1.

PREPARE THE PART SHOWN IN THE SKETCH FROM A MILD STEEL ROD ON A
LATHE

Exp. No: Date:

Aim:

To perform the Step turning, Taper turning, grooving and Knurling operations on lathe

Tools and equipment’s required:

Lathe, workpiece, Single point cutting tool, grooving tool, knurling tool

(Prepare the specimen as per the dimension)

Procedure

1. Cut material to length, with allowance for facing

2. Face one end in the centre lathe.

3. Hold in the job in the 3 jaw chuck

5. Carry out the following operations

Plain turn the job and reduce to 23 mm diameter and reduce it to 20 mm for a length of 40 mm

Perform grooving for a width of 10 mm to reduce it to 17 mm diameter

Turn the next side of the job perform grooving and taper turning by setting the compound rest

to the taper angle calculated

𝐷−𝑑
tan ∝=
2𝑙

Where D – Larger diameter

d - Smaller diameter

l – length of the taper

6. Finally perform the knurling operation

Result:

The specimen is prepared according to the sketch by carrying out different operations in the lathe.
 2. DETERMINATION OF CUTTING FORCE MEASUREMENT USING LATHE TOOL
DYNAMOMETER

Exp. No: Date:

Lathe tool dynamometer is a multi- component dynamometer that is used to measure forces during the
cutting operations. The forces during machining are dependent on depth of cut, feed rate, cutting speed,
tool material and geometry, material of the work piece and other factors such as use of lubricants during
machining.

Aim:

To measure the cutting forces generated during turning operation on mild steel specimen under various
cutting conditions.

Tools And Equipment’s required:

Lathe Tool Dynamometer and single point cutting tool.

Procedure:

1. The work piece is held in the chuck and facing operation is performed to make the end face of the
work piece flat.
2. The tool is fed manually to start the cutting operation and then automatically.
3. Force Indicator is connected to 230 V, single phase supply and switch on power supply.
Waited for 5 to 10 minutes to balance the channels to get zero readings on display.
4. The forces generated (Fx- feed force, Fy-cutting force, Fz-radial force) during machining
operations are measured by varying the cutting speed by keeping depth of cut and feed constant.
5. Repeat the procedure by varying depth of cut with constant cutting speed, feed and by varying
feed with constant cutting speed, depth of cut.
Observations

S.No Spindle speed feed Depth of Fx (N) Fy (N) Fz (N) Resultant

(rpm) (mm/rev) cut ( mm)

Graph:

 Plot graph between varying process parameters and cutting force

 Comment on (two/three line statement) all three plot

Result

Thus the cutting forces are measured for different cutting conditions on mild steel specimen using lathe
tool dynamometer
 3. MACHINING A KEYWAY BY USING SLOTTING MACHINE AND PERFORM ANGULAR
MACHINING USING SHAPER

Exp. No: Date:

Aim:
To machine an internal keyway using Slotting Machine and machine a taper using shaper machine

Tools and equipment’s required:

Mandrel Slotting Machine, Shaper, Vernier caliper, , Scriber, Divider and Steel Rule.

All dimensions are in mm

Procedure:
1. The given workpiece is measured for its initial dimensions.
2. With the help of scriber mark the keyway dimensions in the workpiece.
3. Fix the workpiece in the vice of the slotting machine.
4. After fixing the workpiece and the slotting tool, allow the ram to vertically reciprocate.
5. Start the slotting process by giving the required depth by horizontally moving the vice.
6. Slowly increase the depth of cut and repeat the procedure to make the required shape.
7. The workpiece is now checked for final dimensions.

Procedure:
1. The given workpiece is measured for its initial dimensions.
2. With the help of scriber mark the keyway dimensions in the workpiece.
3. Fix the workpiece in the vice of the shaper.
4. Tool slide is tilted at an angle for taper and set the down feed
5. Start the process by giving the required depth and horizontally moving the vice.
6. Slowly increase the depth of cut and repeat the procedure to get the required shape.
7. The workpiece is now checked for final dimensions

Result:

Thus an internal keyway and taper is machined using the slotting machine and shaper respectively
 4. GEAR CUTTING USING MILLING (SPUR GEAR CUTTING)

Exp. No: Date:

Aim:
To machine a spur gear from the given module using Milling machine

Tools And equipment’s required:

Milling machine, Vernier caliper and Mandrel.

