me6465 manufacturing technology manual

P.M SUBRAMANIAN, ASST PROF (AUTO), GRT INSTITUTE OF ENGINEERING & TECHNOLOGY

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DEPARTMENT OF AUTOMOBILE ENGINEERING

SEMESTER – III

ME6465 MANUFACTURING TECHNOLOGY LABORATORY

LAB MANUAL


ME6465 MANUFACTURING TECHNOLOGY LABORATORY L T P C

0 0 3 2

OBJECTIVES:

Demonstration and study of the various machines. The Main emphasis will be on a

complete understanding of the machine capabilities and processes.

LIST OF EXPERIMENTS

UNIT I LATHE PRACTICE

a. Plain Turning

b. Taper Turning

c. Thread Cutting Estimation of machining time for the above turning processes.

UNIT II DRILLING PRACTICE

a. Drilling b. Tapping c. Reaming.

UNIT III MILLING

a. Surface Milling. b. Gear Cutting. c. Contour Milling.

UNIT IV PLANNING AND SHAPING

a. Cutting Key Ways. b. Dove tail machining.

TOTAL: 45 PERIODS


INDEX

S.No Date Name of the Experiment Mark Signature

1 STUDY OF LATHE

2 FACING & PLAIN TURNING USING A LATHE

3

TAPER TURNING OPERATION

(COMPOUND REST METHOD) USING A

LATHE

4 EXTERNAL V- THREAD CUTTING USING A

LATHE

5 INTERNAL THREAD CUTTING OPERATIONS

USING A LATHE

6 STUDY OF RADIAL DRILLING MACHINE

7 DRILLING , REAMING AND TAPPING

8 STUDY OF MILLING MACHINE

9 SURFACE MILLING

10 GEAR CUTTING

11 STUDY OF SHAPER

12 STUDY OF PLANER

13 CUTTING KEY WAYS IN SHAPER/PLANER

14 DOVE TAIL MACHINING IN SHAPER/PLANER

15 ESTIMATION OF MACHINING TIME FOR THE

LATHE OPERATIONS

TOTAL


EXP NO: 01 STUDY OF LATHE

DATE:

AIM:

To understand the working principle and operations done in lathe machine.

To identify the various components of lathe machine and its function.

MACHINING PROCESSES

Machining is one of the processes of manufacturing in which the specified shape to the

work piece is imparted by removing surplus material. Conventionally this surplus

material from the work piece is removed in the form of chips by interacting the work

piece with an appropriate tool. This mechanical generation of chips can be carried out

by single point or multi point tools or by abrasive operations these are summarized

below:

Machining Processes

Single point tool operations Multi-point tool operations Abrasive operations

1. Turning 1. Milling 1. Grinding

2. Boring 2. Drilling 2. Lapping

3. Shaping 3. Tapping 3. Honing

4. Planing 4. Reaming 4. Super-finishing

5. Hobbing

6. Broaching

7. Sawing


Multi-point tool operations

The process of chip formation in metal cutting is affected by relative motion between the

tool and the work piece achieved with the aid of a device called machine tool. This

relative motion can be obtained by a combination of rotary and translatory movements

of either the tool or the work piece or both. The kind of surface that is produced by the

operation depends on the shape of the tool and the path it traverses through the

materials.

When the workpiece is rotated about an axis and the tool is traversed in a definite path

relative to the axis, a surface of revolution is generated. When the tool path is parallel to

the axis, the surface generated is a cylinder as in straight turning or boring operations.

Similarly, planes may be generated by a series of straight cuts without rotating the

workpiece as in shaping and planning operations (Fig.3).

In shaping the tool is reciprocating and the work piece is moved crosswise at the end of

each stroke. Planning is done by reciprocating the work piece and crosswise movement

is provided to the tool.

Surface may be machined by the tools having a number of cutting edges that can cut

successively through the work piece materials. In plane milling, the cutter revolves and

moves over the work piece as shown Fig. 4. The axis of the cutter is parallel to the

surface generated.

Similarly in drilling, the drill may turn and be fed into the work piece of the work piece

may revolve while the drill is fed into it (Fig.5).

