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FACULTY OF ENGINEERING

Department of Mechanical and Automobile Engineering

DEPARTMENT OF
MECHANICAL AND AUTOMOBILE
ENGINEERING

LABORATORY MANUAL
ME 434/AU335 PRIMARY
MANUFACTURING/MANUFACTURING
PROCESS

ME434/AU335 Primary Manufacturing/Manufacturing Process


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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

Lab Component for subjects


ME434/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.

PART-B: SHAPING AND MILLING OPERATIONS


Cutting of V Groove/ dovetail / Rectangular groove using a shaper.

Cutting of Gear Teeth/Hexagonal head and slot using Milling Machine.

Demonstration on Surface grinding operation

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

Abstract about the Lab


Metal cutting and Production lab provides the student with knowledge about various machine
tools such as to identify machine parts and their functions; select layout tools and techniques;
define machine shop terminology; perform basic setups; calculate common shop formulas;
perform semi-precision layout; execute grinding techniques; demonstrate basic machine
Operations; and apply proper measuring tools.

Course Learning Objectives (CLOs):

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

Course Outcomes (COs):

At the end of the course the students will be able to

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.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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.

3. Break the sharp edges in jobs

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.

6. Do not remove chip while machine is running.

7. Ensure proper bucking of m/c slides or pay attention or alertness.

8. Care should be taken while selecting rapid or feed .

9. Follow safety precautions while approach with cutter to avoid tool damage.

10. Use coolants for heat dissipation.

11. Use goggles for sparks, spatters, avoid the watch clearly with bare eyes.

12. Avoid sharp edge tools.

13. Ensure clamping on surface grinding m/c before take a cut.

14. Select proper speed or feed or depth of cut.

15. Aim for easy chip disposal system.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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

Facing and Plain turning on


2.
lathe machine

Step turning and Taper 30 - 35


3.
turning on lathe machine.

Thread cutting and knurling


4.
on lathe machine.

V-Groove cutting on shaping


5. 36 - 37
machine

Hexagonal head and slot


6. 38 - 39
Milling

7. Viva Questions and Answers 40 - 51

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

Ex.No.1 INTRODUCTION OF GENERAL PURPOSE


Date: MACHINES
INTRODUCTION
Machining is the process of converting the given work piece into the required shape and size with
help of a machine tools such as Lathe, Drilling machine, Milling machine, Shapers Grinders etc..

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

The Engine Lathe:


The engine lathe is the most important member and it is so called as Engine Lathe because in
early days it were driven by steam engines. It has all basic components i.e., head stock, tail stock.
The head stock contains additional mechanism for driving the lathe spindle at multiple speeds. The
engine lathe can feed the cutting tool both in cross and longitudinal direction with the help of
carriage, feed rod and lead screw. Engine lathes are classified according to the various designs of
the head stock and methods of transmitting power to the machine. Different types of lathes are
classified according to the power.

The Capstan and Turret Lathe:


These lathes are used for production work. In this the tailstock is replaced by a hexagonal turret,
on the face of which multiple tools may be fitted and feed into the work in proper sequence. The

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Department of Mechanical and Automobile Engineering

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:

The height of the centres measured from the Lathe bed.

The swing diameter over bed

The length between centres

The swing diameter over carriage

The maximum bar diameter

The length of the bed.

Power input

Speed obtained etc

Description of Lathe parts:


The principle parts of the lathe are lathe bed, head stock, tail stock, carriage, Tool post, Apron
etc

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.

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Department of Mechanical and Automobile Engineering

(3) By variable speed motor.

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.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

Lathe Accessories and Attachments:


The Lathe accessories are used either for holding and supporting the work are the holding the tool.
They are centres catch plates and carries, chucks, collects, face plates, mandrels and rests.

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.

Carries and Catch Plates:


Carries and catch plates are used to drive a work piece when it is held between two centers carries
are driving dugs are attached to the end of the work piece by a set screw and catch plates are either
screwed are bottled to the nose of the head stock spindle . The projecting pin of a single pin catch
plate drives the and are tail by a carries attached to the work piece two pins of a double pin catch
plate engage with the double are double slotted carries and provide uniform drive . The tail type is
used in conjunction with a face plate are slotted catch plate.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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

Three jaw universal chuck

Drill chuck

Combination chuck

Magnetic

Air or hydraulic operated chuck.

