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DEPARTMENT OF
MECHANICAL AND AUTOMOBILE
ENGINEERING
LABORATORY MANUAL
ME 434/AU335 PRIMARY
MANUFACTURING/MANUFACTURING
PROCESS
Syllabus
PART-A: LATHE OPERATIONS
Preparation of two models on lathe involving Plain turning, Taper turning, Step turning, Thread
cutting, Facing, Knurling, Drilling, Boring, Internal Thread cutting and eccentric turning.
1. Operate Machine tool equipment commonly found in industry like Lathe Machine Shaper
Machine, Milling Machine and grinding machine.
2. Manufacture parts from various materials in accordance with specifications from
blueprints, electronic drawings and shop sketches
3. Apply safety principles in a work environment to minimize hazards and prevent losses
to productivity
4. Demonstrate employability skills needed to obtain and retain employment in machine
tool and related fields
1) Select appropriate testing methods and identify equipment required for the testing Apply
knowledge of Machine tool operations in Industry
2) Ability to infer sequence of operations to carried out on different machine tools
3) Apply safety principles in work environment to minimize losses
4) Problem solving skills are enhanced.
Safety Precautions
1. Attention to be paid for clamping the job, tool, tool holders or supporting items.
2. Care should be taken for avoiding accidental contact with revolving cutters.
4. Do not handle chips with bare hands, use brush or hand gloves.
5. Pay attention while selecting tools or blades for the proposed use to avoid accidents.
9. Follow safety precautions while approach with cutter to avoid tool damage.
11. Use goggles for sparks, spatters, avoid the watch clearly with bare eyes.
Table of Contents
Description of
Sl.No Date Page No Marks Sign of Faculty
Experiments
Introduction of general
purpose machines- Lathe ,
1. Drilling machine, Shaping 6 - 29
machine, Milling machine
and Grinding machine
LATHE
Lathe is the machine tool which is used to perform several operations on the work piece. Lathe is
useful in making several parts which is further assembled to make new machine.
Hence lathe is known as mother of all machines.
Type of Lathe:
Lathes of various designs and constructions have been developed to suit the various conditions of
metal machining. The types of lathes are.
1. Speed Lathe
2. Engine Lathe
(a) Belt drive
(b) Individual motor drive
(c) Gear head Lathe
3. Bench Lathe
4. Tool room Lathe
5. Capstan and turret Lathe
6. Special purpose
(a) Wheel Lathe
(b) Gap bed Lathe
(c) T-Lathe
(d) Duplicating Lathe
7. Automotive Lathe
advantage is that several different types of operations can be done on a work piece without re-
setting of work or tools, and a number of identical parts can be produced in the minimum time.
Specifications of Lathe:
The size of the lathe is specified as follows:
Power input
Bed:
The lathe bed forms the base of the mechanism. The head stock, and the tail stock are located at
either end of bed and the carriage rests over the lathe bed and slides on it. On the top of the bed
there are two sets of slides or guide ways, outer ways and inner ways. The outer ways provide
bearing and sliding surfaces are accurately machined to make them parallel to the lathe axis
absolutely horizontal and sufficiently plain. In guide ways of the lathe bed may be flat and
inverted --v having an included angle of 90. The bed material should have high compressive
strength, should be wear resistant and absorb vibrations. Cast iron alloyed with Nickel and
Chromium.
Head Stock:
The head stock is secured permanently on the inner ways at the left hand end of the lathe bed and
it provides mechanical means of rotating the work at multiple speeds. It has a hollow spindle and
mechanism for driving and altering the spindle speed. The spindle of the head stock is made of
carbon or Nickel chrome steel. There are two common types of spindle noses the threaded design
which carries the chuck, driving plate and face plate and the flanged nose which enable them to be
directly attached. For obtaining different speeds of lathe there are three methods:
(1) By belt drive on cone pulley fitted on the headstock spindle with are without a back
gear arrangement
(2) By all gear drive using sliding gears of clutches.