The machine tools, in general, provide two kinds of relative motions. The primary motion

is responsible for the cutting action and absorbs most of the power required to perform

the machining action.

The secondary motion of the feed motion may proceed in steps or continuously and

absorbs only a fraction of the total power required for machining. When the secondary

motion is added to the primary motion, machine surfaces of desired geometric

characteristics are produced. .


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 ma

machine. Hence lathe is known as “mother of machines”.



piece. Lathe is useful in making several parts which is further assembled to ma

machine. Hence lathe is known as “mother of machines”.



piece. Lathe is useful in making several parts which is further assembled to make new


BASIC WORKING PRINCIPLE OF LATHE

In lathe, the work piece is held in the chuck, a work holding device. The cutting tool is

mounted in the tool post. The chuck is rotated by means of power. When the chuck

rotates, the work piece also rotates. The tool is moved against the rotating work piece

by giving small amount of depth of cut. The material is removed in the form of chips.

Continuous feed and depth of cut is given until the required dimensions are obtained in

the work piece.

TYPES OF LATHE MACHINES

There are different types of lathe machines, they are

Centre lathe

Tool room lathe

Bench lathe

Capstan lathe

Turret lathe

Automatic lathe

DESCRIPTION OF LATHE

Lathe is a machine which has several parts in it. They are

Bed

It is the base of the machine. On its left side, the head stock is mounted and on its right

it has movable casting known as tailstock. Its legs have holes to bolt down on the

ground.

Head stock

It consists of spindles, gears and speed changing levers. It is used to transmit the

motion to the job. It has two types one is the headstock driven by belt and the other one

is the gear driven.


Carriage

Carriage is used to carry a tool to bring in contact with the rotating work

draw from such a contact. It operates on bed ways between the headstock and tail

stock.

Saddle

It is a ‘H’ shaped part fitted on the lathe bed. There is a hand wheel to move it on the

bed way. Cross slide, compound rest, tool post are fit

Cross slide

It is on the upper slide of saddle in the form of dove tail. A hand wheel is provided to

drive the cross slide. It permits the cross wise movement of the tool (i.e.) movement of

tool towards or away from the operator

Compound rest

It is fitted over the cross slide on a turn table. It permits both parallel and angular

movements to cutting tool.

Tool post

It is fitted on the top most part of the compound rest. Tool is mounted on this tool post.

Cutting tool is fixed in it with the help of screws.

Apron

It is the hanging part in front of the carriage. It accommodates the mechanism of hand

and power feed to the cutting tool for carrying out different operations


Carriage is used to carry a tool to bring in contact with the rotating work



bed way. Cross slide, compound rest, tool post are fitted on this saddle.



tool towards or away from the operator



ith the help of screws.


and power feed to the cutting tool for carrying out different operations


Carriage is used to carry a tool to bring in contact with the rotating work piece or to with









.

Lead screw

It is a long screw with ACME threads. It i

feed or feed for thread cutting operation.

Tail stock

It is located at the right end of the lathe bed and it

bed. It is used for supporting lengthy jobs and also carries tool to

such as tapping,

WORK HOLDING DEVICES

Lathe centers

They are used to support work. It has two categories of centers. Live center is one

which is fitted in the headstock spindle. Dead is another one which is fi

stock.


It is a long screw with ACME threads. It is used for transmitting power for automatic

feed or feed for thread cutting operation.

It is located at the right end of the lathe bed and it can be positioned anywhere in the

bed. It is used for supporting lengthy jobs and also carries tool to carry out operations

drilling, reaming.


which is fitted in the headstock spindle. Dead is another one which is fi


s used for transmitting power for automatic

be positioned anywhere in the

carry out operations

drilling, reaming.


which is fitted in the headstock spindle. Dead is another one which is fitted in the tail


Chuck

It is a device used to hold a job. It is easily fitted on the thread cut on the end of head

stock spindle. Various types of chuck are

Two jaw chuck b) three jaw chuck

Magnetic chuck

Face plate

Three Jaw Universal self-Four Jaw Independent chuck



stock spindle. Various types of chuck are

b) three jaw chuck c) four jaw chuck d) collet chuck

Four Jaw Independent chuck



d) collet chuck


Lathe carriers or dog’s

Steady rest

Clamped to the lathe ways, it uses adjustable fingers to contact the workpiece and align

it. Can be used in place of tailstock or in the middle to support long or unstable parts

being machined

Mandrel

Mandrel used to hold hollow jobs.

