A Project report on

Manufacture of Components for General Purpose Machinery

Submitted in the partial fulfillment of the requirements for the award of degree BACHELOR OF TECHNOLOGY IN Mechanical Engineering Submitted By Manchikanti Nikhilesh Ravirala Venkata Ramana Mood Vidish Naik 09D41A0305 09D41A0317 09D41A0350

Under the Guidance of

Mr.N.V.S.RAMCHANDRA RAO
Deputy Manager, Small parts, Hindustan Machine Tools-Praga Division

Department of Mechanical Engineering, SRI INDU COLLEGE OF ENGINEERING AND TECHNOLOGY (Affiliated to Jawaharlal Nehru Technological University, Hyderabad)

2012

SRI INDU COLLEGE OF ENGINEERING AND TECHNOLOGY

Department of Mechanical Engineering

CERTIFICATE

This is to certify that the project report titled Manufacture of components for General Purpose Machinery is being submitted by Manchikanti Nikhilesh, Ravirala Venkata Ramana, Mood Vidish Naik bearing Roll Nos. 09D41A0305, 09D41A0317, 09D41A0350 in IV B.Tech II semester Mechanical Engineering, is a record bonafide work carried out by them. The results embodied in this report have not been submitted to any other University for the award of any degree.

Internal Guide: M.Srinivas Rao External Guide: Mr.N.V.S.Ramchandra Rao << HOD>>

ACKNOWLEDGEMENT
The project entitled MANUFACTURE OF COMPONENTS FOR GENERAL PURPOSE MACHINERY is the sum of total efforts of our batch. It is our duty to bring forward each and every one who is directly or indirectly in relation with our project and without whom it would not have gained a structure. We express our grateful thanks to M.SRINIVAS RAO, HEAD OF DEPARTMENT (MECHANICAL ENGINEERING), SRI INDU COLLEGE OF ENGINEERING & TECHNOLOGY for their support in completing our project. We express our sincere gratitude to Sri N.V.S RAMACHANDRA RAO, Dy. Manager, small parts (production MT-2 shop) for spending his valuable time and suggestions, guidance made by him at various stages of this work done at HMT MACHINE TOOLS LTD, PRAGA DIVISION.

DECLARATION

We hereby declare that the whole work done in completing this project is our own effort and we have not copied it from anywhere. During our project, our project guide Mr. N.V.S.Ramachandra Rao garu guided us to complete our project taking his valuable time. We are very thankful to HMT MACHINE TOOLS LTD, PRAGA DIVISION for giving us opportunity to do our project in this esteemed organization.

PROJECT MEMBERS
Machikanti Nikhilesh Ravirala Venkata Ramana Mood Vidish Naik

COMPANY PROFILE
H.M.T Machine Tools PRAGA Division is one of the leading machine tool manufacturing units in India. Established in 1943, pragas products are well known in the field of machine tools. The company is organized in two divisions viz the machine tool and CNC division which pulsates with the activities of employees, turning out a wide range of products. The two divisions equipped with modern facilities for design, development and manufacture of machine tools, are manned by qualified personnel with proven record of technical knowledge and exquisite craftsmanship acquired over a period of years. MANUFACTURERS OF Surface Grinding Machines Cutter & Tool Grinding Machines. Thread Rolling Machines. Spline Rolling Machines. Pulley Forming Machines. Tube finishing machines. Milling Machines. Horizontal Machining Centres. CNC Lathe Machines. CNC Milling Machines. CNC Surface Grinding Machines. CNC Cutter & Tool Grinding Machines. Praga are also manufacturers of Customer Tooling for the above Machinery like: Jigs &fixtures. Mountings.

 Accessories. Tooling for the above mentioned cold forming processes.

Praga is collaborated with some of the world famous companies like Jones & Shipman of U.K., Gambin of France, Escoffier of France, George Fischer of Switzerland, Mitsubishi Heavy Industries Japan and Keiyo Seiki also of Japan. The collaborations have culminated in Praga producing Machine tools of the highest quality conforming to international standards. Praga has contributed to the development of the machine tool industry in the country and the creation of a vast band of skilled technicians. Thus Praga, today is a name of reckon with in the Machine Tool Industry. In compliances of the directives of the Govt. of India actions have been initiated for the merger of Praga tools limited with HMT limited. Bangalore obtaining of necessary approvals and sanctions of BIFR and Government of India with effect from (13-06-2008) and all formalities completed on (20-06-2009). Praga tools limited renamed as m/s HMT Machine Tools Limited-VI (Praga division-HYD) from this data all the guidelines and policies, rules and regulations and facilities are applicable to the Praga employees as per HMT Machine Tools Limited.

CONTENTS
Abstract List of Tables Symbols, Codes& Abbreviations 1. Introduction 1.1 Motivation 1.2 Objective of Project 1.3 Limitations of Project 2. CLASSIFICATION OF OPERATIONS 2.1 Milling 2.1.1 Classification of milling 2.1.2 Methods of milling 2.2 Turning 2.2.1 Adjustable cutting factors in turning 2.2.2 Lathe related operations 2.2.3 Cutting tools for lathes 2.2.4 Turning machines 2.3 Other 3. MILLING 3.1 Motor Flange 3.2 Steady Support 3.3 Bevel Gear Bracket 3.4 Rear Bearing Support 4. TURNING 4.1 Spindle Pulley 4.2 Front Spindle 4.3 Rear Spindle 4.4 Front Bearing Cover

5. MILLING, TURNING and OTHER 5.1 Coupling 5.2 Feed Crank Disc 5.3 Worm Wheel 5.4 Worm Shaft 6. HEAT TREATMENT 6.1 Annealing 6.2 Hardening and Tempering 6.3 Hardenability 6.4 Surface hardening 6.5 Carburizing 7. Quality Control Equipment and Inspection 8. CONCLUSION : First Paragraph Second Paragraph Project Conclusion Future enhancement

ABSTRACT
Manufacture of components for GPM (General Purpose Machinery) from raw material stage to finishing stage. The GPM relates various machines, components such as turning, milling / machining centers, grinding, gear cutting drilling, die casting & plastic injection moulding, special purpose machines, refurbishing and retrofitting, special application components / jigs / fixtures.