Tail Stock:
The tail stock is located on the inner ways at the right hand side of the bed. It is used to support
the other end of the work when it is being machined between centers. It holds a tool for performing
operation such as drilling reaming. tapping etc. The tail stock is moved toward are away from the
operator. To accommodate different lengths of work, the body of the tail stock can be adjusted
along the ways by sliding it to the derived position where it can be clamped by bolts & plates Other
features are incorporated for accurate length setting and felt wipes pads on the base and spindle
Carriage:
The carriage of lathe have several parts that serve to support, move and control the cutting tool,
Saddle, cross slide, compound rest, tool post and apron are the main parts that the carriage consists.
Saddle:
The saddle in an H- shaped casting that fits over the bed and slides along the guide ways. It carries
the cross slide and too post.
Cross Slide:
It comprises a casting machined on the underside for attachment to the saddle and carries locations
on the upper face for the tool post or compound rest Automatic movement of cross-slide can be
obtained.
Compound rest:
The compound rest or compound slide is mounted on the top of the cross slide and has a circular
base graduates in degrees. It is used for obtaining angular ends and short tapers as well as
convenient positioning of the tool to the work
Tool Post: -
This is located on the top of the compound rest hold the tool and to enable it to be adjusted in a
convenient work position. The type and mounting of the tool post depends upon the class of work
for which it is to be used.
Apron:
The apron is fastened to the saddle and hangs over the front of the bed. It consists gears, clutches
and levers for aperciling the carriage by hand and power feeds. Usually a chasing dial is fitted
either to the side are tap of the apron and consists of a graduated dial.
Centres: -
The most common methods of holding the work in a lathe is between the two centres; live centre
and dead centre. These two take up the thrust due to metal cutting and the entire load of the work
piece on small bearing surface Different type of centres are used for holding different type of
works.
The ordinary type centre is the type used for most general work. In the tipped centre. The
point consists of a hard alloy tip brazed into and ordinary steel shank. The ball centre is used to
minimize we are and strain on the ordinary centre while tape turning by set over method. The holy
centre is little less than holy of the centre ground away while facilitates facing of the bar ends
without removal of the centres. The rotating are friction less center is always used in tail stock for
supporting heavy work revolving at high speed.
Chucks:
It is most important devices for holding and rotating a piece of work in a lathe work piece of short
length and large diameter are of irregular shape which cannot be conveniently mounted between
centres are held rigidly in a chuck. A chuck is atf ached to the lathe spindle by means of bolts with
the back plate screwed on to the top spindle nose. Different types of chucks are
Four jaw independent chuck
Collect chuck
Drill chuck
Combination chuck
Magnetic
Magnetic Chuck:
It is used for holding a very thin work piece made of magnetic material which cannot be held in
an ordinary chuck. It is also used where any distortion of the work piece due to pressure of the
jaws is undesirable. The holding power of chuck is obtained by the magnetic flux relating either
from the electromagnetic flux or from the permanent magnets introduced with in the chucks. In
ON position flux passes through the work piece and grips it. And in OFF position it is short
circuited and the flux passage mall by stopped, it causes the work piece free.
Face Plates:
A face plate consists of a circular disc bored out and threaded to fit the nose of the lathe spindle.
This has the radial, plain and T-slots for holding work by bolts and clamps. Face plates are used
for holding work pieces while cannot be conveniently held between the centres or by chucks.
Angle Plates:
This is C.I plate having two faces machined to make me absolutely at right angles to each other.
Holes & slots are provided on both faces so that it may be clamped on face plate and can hold the
work piece on the other face by bolts and clamps. Angle plates are used in conjunction which a
face plate when the holding surface of the work piece should be kept horizontal, as for example,
in machining a flange of pipe elbow.. When the eccentric jobs are bolted on the face plate a balance
weight or counter weight must be added.
Mandrels:
A mandrel is a device for holding and rotating a hollow piece of work that has been previously
drilled or bored. The work receives with me mandrel should be true with accurate centre holes for
machining outer surface torsion. The ends of a mandrel are slightly smaller in diameter and
attached to provide effective gripping surface of one lathe dog set screw. The mandrel is rotated
by the lathe dog and the catch plate and it drives the work by friction. Different types of mandrels
are: plain mandrel, step mandrel, collar mandrel, gang mandrel, expansion mandrel.