All dimensions are in mm

Procedure:
Calculate the gear tooth proportions.

Blank diameter =(Z+2)m

Tooth depth = 2.25 m
Tooth width = 1.5708 m
where,
Z = Number of teeth required
m = module

Indexing calculation
Index crank movement = 40 / Z

The dividing head and the tail stock are bolted on the machine table. Their axis must be set parallel to the
machine table.

1. 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.
2. The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.
3. Set the speed and feed for machining.
4. For giving depth of cut, the table is raised till the periphery of the gear blank just touches the
cutter.
5. The micrometer dial of vertical feed screw is set to zero in this position.
6. Then the table is raised further to give the required depth of cut.
7. The machine is started and feed is given to the table to cut the first groove of the blank.
8. After the cut, the table is brought back to the starting position.
9. Then the gear blank is indexed for the next tooth space.
10. This is continued till all the gear teeth are cut.
Calculation:

Z = No. of teeth = 22

m = module = 2 mm

Blank Diameter = (Z + 2) m
= (22 + 2) 2
= 48 mm

Tooth Depth = 2.25 m

= 2.25 * 2
= 4.5 mm

Indexing Calculation = 40 / Z
= 40 / 22
= 1 - 17/22

Result:

Thus the required gear is machined using the milling machine to the required number of teeth.
5. GRINDING OF SINGLE POINT CUTTING TOOL AS PER GIVEN SPECIFICATIONS
(TO CHECK THE TOOL ANGLES) IN A TOOL AND CUTTER GRINDER

Exp. No: Date:

Aim:
To grind a single point cutting tool
Tools and Equipments required:
Tool and cutter grinder, single point cutting tool.
Tool signature is 10-10-10-6-10-12-0.8

Procedure
1. Tool is held in the tool fixture
2. The grinding is carried out by setting the horizontal and vertical bases according to the tool
signature.
3. The shank position is maintained horizontal to prepare the end cutting edge angle by swiveling
the horizontal base by 10° in the anticlock wise direction.
4. The shank position is maintained horizontal to prepare the end clearance angle by swiveling the
vertical base by 12° in the anticlock wise direction.
5. Now, the shank position is maintained vertical to prepare the back rake angle by swiveling the
vertical base by 10° in the anticlock wise side of the operator.
 6. The shank position is maintained vertical to prepare the side rake angle by swiveling the
horizontal base by 10° in the clock wise side from the operators view.
7. The shank position is maintained vertical to prepare the side cutting edge angle by swiveling the
vertical base by 12° in the clock wise side from the right side of the operator.
8. The shank position is maintained vertical to prepare the side clearance edge angle by swiveling
the horizontal base by 6° in the anticlock wise direction.
9. The prepared tool is removed from the machine for measuring the angle measurements in tool
makers microscope

RESULT:
Thus the tool is machined to the given dimensions using tool and cutter grinder.
 6. TOOL WEAR MEASUREMENT OF SINGLE POINT CUTTING TOOL USING TOOL
MAKERS MICROSCOPE

Exp. No: Date:

Aim:
To determine tool wear of single point cutting tool.

Apparatus required:
Tool maker’s microscope, Single point cutting tool, mild steel rod and Lathe machine
Procedure:
1. Switch on the main and the object is placed on the glass table to get the clear image.
2. To measure the angle of the tool, coincide one of the lines of the cross lines with the flank
of the tool.
3. Note-down the reading of the protractor.
4. Now rotate the protractor in turn the cross lines in such a way that same line coincides with the
opposite flank.
5. Note-down the reading of the protractor. Difference of the two reading gives the included angle of the tool.

Observations:
S.no Tool angles Initial reading Final reading True value

Result:
The various angles of single point cutting tool was measured by using Tool maker’s Microscope.
 7. MEASUREMENT OF TAPER ANGLE USING SINE-BAR

Exp. No: Date:

Aim:
To determine angle of given specimen

Apparatus required:
Dial Gauge, Sine bar and specimen
Procedure:
1. The given component is placed on the surface plate.
2. One roller of sine bar is placed on surface plate and bottom surface of sine bar is seated on the
taper surface of the component.
3. The combination of slip gauges is inserted between the second roller of sine bar and the surface
plate.
4. The angle of the component is then calculated by the formula given above.