Tables: Drill sizes for tapped hole

Size M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 Pitch 0.5 0.7 0.8 1.0 1.3 1.5 1.8 2.0 2.0 2.5 2.5 2.5 3.0 Drills 2.5 3.3 4.2 5.0 6.8 8.5 10.2 12.0 14.0 15.5 17.5 19.5 21.0

Symbols, Codes and Abbreviations Diameter GPM General Purpose Machinery

GENERAL CODES OF A CNC MACHINE 0. G00 X---- Y---- Z--- RAPID POSITIONING TO THE SPECIFIED POINT 1. G01 X---- Y---- F--- LINEAR INTERPOLATION X= END POINT X - COORDINATE Y= END POINT Y-COORDINATE F= FEED IN MM/MIN FOR G94 = FEED IN MM/REV FOR G95 2. G02 X--- Y--- I--- J--- C.W. CIRCULAR INTERPOLATION X= END POINT X-COORDINATE Y= END POINT Y-COORDINATE I= (CENTER POINT START POINT) OF X

J= (CENTER POINT START POINT) OF Y 3. G03 X--- Y--- I--- J--- C.C.W. CIRCULAR INTERPOLATION X= END POINT X-COORDINATE Y= END POINT Y-COORDINATE I= (CENTER POINT START POINT) OF X J= (CENTER POINT START POINT) OF Y 3A. G02X----Y----R---G03 X----Y----R---G02 X----Y----CR=---G03 X----Y----CR=---4. G04 P---G04 F---or or DWELL FOR X or F SECS or milliSECS G04 X---P R = CR = CIRCLE or ARC RADIUS

5. G07 6. G09 7. G10 8. G16 X----Y---(FANUC SYSTEM)

IMAGINARY AXIS DESIGNATION EXACT STOP CHECK SETTABLE WORK OFFSET POLAR COORDINATES ON X= LENGTH OF LINE

Y= ANGLE +ve IN CCW direction FROM +X-AXIS 9. G15 (FANUC SYSTEM) 10. G110 RP----- AP---(SINUMERIK SYSTEM) POLAR COORDINATES ON RP= LENGTH OF LINE or POLAR RADIUS AP= POLAR ANGLE +ve IN CCW direction FROM +X AXIS 11. G17 12. G18 13. G19 14. G20 15. G21 16. G22 17. G23 18. G27 SELECTION OF XY-PLANE SELECTION OF YZ-PLANE SELECTION OF ZX-PLANE INCHES INPUT METRIC INPUT STORED STROKE LIMIT ON STORED STROKE LIMIT OFF REFERENCE POINT RETURN CHECK 19. G28 20. G29 21. G30 RETURN TO REFERENCE POINT RETURN FROM REFERENCE POINT RETURN TO 2nd, 3rd & 4th REFERENCE POINTS 22. G31 23. G33 SKIP CUTTING THREAD CUTTING POLAR COORDINATES OFF

24. G40

CUTTER COMPENSATION CANCEL

25. G41 26. G42 27. G43

CUTTER COMPENSATION LEFT CUTTER COMPENSATION RIGHT TOOL LENGTH COMPENSATION + DIRECTION

28. G44

TOOL LENGTH COMPENSATION - DIRECTION

29. G45 30. G46 31. G47 32. G48 33. G49

TOOL OFFSET INCREASE TOOL OFFSET DECREASE TOOL OFFSET DOUBLE INCREASE TOOL OFFSET DOUBLE DECREASE TOOL LENGTH COMPENSATION CANCEL

34. G50 35. G51 36. G54 to G59 37. G60 38. G61 39. G64 40. G65 41. G66 42. G67

SCALING OFF SCALING ON WORK COORD. SYSTEMS #1 TO #6 SINGLE DIRECTION POSITIONING EXACT STOP CHECK MODE CUTTING MODE CUSTOM MACRO SIMPLE CALL CUSTOM MACRO MODAL CALL CUSTOM MACRO MODAL CALL CANCEL

43. G68

COORDINATE SYSTEM ROTATION ON

44. G69

COORDINATE SYSTEM ROTATION OFF

45. G90 46. G91 47. G92

ABSOLUTE PROGRAMMING INCREMENTAL PROGRAMMING PROGRAMMING OF ABSOLUTE ZERO POINT

48. G94 49. G95 50. G96 51. G97 58. G98

FEED PER MINUTE FEED PER REVOLUTION CONSTANT SPEED CONTROL ON CONSTANT SPPED CONTROL OFF RETURN TO INITIAL POINT IN A CANNED CYCLE

59. G99

RETURN TO R-POINT IN A CANNED CYCLE

60. G80 61. G73 62. G74 63. G76 64. G81 65. G82 66. G83 67. G84

CANCELLATION OF CANNED CYCLE HIGH SPEED PECK DRILLING LEFT HAND TAPPING PRECISSION BORING CYCLE DRILLING CYCLE DRILLING CYCLE WITH DWELL PECK DRILLING CYCLE RH TAPPING CYCLE

68. G85 69. G86 70. G87 71. G88 72. G89

BORING CYCLE BORING CYCLE BACK BORING CYCLE BORING CYCLE BORING CYCLE

F CUTTING FEED RATE R RADIUS OF THE CIRCLE S SPINDLE SPEED

M-CODES M00 PROGRAM STOP M01 OPTIONAL STOP THIS COMMAND IS ACTIVE ONLY WHEN THE OS-KEY IS PUT ON M02 END OF PROGRAM W/O REWIND M03 SPINDLE CW ROTATION ON M04 SPINDLE CCW ROTATION ON M05 SPINDLE ROTATION OFF M06 TOOL CHANGE M07 MIST COOLANT ON M08 FLOOD COOLANT ON

M09 COOLANT OFF M19 SPINDLE ORIENTATION ON (ORIENTED SPINDLE STOP) M20 SPINDLE ORIENTATION OFF M21 TOOL MAGAZINE RIGHT M22 TOOL MAGAZINE LEFT M23 TOOL MAGAZINE UP M24 TOOL MAGAZINE DOWN M25 TOOL CLAMP M26 TOOL UNCLAMP M27 CLUTCH NEUTRAL ON M28 CLUTCH NEUTRAL OFF M30 END OF PROGRAM WITH REWIND M60 M61 M62 M63 M98 CALL OF SUBPROGRAM M99 END OF SUBPROGRAM M19 to M28 USED FOR MAITENANCE PURPOSES