Universal or Self-centering chuck:


It has three jaws of all are made to slide simultaneously by an equal amount within the slots
provided on the body by rotating any one of the three fun ions which meshes with the teeth cut on
the underside of the scroll disc. The scroll disc having the spiral groove cut on the top face meshes
with the teeth on the jaws when the disc is made to rotate by any one of pinions all the jaw all
moved backward or forward by equal amount. It is suitable for holding round or hexagonal work
force and the job is centered automatically & quickly. But it has less gripping capacity and
centering accuracy is soon lost due to wear.

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,

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Department of Mechanical and Automobile Engineering

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.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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.

(1) Using a centre head and steel rule of a combination set

(2) Using a hermaphrodite caliper.

(3) Using a divider and surface plate

(4) Using a surface gauge

(5) Using a ball centre punch.

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.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

Nomenclature of Cutting Tool:


Cutting tool nomenclature means systematic naming of the various parts and angles of a cutting
tool. The principle underlying cutting tool angles are the same whether the tool is single or multi
point tool or a grinding wheel. The different points of the single point cutting tool are:

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.

Flank: Flank is the surface which face the work piece.

Heel: Heel is the lowest portion of the side cutting and end cutting edge.

Nose: Nose is conjunction of the side and end cutting edges.

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.

Single point tool nomenclature

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

Lathe Operations:
Operations which are performed in a lathe either by holding the work piece between the centres or
by a chuck are.

1. Straight turning 8. Taper turning


2. Shoulder turning 9. Eccentric turning
3. Chamfering 10. Polishing
4. Thread cutting 11. Grooving
5. Facing 12. Spinning
6. Knurling 13. Spring winding
7. Filling 14. Forming

Operations which are performed by holding the work by a chuck or a face Plate or an angle plate
are

1. Drilling 6. Internal thread cutting


2. Reaming 7, Tapping
3. Boring 8. Under cutting
4. Counter boring 9. Parting off
5. Taper boring

Operations which are performed by using special attachments are:

1. Grinding
2. Milling

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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.

Purposes of the shaping machines are as follows:

The main purpose of shaping machine is to machine plane horizontal surface.

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:

As Per Type of Motion.



Crank type

Geared type

Hydraulic type

As Per Position and Travel of Ram



Horizontal type

Vertical type

Travelling head type

As Per Design of Table



Standard shaper

Universal shaper

As Per Cutting Stroke



Push type

Draw type

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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.

Types of Milling Machine:


The Milling Machine may be classified in several forms covering a wide range of work and
capacities. There are some milling machines classified according to size and operation to be
performed.
They are:
(1) Column and knee type
(a) Hand milling machine
(b) Plain milling machine
(c) Universal milling machine
(d) Omniversal milling machine
(e) Vertical milling machine
(2) Manufacturing or fixed bed type
(a) Simplex Milling Machine
(b) Duplex milling machine
(c) Triplex milling machine
(3) Planar type
(4) Special type
(a) Rotary table milling machine
(b) Draw milling machine
(c) Planetary milling machine
(d) Pantograph, profiling and traces controlling machine

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

Column and Knee Type:


In this type, table is mounted on the knee-casting which in turn is maintained on the knee-casting
on the vertical slides of the main column. The knee is vertically adjustable on the column so that
the table can be moved up and down to accommodate work of various heights. The column and
knee type milling machine are classified according to the various methods of supplying power to
the table, different movements of table is supplied by hand control and is useful in machining, slots
and grooves and keyways etc., In a plain milling machine the table may be fed in a longitudinal,
cross or vertical direction. They are much rigid and sturdy. In case of Omniversal milling machine
the table can be fitted in a vertical plane by providing a swivel arrangement at the knee. Also the
entire knee assembly is mounted in such a way that it may be fed in a longitudinal direction
horizontally. The table enables to machine taper spiral grooves in reamers, bevel gears etc., More
ever this knee column type milling machine is mostly used shop work machine. In vertical Milling
Machine the position of the spindle is vertical or perpendicular to the work table.