Plain Mandrel:
It is used when a large number of identical pieces having standard size holes are required to be
mounted on it. The body of the mandrel is slightly tapered, the difference in diameter is 1 to 2 mm
per 100 mm length. The length varies from 55 to 43 0mm. The taper is provided for proper gripping
of the work piece. It is suitable for only one size of bore.
Step Mandrel:
The step mandrel having steps of different diameter employed to drive different work pieces
having different sizes of holes without replacing the mandrel each time. It is suitable for turning
collars, washers and odd jobs.
Lone Mandrel:
It consists of a solid cone attached to the one end of the body and a sliding cone which can be
adjusted by turning a hut at the threaded end. It is suitable for holding work pieces having different
hole diameters by placing the work on two cones and lightning the nut. Avbid forcing the cone
tightly upon the work to prevent spoil as its outer edge.
Expansion Mandrel:
This has a fixed collar at one end and a movable collar at the threaded end which may be adjusted
to its position by a nut. The mandrel is used to hold a set of holler work pieces between two collars
by tightening the nut. The friction between the sides of the work and the collar is sufficient to drive
the work without slipping in the mandrel.
Gang Mandrel:
One type of a mandrel is that consists of a tapered pin which is driven into a sleeve that is parallel
outside and tapered inside. The sleeve has three longitudinal slots, two are hear by cut through and
the third splits it completely. This construction enables an expansion mandrel to grip various work
pieces with different hole diameters with in a limit that cannot otherwise be held in all ordinary
mandrel. The sleeve first placed within the work with pin removed. The tapered pin is then pressed
from the end into the sleeve and the sleeve expands. Gripping the work securely and accurately
can hold work pieces of diameter 0.5 to 2mm.
Rests:
A rest is a mechanical device which supports a long slender work piece, which is turned between
centres at some intermediate point to prevent bending of the work piece due to its own weight and
vibrations set up due to the cutting force that acts on it. A rest should always be used when the
length is 10 to 12 times the diameter of work piece rests when properly set provide greatest
accuracy in machinery and permit heaver depth of cut on the work pieces the two types of rests
used in an engine lathe are the steady or centre rest and the follower rest.
Steady Rest:
It consists of a C.I base, which may be made to slide on the lathe bed ways and clamped at any
desired ways and clamped where a support is necessary. The upper portion is hinged at one end
which facilitates setting and removal of work piece without disturbing the rest. The three jaws are
moved then acts as bearing and holds the work piece rigidly. The main junction is to support a
long slender work. Also used to support the free end of a long work piece for drilling, boring, etc.,
Follower Rest:
It consists C like casting having two adjustable jaws which support the work piece the rest is
bolted to the back end of the carriage. It moves with the carriage movement. The follower rest
prevents the job from away when cut is made and is used in turning operation or where the entire
length of the work piece is required to bed turned without distributing the setting.
Centering:
When the work is required to be turned between centres or between chuck and a centre, conical
shaped boles must be provided at the ends of the work piece: c provide bearing surface for lathe
centers. Centering is the operation of producing conical holes in work pieces. To prepare a
cylindrical work piece for centering, it is first necessary to locate the centre hole by marking off
this is done by rubbing the end with a chuck and the centre may be located by anyone of the
following instruments.
After the centre has been located, a centre punch and a hammer are used to make a deep indentation
to produce the hole to hold and to revolve the work on lathe centres. Centre holes are produced by
using a drill and drill and counter sink tool. This is held on a drill chuck and may be mounted on
the head stock or on the tail stock spindle to provide a conical hole on the ends of the work piece.
The included angle as the hole should be exactly 60 to fit with the 60 point angles of the lathe
centres. The straight hole projected beyond the conical hole serves as a small reserving for
lubricating oil & receives the tip of the dead centre from rubbing with the work piece.
Shank: Shank is that portion of the tool bit which is hot ground to form cutting edges and is
rectangular in cross section.