Follower rest

Bolted to the lathe carriage, it uses adjustable fingers to bear against the work piece

opposite the cutting tool to prevent deflection.

CUTTING TOOLS USED

For making a finished job on lathe machine, various types of cutting tools are used. One

of them is single point cutting tool which is used to perform several operations on the

work piece. Various types of cutting tools are

Facing Tool

It is used for facing the longitudinal ends of the job. Its shape is like a knife.


Rough Turning Tool

It is used to remove excess material from the work piece in quick time. It can be used to

give large depth of cut and work at coarse feed.

Finishing Tool

It is used for getting smooth finish on the work piece. Its point is a little more round.

Radius Tool

Jobs which need round cutting are done with this tool. Its type is

Convex radius tool b) concave radius tool

Parting Tools

It is used to cut the jobs into two parts. It is also used for grooving.

Form Turning Tool

It is used for jobs which require both convex and concave turning.

Thread Cutting Tool

It is used for making internal or external threads on the work piece. The tool nose is

designed with a definite profile for taking threads.

Drill Tool

It is used for making holes of various diameters on the job. Drill bit of various sizes of

diameter are available.


Boring Tool

It used for enlarging the drill hole.

Knurling Tool

Drawing slanting or square projecting lines on the surface o

It is used for making better grip on the surface of a job.

TOOL MATERIALS

The single point cutting tools are made of high speed steel. (H. S. S)

The main alloying elements in 18

chromium and 1 % Vanadium. 5 to 10 % cobalt is also added to improve the heat

resisting properties of the tool.

General purpose hand cutting tools are usually made from carbon steel or tool

steel.

Carbide tipped tools fixed in tool holders, are mostly used i


It used for enlarging the drill hole.

Drawing slanting or square projecting lines on the surface of a job is known as knurling.

It is used for making better grip on the surface of a job.


The main alloying elements in 18 – 4 – 1 HSS tools are 18 % tungsten, 4%

mium and 1 % Vanadium. 5 to 10 % cobalt is also added to improve the heat

resisting properties of the tool.


Carbide tipped tools fixed in tool holders, are mostly used in production shops.


f a job is known as knurling.


1 HSS tools are 18 % tungsten, 4%

mium and 1 % Vanadium. 5 to 10 % cobalt is also added to improve the heat


n production shops.


NOMENCLATURE OF SINGLE POINT CUTTING TOOL

CUTTING TOOL ANGLES

Top rake angle (back rake angle)

If the slope is given to the face or surface of the tool and if this slope is along the tools

length then it is called top rake ang

Side rake angle

If the slope is given to the face or top of the tool along the tools width then it is called

side rake angle. It lies between 6

Clearance angle (relief angle)

Types: 1. Side clearance angle

They are provided to keep surface of the tool clear of the work piece.


NOMENCLATURE OF SINGLE POINT CUTTING TOOL

Top rake angle (back rake angle)


op rake angle. It is usually 15 to 20.


side rake angle. It lies between 6� and 15�.

Clearance angle (relief angle)

Types: 1. Side clearance angle 2. End clearance angle.

They are provided to keep surface of the tool clear of the work piece.





Cutting edge angle

Types: 1. Side cutting edge angle

makes with the axis of the tool 2. End cutting edge angle

angle, the end cutting edge makes with the width of the tool.

Lip angle (cutting angle)

It is the angle between the face and the end surface of the tool.

Nose angle

It is the angle between the side cutting edge and end cutting e

LATHE OPERATIONS

Facing

It is done for getting fine finish (good surface finish) on the face of the job.

Facing tool is set at an angle to the work piece.

The tool is fed from the centre of work piece towards the outer surface against

the rotating work piece.

Depth of cut is low for the facing operation.

Plain Turning

It is done for reducing the diameter of the work piece.

