Industrial Machining Processes and Tooling Techniques

Shaping and Slotting Processes

Shaping: Used for small surfaces and rough work. It is not a precision machine; the tool used is an ordinary or special file.

Slotting Machines: These feature a reciprocating vertical tool-slide. It is essentially a vertical shaper. Its primary functions include internal and external grooving.

Broaching and Gear Manufacturing

Broaching: This process uses a multiple-tooth brush tool that removes material through a rational escalation as the cutting teeth move.

Gear Cutting Systems

Gear production is achieved by shape tools (blades), playback (templates), or generation methods:

• Maag System: A generation system using a rack (zip) method.
• Sunderland System: Utilizes vertical and transverse rack (cremayera) movement.
• Fellows System: Employs a pinion tool to avoid useful downtime.
• Bilgram System: The tool performs a brushing motion while the workpiece performs alternative movements to generate the tooth profile.

Drilling Operations and Equipment

Drilling creates interior surfaces of revolution. The primary elements of a drill include the bed (base and column), support (to fix the workpiece), a mechanical speed device, and a chuck for the subjection of the drill bit (broca).

Types of Drilling Machines

• Desktop: A small-diameter drill resting on a bench.
• Column: Features a cylindrical column.
• Radial: Designed for drilling holes in large pieces.
• Multiple: Machines equipped with specific tooling and provisions.
• Revolver (Turret): Similar to a wheel, it allows for tool changes to perform multiple operations without moving the workpiece.
• Horizontal Boring Drill-Mill: Incorporates vertical milling features in the head (cabezal) and a prismatic drill press.
• Portable: Used for pieces that cannot be disassembled. This includes portable electric workshop machines and portable pneumatic small-range machines powered by compressed air.

Boring and Precision Machining

Boring machines combine the characteristics of the drill, lathe, and milling machine (fresadora), offering a high degree of accuracy.

Boring Machine Categories

• Horizontal: Small column series.
• Mobile: Used for medium and large-scale pieces.
• Horizontal Precision: Small-sized machines incorporating technical advances for small workpieces.
• Specialized Workshops: Used where the main activity is high-precision grinding (rectificado).
• Vertical: Specialized for specific machining sectors.
• Portable: Used for low-precision operations where the piece is not dismounted.

Grinding and Finishing

Grinding is used to rectify actions requiring exacting tolerances.

• Outdoor Cylinder: For grinding exterior surfaces of revolution.
• Universal: Handles internal cylindrical, centerless, and exterior grinding.
• Cylinder: Allows the machining of a variety of materials.
• Specialized: Includes thread and sprocket grinding.

Gear Geometry and Calculations

Key parameters for gear measurement include:

• Q: Step
• M: Module
• Dp: Primitive Diameter
• De: Outer Diameter
• Di: Interior Diameter
• c: Space between teeth
• e: Thickness of the tooth
• h: Total tooth height

Dividing Head Standards

Indexing Ranges: 1: 12, 13 | 2: 14, 16 | 3: 17, 20 | 4: 21, 25 | 5: 26, 34 | 6: 35, 54 | 7: 55, 134 | 8: 135.

Divided Plate Hole Circles: 15, 16, 17, 18, 19, 20, 21, 23, 27, 29, 31, 33, 37, 39, 41, 47, 49.