Formula:
Sin θ = h / L
Where,
h - Height of the slip gauge,L - Distance between the centers,θ - Inclined angle of the specimen

Observations:

Test
Specimen h L Sin  

Result:
The external taper angle of the specimen is measured using Bevel Protractor and Sine bar
 8. MEASURE DIMENSION OF SCREW THREAD USING PROFILE PROJECTOR

Aim:
To determine angle and pitch of given specimen

Apparatus required:
Profile projector and specimen

Projection screen

Screen rotation knob

Stage

Micrometer

Focus wheel

Procedure:
1. The given component is placed on the stage and the magnified image of specimen is obtained on
projection screen
2. Adjust the focus wheel and micrometer to get clear profile of the specimen
3. Rotating screen rotation knob to measure the intruded angle of thread at three different locations
4. Repeat the procedure to measure pitch and height of thread

Result
Thus the angle, height and pitch of the specimen is measured using profile projector
 9. MEASUREMENT OF BORE DIAMETER BY TWO SPHERES METHOD

Aim:

To measure the bore diameter using two spheres.

Apparatus Required:

Cylindrical specimens, Spheres, Micrometer and Height gauge

Specifications: Height gauge:

Range: ______mm L.C: ______mm

Formula:

Bore diameter db = (d1+d2)/2 + {h (d1+d2)-h2}1/2

Where d1= diameter of sphere 1

d2= diameter of sphere 2

h = height from the surface plate to top point of the upper sphere.

Procedure:

1. Here we use two spheres of same or different diameter d1 and d2.

2. The two spheres are placed inside the given bore so that one sphere stands above the other
and the contact between the bore and the sphere are also ensured.
 3. The height ‘h’ from the surface plate level to the top point of higher sphere is measured by
using height gauge.
4. The bore diameter is calculated by using the above formula.
5. Do a model calculation for the calculation for bore diameter.
Diameter of sphere 1:

S.No Micrometer Reading

Diameter of sphere2:

S.No Micrometer caliper Reading

Measurement of Bore diameter:

S.No Vernier Height Gauge reading (mm) Bore diameter

Result:

Thus the bore diameter is measured by using two spheres.

The bore diameter of the given specimen is __________mm.

 10. CALIBRATION OF MICROMETER, VERNIER CALIPER AND DIAL GAUGE

Exp. No: Date:

Aim:

To calibrate the Micrometer and Vernier caliper using slip gauges

Apparatus required:

Micrometer, Vernier caliper and slip gauges

Procedure

1. Slip gauge dimensions are selected based on the range of the instruments used for calibration
2. Clean the fixed vice and micrometer
3. Clamp the micrometer in vice putting cushioning material between micrometer and jaws of vice
to protect the micrometer from probable damage due to clamping force.
4. Make pile of gauge blocks and insert between two anvils of the micrometer/ Vernier caliper/Dial
gauge and take reading.
5. Increase the value of gauge blocks pile and take next few readings.
6. Then decrease the value of gauge blocks pile and take same readings in decreasing order.
7. Tabulate the readings
8. After cleaning the gauge blocks should be placed in their respective places.
 Slip Precision Measuring Instruments Reading (observed) in mm
Gauge
S. Readin Vernier Caliper Micro Meter Dial Gauge
g–
N VS HS
(Actual MSR TR Error PSR TR Error SHR LH TR Error
o R R
) (mm (mm (mm (mm (mm (mm (mm R (mm (mm
(div (div
) ) ) ) ) ) ) (div) ) )
In mm ) )

1.

2.

3.

4.

5.

Plot the Graphs:

(1) Slip gauges combination – Micrometer average

(2) Slip gauges combination – Error

(3) Micrometer average reading – correction

Result:

The given Micrometer and Vernier caliper gauge has been calibrated using M83 slip gauge set.
 11. ROUNDNESS ERROR MEASUREMENT USING DIAL INDICATOR

Aim:

To measure the roundness of given specimen.

Apparatus Required:

Cylindrical specimens, Dial indicator with stand, V block and surface table

Lease square method

This method uses all the data of the profile to establish the centre. In this method a theoretical circle is
located within the polar profile such that the sum of the squares of the radial ordinates between the circle
and the profile is a minimum. The out-of-roundness value is determined by the sum of the maximum
inward and the maximum outward ordinates distances.

Datum point
Procedure
Result:

The roundness error of the given specimens is _____________m