Manufacturing or fixed bed type:


These are comparatively large, heavy and rigid from column and knee type and differs in table
construction. The table is maintained directly on the ways of fixed bed. The table movement is
restricted to reciprocating at right angles to the spindle axis with no provision for cross or vertical
adjustment. The name Simplex, Duplex and Triplex type indicates that the machine is provided
with single, double and triple spindle heads respectively. In a duplex machine, the spindle heads
are arranged one on each side of the table. In triplex type the third spindle is maintained on a cross
rail.

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.

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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.

Horizontal Column and Knee type Milling machine

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.

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FACULTY OF ENGINEERING
Department of Mechanical and Automobile Engineering

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.

Work holding devices:


It is necessary that the work should be properly and securely held on the milling machine table for
effective machining operations.
Different types of work holding devices are
o T-bolts and clamps
o Angle plates
o V-bolts
o Vises : plain vise
Swivel vise
Universal vise
o Special fixtures

Cutter holding devices:


There are several methods of supporting and rotating milling cutters with the machine spindle
depending on the different designs of the cutters. The following are the different devices for
holding and rotating cutters
(1) Arbors
(2) Collets
(3) Adapters
(4) Spring Collets
(5) Bolted cutters
(6) Screwed on cutters

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Milling Machine Attachments:


The attachments are standard or special auxiliary devices intended to be fastened to or joined with
one or more components of the milling machine for the purpose of augmenting the Range,
Versatility, productivity or accuracy of operation. Some classes of milling machine attachments
are used for positioning and driving the cutter by altering the cutter axis and speed, whereas other
classes are used for positioning, holding and feeding the work along a specified geometric path.
The following are the different attachments used on standard column and knee type milling
machine.
(1) Vertical milling attachment
(2) Universal milling attachment
(3) High speed milling attachment
(4) Slotting attachment
(5) Universal spiral milling attachment
(6) Rack milling attachment
(7) Circular milling attachment
(8) Driving head attachment

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

Milling Machine Operations:


The following are the different operations pyramid in a milling machine.
1. Plain milling
2. Face milling
3. Side milling
4. Straddle milling
5. Angular milling
6. Gang milling
7. Form milling

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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.

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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.

Types of Drilling Machine:


1) Based on construction:
Portable drilling machine
Sensitive drilling machine
Radial drilling machine
up-right drilling machine
Gang drilling machine
Multi-spindle drilling machine
2) Based on Feed:
Hand driven
Power driven

Radial drilling machine

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The Radial drilling machine essentially consists of:

A spindle which turns the tool (called drill) which can be advanced in the work piece either
automatically or by hand.

A work table which holds the work piece rigidly in position.

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.

Parts of Drilling Machine:

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.

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Twist drill Nomenclature

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.

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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

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(b) Right hand helical cutter


(c) Left hand helical cutter
(d) Alternate helical teeth cutter
(3) According to the purpose of use of the cutter
(a) Standard milling cutter
(b) Special milling 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.

Cylindrical Centre-less Grinder:


Centre-less grinding is a method of grinding exterior cylindrical, tapered and formed surfaces on
work pieces that are not held and rotated on centers. The work is placed upon the work rest, and
the lather, together with regulating wheel, is fed forward, forcing the work against the grinding
wheel is feed forward centre-less grinding may be done in one of the three ways.
Through feed
In feed
End feed

Some advantages of centre-less grinding are:


As a true floating conditions exists during the grinding process, less metal to be
removed.
The process is continuous and adopted for production work
The size of the work is easily controlled.
Disadvantages:
Work having un-multiple diameters is not easily handled.

Cylindrical Centre type grinder:


These are primarily intended for grinding plain cylindrical parts also for grinding controlled
cylinders, tapers, faces & Shoulders, fillets and even cams and crankshafts. In this type work piece
is held between dead centers and by rotating by a dog and driver on the face plate.

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,

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(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.