A cutting tool with 70 setting angle is used for roughing operation.

More feed is given for rough turning while less f

Work piece is held in chuck and tool is set to center height of the work piece.


Types: 1. Side cutting edge angle – (generally 15�) it is an angle, the sid

makes with the axis of the tool 2. End cutting edge angle – (from 7� t

angle, the end cutting edge makes with the width of the tool.

Lip angle (cutting angle)

It is the angle between the face and the end surface of the tool.

It is the angle between the side cutting edge and end cutting edge.


Facing tool is set at an angle to the work piece.


Depth of cut is low for the facing operation.

It is done for reducing the diameter of the work piece.

setting angle is used for roughing operation.

More feed is given for rough turning while less feed is given for finishing.



side cutting edge

� to 15�) it is an



eed is given for finishing.



Step Turning

It is similar to the process of turning but in this case different diameter in step of

various sizes is taken on the work piece.

Taper Turning

It is different from the turning operation.

Taper is defined as uniform change in the diameter of a work piece measured

along its length.

Where D –

d –

l –



various sizes is taken on the work piece.

It is different from the turning operation.


large Diameter

Small diameter

Length of taper





Knurling

It is process of making serrations on the work piece.

Knurling tools of different shape and size are used to make grip on the work

piece. It has two hardened steel rollers.

The tool is held in tool post and pressed against the rotating work piece.

Work piece is rotated at lower speed and small amount of feed is given.

Drilling

It is a process of making a hole on the work piece

Job is held in chuck while the drill is held in the tail stock sleeve.

Feed is given by rotating the hand wheel in the tail stock which pushes the

tailstock sleeve.

Cutting Speed

It is the peripheral speed of the work past the cutting tool.

It is the speed at which metal is removed by the tool from the work piece.

It is expressed in meter / minute.

Cutting speed= (π ×diameter ×R.P.M)/1000 = πDN/1000 in m/min

D – Diameter in mm

N – Spindle speed in rpm

Feed

It is defined as the rate of tool travel across a surface cutting it.

It is the distance of the tool advances for each revolution of the work piece.

It is expressed in mm/revolution.


Depth of Cut

It is the perpendicular distance measured from the machined surface to the uncut

surface of work. It is expressed in mm.

Depth of cut= (d1- d2)/2

d1 = diameter of work before machining

d2 = diameter of work after machining

SAFETY PRECAUTIONS

Job should be tightly held in the chuck.

If the job is held in between the centers, then apply grease on the nose of dead

center, otherwise it will burnt out due to excess heat.

Do not measure the job while it is rotating.

Do not leave the chuck key in the chuck.

Do not try to stop the lathe chuck or job with hands

Do not handle metal chips by hand.

Do not give more depth of cut while the job is rotating at high speed.

Tighten the tool I n the tool post.

Do not stand close to the rotating job or bring your face to it.

Do not reduce or increase the speed during the lathe operations.

RESULT:

Thus the working principle and operations done in lathe have been studied.


EX.NO:2 MACHINING A WORK PIECE BY FACING, PLAIN TURNING

USING A LATHE

DATE:

AIM:

To machine a work piece by facing, plain turning operations using a lathe.

MATERIALS REQUIRED:

Mild steel polished round rod - 32 X 100 mm

TOOLS REQUIRED:

1. Lathe machine

2. Cutting tool

3. outside Caliper

4. Steel Rule

5. Vernier Caliper

SKETCH:


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 machine is switched off.

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

and checked.

RESULT:

The given work piece is subjected to facing and plain turning operations to

become a finished work piece as shown in figure.


EX.NO: 3 MACHINING A WORK PIECE BY TAPER TURNING OPERATION

(COMPOUND REST METHOD) USING A LATHE

DATE:

AIM:

To machine a work piece by facing, plain turning and taper turning

operation (compound rest method) using a lathe.