Face: Face is the surface against which the chip slides upward.
Heel: Heel is the lowest portion of the side cutting and end cutting edge.
Rake: Rake is the slope of the tape away from the cutting edge. There are two types back rake
angle and side rake.
Side clearance: Side clearance is that the plane the forms the flank or side of a tool has been
ground back at an angle sloping down from the side cutting edge.
End cutting edge angle: Indicates that the plane which forms the end of a tool has been ground
back at an angle sloping from the hose to the side of the shank.
Lip or Cutting angle: It is the included angle when the tool has been grand wedge at shaped.
Lathe Operations:
Operations which are performed in a lathe either by holding the work piece between the centres or
by a chuck are.
Operations which are performed by holding the work by a chuck or a face Plate or an angle plate
are
1. Grinding
2. Milling
SHAPER
The shaper is a reciprocating type of machine tool used to produce flat surface. The surface may
be horizontal, vertical or inclined. Modern shaper can generate contoured surfaces also. The metal
working shaper was developed in the year 1836 by James Nesmyth an English man.
It is possible to form vertical and angular surfaces also. With proper tools and
accessories even irregular surfaces can be formed.
Working Principle.
The job is rigidly fixed on the machine table. The single point cutting tool held properly in the tool
post is mounted on a reciprocating ram. The reciprocating motion of the ram is obtained by a quick
return motion mechanism. As the ram reciprocates, the tool cuts the material during its forward
stroke. During return, there is no cutting action and this stroke is called the idle stroke. The forward
and return strokes constitute one operating cycle of the shaper.
Types of Shaper.
Shapers are classified as follows:
Shaping Machine
Major parts of shaper are
Base
Column
Cross rail
Table
Ram
Tool head
Base:
It is made of cast iron to absorb vibration and it takes the entire load coming on the machine.
Column:
It is made of cast iron. It has a hollow box construction. Quick return mechanism for ram is placed
inside the column. There is two guide ways at the top in which the ram reciprocates horizontally.
There are two guide ways at the front vertical face of column in which cross rail can moves
vertically.
Cross rail:
The cross rail has got two horizontal guide ways in the face. Horizontal cross feed screw is fitted
in the crossed side. For vertical movement of the slide elevating screw is provided.
Table:
It is rectangular hollow cast iron block the table slide on horizontal guide ways of cross rail. The
surface has T-slots for clamping work. The table can be moved horizontally by rotating cross feed
screw. The front face of the table is supported by the adjustable table support
Ram:
Ram carries the tool head at its flank end. Ram reciprocates on the guide ways. It is connected to
the quick return mechanism; stroke of ram can be adjusted by hand wheel at the top.
Tool head:
Vertical and angular feed can be given to the tool head, the slide can be moved vertically by
rotating down feed screw. There is swivel base for the tool head graduated in degrees the tool can
be swivelled to any required angle. Apron can be titled to the right or left and clamped in that
position. A tool block is hinged inside the box and is rigidly placed inside the clapper box. During
the return stroke the tool block lifts out of clapper box. This prevents the rubbing of the tool on the
job.
MILLING MACHINE
A milling machine is a machine tool that removes the metal as the work is feed against a rotating
multipoint cutter. The cutter rotates at a high speed and because of the multiple cutting edges it
removes metal at a very fast rate. The machine can also hold one or more number of cutters at a
time. This is superior to other machines as regards accuracy and better surface finish.
Planer Type:
The planer miller as it is called is a massive machine built up for heavy duty work, having spindle
heads adjustable in vertical, in transverse directions. It resembles a planar and like a planar, it has
a cross rail capable of being raised or lowered carrying the cutters, their heads, and the saddles, all
supported by rigid uprights. There may be a number of independent spindles carrying cutters on
the rail as well as two heads on the uprights. This arrangement as independently driving multiple
cutter spindles enables number of work surfaces to be machined simultaneously there by obtaining
great reduction in production time.
