Multiple head type horizontal boring machine

Multiple head type horizontal boring machine resembles a double housing planer or a Plano-miller.

The table is supported on a long bed on which it reciprocates.

In there two vertical columns at two sides of the bed, nearly at the middle of the bed.

The two columns are bridged by a Crossrail.

This machine has two, three or four headstock.

This type of machine may be used as both a horizontal and vertical boring machine.

The machining operations can be performed simultaneously at different work surfaces.

Planer type horizontal boring machine

Planer type horizontal boring machine the table type but table slide directly on the bed instead of on a saddle and reciprocates at right angles to the spindle similar to a planer.

The end supporting column may be adjusted towards or away from the table for accommodating different widths of work.

This types of boring machine suitable for supporting a long work.

Floor type horizontal boring machine

The floor type horizontal boring machine having no table uses a stationary floor-plate on which T-slots are provided to hold the work.

The headstock supporting column and the end supporting column are mounted on the runways which are placed at right angles to the spindle axis.

Any crosswise adjustment or cross-feed movement is provided by the spindle itself and not by the work.

Table type horizontal boring machine

This is the most common type of all horizontal boring machines because the work is mounted on the table which is adjustable and feed is given by hand or power lengthwise or crosswise with respect to the bed of the machine.

The head stock may be adjusted vertically on the column and the spindle has a horizontal feed motion.

The machine consists of bed, head stock supporting column, end supporting column, head stock, saddle and table and boring bar.

This type of machine is suitable for general purpose work where other operations in addition to boring are required to be performed.

 

Horizontal boring machine

In a horizontal boring machine, the work is supported on a table which is stationary and the tool revolves in a horizontal axis.
A horizontal boring machine can perform boring, reaming, turning, threading, facing, milling, grooving and many other operations with suitable tools.
Different types of horizontal boring machines have been designed to suit different purposes.

Parts of Horizontal boring machine :

Bed :
The bed is fitted on the floor of the shop and has a box-like casting.
The bed supports the columns, tables and other parts of the machine.

Headstock supporting column :
The column provides supports to the headstock and guides it up and down accurately by the guideways provided on the face of the column.

End supporting column :
The end supporting column situated at the other end of the bed houses the bearing block for supporting a long boring bar.

Headstock :
The headstock mounted on the column supports, drives, and feed the tool.
The headstock may be moved up and down on the column for setting the tool for different heights of the work.

Saddle and table :
The table supports the work and provided with T-slots for clamping the work or for holding devices.
The saddle allows the work to be moved longitudinally on the bed.
The table may be moved crosswise on the saddle.

Boring bars :
The boring bar supports the cutter for boring operations on jobs having large bore diameters. 

Size of horizontal boring machine :

The size of that is specified by the diameter of its spindle in mm.
Spindle diameter varies from 75 to 355 mm.
Other important dimensions such as spindle motor horsepower, column heights, size of the table or size of the floor plate, spindle speed, feed and length of feeds, floor space required, the weight of the machine should be stated.

Boring machine mechanism :

The boring machine has different controls for movements of the different parts of the machine. A table type machine has movements mentioned below :

1. The headstock and the end supporting block may be moved up and down.
2. The spindle may be rotated with different speeds.
3. The spindle may be moved in or out by hand or power for feeding.
4. The saddle or table may be moved by hand pr power.
5. The columns may be moved by hand or power.

As all the controls are housed in a particular position of the machine the operator may give closed attention on the work while controlling the machine.

Work holding device for horizontal boring machine :

• Conventional work holding devices comprise of T-bolts and clamps, angle plates, step blocks etc.
• Special jigs are used in mass production work.

Horizontal boring machine operations :

In boring machine used for milling operation and the milling cutter may be fitted to the spindle. 

Facing cutter is used for machining flat vertical surfaces for face milling operation.

End mills are used to produce grooves and slots.

Other operations such as following below :

• Drilling 
• Reaming
• Counter boring
• Tapping
• Spot facing

Boring tool mountings for horizontal boring machine :

The different equipment for mounting cutters in horizontal boring machine are :

• Boring bar
• Boring head or cutter head
• Facing head

There are different boring tool used in boring bars are of different shapes and sizes for different types of operation.

Types of Boring Machine

The boring machine may be classified into four types. we can check it our below :

1. Horizontal boring machine 

• Table type
• Floor-type
• Planer type
• Multiple head type

2. Vertical boring machine

• Vertical turret lathe
• Standard vertical boring machine

3. Precision boring machine

4. Jig boring machine

• Vertical milling machine type
• Planer type

Boring machine introduction

The first boring machine tool was invented by John Wilkinson in 1775.