1. INTRODUCTION
Classification of components is based upon the types of operation involved in the manufacturing process. Manufacturing is defined as a process of making finished goods (as per requirement) from raw materials. This involves varies mechanical operations. GPM refers to General Purpose Machinery, the word specifies to a range of machines that are most commonly used in manufacturing (or production) in an industry. 1.1 Motivation: Throughout the centuries, people have challenged to make their lives easier. One way to accomplish this was to invent tools that make jobs less difficult. We know these tools as machines. The tools most of us think about when we hear the word "machine" are actually a combination of two or more simple machines. We use simple machines every day. We are dependent on simple machines in many aspects of our lives. You need a bottle opener to open a soft drink bottle. A carpenter needs a hammer to separate two boards that have been nailed together incorrectly. A furniture mover needs to use a ramp to bring up heavy cabinet in to the back of a truck. In the same way even for a machine to be manufactured for an industry there are certain machine manufacture techniques. These can be enhanced with proper approach in component designs and simplifying the

manufacturing process. This manufacturing process includes to the study of proper machining operations. 1.2 OBJECTIVE OF PROJECT: Machines do not increase the work you put into them. The work that comes out of a machine can never be greater than the work that goes into it. In reality, the work output is always less than the work input. These enable various construction companies and organizations to complete their targeted task in an easy way. These machines help in reducing the manual labor and also the risk factor, which is usually a constant worry. It becomes very important to check the latest arrivals in order to meet the industrial needs. Hence we suppose our project could provide an intimate study regarding the basic manufacturing technologies and their processes for those who try to establish an unaccounted growth of their organization. 1.3 LIMITATIONS OF PROJECT: Even though our project subjects to a brief study on various machining processes, these operations are restricted only to the specified components and dimensions, the operational features vary accordingly with the required component design. However these explain well how the operational techniques are being adopted in making a component more flexible for the machinery. Our project is confined only to the components that are being described here.

2. CLASSIFICATION OF OPERATIONS
Machining is not just one process; it is a group of processes. The common feature is the use of a cutting tool to form a chip that is removed from the work part, called swarf. To perform the operation, relative motion is required between the tool and work. This relative motion is achieved in most machining operation by means of a primary motion, called "cutting speed" and a secondary motion called "feed'". The shape of the tool and its penetration into the work surface, combined with these motions, produce the desired shape of the resulting work surface. There are many kinds of machining operations, each of which is capable of generating a certain part geometry and surface texture. In turning, a cutting tool with a single cutting edge is used to remove material from a rotating work piece to generate a cylindrical shape. The speed motion in turning is provided by the rotating work part, and the feed motion is achieved by the cutting tool moving slowly in a direction parallel to the axis of rotation of the work piece. Drilling is used to create a round hole. It is accomplished by a rotating tool that is typically has two or four cutting edges. The tool is fed in a direction parallel to its axis of rotation into the work part to form the round hole. In boring, the tool is used to enlarge an already available hole. It is a fine finishing operation used in the final stages of product manufacture.

 In milling, a rotating tool with multiple cutting edges is moved slowly relative to the material to generate a plane or straight surface. The direction of the feed motion is perpendicular to the tool's axis of rotation. The speed motion is provided by the rotating milling cutter. 2.1 MILLING: Milling is the process of cutting away material by feeding a work piece past a rotating multiple tooth cutter. The cutting action of the many teeth around the milling cutter provides a fast method of machining. The machined surface may be flat, angular, or curved. The surface may also be milled to any combination of shapes. The machine for holding the work piece, rotating the cutter, and feeding it is known as the Milling machine. 2.1.1 CLASSIFICATION OF MILLING Peripheral Milling In peripheral (or slab) milling, the milled surface is generated by teeth located on the periphery of the cutter body. The axis of cutter rotation is generally in a plane parallel to the work piece surface to be machined.

 Face Milling In face milling, the cutter is mounted on a spindle having an axis of rotation perpendicular to the work piece surface. The milled surface results from the action of cutting edges located on the periphery and face of the cutter. End Milling The cutter in end milling generally rotates on an axis vertical to the work piece. It can be tilted to machine tapered surfaces. Cutting teeth are located on both the end face of the cutter and the periphery of the cutter body. 2.1.2 METHODS OF MILLING: Up Milling Up milling is also referred to as conventional milling. The direction of the cutter rotation opposes the feed motion. For example, if the cutter rotates clockwise, the work piece is fed to the right in up milling.

 Down Milling Down milling is also referred to as climb milling. The direction of cutter rotation is same as the feed motion. For example, if the cutter rotates counter clockwise, the work piece is fed to the right in down milling.

The chip formation in down milling is opposite to the chip formation in up milling. The figure for down milling shows that the cutter tooth is almost parallel to the top surface of the work piece. The cutter tooth begins to mill the full chip thickness. Then the chip thickness gradually decreases. Other milling operations are shown in the figure

2.1.3 Types of Milling Machines Milling machines can be broadly classified into the following types: Column and knee type of milling machines Bed type Rotary table Tracer controlled 2.2 TURNING Turning is the machining operation that produces cylindrical parts. In its basic form, it can be defined as the machining of an external surface:

With the work piece rotating, With a single-point cutting tool, and With the cutting tool feeding parallel to the axis of the work piece and at a distance that will remove the outer surface of the work.

Taper turning is practically the same, except that the cutter path is at an angle to the work axis. Similarly, in contour turning, the distance of the cutter from the work axis is varied to produce the desired shape. Even though a single-point tool is specified, this does not exclude multiple-tool setups, which are often employed in turning. In such setups, each tool operates independently as a single-point cutter.

2.2.1 Adjustable cutting factors in turning The three primary factors in any basic turning operation are speed, feed, and depth of cut. Other factors such as kind of material and type of tool have a large influence, of course, but these three are the ones the operator can change by adjusting the controls, right at the machine. Speed, always refers to the spindle and the work piece. When it is stated in revolutions per minute (rpm) it tells their rotating speed. But the important figure for a particular turning operation is the surface speed, or the speed at which the work piece material is moving past the cutting tool. It is simply the product of the rotating speed times the circumference (in feet) of the work piece before the cut is started. It is expressed in surface feet per minute (sfpm), and it refers only to the work piece. Every different diameter on a work piece will have a different cutting speed, even though the rotating speed remains the same. Feed, always refers to the cutting tool, and it is the rate at which the tool advances along its cutting path. On most power-fed lathes, the feed rate is directly related to the spindle speed and is expressed in inches (of tool advance) per revolution (of the spindle), or ipr. The figure, by the way, is usually much less than an inch and is shown as decimal amount. Depth of Cut, is practically self explanatory. It is the thickness of the layer being removed from the work piece or the distance from the uncut surface of the work to the cut surface, expressed in inches. It is important to note, though, that the diameter of the work piece is reduced by two

times the depth of cut because this layer is being removed from both sides of the work. 2.2.2 LATHE RELATED OPERATIONS The lathe, of course, is the basic turning machine. Apart from turning, several other operations can also be performed on a lathe. 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. 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 face plate. 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 work piece.