Special Type:
Milling machines of non-conventional design have been developed to suit special purposes. The
features they have in common are the spindle for rotating the cutter and provision for moving the
tool or the work in different directions. In special type milling machines there are rotary table
machine. Drum milling machine, planetary milling machine, pantograph, profiling and tracer
controlling milling machine.
PRINCIPAL PARTS:
Base:
The base of the machine is a grey iron casting accurately machined on its top and bottom surface
and serves as a foundation member for all the other parts which rest upon it. It carries the column
at its one end.
Column:
It is maintained vertically upon the frame. Many mechanisms for the spindle and table feed are
maintained on it. Front face has the guide ways for supporting the knee.
Knee:
It slides up and down on the vertical ways of the column face. The adjustment is effected by screw
mechanism. The knee houses the feed mechanism of the table and different controls to operate it.
Saddle:
On the top of the knee is placed saddle, which slides on guide ways set exactly at 900 to the column
face. A cross feed screw near the top of the knee engages a nut on the bottom of the saddle to move
it horizontally, by a hand power for cross feed.
Table:
The table rests on ways of the saddle and travels longitudinally.
Overhanging arm:
Maintained on the top of the column extends beyond the column face and serves as a bearing
support for the other end of the arbor.
Arbor:
An arbor may be considered as an extension of the machine spindle on which milling cutters are
securely mounted and rotated, the arbors are made with taper shanks for proper alignment with the
machine spindles having taper holes at their nose.
Front brace:
The front brace is an extra support that is fitted between the knee and the over arm to ensure further
rigidity to the arbor and knee.
Milling Cutters:
The milling cutters are revolving tools having one or several cutting edges of identical form equally
spaced on the circumference of the cutter. The cutting elements are called teeth, which
intermittently engages the work piece and remove material by relative movement of the work piece
and cutter. Milling cutters are classified as
(1) According to the constructional features of the cutter
(a) Solid cutter
(b) Tipped Solid cutter
(c) Inserted teeth cutter
(2) According to the relief characteristics of cutter teeth
(a) Profiler relieved cutter (b) Form relieved cutter
(3) According to the methods of mounting the centre
(a) Arbor type cutter
(b) Shank type cutter
(c) Facing type cutter.
(4) According to the direction of rotation of cutter
(a) Right hand rotational cutter
(b) Left hand rotational cutter
8. Profile milling
9. End milling
10. Saw milling
11. Milling keyways, grooves and slots
12. Gear cutting
13. Helical milling
14. Cam milling
15. Thread milling
Types of cutters and typical milling operations ( a) Slotting with a straight-tooth side-milling
cutter. ( b) Slotting with a concave slitting saw. ( c) Plain milling. (d) Angle milling. (e) and ( f)
Form milling. ( g) Straddle milling ( h) Profile milling with an end mill.
DRILLING MACHINE
The drilling machine or drill press is one of the most common and useful machine employed in
industry for producing forming and finishing holes in a work piece.
A spindle which turns the tool (called drill) which can be advanced in the work piece either
automatically or by hand.
Working principle:
The rotating edge of the drill exerts a large force on the work piece and the hole is generated. The
removal of metal in a drilling operation is by shearing and extrusion.
1. Base: The base is a heavy casting that supports the machine structure; it provides rigid mounting
for the column and stability for the machine. The base is usually provided with holes and slots
which help to Bolt the base to a table or bench and allow the work-holding device or the work
piece to be fastened to the base.
2. Column: The column is a vertical post that Column holds the worktable and the head containing
the driving mechanism. The column may be of round or box section.
3. Table: The table, either rectangular or round. Drill machine/press in shape supports the work
piece and is carried by the vertical column. The surface of the table is 90-degree to the column and
it can be raised, lowered and swiveled around it. The table can be clamp/hold the required the work
piece. Slots are provided in most tables to allow the jigs, fixtures or large work pieces to be securely
fixed directly to the table.
4. Drilling Head: The drilling head, mounted close to the top of the column, houses the driving
arrangement and variable speed pulleys. These units transmit rotary motion at different speeds to
the drill spindle. The hand feed lever is used to control the vertical movement of the spindle sleeve
and the cutting tool.