The boring machine is one of the most versatile machine tools used to bore holes in large and heavy parts such as engine frames, steam engine cylinders, machine housings etc which are practically impossible to hold and rotate in an engine lathe or a drilling machine.

By the use of the boring machine the range of speeds and feeds provided to various traversing components allow drilling, milling and facing operation with equal facility.

By the fitting of simple attachments, the use of the machine can be extended to include screw cutting, turning, planetary grinding or gear cutting.

What is polorization

Light is electromagnetic in nature. The light is transverse in nature. 

The vibration of the electric field and magnetic field are perpendicular to each other and they are also perpendicular to the direction of propagation of light.

The light in which electric field has the freedom to vibrate in all direction which is perpendicular to the propagation of light is known as unpolarised light.

Unpolorised means it has the freedom and it does not have any restrictions.

The light in which the electric field can vibrate only in one direction in another word there is restriction of vibration of an electric field such light is known as polarised light.
The phenomenon in which unpolarised light is converted into polarized light is known as polarization.

There are different method unpolarised light converted into polarised light :

• Using polarising materials.
• By reflection of light.
• By scattering of light. 
• By doable refraction of light.

What is diffraction

Diffraction :

Diffraction is the bonding of light around an edge of the obstacle such as the edge of the slit we can diffraction of light through the crack between two fingers at the distant source.

Diffraction of any kind of waves depends upon the wavelength and the size of the obstacle. 

For significant diffraction, the ratio of λ/d should be 1. 

There are two types of diffraction :

1. Fresnel diffraction
2. Fraunhofer diffraction

Optical wavelength

What is Optical Wavelength?

When there is a medium which has refractive index µ we have to use optical wavelength λ_µ.

The relation between optical wavelength and geometrical wavelength is given by 

λ_µ = λ / µ 

λ_µ = Optical wavelength

λ = Geometrical wavelength

µ = Refractive index of medium

Electromagnetic spectrum definition

The electromagnetic waves can be characterised by the parameters like wavelength, frequency, phase and state of polarization.

Wavelength :
The distance between two-crust or two throughs is known as wavelength. 
Wavelength denoted by λ.

Frequency : 
Frequency is the quantity that represents a number of oscillations that particle carries out in unit time.
Frequency denoted by ν.

Wavelength (λ) = c / Frequency (ν)

Where c = velocity of electromagnetic wave

Wavelength × Frequency = Velocity of the wave

The wavelength of the electromagnetic wave varies from 10^-12 meters to 10⁴ meters.

Phase :

The electromagnetic wave can be represented by a sine or cosine function.

E = E₀ Sin (wt + Φ )

Where E = Position of a wave at time t

E₀ = Maximum displacement of Amplitude

(wt + Φ ) = Phase of the wave

Φ = Initial phase or phase difference

Phase difference :

The difference between the phase if the two waves or phase of two position of a single wave is known as phase difference.

Wave optics Introduction

In a one-word optics can define that science of light.
Light has dual nature sometimes it behaves like a wave and sometimes it behaves like a particle.
In other word deal with optics is the branch of physics dealing with the study of optical phenomena.
The phenomena like reflection and refraction are explained by corpuscular theory. but the phenomena like interference, diffraction and polarisation can not explain the particle nature of light.
In optics, we consider the light as a wave.

We have also seen terms in optics are following below :

• Light 
• Electromagnetic Spectrum
• Wavelength
• Frequency
• Phase
• Phase difference
• Coherence
• Interference 

Coherence definition in physics

Coherence :

If the phase difference between two waves or phase difference between two positions of the single wave remains constant, such waves are known as coherent waves and phenomenon is called coherence.

If the phase difference between two sources changes then sources are known as incoherent. Sunlight, incandescent lamp. tube light etc is an example of the incoherent source.

There are two methods by which we can produce a coherent source :

• Division of wavefront
• Division of amplitude

Types of coherence :

• Temporal coherence
• Spatial coherence

Measurement of coherence :

The coherence of any source can be measured by the visibility of contrast of the fringe system produced by the source. It is given by 

V = I_max - I_min / I_max + I_min 

Where I_max = Maximum Intensity of bright fringe

I_min = Minimum Intensity of dark fringe

Ruby Definition

Ruby :

Ruby is synthetic aluminium oxide ( Al₂O₃ ) with 0.05 weight of chromium oxide ( Cr₂O₃ ) added to it.

It is the chromium that gives the ruby its characteristics red colour.

Full form of LASER

What is the full form of LASER?

Answer :

• Light Amplification of Stimulated Emission of Radiation

What does LASER mean?