MATERIALS REQUIRED:


TOOLS REQUIRED:

1. Lathe machine 4.Steel Rule

2. Cutting tool 5.Vernier Caliper

3. Outside Caliper 6.Spanner

CALCULATION:

The taper angle is calculated using the following formula:

Taper angle (α) = (D-d/2l)

Where

D = large diameter of taper in mm

d = small diameter of taper in mm

l = length of tapered part in mm

α = angle of taper


SKETCH:

PROCEDURE:


2. The cutting tool is set in a tool post such that the point of the Cutting tool





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.



and checked.

RESULT:

The given work piece is subjected to facing, plain turning and taper turning

operation (compound rest method) to become a finished work piece as shown in figure.


EX.NO: 4 MACHINING A WORK PIECE BY V- THREAD CUTTING OPERATIONS

USING A LATHE

DATE:

AIM:

To machine a work piece by facing, plain turning and external thread

cutting operations using a lathe.

MATERIALS REQUIRED:


TOOLS REQUIRED:

1. Lathe machine 4.Parting Tool

2. Turning tool 5.Steel Rule

3. Vernier Caliper 6. External V – thread cutting tool

SKETCH:


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:







5. The speed of the work piece is reduced.

6. The machine is switched off and the change gears of calculated teeth (as per

calculation) are connected.

7. Again the machine is switched on.

8. The external thread cutting operation is done using external V–thread cutting tool

by engaging thread cutting mechanism.



and checked.

RESULT:

The given work piece is subjected to facing, plain turning and external

thread cutting operations to become a finished work piece as shown in figure.


EX.NO: 5 MACHINING A WORK PIECE BY BORING AND INTERNAL THREAD

CUTTING OPERATIONS USING A LATHE

AIM:

To machine a work piece by facing, plain turning, boring and internal

thread cutting operations using a lathe.

MATERIALS REQUIRED:


TOOLS REQUIRED:

1. Lathe machine 5.Outside Caliper

2. Turning tool 6.Steel Rule

3. Boring tool 7.Vernier Caliper

4. Internal V – thread cutting tool

SKETCH:


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:







5. The speed of the work piece is reduced.

6. The boring operation is done using boring tool.

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 internal thread cutting operation is done using internal V–thread cutting tool

by engaging thread cutting mechanism.


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

and checked.

RESULT:

The given work piece is subjected to facing, plain turning, boring and

internal thread cutting operations to become a finished work piece.


EX.NO: 6 STUDY OF RADIAL DRILLING MACHINE

DATE:

AIM:

To understand the working principle and operations done in drilling machine.

To identify the various components of drilling machine and its function.

DESCRIBTION:

In Radial Drilling Machine (RDM), Medium to large & heavy work piece can be drilled.

Radial Drilling Machine consists of heavy, round, vertical column mounted on a large

base. The Column supports a radial arm which can be raised & lowered. The Arm can

be swung around any position over the work bed. In Radial Drilling Machine the arm can

be locked at any desired position as per job size.


Drill head-mechanism for rotating & feeding the drill (mounted on radial arm) and can be

moved horizontally on the guide ways & clamped at any desired position. The 3

movements in RDM permit the drill to be located at desired position. Radial Drilling

Machine can be used for drilling several holes on the same work piece. Radial Drilling

Machine is versatile and work on large WP.

In Radial Drilling Machine the Base have t-slots for mounting large work piece. The

Column has radial arm, drill head and motor. The elevating screw is rotated by motor.

The radial arm can be swiveled around the column. The Radial arm has drill head, Drill

head has separate motor, spindle, drill and drill bit. The Spindle head and feed

mechanism can be manual or automatic.

TYPES:

Plain RDM: The provisions are made for vertical adjustment of the arm, horizontal

movement of drill head along the arm & Circular movement of the arm in horizontal

plane about the vertical column.

Semi universal Machine: In addition to the 3 movements, drill head can be swung

about a horizontal axis perpendicular to the arm. It can drill hole at an angle to

horizontal plane.

Universal Machine: In addition to the 4 movements, the arm holding the drill head can

be rotated on a horizontal axis .These 5 movements enable to drill.

DRILLING MACHINE SPECIFICATION

Portable Drilling machine –Max Dia of the drill that it can hold.

Upright & Sensitive Drilling machine-diameter of the largest piece that can be centered

under the spindle.