The system is called the sensitive drilling machine/press as the operator is able to sense the
progress of drill with hand-faced.
Specification of drilling machine:
1) The size of the working table and capacity of the machine.
2) Maximum size of the work piece on the particular machine.
3) Maximum diameter of drill on the particular machine.
4) Number of spindles on the particular machine.
5) Length of arm and column diameter must be specified for radial drilling machine.
1. Body clearance is the portion of the body surface with reduced diameter which provides
diametral clearance.
2. Face is the portion of the flute adjacent to the lip on which chip flows as it is cut from the work
piece.
3. Flank is the conical surface of a drill point which extends behind the lip to the following flute.
4. Flutes are helical grooves cut on the cylindrical surface of the drill and provide the lip.
5. Heel is the edge formed by the intersection of flute surface and the body clearance.
6. Land is the cylindrically ground narrow strip on the leading edges of drill flutes. It keeps the
drill aligned. It is also known as margin.
7. Point is the cone shaped sharpened end of the drill that produces lips, faces, flanks and chisel
edge of the drill.
8. Lips also known as cutting edges are the edges formed by the intersection of flanks and faces.
They are two in number with identical length and angle.
9. Web is the thickness of the drill between the flutes which extends from point towards the
shank. The point end of the web forms the chisel edge.
10. Shank is the cylindrical portion of the drill which is used to hold and drive the drill. It extends
from the neck and it may be either straight or tapered.
11. Tang is flattened end of the taper shanks which fits into socket or drill holder. It ensures
positive drive of the drill from the drill spindle.
GRINDING MACHINE
Grinding is a metal cutting operation performed by means of a abrasive wheel that acts as cutting
tool. This is used to finish work pieces which are showing a high surface quality, accuracy of shape
and dimension. In grinding operation a little metal 0.25 to 0.5 mm with an accuracy of order
0.00025 mm can be obtained columns and status were shaped and finished with a globular stone
which abraded the surface.
Types of Grinding:
Grinding is done on surfaces of almost all conceivable shapes and mat dials of all kinds. Grinding
may be classified broadly into two groups.
1. Rough or non-precision grinding
2. Precision grinding
Rough Grinding:
The common forms of rough grinding are snagging and offhand working where the work is held
in the operators hand. The work is pressed hold against the wheel or vice-versa. The accuracy and
surface finish is obtained are of secondary importance.
Precision Grinding:
This is concerned with producing good surface finish and high degree of accuracy. The wheel or
work both are guided in precise paths.
Grinding in accordance with the type of surface to the ground is classified as.
External cylindrical grinding
Internal cylindrical grinding
Surface grinding
Form grinding
Types of Grinding Machines:
According to the quality of surface finish grinding machines are classified as.
1. Rough Grinders
(a) Floor stand and bench grinders
(b) Portable and flexible shaft grinders
(c) Swing frame grinders
(d) Abrasive belt grinders
(2) According to the direction of helix of the cutter teeth
(a) Parallel or straight teeth cutter
Rough Grinders:
A floor-stand grinder as a horizontal spindle with wheels usually at both ends and is maintained
on a base or pedestal. A motor at floor level drives the wheel spindle through a belt. A flexible
shaft grinder has the grinding wheel on the end of a long flexible shaft driven.by a motor on a
relatively station from widely separated areas. The swing frame type grinder has a horizontal frame
about 2 to 3 m long suspended at its centre of gravity so as to move freely within the area of
operation. This machine is moved around with a job crane suspended from columns or by mobile
units.
In this
(1) The work must revolve
(2) The wheel must revolve
(3) The work must pass the wheel
(4) The wheel must pass the work,
(5) The main feature in this type is that the operation may be stopped automatically.
A plain grinding machine is essentially a lathe on which a grinding wheel has been substituted
for the single point tool: It consists of following parts.
Base:
The base is the main casting that rests on the floor and supports the parts mounted on it. On the
top of the base are precision horizontal ways set at right angles for the table to slide on.