The laser is a device that can amplify light and produce a highly directional, intense, monochromatic, and coherent beam.


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Application of laser

The main characteristics of laser radiation are following below.

• Coherence
• Very narrow bandwidth
• High directionality
• Extreme brightness

With the above characteristics, the lasers have a wide range of application in different disciplines such as physics, chemistry, medicine, engineering etc. 

Application of laser : 

• The laser is a coherent source, measurement of distances based on interferromagnetic techniques is made much simpler.
• The large distance can be also measured by laser. 
• The time taken for a laser pulse to travel from the laser to the target and back again is measured. Using such a method, the distance between earth and moon have been determined to an accuracy of +-0.15 m.
• The laser beam is highly intense hence it can be used in application like Laser beam welding, Laser cutting of material.
• The laser also is suitable for machining and drilling holes.
• The most successful therapeutic application of the laser has been in eye-surgery for the detached retina.
• Lasers also can serve as war-weapon for military purpose.
• The laser can be used for investigating the structure of molecules.
• Lasers also being employed for separating the various isotopes of an element.
• The narrowness of bandwidth of lasers, the strongest capacity for information in computers is improved.
• Due to a narrow bandwidth, lasers are used in microwave communication. so in the field of communications, laser offers unusual advantages.
• Lasers have also been used for the treatment of dental decay, the destruction of malignant tumours and the treatment of skin diseases.
• Genetic research using laser is quite popular.
• The IBM corporation is trying to transmit an entire memory bank from one computer to another by using a laser beam.

Disadvantages of manual process planning

Manual process planning (MPP) has many disadvantages. In this article, you can check it out some information on the disadvantages of manual process planning to know more about it.

Disadvantages of manual process planning :

• MPP is largely subjective.
• Incorporation of process changes is extremely difficult.
• The quality of the process plan is directly related to the experience and skill of the planner.
• It is difficult to check if the process plan is consistent and optimized.
• It is tiresome to search manually the process plans of similar parts form a large amount of documentation of the company.
• Technological changes of batch sized require the change in process plan.
• MPPs are slow to respond.

What is rigid body

What is Rigid body?

Answer :

A body is said to be rigid if, under the action of forces, it does not suffer any distortion.

Another way to said that the distance between any two points on the body remains constant.

Electron beam machining

Electron beam machining is processed by a high-velocity focused stream of electrons which heats, melts and vaporizes the work material at the point of bombardment thus metal will be removed. 

The production of free electrons is obtained from thermo-electronic cathodes wherein metal are heated to the temperature at which the electrons have sufficient speed for escape and make the space around the cathode. Thus the electrons accelerate and are carried by an electric field and by controlled magnetic fields are using for focusing and concentration of that electric field. The kinetic energy of a beam of free electrons is transformed into heat energy thus the interaction of the electrons with the workpiece material. Therefore EBM is also called thermo-electric process.

Operation principle of electron beam machining :

A beam of electrons is emitted from the electron gun which is basically a triode consisting of

• A cathode which is a hot tungsten filament ( 2500 degree C ) emitting high negative potential electrons.
• A grid cup, negatively based with respect to the filament.
• An anode which is heats at ground potential, and through which the high-velocity electrons pass.

A gun is supplied with electric current from a high voltage D.C source. The flow of electrons is controlled by the negative bias applied to the grid cup. The electrons passing through the anode are accelerated to two-third of the velocity of light by applying 50 to 150 kV at the anode and this speed id maintained till they strike the workpiece.
A magnetic deflection coil is used to make the electron beam circular and its a cross-sectional diameter is 0.01 to 0.02 mm and deflect it anywhere.
A microscope with a magnification of 40 on the workpiece enables the operator to accurately locate the beam impact and observe the machining operation.
As the beam impacts on the workpiece surface the kinetic energy of high-velocity electrons is converted into the thermal energy and it vaporized the material at the spot of its impact.

The application of the above process is also found in electron-beam drilling in which an organic or synthetic backing material is sandwiched on the other side of the component.

Accuracy :
Tolerance is about 10% of slot width or hole diameter.
Taper about 4 degrees included angle 
Depth to diameter ratio can reach 20:1 with multiple pulses.
Heat affected zone of up to 0.03 mm deep has been observed.

Application of EDM

The EDM provides economic advantages for making stamping tools, wire drawing and extrusion dies, header dies, intricate mould cavities.

It extremely used in aerospace industries, refractory metals, hard carbides and hardenable steels.

EDM application : 

• Drilling of micro-holes
• Thread cutting
• Helical profile milling
• Wire-cutting EDM
• Rotary forming
• Curved hole drilling
• Vacuum tubes