Horizontal spindle reciprocating table


Horizontal spindle rotary label
Vertical spindle reciprocating table
Vertical spindle rotary table

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Tool and cutter Grinder:


Tool and cutter grinders used mainly to sharpen and recondition multiple tooth cutters like reamers,
milling cutters, drills, laps, knobs and other type of tools used in the snap with various attachments.
They can also do light surface, cylindrical and internal grinding to finish such items as figs,
fixtures, die and gauge details and shaper single point tools. They are two types

(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.

Work holding devices and attachments:

The work holding devices and attachments cover a wide range and include the following.

Work holding and supporting devices


Equipment of contain grinding
Attachments to improve grinding results
Measuring and sizing devices

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Part A Model 1(Lathe Operations)


Sketch of given model

Observations: Record the following in a tabular form:


Type of
Speed given to Feed given to
Machine Type Size Surface
&
Make
Note: All Dimensions in mm
Tool Work Tool Work Produced

lathe

Calculations:

Signature of faculty

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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:

A mild steel bar of 25 mm diameter and 125 mm length

TOOLS AND EQUIPMENT USED:

Lathe machine, cutting tool, outside Caliper, Steel Rule, Vernier Caliper and Vernier height
gauge

PROCEDURE :

1. The given work piece is checked for its dimension.

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.

6. Finally the dimension of work piece is again checked.

RESULT: Required specimen obtained according to specified operations


(Facing and Plain turning operations) with given dimensions.

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Ex.No.2 STEP TURNING (GROOVING) AND TAPER


Date: TURNING OPERATIONS (COMPOUND REST
METHOD)

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:

A mild steel bar of 25 mm diameter and 125 mm length

TOOLS AND EQUIPMENT USED:

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 :

1. The given work piece is held firmly in a lathe chuck.

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.

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4. By giving Cross feed and longitudinal feed to the cutting tool (grooving tool) to
obtained Steps at specified dimension.

5. The compound rest is swiveled for the calculated taper angle.

6. By giving angular feed to the cutting tool through the compound slide the taper
turning operation is done.

7. The machine is switched off.

8. The work piece is removed from the chuck and all the dimensions are measured
and checked.

RESULT: Required specimen obtained according to specified operations


(Grooving and Taper turning operations) with given dimensions.

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Ex.No.3 V- THREAD CUTTING AND KNURLING


Date: OPERATIONS

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:

A mild steel bar of 25 mm diameter and 125 mm length

TOOLS AND EQUIPMENT USED:

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 :

1. The given work piece is held firmly in a lathe chuck.

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.

5. The speed of the work piece is reduced.


6. The knurling operation is done using knurling tool.

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7. The machine is switched off and the change gears of calculated teeth (as per
calculation) are connected.

8. Again the machine is switched on.

9. The external thread cutting operation is done using external Vthread cutting tool
by engaging thread cutting mechanism.

10. The machine is switched off.

11. The work piece is removed from the chuck and all the dimensions are measured
and checked.

RESULT: Required specimen obtained according to specified operations


(Knurling and V-Thread cutting operations) with given dimensions

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Part B Model 1(Shaping-V Groove cutting)


Sketch of given model

Observations: Record the following in a tabular form:


Type of
Speed given to Feed given to
Machine Type Size Surface
&
Make

Note: All Dimensions inTool


mm Work Tool Work Produced

Shaping
M/c

Calculations:

Signature of faculty

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Ex.No.4

Date: V GROOVE CUTTING

AIM:

To perform V groove on the given work piece using shaping machine

MATERIAL REQUIRED:

A Cast Iron block of 50mm square piece.

TOOLS AND EQUIPMENT USED:

Shaping machine, H.S.S tool bit, Vernier calipers, V tool, Vernier height gauge, Plain tool, Dial
indicator

PROCEDURE :

1. The given work piece is measured for its initial dimensions


2. With the help of scriber, mark the V-Shape dimensions in the work piece.
3. Fix the work piece in the vice of the shaping machine.
4. After fixing the work piece and the shaping tool, allow the ram to reciprocate.
5. Start the shaping process by giving the required depth by lowering the tool.
6. Slowly increase the depth of cut and repeat the procedure to make the v- shape.
7. The work piece is now checked for final dimensions.