Max size of drill that the M/c can operate, table dia, maximum spindle travel, numbers of

spindle speeds and feeds available.

Morse Taper No of the drill spindle, power input, floor space required, net wt of the

M/c, etc.


DRILLING OPERATIONS


RESULT:

Thus the working principle and operations done in radial drilling machine have

been studied.


EX.NO: 7 DRILLING, REAMING AND TAPPING

DATE:

AIM: To make drilling, Reaming and Tapping in the given work piece for the required

dimensions.

MATERIALS REQUIRED:

MS Square Work piece (50X 50)

TOOLS REQUIRED:

Steel rule, Flat file (rough and smooth), Drill bit (8 mm, 10 mm, 10.5 mm),

Reaming tool, Try square

SKETCH:


PROCEDURE:

1. The work piece was fitted in the vice and filed to the required dimensions.

2. The squareness of the work piece was checked.

3. Drawing punches were made for various drills.

4. The job was fitted on the radial drilling machine.

5. The 20 mm ,10.5 mm,8 mm, 6.5 mm-drill bit were used for drilling in the

required place and drilling operation were made on the work piece.

6. Reaming was done on the 8 mm hole using the Reaming tool size of 8 mm

diameter. And tapping was done on the 6.5 mm drill and 10.5 mm drill. The

work piece was removed from the radial drilling machine.

RESULT:

Thus the given job was drilled, reamed and tapped to the required dimensions.


EX.NO: 8 STUDY OF MILLING MACHINE

DATE:

AIM:

To understand the working principle and operations done in milling machine.

To identify the various components of milling machine and its function.

DESCRIBTION:

In milling machine work is feed against rotating multipoint cutter. The metal is removed

in form of small chips. The material removal rate is high .The tool is rotating at high

speed and it has many cutting edges. The multipoint cutting tool used here gives better

surface finish. It can machine flat & irregular surface. The cutter is mounted on rotating

spindle or arbor. The feed can be given in longitudinal, crosswise, vertical and angular

direction. In milling operation one cutting edge will do cutting and other cutting edge will

be idle and cooled. The stress on cutting edge is not continuous thus giving more life to

cutting edge.


SPECIFICATION

• Table Length and Width

• Maximum Longitudinal Cross table

• Number of Spindle speeds

• Power of driving motor

• Floor space and net weight

• Spindle nose taper size

• Type of milling machine

HORIZONTAL MILLING MACHINE

The column and knee type milling machines suitable for floor work, maintenance

work, tool room work. It has vertical column on its base .The column has machined

guide ways on front face in which knee slides up and down on these ways. The

column has housing for speed and feed mechanisms. The knee has saddle and

work table. The horizontal type has axis of rotation of arbor in horizontal direction.

The vertical type has axis of rotation of arbor in vertical direction.

The plain or horizontal milling machine has base made of grey cast iron used as

reservoir for storing cutting fluid. The column is main support for machine houses


motor and other driving mechanisms, guide ways. The knee projects from column,

slides up and down. The knee support saddle and table. It can be moved up and

down by elevating screw.

The saddle supports and carries table and provide traversed movement. The table

top surface is accurately machined and has t slots along the length for hold work

piece. The table rests on guide ways of saddle. It travels longitudinally in horizontal

plane to support work piece. The over arm is mounted on top of column and guided

by it. It hold outer end of arbor to prevent it from bending. The arbor holds the

cutter, tapered at one end to fit the spindle nose. There are2 slots to fit the nose

keys for locating and driving it.

BED TYPE MILLING MACHINE –FIXED BED TYPE SIMPLEX

The bed type milling machine is large, heavy & rigid .The vertical motion is given to

spindle head instead of table. The table is mounted on fixed bed instead of saddle

and knee. The bed is fixed and it can’t move up, down or cross wise. The adjustable

spindle head has spindle which can move up and down.


MILLING CUTTERS TYPES


MILLING OPERATIONS

RESULT:

Thus the working principle and operations done in milling machine have been

studied.


EX.NO: 9 SURFACE MILLING

DATE:

AIM:

To Machine a flat surface using milling machine (Conventional /Climb Method).

MATERIALS REQUIRED:

Work piece of required dimensions.