Facing, Facing is the producing of a flat surface as the result of a tool's being fed across the end of the rotating work piece. Unless the work is held on a mandrel, if both ends of the work are to be faced, it must be turned end for end after the first end is completed and the facing operation

repeated. In the facing of casting or other materials that have a hard surface, the depth of the first cut should be sufficient to penetrate the hard material to avoid excessive tool wear.

Parting, Parting is the operation by which one section of a work piece is severed from the remainder by means of a cutoff tool. Because cutting tools are quite thin and must have considerable overhang, this process is less accurate and more difficult. The tool should be set exactly at the height of the axis of rotation, be kept sharp, have proper clearance angles, and be fed into the work piece at a proper and uniform feed rate.

Threading, Lathe provided the first method for cutting threads by machines. There are two basic requirements for thread cutting. An

accurately shaped and properly mounted tool is needed because thread cutting is a form-cutting operation. The resulting thread profile is determined by the shape of the tool and its position relative to the work piece. The second by requirement is that the tool must move longitudinally in a specific relationship to the rotation of the work piece, because this determines the lead of the thread. This requirement is met through the use of the lead screw and the split unit, which provide positive motion of the carriage relative to the rotation of the spindle.

2.2.3 CUTTING TOOLS FOR LATHES Tool Geometry, For cutting tools, geometry depends mainly on the properties of the tool material and the work material. The standard terminology is shown in the following figure. For single point tools, the most important angles are the rake angles and the end and side relief angles.

The back rake angle affects the ability of the tool to shear the work material and form the chip. It can be positive or negative. Positive rake angles reduce the cutting forces resulting in smaller deflections of the work piece, tool holder, and machine. If the back rake angle is too large, the strength of the tool is reduced as well as its capacity to conduct heat. In machining hard work materials, the back rake angle must be small, even negative for carbide and diamond tools. The higher the hardness, the smaller is the back rake angle. For high-speed steels, back rake angle is normally chosen in the positive range. Most lathe operations are done with relatively simple, single-point cutting tools. On right-hand and left-hand turning and facing tools, the cutting takes place on the side of the tool; therefore the side rake angle is of primary importance and deep cuts can be made. On the round-nose turning tools, cutoff tools, finishing tools, and some threading tools, cutting takes place on or near the end of the tool, and the back rake is therefore of importance. Such tools are used with relatively light depths of cut. Because tool materials are expensive, it is desirable to use as little as possible. It is essential, at the same, that the cutting tool be supported in a strong, rigid manner to minimize deflection and possible vibration. Consequently, lathe

tools are supported in various types of heavy, forged steel tool holders, as shown in the figure.

The tool bit should be clamped in the tool holder with minimum overhang. Otherwise, tool chatter and a poor surface finish may result. In the use of carbide, ceramic, or coated carbides for mass production work, throwaway inserts are used; these can be purchased in great variety of shapes, geometrics (nose radius, tool angle, and groove geometry), and sizes.

2.2.4 TURNING MACHINES The turning machines are, of course, every kinds of lathes. Lathes used in manufacturing can be classified as engine, turret, automatics, and numerical control etc.

They are heavy duty machine tools and have power drive for all tool movements. They commonly range in size from 12 to 24 inches swing and from 24 to 48 inches center distance, but swings up to 50 inches and center distances up to 12 feet are not uncommon. Many engine lathes are equipped with chip pans and built-in coolant circulating system. Turret Lathes, In a turret lathe, a longitudinally feed able, hexagon turret replaces the tailstock. The turret, on which six tools can be mounted, can be rotated about a vertical axis to bring each tool into operating position,

and the entire unit can be moved longitudinally, either annually or by power, to provide feed for the tools. When the turret assembly is backed away from the spindle by means of a capstan wheel, the turret indexes automatically at the end of its movement thus bringing each of the six tools into operating position. The square turret on the cross slide can be rotated manually about a vertical axis to bring each of the four tools into operating position. On most machines, the turret can be moved transversely, either manually or by power, by means of the cross slide, and longitudinally through power or manual operation of the carriage. In most cased, a fixed tool holder also is added to the back end of the cross slide; this often carries a parting tool.

Through these basic features of a turret lathe, a number of tools can be set on the machine and then quickly be brought successively into working

position so that a complete part can be machined without the necessity for further adjusting, changing tools, or making measurements. CNC Machines, Nowadays, more and more Computer Numerical Controlled (CNC) machines are being used in every kinds of manufacturing processes. In a CNC machine, functions like program storage, tool offset and tool compensation, program-editing capability, various degree of computation, and the ability to send and receive data from a variety of sources, including remote locations can be easily realized through on board computer. The computer can store multiple-part programs, recalling them as needed for different parts.

2.3 Other Other conventional machining operations include shaping, planing, broaching and sawing. Also, grinding and similar abrasive operations are often included within the category of machining.

3. MILLING
3.1 Motor Flange Purpose: It is obvious that every machine is setup with a motor which provides the complete rotary motion required. This Motor rests on the current component Motor Flange. The dovetail of the motor flange allows the sliding movement

of the motor. This sliding action lets motor movement to and fro and enables

in tightening of the v-belts. The step wise operations included in making of the motor flange are: 0. Raw material: The raw material here is the cast iron moulding as show in the figure

Facing of the flat side on the raw material is to be done. It is done either on a milling machine or on a turning lathe where the raw material can be held rigid.

1. On a center lathe: The raw material is held in individual four jaw chuck such that

the facing operation can be carried. The facing tool used here is the parting tool. Further to the center of the face a bore of 30 is to be made.