RESULT: Thus, a V-Shape is made in the given work piece to the dimensions using
Shaping machine.

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Part B Model 1 (Hexagonal head and the slot)


Sketch of given model

Observations: Record the following in a tabular form:


Type of
Speed given to Feed given to
Machine Type Size Surface
&
Make
Tool Work Tool Work Produced

Milling
M/c

Note: All Dimensions in mm


Calculations:

Signature of faculty

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Ex.No. 5

Date: HEXAGONAL HEAD AND THE SLOT

AIM:

To perform hexagonal head and the slot cutting on the given blank using Milling machine

MATERIAL REQUIRED:

A cast iron block of 60 mm diameter and 20 mm width.

TOOLS AND EQUIPMENT USED:

Milling machine, Vernier caliper, Indexing head and Mandrel.

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.

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Viva Questions and Answers


1. What is a lathe?
Ans. Lathe is a machine, which removes the metal from a piece of work to the required
shape &size

2. What are the various operations can be performed on a lathe?


1. Turning 6. Thread cutting 11. Grooving
2. Facing 7. Drilling
3. Forming 8. Boring
4. Knurling 9. Recessing
5. Chamfering 10. Tapping

3. What are principle parts of the lathe?


Bed, headstock, tailstock, carriage, cross slide, tool post.

4. What are the types of headstock?


Back geared type, all geared type

5. State the various parts mounted on the carriage?


Saddle, compound rest, cross slide, tool post.

6. What are the four types of tool post?


1. Single screw

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

8. State any two specification of lathe?


1. The height of centers from the bed

2. The maximum length of the bed

9. List any four types of lathe?


1. Engine lathe
2. Bench lathe
3. Tool room lathe
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4. Semi-automatic lathe
5. Automatic lathe

10. What is a semi-automatic lathe?


The lathe in which all the machining operations are performed automatically and
loading and unloading of work piece, coolant on or off is performed manually.

11. What is copying lathe?


The tool of the lathe follows a template or master through a stylus or tracer.

12. State the various feed mechanisms used for obtaining automatic feed?
1. Tumbler gear mechanism

2. Quick change gearbox

3. Tumbler gear- Quick change gearbox

4. Apron mechanism

13. List any four holding devices?


1. Chucks

2. Centers

3. Face plate

4. Angle plate

14. What are the different operations performed on the lathe?


Centering, straight turning, rough turning, finish turning, shoulder turning, facing,
chamfering, knurling, etc...

15. Define the term Conicity?


The ratio of the difference in diameters of tapers its length k= D-d
l
d- Smaller diameter
D-larger diameter
l- Length of the taper

16. State any two specifications of capstan lathe & turret lathe?
1. Number of spindle speed

2. Number of feeds for the turret or saddle

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17. Compare the advantage of capstan lathe & turret lathe?


1. Heavier & larger work piece chucking can be done

2. More rigid hence it withstand heavy cuts

18. What is tooling?


Planning of operations sequence & preparation of turret or capston lathe are
termed as tool- layout or tooling.

19. What are the three stage of a tool-layout?


1. Planning & scheduling

2. Detailed sketching of various machining operation sequence

3. Sketching the plan showing various tools

20. What are the different drives used in copying lathe?


1. Mechanical drives

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

22. What is shaper?


The machine, which is having a reciprocating type of machine tool with a single
point cutting tool, used to produce flat surfaces called as Shapers

23. List any four important parts of a Shaper?


Table, Tool head, Ram, Cross rail

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

25. Mention any four-shaper specification?


1. Maximum length of stroke
2. Type of driving mechanism
3. Power of the motor

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4. Speed &feed available

26. How the planer differs from the shaper?


In planner-the work reciprocate while the tool is stationary .
In shaper-the tool reciprocate while the work is stationary

27. State the use of planer?


The planer is used for machining heavy & large casting Ex. lathe bed ways, machine
guide ways

28. List the various types of planners?


1. Double housing

2. Open side planer

3. Pit planer

4. Edge planer

5. Divided table planer

29. Name the various parts of a double housing planer?


1. Bed

2. Table

3. Columns

4. Cross rail 5. Tool head

30. Mention any four specification of planer?


1. Maximum length of the table

2. Total weight of the planer

3. Power of the motor

4. Range of speeds & feed available

5. Type of drive required

31. What is meant by drilling?


Drilling is the process of producing hole on the work piece by using a rotating cutter
called drill

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32. What is gang -drilling machine?