TOOLS REQUIRED:

Milling machine, Vernier caliper,

SKETCH:

In Peripheral Milling, Milled Surface is parallel To Cutter Axis. In Up milling or

conventional milling cutter rotates opposite to direction of feed of work piece. In down

milling or climb milling cutter rotates in same direction of travel of work piece.


PROCEDURE:

1. Before setting up a job, be sure that the work piece, table, the taper in the

spindle, and the arbor or cutter shank are free from chips, nicks, or burrs. Do not

select a milling cutter of larger diameter than is necessary.

2. Check the machine to see if it is in good running order and properly lubricated,

and that it moves freely, but not too freely in all directions.

3. Consider direction of rotation. Many cutters can be reversed on the arbor, so be

sure you know whether the spindle is to rotate clockwise or counterclockwise.

4. Feed the work piece in a direction opposite the rotation of the milling cutter

(conventional milling).Do not change feeds or speeds while the milling machine is

in operation. When using clamps to secure a workpiece, be sure that they are

tight and that the piece is held so it will not spring or vibrate under cut.

5. Use recommended cutting oil liberally. Use good judgment and common sense in

planning every job.

6. Set up every job as close to the milling machine spindle as circumstances will

permit.

RESULT:

Thus a flat surface is machined to required dimensions using milling machine.


EX.NO: 10 GEAR CUTTING

DATE:

AIM:

To machine a spur gear to the given module and number of teeth in the given work

piece.

MATERIALS REQUIRED:

Blank of Dia 50 mm and length 50 mm

TOOLS REQUIRED:

Milling machine, Vernier caliper, Mandrel.

SKETCH:


PROCEDURE:

1. 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

2. Indexing calculation Index crank movement = 40 / Z

3. The dividing head and the tail stock are bolted on the machine table. Their axis must

be set parallel to the machine table.

4. 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.

5. The cutter is mounted on the arbor. The cutter is centered accurately with the gear

blank.

6. Set the speed and feed for machining.

7. For giving depth of cut, the table is raised till the periphery of the gear blank just

touches the cutter.

8. The micrometer dial of vertical feed screw is set to zero in this position.

9. Then the table is raised further to give the required depth of cut.

10. The machine is started and feed is given to the table to cut the first groove of the

blank.

11. After the cut, the table is brought back to the starting position.

12. Then the gear blank is indexed for the next tooth space.

13. This is continued till all the gear teeth are cut.


CALCULATION :

Z = No. of teeth = 23

m = module = 2 mm

Blank Diameter = (Z + 2) m= (23 + 2) 2 = 50 mm

Tooth Depth = 2.25 m= 2.25 * 2 = 4.5 mm

Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23

RESULT:

Thus the required gear is machined using the milling machine to the

required number of teeth.


EX.NO: 11 STUDY OF SHAPER

DATE:

AIM:

To understand the working principle and operations done in shaping machine.

To identify the various components of shaper and its function.

DESCRIBTION:

The shaper is a relatively simple machine used for machining flat surfaces which may

be horizontal, vertical or inclined with single point cutting tool. Here the tool reciprocates

and the work is stationery. Tooling is simple, and shapers do not always require

operator attention while cutting. The tool is fitted on the tool post on the front end of the

ram. The ram reciprocates along with the tool to remove the metal in the forward stroke

called as cutting stroke. The tool does not cut the metal in the return stroke called as

idle stroke. Therefore one pass is nothing but the combination of one cutting stroke and

one idle stroke.


SHAPER PARTS:

BASE:

The base is a heavy and robust in construction which is made of cast iron by

casting process. It should absorb vibration due to load and cutting forces while

machining.

RAM:

The ram slides back and forth in dovetail or square ways to transmit power to the

cutter. The starting point and the length of the stroke can be adjusted.

CLAPPER BOX:

The clapper box is needed because the cutter drags over the work on the return

stroke. The clapper box is hinged so that the cutting tool will not dig in. Often this

clapper box is automatically raised by mechanical, air, or hydraulic action.


