MMT LAB MECHANICAL / VI SEM

MACHINING & MACHINE TOOLS LAB

(ME692)
(For 3rd Year B.Tech Mechanical Engineering)

JIS COLLEGE OF ENGINEERING, KALYANI, NADIA

Mechanical Engineering Department
MMT LAB MECHANICAL / VI SEM

GENERAL INFORMATION

This laboratory is aimed at providing an introduction to the Know-how of common

processes used in industries for manufacturing parts by removal of material in a controlled
manner. Auxiliary methods for machining to desired accuracy is covered. The emphasis
throughout the laboratory course will be on understanding the basic features of the processes
rather than details of constructions of machine, or common practices in manufacturing or
acquiring skill in the operation of machines. Evidently, acquaintance with the machine is desirable
and the laboratory sessions will provide adequate opportunity for this.
MMT LAB MECHANICAL / VI SEM

GENERAL INSTRUCTIONS AND SAFETY RULES

1. Students should wear the uniform and closed foot wear. Students inappropriately dressed
for lab, at the instructor’s discretion, be denied access).
2. When you handle chemicals wear eye protection (chemical splash goggles or full face
shield).
3. When you work with furnaces for heat treatment procedures or other thermally activated
equipment you should use special gloves to protect your hands.
4. To protect clothing from chemical damage or other dirt, wear a lab apron or lab coat. Long
hair should be tied back to keep it from coming into contact with lab chemicals or flames.
5. In case of injury (cut, burn, fire etc.) notify the instructor immediately.
6. In case of a fire or imminently dangerous situation, notify everyone who may be affected
immediately; be sure the lab instructor is also notified.
7. If chemicals splash into someone's eyes act quickly and get them into the eye wash station,
do not wait for the instructor.
8. In case of a serious cut, stop blood flow using direct pressure using a clean towel, notify
the lab instructor immediately.
9. Eating, drinking and smoking are prohibited in the laboratory at all times.
10. Never work in the laboratory without proper supervision by an instructor.
11. Never carry out unauthorized experiments. Come to the laboratory prepared. If you are
unsure about what to do, please ask the instructor.
12. Except the scientific calculator, any other electronic devices are not permitted to use inside
the Laboratory.
13. Any damage to any of the equipment/instrument/machine caused due to carelessness, the
cost will be fully recovered from the individual (or) group of students.
MMT LAB MECHANICAL / VI SEM

Experiment No: 1
Aim: To study of Tool Geometry of an SPTT in ASA system.
Theory:
Sketch a single point turning tool, visualize its angles in ASA system and define them properly.

Result: Hence the study of Tool Geometry of an SPTT in ASA system is completed.
MMT LAB MECHANICAL / VI SEM

Experiment No: 2
Aim: To study of Tool Geometry of an SPTT in ORS.
Theory:
Sketch a single point turning tool, visualize its angles in ORS and define them properly.

Result: Hence the study of Tool Geometry of an SPTT in ORS system is completed.
MMT LAB MECHANICAL / VI SEM

Ex. No: 03 SPUR GEAR CUTTING IN MILLING MACHINE

AIM: To perform spur gear cutting using vertical milling machine on a work piece.
INTRODUCTION:
Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk with
the teeth projecting radially, and although they are not straight-sided in form (they are usually of
special form to achieve constant drive ratio, mainly involute), the edge of each tooth is straight and
aligned parallel to the axis of rotation. These gears can be meshed together correctly only if they are
fitted to parallel shafts.

MATERIAL USED
Cast iron blank

TOOLS REQUIRED

1. Vertical Milling machine

2. Vernier caliper
3. Holding Materials
4. Milling Tools
5. Mandrel

CALCULATION:

Z = No. of teeth = 20
Blank Diameter = (Z + 2) /DP
= (20 + 2)/10=2.2” or 55.88mm
DP= Diametral Pitch=10
Indexing Calculation = 40 / Z = 40 / 20 = 2
DIRECT INDEXING
Indexing Ratio = 40/Z = 40/20
Where Z= required number of divisions = 20
Standard Brown and Sharp Index Plates
No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 31, 33
No.3: 37, 39, 41, 43, 47, 49
Example: It is required to divide the periphery of a job into 60 divisions.
Crank Movement (Indexing Ratio) according to simple Indexing = 40/60 = 2/3
2 2 6 12
= × =
3 3 6 18
The crank has to move 12 holes on 18 holes circle.
MMT LAB MECHANICAL / VI SEM
PROCEDURE:
a) Calculate the gear tooth proportions.
Blank diameter = (Z + 2)/DP = (20+2)/10=2.2” or 55.88mm
Z = Number of teeth required
DP= Diametral Pitch=10
Index crank movement = 40 / Z =2
b) The dividing head and the tail stock are bolted on the machine table. Their axis must be set
parallel to the machine table.
c) The gear blank is held between the dividing head and tailstock using a mandrel. The mandrel
is connected with the spindle of dividing head by a carrier and catch plate.
d) The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.
e) Set the speed and feed for machining.
f) For giving depth of cut, the table is raised till the periphery of the gear blank just touches the
cutter.
g) The micrometer dial of vertical feed screw is set to zero in this position.
h) Then the table is raised further to give the required depth of cut.
i) The machine is started and feed is given to the table to cut the first groove of the blank.
j) After the cut, the table is brought back to the starting position.
k) Then the gear blank is indexed for the next tooth space.
l) This is continued till all the gear teeth are cut.