When a number of single spindles with essential speed & feed are mounted side by side
on one base and have common worktable is known as gang drilling machine.

33. Mention any four specification of drilling machine?


1. Maximum size of the drill in mm that the machine can operate

2. Table size of maximum dimensions of a job can mount on a table in square


meter
3. Maximum spindle travel in mm

4. Number of spindle speed & range of spindle speeds in r.p.m.

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

36. What is broaching?


Broaching is a process of machining a surface with a special multipoint cutting tool
called broach which has successfully higher cutting edges in a fixed path

37. Indicate any two specification of a broaching machine?


1. Maximum length of stroke in mm

2. Maximum force developed by the slide in tones

38. What are the advantages and limitation of broaching?


Advantages:

1. Roughing, semi finishing & finishing cuts are completed in one pass of the

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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

2. Broaching a key way

40. What is boring?


Boring is a process of enlarging &locating previously drilled holes with a single
point cutting tool.

41. What are the application of boring?


The boring machine is designed for machining large &heavy work piece in mass
production work of engine frame, cylinder, machine housing etc.

42. Specify the importance of jig boring machine?


1. A jig boring machine is a precision boring machine used for boring accurate
holes at proper center to center distances.
2. The machining accuracy of holes produce by this machine tool lies with in a
range of 0.0025mm.

43. State the purpose of grinding?


1. To remove small amount of metal from work pieces & finish then to close
tolerances.

2. To obtain the better surface finish.

44. What is the function of cutting fluids?


1. It is used to cool the cutting tool & the work piece.

2. It improves the surface finish as stated earlier.

3. It causes the chips to break up into small parts.

4. It protects the finish surface from corrosion.

5. It prevents the corrosion of work & machine.

45. What are the properties of cutting fluid?


1. High heat absorbing capacities.

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2. It should have good lubricant properties.

3. High flash point.

4. It should be odourless.

5. It should be non-corrosive to work & tool.

46. What are causes of wear?


The tool is subjected to three important factors such as force, temperature and sliding
action due to relative motion between tool and the work piece. So the tool is wear easily.

47. What are the specifications of the milling machine?


1. The table length &width.

2. Number of spindle speeds &feeds.

3. Power of driving motor.

48. Mention the various movements of universal milling machine table?


1. Vertical movement-through the knee.

2. Cross vise movement-through the saddle.

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. The universal milling machine is provided with auxiliaries such as dividing


head, vertical milling attachment, rotary table etc. Hence it is possible to make
spiral, bevel gears, twist drills, reamers etc on universal milling machine.

50. What are the cutter holding devices?


1. Arbors

2. Adaptors

3. Collets
51. List the various type of milling attachment?
1. Vertical milling

2. Universal milling

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3. High speed milling

4. Rotary
5. Slotting

6. Rack milling

52. Write any ten nomenclature of plain milling cutter?


Body of cutter, cutting edge, face, fillet, gash, lead, land, outside dia, root dia, cutter

53. What are the advantages of milling process?


1. It does not require a backlash eliminator.

2. Mild surface does not have built up edge.

54. What are the down milling processes?


1. Cutter with higher rake angle can be used. This reduces power requirements.

2. Cutter wear is less because chip thickness is maximum at the start of cut.

55. List out the various milling operations?


1. Plain or slab milling.

2. Face milling.

3. Angular milling.

4. Gang milling.

5. End milling.

6. Gear cutting.

56. What does term indexing mean?


Indexing is the process of dividing the periphery of a job into equal number of
divisions.

57. What are the three types dividing heads?


1. Plain or simple.

2. Universal.

3. Optical.

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58. What is cam milling?