This is done using a twist drill of 28mm and further +1 to 1.5mm using the boring tool. A counter bore of 110H7 is made using the same counter

boring tool for 4mm depth. 2. On a milling center: After the formation of counter bore on the component the component is sent for milling operations. The four sides of the component are milled on a horizontal

milling machine making the component 160mm x 160mm dimensionally (l & b). Here the job is held in a circular chuck which acts like a support and sufficient packing is made required for the milling operation. For this initially one side of the job is milled by making 80mm centre distance from centre to the side. Further the other sides are milled with reference to the first side with perpendicularity and squareness. The job is now remained with milling on the other face of the component and dovetail making. This is done manually on a horizontal milling machine or using CNC. Where the tools required will be the mill face cutter, mill cutter with radius and dovetail cutter. 3. On manual milling machine:

Initially the job is milled on either side of the steps provided

for the flange with a 28mm mill cutter such that it measures 120mm between the milled portions externally. The dove tail is formed by an appropriate milling of the job by passing the dove tail cutter of 28 diameter and 600 dovetail, such that the dovetail formed exactly cuts 600 dovetail without disturbing the 120mm distance.

Finally the fillet depth is milled with a side and face mill cutter

of 5mm fillet radius to a depth of 5mm. 4. On a radial drilling machine: Four holes of 9 through and counter bore of 13.5 to a depth

of 8mm from the bottom flat face are to be done at equidistant maintaining a pitch circle diameter (P.C.D) of 130mm. the job. 5. Inspection: The component is inspected for the pitch circle diameter of 130 and dove tails using the quality control equipment. The four holes are aligned exactly opposite with each side of

3.2 STEADY SUPPORT 1st operation: Obtaining the required thickness and width (40.5mm, 53.5mm resp.) of the job from raw material. Raw material: 60mm thick & 63mm wide, mild steel block. Width & thickness are obtained on a vertical milling machine (speed range-20 to 1500 rpm) using a the spindle speed of 270rpm. First a face is made flat & with reference to it i.e., fixing the flattened side onto the fixed jaw of the machine, other sides made flat & perpendicular to the previous flattened side. Thus work piece moves in CW or CCW direction during the cycle of operations. The perpendicularity is checked with a tri square. 2nd operation: Length (200mm) is obtained on a horizontal milling machine. With base as a reference the face 43.5x53.5 is milled perpendicular to the reference side. With this face as the reference further the length 200mm is obtained by milling on the other side. 3rd operation: In a vertical milling machine, the taper (1- refer fig.) at the side of the job is cut at an angle of 600 by tilting the mill cutter in the required angle (600). cutter having a diameter of 120mm and

4th operation: The other stock to be removed (2- refer fig.) on the other part of the side face is removed (Insert fig.) is obtained. 5th operation: The 19 holes are drilled through on the front side on a drilling machine (5mm drill each) & tapped with M6. The work piece is held on parallel blocks & drilling is done i.e., two holes of 12mm diameter is made & counter boring of 20x4mm deep is done on the top. Other 3 holes of 5mm drill and tapping is done. Care should be taken that the parallel blocks do not lie beneath the holes to be drilled i.e., they should be kept away. 6thoperation: Heat treatment will be done immediately after the last metal cutting operation (or) before the 1st grinding process. The required heat treatment process is explained in Heat treatment processes chapter 6.

3.3 BEVEL GEAR BRACKET On horizontal milling machine: For the bottom side. Hold in vice; mill thick 2nd side & keep for grinding For the two profile sides of the component which are parallel. Hold in vice; mill flat on R28mm For two other sides of 16mmx32mm. Hold in vice; mill width to 16mm height. Inspect The milling for 16x32 is carried as: 5. Mark for center 6. Mill length one side to maintain 34mm from bore center 7. Mill length second side to 74mm Further to carry the drilling operations the component is initially heat treated. 8. Stress relieve 9. Surface grind thickness in batches 10. Surface grind bottom face, second side On radial drilling machine: 11. Hold in jig the component and drill 2 holes 6.75x27 with M8 drill 12. 2 holes 5.8x8 ream6 M8; drill 6 through

On the same drilling machine tapping operations are done at lower spindle speed. 13. Clamp on table tap, M8x20deep 2 holes Again on the drilling machine: 14. Bore 35H7; bore 47H10x30.02; *-0.05 from base chamfer both side 15. Chamfer both sides of the component On the surface grinding machine: 16. Surface grinds other side to maintain 30.02-0.5 Inspection: 17. Inspection of all the milled sides and the holes is done. On a die grinding machine: 18. Die grind (it is done on areas where machining is undone) Final step: 19. Painting 20. Inspection of all the operations including profile.

3.4 REAR BEARING SUPPORT Raw material- a cast iron block of 150mmx130mmx110mm On milling machine: The block is milled all the sides on a vertical milling machine, obtaining the dimensions as shown in the figure. The two chamfers each 15x15 at the two regions are made by inclining the milling cutter. The back side of the component i.e., opposite to the chamfered side is to be milled accordingly. This is done by holding the chamfered side on the bed. The two slots are milled perpendicular to each other, of width 20mm.

On radial drilling machine: A major drill through of 54mm is made 36mm away from the chamfered side. This bore on the right face is extended to a diameter of 90 for a depth of 2.8mm. This operation can also be done using a milling tool.

 At the left face the bore 54 is extended to 62 for a depth of 86mm with a fillet radius of 3mm provided at the end. Further the 62 is also extended to 96 to a depth of 8mm from the face.

The extended regions here are concentric with the 54 bore. The chamfered face and the behind face are drilled accordingly with the through holes and drills respectively. On CNC lathe: The drills of M6 with depth 12mm on right face and 20mm on the left face are done on horizontal machining center using canned cycles. A groove of 2.5mm thick and diameter65.5 is made inside the 62 bore at 40mm away from the left face. This groove is obtained by using a cutter of 2.5mm thickness and diameter less than 62. On milling machine: The through holes made on the chamfered face are milled to form the counter bore to the drilled hole using a 14.5mm side and face mill cutter to a depth of 28mm from the face.

Inspection: The component is inspected for all the center distances.

4. TURNING
4.1 SPINDLE PULLEY 0. Raw material here used is the casting of cast iron alloys as show in

the picture.

1.

Facing on the side having the same plane of faces for inner and outer

diameters is done. Using a parting tool, a groove of 3 3/8 major diameter and 1 3/8 minor diameter is made to a depth 5/8 is made on a turret lathe. 2. Mark the center on the face using a center drill. A through hole of

diameter 17/32 is made.

3.

A taper bore is made using a parting tool maintaining major diameter

0.8 and minor diameter 17/32 for a length 21/16. 4. 5. Turning of outer diameter maintaining 4 is done. Facing is done on the other side making the width 1 . Another

facing for the smaller diameter away from the outer plane is done. 6. The groove with major diameter 3 3/8 and minor diameter 1 is

turned to a depth of 13/16 from the outer plane.

