at
times.
Possibility of damage to the machine.