RESULT:
The given work piece as is subjected to gear generating operation to become a finished work piece.

CALCULATIONS:

PRECAUTIONS
a) The milling machine must be stopped before setting up or removing a work piece, cutter or
other accessory
b) Never stop the feeding of job when the cutting operation is going on, otherwise the tool will
cut deeper at the point where feed is stopped.
c) All the chips should be removed from the cutter. A wiping cloth should be placed on the
cutter to protect the hands. The cutter should be rotated in the clockwise direction only for
right handed tools.
d) The work piece and cutter should be kept as cool as possible (i.e. coolant should be used
where necessary to minimize heat absorption).
e) The table surface should be protected with a wiping cloth.
f) Tool must be mounted as close to the machine spindle as possible.
MMT LAB MECHANICAL / VI SEM

Experiment No: 04

Aim: Study of chips and determination of chip reduction co-efficient in turning mild steel by HSS tool with
different depth of cut.

Aims:
i. To study different types of chip (type, shape and color)
ii. To determine chip reduction co-efficient (ξ)

Theory: Define CRC and visualize a1 & a2 properly.

Chip Shape:
Chip shape depends in the state of chip curling. Chip shape may be ribbon-like, helical (tubular), spiral, one
turn, half turn etc.

Chip Color:
Chip color depends generally on the cutting conditions (cutting velocity, depth of cut, feed rate etc). In dry
cutting the chip color is generally blue or burned blue. In wet conditions chip color generally in metallic,
golden, or blue.

Machine, Equipment and Work Material:

i. Lathe machine
ii. Work material (Mild Steel)
iii. Cutting tool (HSS)
iv. Slide calipers
v.
vi.
vii.

DATA SHEET
Study of chips in turning mild steel by HSS tool
Work material:
Diameter:
Cutting tool:
Material:
Cutting conditions
Cutting velocity:
Feed rate:
Depth of cut:
Environment:

S0 N Vc t (mm) a1(mm) a2(mm) ξ Chip

(mm/rev) (rpm) (m/min) type shape color
MMT LAB MECHANICAL / VI SEM
MMT LAB MECHANICAL / VI SEM

EXPERIMENT NO.: 05
NAME OF EXPERIMENT: Measurement of cutting forces (Pz and Px or Py) in straight
turning.
AIM: To measure cutting forces in straight turning at different feeds and velocities.
PRINCIPLE: Tool dynamometers are basically a strain gauge based sensors, which senses
cutting forces in different direction. The cutting force dynamometer like lathe tool
dynamometer, drill tool dynamometer, mill tool dynamometer, grinding tool dynamometer are
specially designed cutting force sensing devices which can be mounted directly on a particular
machines and conduct experiment.

APPARATUS / UTILITIES REQUIRED:

Lathe tool dynamometer, cutting tool
MMT LAB MECHANICAL / VI SEM

PROCEDURE:
 Check the connections made to the instrument. Switch on the power to the instrument
through rocker switch at the front panel.
 Allow the instrument in ON position for 10 min for initial warm-up.
 Adjust the Potentiometer in front panel till the display reads “000”. Now the instrument is
ready to use.
 Mount the job on the lathe machine.
 Adjust the speed of the machine.
 Adjust the cut and feed required.
 The instrument will start showing the force coming on the sensor in kg as soon as the tool
starts removing the metal from the job.
 Experiment can be conducted for different combinations of feed, speed and depth of cut.

OBSERVATION TABLE:
Speed Feed rate Depth of cut FX FY FZ
MMT LAB MECHANICAL / VI SEM
MMT LAB MECHANICAL / VI SEM

Experiment No. 06 Date:

CONVERSION OF CIRCULAR ROD INTO SQUARE ROD

AIM : To perform shaping operation of given mild steel rod.

MATERIAL REQUIRED

Mild steel rod of 25 mm diameter and 100 mm length

MACHINNE REQUIRED

Shaper machine/ Grinding Machine/ Lathe

CUTTING TOOLS

H.S.S. Tool bit of the required slot size/ Grinding Wheel

SEQUENCE OF OPERATIONS

1 .Fix the specimen in the machine vice

2 .By giving the required feed and depth of cut, the required cut is being made progressively.

PROCEDURE

• Dimension of the work piece is measured and made to the required dimensions.

• Fix the job in vice and adjust the tool in the tool head.

• Start the machine during forward stroke only remove the material and during the return stroke is
idle.

• Do the operation to get one side completely flat then repeat the process on four sides of the
workpiece.

• Rotate the job after completion of each side is flat.

• Then check the flatness by using slip gauges. To get the required component.

Required Drawing:

PRECAUTION:

Choose proper feed and depth of cut.

Feed should be controlle4d to avoid to any damage to the cutting tool.

Fix the work piece is properly into the vice.

During cutting to supply coolant in between to the work piece and tool.
MMT LAB MECHANICAL / VI SEM
Adjust the stroke length properly.