7. 8.

Counter bore of 1 is done to a depth of 5/8. Threads are turned at 20TPI (threads per inch) on the 1 diameter

to a length of 7/16. 9. Further the component is sent for making a crown of 7 at an outer

diameter of 3 leaving the 1/8 thick portion at the ends. This is obtained using a plunge cutter of 7 radiuses or by part programming on a CNC turning center. 10. Inspection: The pulley is inspected for all the dimensions including

taper, crown and counter bores using the quality control equipment.

4.2 FRONT SPINDLE 1. Raw material (fig.) here is a ms rod of required length and

diameter to be turned. 2. 3. 4. Facing is done on both sides for appropriate length. The job is initially turned to 48mm. Hold one side in chuck. Then turning is done to 36 through the

length (185+27=) 212mm. 5. Then turn to 33.8mm to the length (185-10=) 175mm & provide an

undercut at the step. 6. 7. 8. jaws. 9. Now the tapered section of the bore is made to a minor diameter of Then turn the length 27mm to 25mm Bore of 11mm through is done Remove the work piece and fix it into the chuck holding with the soft

20.2mm and length 84mm with a major diameter 23.825. 10. To a length 40mm turning is done to a dia. 45.5. 11. On a milling machine key way is made of length 11mm. 12. Further threads M25x1.5P are turned on lathe. 13. Inspection and component stores.

4.3 REAR SPINDLE 0. Raw material Cylindrical rod of 50 and length 180mm. 1. Initially on a turning lathe, 50 hold in chuck and turning made of 30 with h10 tolerance to a length of 117mm with one face as reference. Step turning at the end of 30 to a diameter 20mm is also made for M20 for a length 15mm. Groove of 1mm width is made 10mm away from 50 face (at a length 117mm from reference face) of depth 27. After the groove the 30 is turned to 28.7 h7. An undercut provided to 30 at the 50 face. Center is marked to the reference face. 2. The other side 28.7 is hold in soft jaws. Facing is done and a length of 170mm is obtained. 50 is turned to45 along the total length. 25 is turned for a length of 43mm from the end. Chamfers are provided at the end of diameter turning at each diameter. Taper is turned for a major diameter of 25mm and a minor diameter of 2mm. This taper is obtained by form tool of 300 and linear feed. 3. On key way milling machine:

 A key way of length 10mm is made on the M20 diameter. 4. Threads are turned to a length of 13mm on M20x1P. 5. Heat Treatment: The heat treatment is done for making the spindles hard by the process hardening of the steels as explained in chapter 6. 6. Inspection The component is inspected for the various lengths, diameters and for the taper using quality control equipment.

4.4 FRONT BEARING COVER 1. 2. Raw material The job is turned to a 10mm thick disc and 165mm by turning and

facing as required. 3. A bore of 112mm is made through concentric with the outer A step is obtained of 1mm thick and a diameter of 130mm-0.1-0.15 by

diameter 4.

turning.

5.

Using an end mill cutter a flat side is obtained 152.5mm away from

the other end. 6. With reference to the center and pitch circle diameter of 150mm, 4 To the same holes a counter sink from 16.2 with 900 angle are holes each 900 apart are drilled with 8.5mm drill according to the drawing. 7. made. 8. 9. 10. The component is sent for grinding. Blackening is done. Inspected for diameters and center distances.

5. MILLING, TURNING & OTHER

5.1 COUPLING 0. Raw material A pattern with required allowances for coupling is made in the pattern shop and casting is done from the mould obtained. The material used is cast iron.

1. 140 held in chuck, Turn 90g6. 140 to 141, Drill 55 The turning operations are carried on a turret lathe in which the tool post carries the turning tool while the turret carries the necessary drill bits. The job is set on the individual four jaw chuck holding the part of job having the higher diameter (say 140+10) by aligning it to the center of

the chuck and the 90 is obtained. Further 140+10 are also turned to 141 for certain length. The tool post is set back. The center of the 90 is marked with a center drill bit held in the turret. Next at a very low speed of spindle 55 is drilled with a drill bit of 55 held in turret head.

2. 90g6 held in soft chucks. 1400.3 finished (with low speed and low depth of cut). After drilling is done the job is removed from the chuck and the 90 is held in the chuck with soft jaws and the 140+10 is turned to 140 along the total length.

3. 66 width pocket milling + Bottom face of 66 width (pocket) 90g6 held in chuck On a horizontal milling machine job is fixed in a chuck holding 90g6. Using a side & face milling cutter, the pocket of 66width to a length measuring 71 from the bottom of the component (90g6 face). In Horizontal milling machine: for side & face cutter: of cutter = Bottom face; Side face = width

4. Part is sent to CNC machining centers for 39.72 H7 bore and recesses + profile. Here the CNC operation is included for making of the profile, making drills to hold the arms of cross piece and groove for the circlip which is a locking of the cross piece bearing. CNC progam:
N10 T1 M100 B0 ; M6 ; (T1CENTRE DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H1 ;T2 ; M3 S1000 M7 ; G98 G81 R5.0 Z-6.5 F40 ; M5 M9 ; M100 ; M6 ; N20 T2 ; M6 ; (T2 DIA 14 DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H2 ;T3 ; M3 S450 M7 ; G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ; N30 T3 ; M6 ; (T3 DIA 25 U DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H3 ;T4 ; M3 S500 M7 ; G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ; N40 T4 ; M6 ; (T4 DIA 31 U DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H4 ;T5 ; M3 S500 M7 ; G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ; N50 T5 ; M6 ; (T5 DIA 38 U DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H5 ;T6 ; M3 S500 M7 ;

G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ; N60 T6 ; M6 ; (T6 DIA 25 END DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H5 ; M3 S450 M7 ; (PROFILE FIRST SIDE) R1=4 ; RAM : R2=R1+10 ; R1=R2 ; G0 X110.0 Y35.0 ; G0 Z5.0 ; G01 Z-R2 F40 ; G0 X87.5 Y-54.0 G42 F30 ; X59.9877 ; G02 X45.7218 Y-43.6353 CR=15 ; G01 X28.5317 Y9.2705 ; G03 X-28.5317 Y-9.2705 CR=30 ; G01 X-45.7218 Y43.6553 ; G02 X-59.9877 Y-54.0 CR=15 ; G01 X-87.5 Y-54.0 ; G0 Z75.0 ; Z125.0 G40 ; IF R3<34 GO TO 'RAM' ; M5 ; M100 ; M00 ; B180 ; N70 M6 ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100 G43 H5 ;T1 ; M3 S450 M7 ; (PROFILE SECOND SIDE) R1=4 ; RAM : R2=R1+10 ;