Table:
These are lower and upper type. The lower table slides on ways on the bed and provides traverse
of the work past the grinding wheel. The upper block (table) has T -slots for securing the head stock
and tail stock or float stock and can be positioned along the table to suit the length of the work.
Head stock:
The head stock supports the work piece by means of a dead centre and drives it by means of a dog,
as it may hold and drive in a work piece.
Tail Stock:
This may adjusted and clamped in various positions to accommodate different lengths of work
piece.
Wheel head:
It carries a grinding wheel and its driving motor is mounted on a slide at the top and rear of the
base. It may be removed perpendicular to the table ways.
Cross feed:
The grinding wheel is fed to the work by hand or power as cross feed control. In this type of the
operation may be stopped automatically when the work piece has been finished to the size. In one
method it uses an automatic calipee type ganging attachment to measure the work piece and stop
the operation at the proper time.
Surface Grinder:
Surface grinding machines are employed to finish plane or flat surfaces. Also capable of grinding
irregular, curved, tapered, convene and concave surfaces. The two classes are: One has
reciprocating tables for work tables for continuous rapid grinding. In an horizontal type of grinding
machine, grinding is normally done on the periphery of the wheel the area of contact is small and
the speed is uniform over the grinding surface. Small grain wheels can be used and the finest
finishes obtained the different types are.
(1) Universal tool and cutter grinders: They are particularly intended for sharpening of
miscellaneous cutters.
(2) Single-purpose grinders: These are used for grinding tools such as drills, tool- bits etc.,
in large production plates where large amounts of grinding tools such as drills, work is
necessary to keep production. Tools can be ground uniformly and with accurate cutting
angles.
The work holding devices and attachments cover a wide range and include the following.
lathe
Calculations:
Signature of faculty
Ex.No.1
FACING AND PLAIN TURNING OPERATIONS
Date:
AIM:
To perform Facing and Plain Turning Operation using Lathe machine on a given material made
of Mild steel.
MATERIAL REQUIRED:
Lathe machine, cutting tool, outside Caliper, Steel Rule, Vernier Caliper and Vernier height
gauge
PROCEDURE :
2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly,
ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts using spanner.
4. Facing is done with cutting tool moving from the centre of work piece towards outside.
It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and
it is done until the required diameter of the job is obtained.
AIM:
To perform Facing, Plain Turning, Step turning and Taper Turning Operation using Lathe
machine on a given material made of Mild steel.
MATERIAL REQUIRED:
Lathe machine, cutting tool, outside Caliper, Steel Rule, spanner, Vernier Caliper and
Vernier height gauge
CALCULATION:
The taper angle is calculated using the following formula:
Dd
Taper angle () = tan1
2l
Where
D = large diameter of taper in mm
d = small diameter of taper in mm
l = length of tapered part in mm
= angle of taper
PROCEDURE :
2. The cutting tool is set in a tool post such that the point of the Cutting
tool coincides with the lathe axis.
3. The machine is switched on to revolve the work piece at the selected speed.
4. By giving Cross feed and longitudinal feed to the cutting tool (grooving tool) to
obtained Steps at specified dimension.
6. By giving angular feed to the cutting tool through the compound slide the taper
turning operation is done.
8. The work piece is removed from the chuck and all the dimensions are measured
and checked.
AIM:
To perform Facing, Plain Turning, Step turning, Taper turning, V-Thread cutting and Knurling
Operation using Lathe machine on a given material made of Mild steel.
MATERIAL REQUIRED:
Lathe machine, cutting tool, outside Caliper, Steel Rule, V- tool, Knurling tool, Vernier
Caliper and Vernier height gauge
CALCULATION:
The number of teeth on change gears is calculated using the following formula:
Driver teeth/ Driven teeth = Pitch of the work / pitch of the lead screw
PROCEDURE :
2. The cutting tool is set in a tool post such that the point of the Cutting
tool coincides with the lathe axis.
3. The machine is switched on to revolve the work piece at the selected speed.
4. By giving Cross feed and longitudinal feed to the cutting tool, the facing and turning
operations are done respectively.