Cam milling is operation of producing cams in the milling machine by the use
universal dividing head &a vertical milling attachment.

59. What are the different types of thread milling?


1. Thread milling by single form cutter.

2. Thread milling by multi form cutter.

60. What are the other forming methods for manufacturing gears?
1. Gear cutting by single point form tool.

2. Gear cutting by shear speed shaping process.

3. Gear broaching.

4. Template method.

5. Gear milling using a formed end mill.

61. List the gear generating process?


1. Gear shaping process.

2. Gear planning process.

3. Gear hobbing process.

62. Mention the applications of gear shaping process?


1. Gear shaping used for generating both internal & external spur gears.

2. Helical gears can also be generated using special attachments.

63. What are the limitations of gear hobbing?


1. Internal gears cannot be generated.

2. Hobbing process cannot be applied very near to shoulders.

64. What are the advantages of gear planning process?


1. Any given model can be cut using a single cutter.

2. It is a simple flexible &accurate method of generating gears.

65. List the various gear finishing processes?


1. Gear shaving.

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2. Gear burnishing.

3. Gear grinding.

4. Gear lapping.

66. Mention the advantages &limitations of gear shaving process?


Advantage:
The process can be used for both internal & external gears.
Limitations:
This process is only applicable to unhardened gears.

67. What are the purposes of gear grinding process?


1. To improve the surface finish of teeth.

2. To increase the accuracy of the teeth.

68. What is gear lapping?


Gear lapping is also employed for hardened gear teeth by an abrasive action.

69. Explain the cutting shaping process?


The required shape of metal is obtained by removing the Unwanted material from the
work piece in the form of chips is called cutting shaping. Ex: turning, drilling, milling,
boring, etc...

70. Mention the various parts of single point cutting tool?


1. Shank

2. Face

3. Flank

4. Base

5. Nose

6. Cutting edge

71. What is tool signature?


The various angles of tools are mentioned in a numerical number in particular
order. That order is known as tool signature.

72. What is effect of back rake angle &mention the types?


Back rake angle of tool is increases the strength of cutting tool& cutting action. It can
be classified in to two types

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Positive rake angle


Negative rake angle

73. What is side rake angle & mention its effects?


The angle between the tool face & the line parallel to the base of the tool. It is used to
control chip flow.

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

75. When will the negative rake angles be used?


1. To machine high strength alloys

2. The feed rates are high

76. Define orthogonal & oblique cutting?


Orthogonal cutting:
The cutting edge of tool is perpendicular to the work piece axis.
Oblique cutting:
The cutting edge is inclined at an acute angle with normal to the cutting velocity
vector is called oblique cutting process

77. What is cutting force?


The sheared material begins to flow along the cutting tool face in the form of small
pieces. The compressive force applied to form the chip is called cutting force.

78. What is chip thickness ratio?


The ratio of chip thickness before cutting to chip thickness after cutting is called chip
thickness ratio.

Chip thickness ratio, r = t1 /t2 or l2 /l1

79. What are the purposes of chip breakers?


The chip breakers are used to break the chips in to small pieces for the removal,
safety & to prevent to machine & work.

80. Define machinability of metal?


Machinability is defined as the ease with which the material can be satisfactorily
machine.

81. What are the factors affecting the machinability?


1. Chemical composition of work piece material.
2. Microstructure of work piece material

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82. What is machinability index?


It is the comparison of machinability different material to standard material. US
material standards for 100% machinability are sae1112 hot rolled steel.
Machinability index I = Cutting speed of metal investigated for 20 minutes tool life

Cutting speed of standard steel for 20 minutes tool life

83. How tool life is defined?


Tool life is defined as time elapsed between two consecutive tool resharpening.
During this period tools serves effectively and efficiently.

84. What are the factors affecting tool life?


1. Cutting speed

2. Feed & depth of cut

3. Tool geometry

4. Tool material

85. Express the tailors tool life equation?

Tailors tool life equation:

VTn=C

V=Cutting speed in m/min


T=Tool life in minutes
C=Constant
n=Index depends upon tool & work.

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