R1=R2 ; G0 X110.0 Y35.0 ; G0 Z5.0 ; G01 Z-R2 F40 ; G0 X87.5 Y-54.0 G42 F30 ; X59.9877 ; G02 X45.7218 Y-43.6353 CR=15 ; G01 X28.5317 Y9.2705 ; G03 X-28.5317 Y-9.2705 CR=30 ; G01 X-45.7218 Y43.6353 ; G02 X-59.9877 Y-54.0 CR=15 ; G01 X-87.5 Y-54.0 ; G0 Z75.0 ; Z125.0 G40 ; IF R3<34 GO TO 'RAM' ; M5 ; M100 ; N75 M00 ; N80 T1 ; M100 B0 ; M6 ; (T1 CENTRE DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H1 ;T2 ; M3 S1000 M7 ; G98 G81 R5.0 Z-6.5 F40 ; M5 M9 ; M100 ; M6 ; N90 T2 ; M6 ; (T2 DIA 14 DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H2 ;T3 ; M3 S450 M7 ; G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ;

N100 T3 ; M6 ; (T3 DIA 25 U DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100 G43 H3 ;T4 ; M3 S500 M7 ; G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ; N110 T4 ; M6 ; (T4 DIA 31 U DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H4 ;T5 ; M3 S500 M7 ; G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ; N120 T5 ; M6 ; (T5 DIA 38 U DRILL) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H5 ; M3 S500 M7 ; G98 G81 R5.0 Z-36.0 F40 ; M5 M9 ; M100 ; N130 T19 ; M100 ; M6 ; (T19 DIA 39 S.F.BORING BAR) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100 G43 H19 ; M3 S500 ; G98 G81 R5.0 Z-142.0 F12 ; M5 M9 ; M100 ; M6 ; N140 T20;

M6 ; (T20 DIA 39.8 FINE BORING BAR) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H20 ; M3 S500 ; G0 Z5.0 ; G01 Z-34.0 F12 ; Z-100.0 F200 ; Z-142.0 F12 ; M19 ;

G0 Z100.0 ; M9 ; N150 T21; M6 ; (T21 DIA 41.8 RECESS) ; G0 G90 G54 X0.0 Y0.0 ; G0 Z100.0 G43 H21 ; M3 S150 ; G0 Z5.0 ; G01 Z-11.1 F50 ; X3.85 F4 ;

G02 I-3.85 ; G01 X0.0 Y0.0 F100 ; Z-130.75 F200 ; G01 X3.85 F4 ; G02 I-3.85 ; G01 X0.0 Y0.0 F100 ; G0 Z100.0 ; M5 M19 ; M100 ; M6 ; M30 ;

5. Broaching of Internal splines:

The internal splines with 55 as the internal diameter and 60 as the external diameter are broached on a vertical broaching machine with the necessary tool.

6. Relief milling for inserting cross pieces in assembly: Relief is made for easy movement of cross piece during the assembly of cross piece. This is done using a milling cutter of 40 width for a thickness of 5mm of the material at the 40H7 hole. The tool is a end mill cutter milling done on horizontal milling machine. 7. Phosphate = Blackening. This blackening process is explained in Heat treatment. 8. Inspection & Dispatch: The component is inspected accordingly as reference to the drawing using quality control equipment and dispatched for assembly.

5.2 FEED CRANK DISC 0. Raw material Raw material here is a cylindrical rod piece of required length. 1st stage: For a raw cylinder facing is done on one side. The required step turning operation is performed. The center to the component on face is marked. Chamfer provided at each stage 2nd stage: on lathe Further the facing on the other side is made by holding the already turned region in soft jaws. (Ex. If diameter obtained by turning is 40.04 then the soft chuck is 40.04 exactly) The turned diameters should be concentric. Center on the face is marked. Center drill is used to obtain a small hole of 6.5 deep enhancing the further drilling operations. 15.87mm (3/5) drill bit is used and bore is made through Step turning of the inner depth is made. 3rd stage: Milling The next operation is milling of the job making a slot to the required depth on vertical milling machine by fixing the smaller diameter of the job on the bed.

 Using a T-slot milling tool of width 20.06mm (13/16), the required Tslot is obtained. 4th stage: Key way made on a vertical slotting machine. 5th stage: Drills to the required dimensions are made. The holes to be drilled are made with reference to the appropriate sides and the bore in the center. This is done on CNC vertical machining center(VMC 500) with CNC coding. CNC Program:
N10 T1; G0 G90 G55 X0 Y0 Z100 D1; M3 S1000 M7 F40; MSG(C-DRILL); MCALL CYCLE 81(100,0,5,6.5,6.5); X0 Y-23.812; MCALL CYCLE 81( 100,0,5,23.8,23.8); X-11.113 Y0; X28.575 Y0; MCALL; M19 M9; N20 T14; L90; G0 G90 G55 X0 Y0 Z100 D1; M3 S1000 M7 F40; MSG(3.3 DRILL); MCALL CYCLE 81(100,0,5,20,-20) X-11.113 Y0; X28.575 Y0; MCALL; M19 M9; N30 T7; L90; G0 G90 G55 X0 Y0 Z100 D1; M3 S650 M7 F30; MSG(11.1 DRILL); MCALL CYCLE 81(100,0,5,25,25); X0 Y-23.812; MCALL; M19 M9; M30;

6th stage: Heat treatment is to be done before the 1st grinding process. This involves blackening of the component. 7th stage: Grinding is done as required. 8th stage: Inspection of the total components diameters, thickness and center distances.

5.3 WORM WHEEL 1. 2. 3. 4. 5. Raw material( toughened brass) Bore turning is made to obtain the bore of diameter 55mm. Outer diameter of 136mm is turned. Facing is done to obtain the width of 50mm. Step turning is done on either side such that it measures a diameter

of 86mm to a length of 5mm on either side provided with a fillet of 2mm radius.

6.

2 Key ways are made on a key way slotting machine according to the

dimensions. 7. Using a plunge cut of radius 16.83(having a center at a distance of

80mm from the center of the job) a radial depth is obtained on the outer diameter.

8.

On a gear hobbing machine, the gear teeth are cut as per the

dimensions.

9.