7. The machine is switched off and the change gears of calculated teeth (as per
calculation) are connected.
9. The external thread cutting operation is done using external Vthread cutting tool
by engaging thread cutting mechanism.
11. The work piece is removed from the chuck and all the dimensions are measured
and checked.
Shaping
M/c
Calculations:
Signature of faculty
Ex.No.4
AIM:
MATERIAL REQUIRED:
Shaping machine, H.S.S tool bit, Vernier calipers, V tool, Vernier height gauge, Plain tool, Dial
indicator
PROCEDURE :
RESULT: Thus, a V-Shape is made in the given work piece to the dimensions using
Shaping machine.
Milling
M/c
Signature of faculty
Ex.No. 5
AIM:
To perform hexagonal head and the slot cutting on the given blank using Milling machine
MATERIAL REQUIRED:
CALCULATION:
Indexing calculation
Index crank movement = 40 / N N = Number of faces required
PROCEDURE :
1. Fit the helical cutter on the arbor and the specimen between the centers of the dividing head
and the tail center.
2. Carefully adjust the work piece so that the cutter just touches the top surface of the
specimen.
3. Calculate the necessary depth of cut and then mill the six faces of the hexagonal head in
succession.
4. Change the cutter and mill the rectangular slot.
RESULT: The hexagonal head and the slot is machined using the milling machine to the
required number of teeth.
2. Open side
3. Four bolt
4. Four way
7. What is an apron?
The integral part of several gears, levers clutches mounted with the saddle for
moving the carriage along with lead screw while thread cutting
4. Semi-automatic lathe
5. Automatic lathe
12. State the various feed mechanisms used for obtaining automatic feed?
1. Tumbler gear mechanism
4. Apron mechanism
2. Centers
3. Face plate
4. Angle plate
16. State any two specifications of capstan lathe & turret lathe?
1. Number of spindle speed
2. Air drives
3. Hydraulic drives
21. What are the components that can be turned on a copying lathe?
1. Cam shaft
2. Crank shaft
3. Journal bearings
24. How the feed & depth of cut is given to the shaper?
Feed is given by rotating the down feed screws of tool head depth of cut is given by
rotating by raising or elevating the table
3. Pit planer
4. Edge planer
2. Table
3. Columns
34. List any four machining operations that can be performed on a drilling machine?
1. Drilling
2. Counter sinking
3. Tapping
4. Trepanning
35. What are the different ways to mount the drilling tool?
1. Fitting directly in the spindle
2. By using a sleeve
3. By using a socket
4. By means of chucks
1. Roughing, semi finishing & finishing cuts are completed in one pass of the
broach
2. Broaching can be used for either external or internal surface finish
Limitation:
1. High initial cost of the broach tool compare to other tools
2. Job work or batch work is not advisable due to the high tool cost.
39. What are the different operations that can be performed on a broaching machine?
1. Broaching splines
4. It should be odourless.
49. State any two comparisons between plain &universal milling machine?
1. In plain milling machine the table is provided with three movements,
longitudinal, cross &vertical. In universal milling machine in addition to these
three movements, there is a forth movement to the table. The table can be
swiveled horizontally & can be fed at angles to the milling machine spindle.
2. Adaptors
3. Collets
51. List the various type of milling attachment?
1. Vertical milling
2. Universal milling
4. Rotary
5. Slotting
6. Rack milling
2. Cutter wear is less because chip thickness is maximum at the start of cut.
2. Face milling.
3. Angular milling.
4. Gang milling.
5. End milling.
6. Gear cutting.
2. Universal.
3. Optical.
60. What are the other forming methods for manufacturing gears?
1. Gear cutting by single point form tool.
3. Gear broaching.
4. Template method.
2. Gear burnishing.
3. Gear grinding.
4. Gear lapping.
2. Face
3. Flank
4. Base
5. Nose
6. Cutting edge
74. What are all the conditions for using positive rake angle?
1. To machine the work hardened materials
2. To turn the long shaft of small diameter
3. Tool geometry
4. Tool material
VTn=C