Grinding of the inner bore and the teeth are carried on the respective

grinding machines. 10. The component is inspected for the gear teeth and bore dimensions

5.4 WORM SHAFT Raw material A rod of 50mm diameter and 415mm length is the raw material here. On a Lathe: Facing is done on both ends of the job to obtain a length of 407mm. Initially turning of the rod for overall length is done to a diameter of 45mm. Further turning for this component involve various diameters. Hence it is easily done on a copy lathe where the previously finished job is set in the lathe and tool moves accordingly copying the dimensions as per the finished job. The depth at each time is to be manually adjusted until the required steps are obtained.

On milling machine: An end of the worm shaft where the diameter is 25mm is flattened on either side to obtain width of 22mm. In the heat treatment section, the blackening of the component is done. On thread milling machine: The worm thread is obtained by inclining the tool post to the desired angle and the tool used is a mill cutter of teeth width equal to width of worm thread.

Inspection: The diameters and the thread dimensions are checked.

6. HEAT TREATMENT
Heat treatment is generally applied to steels to impart specific mechanical properties such as increased strength or toughness or wear resistance. Heat treatment is also resorted to relieve internal stresses and to soften hard metals to improve machinability. Heat treatment is essentially a process of heating the steels to a pre-determined temperature followed by a controlled cooling at a pre-determined rate to obtain desired end results. The heat treatment process can be classified into: 1. Recrystallization Annealing which is employed to relieve internal stresses, reduce the hardness and to increase the ductility of strain hardened metal. At first, upon an increase in the heating temperature the elastic distortions of the crystal lattices are eliminated. At higher temperature new grains for and begins to grow (recrystallization). 2. Full annealing which involves phase recrystallization and is achieved by heating alloys above the temperature required for phase transformation. This is followed by slow cooling. Full annealing substantially changes the physical and mechanical properties and refines a coarse grained structure. 3. Quenching wherein hardening alloys are heated above the phase transformations temperature and are then rapidly cooled (quenched). 4.Tempering involves the reheating of hardened of hardened steel to a temperature below that required for phase transformation so as to bring it nearer to an equilibrium state.

6.1 Annealing Annealing is the process necessary to obtain softness, improve machinability, increase or restore ductility and toughness, relieve internal stresses, reduce structural non-homogeneity and to prepare for subsequent heat treatment operations. The Process consists of heating the metal to the required temperature depending upon the carbon content and other alloying elements of the steel and then cooling in the furnace at a slow rate. Most of the cast iron components are annealed at a low temperature before final machining. 6.2 Hardening and tempering In this process steel is heated to predetermined temperature and then quenched in water, oil or molten salt baths. Hardening followed by tempering is done to improve the mechanical properties of steel. Tempering consists of reheating the hardened steels to a temperature below lower critical values followed by cooling at a desired rate. 6.3 Hardenability It is defined as the capacity to develop a desired degree of hardness usually measured in terms of depth of penetration. The higher the carbon content, the harder a steel will be after hardening owing to a martensite structure. 6.4 Surface hardening

This is a selective heat treatment in which the surface layer of metal is hardened to a certain depth whilst a relatively soft core is maintained. The principal purpose of surface hardening is to increase the hardness and wear resistance of the surface. Surface hardening may be accomplished with or without changing the chemical composition of the surface. 6.5 Carburizing This is a process for saturating the surface layer of low carbon steels with carbon. Several methods are employed for this purpose such as pack carburizing, gas carburizing and liquid carburizing. After carburizing, regardless of the process employed, the material is heat treated to produce a hard surface resistant to wear. The heat treatment process for carburized parts consists of the following: a) Normalizing after carburizing at temperatures of 8800-9000 to improve the core structure of the work which is over heated by carburizing. b) Hardening at 750-8500to eliminate the effects of overheating and to impart a high hardness to the carburized layer and c) Tempering at 1500 to 1800

7. QUALITY CONTROL EQUIPMENT and INSPECTION

Verniers are used for checking external and internal dimensions that are controlled within 0.2mm and above. Gear tooth vernier is used for checking chordal thickness of bevel gears at major diameter in its taper.

Micrometers are used for checking dimensions of shafts and __________ controlled within 0.01 to 0.05.

 Three point bore micrometer is used for checking bores of tolerance 0.03 to 0.08.

Bore indicators are used for checking bores of tolerance 0.001 to 0.025.

Flange micrometers are used for checking accurate dimensions on stepped faces. Pitch micrometers are used for checking effective diameters of threads.

 Groove micrometers are used for checking groove diameters of external grooves. For checking groove diameters, we use inside caliper and an external micrometer.

Height gauges are used for checking parallelisms, run outs, concentricity and so on. On surface plate we use height master for comparing the heights or distances of holes, faces etc.

 Universal hardness tester is used for checking hardness of work pieces after we calibrate it by cross checking with a master piece provided for this purpose.

Surface finish tester is used for checking the surface finish of ground & tapped surfaces in RA and RMS values after calibrating it on master piece. Sine bar is used for checking the accuracy of angles of tapered surfaces.

Centrimeter is used for checking the center distances of two holes directly.

 Profile projector is used for checking the irregular contours of work pieces by comparing the shadow magnified (by 10, 20, 50, 100 times) with a shadow graph drawn on transparent sheets by designs depth.

Universal microscope is used for checking the threads, serration profiles by comparing them with oculars containing ideal (error free) profiles duly printed on them. Plug gauges are used for checking the lower and upper limits of holes. Similarly we use ring gauges for calibrating bore indicators before we check work pieces with them.

 Pins or rollers are used for checking O.W.M on threads/serrations

Sample mics:

8. CONCLUSION
Every aspect of this project has been interesting throughout. Concluding a project doesnt just simply, the project ending without serving a purpose that it should be. Conclusion includes all the summary of a project which may have in them - the literature survey, procurement of raw materials, machinery required for production, production processes, and time estimation for manufacturing and feasibility studies. It becomes very important to check the latest arrivals in order to meet the industrial needs. Hence we suppose our project could provide an intimate study regarding the basic manufacturing technologies and their processes for those who try to establish an unaccounted growth of their organization.

BIBLIOGRAPHY:
Machine tool design handbook Central machine tool institute, Banglore Workshop technology- Raghuwamshi Metrology and surface engineering R.K.Jain References: http://www.mfg.mtu.edu/marc/primers/turning/turn.html www.wikipedia.org The encyclopedia www.pragatools.org