TABLE:

The table is moved left and right, usually by hand, to position the work under the

cutter when setting up. Then, either by hand or more often automatically, the table is

moved sideways to feed the work under the cutter at the end or beginning of each

stroke.

SADDLE:

The saddle moves up and down (Y axis), usually manually, to set the rough

position of the depth of cut. Final depth can be set by the hand crank on the tool h

COLUMN:

The column supports the ram and the rails for the saddle. The mechanism for

moving the ram and table is housed inside the column.

TOOLHEAD:

The tool head is fastened to the ram on a circular plate so that it can be rotated

for making angular cuts. The tool

for precise depth adjustments.

• Holds the tool rigidly

• Allows the tool to have an

• The vertical slide of th

work at any desired angle.

• Apron consisting of a

upon the vertical slide by a screw.




oved sideways to feed the work under the cutter at the end or beginning of each


position of the depth of cut. Final depth can be set by the hand crank on the tool h


moving the ram and table is housed inside the column.

head is fastened to the ram on a circular plate so that it can be rotated

ular cuts. The tool head can also be moved up or down by its hand crank

for precise depth adjustments.

rigidly, provides vertical & angular movement.

Allows the tool to have an automatic relief during return stroke.

The vertical slide of the tool head is graduated in degrees so that we can

any desired angle.

consisting of a clapper box, clapper block and tool post

upon the vertical slide by a screw.




oved sideways to feed the work under the cutter at the end or beginning of each


position of the depth of cut. Final depth can be set by the hand crank on the tool head.


head is fastened to the ram on a circular plate so that it can be rotated

head can also be moved up or down by its hand crank

return stroke.

so that we can

clapper block and tool post is clamped


• On the forward cutting stroke

to make rigid tool support.

• On the return stroke

block out of the clapper box by a sufficient amount preventing the tool cutting

edge from dragging and consequent wear.

SHAPER - SPECIFICATIONS

• Length and breadth of the bed

• Maximum axial travel and vertical travel of the bed

• Maximum stroke length (of the ram / tool)

• Range of number of strokes per minute

• Range of table feed

• Power of the main drive

• Space occupied by the mach

SHAPING OPERATIONS

The tool post has been turned at an angle so that side of the material can be machined

Major Applications: Square edges, side machining of blocks, etc

The tool post is not angled so that the tool can be used to level a surface.

Major Applications: Surface cutting of metal work piece etc.


forward cutting stroke the clapper block fits securely to the

tool support.

return stroke, a slight frictional drag of the tool on the work lifts the


edge from dragging and consequent wear.

FICATIONS

• Length and breadth of the bed

• Maximum axial travel and vertical travel of the bed

• Maximum stroke length (of the ram / tool)

• Range of number of strokes per minute

• Space occupied by the machine


Major Applications: Square edges, side machining of blocks, etc


or Applications: Surface cutting of metal work piece etc.


the clapper block fits securely to the clapper box

, a slight frictional drag of the tool on the work lifts the





The top slide is slowly feed into the material so that a ‘rack’ can be machined for a rack

and pinion gear system

Major Applications: Teeth cutting in gears and other applications where teeth like

structures are required.








JOB SURFACES GENERATED BY SHAPER

RESULT:

Thus the working principle and operations done in shaping machine have been

studied.


JOB SURFACES GENERATED BY SHAPER





EX.NO: 12 STUDY OF PLANER

DATE:

AIM:

To understand the working principle and operations done in planning machine.

To identify the various components of planer and its function.

DESCRIBTION:

The Planer is a very large reciprocating machine tool used for machining flat surfaces

which may be horizontal, vertical or inclined with single point cutting tool. Here the work

reciprocates and the tool is stationery. Planer is mainly used for machining large and

heavy work pieces like lathe bed ways, machine guide ways etc.

The work is mounted on the table by any one of the work holding devices. Two vertical

columns connected by a cross rail mounts the tool head. The tool cuts the work piece

when the table reciprocates. In Planer also, the metal is removed during the cutting

stroke called forward stroke and no metal is removed during the return stroke called idle

stroke. Cutting stroke takes place at a slower speed and return stroke with faster speed.


PARTS OF A PLANER

1. Bed

2. Table

3. Columns

4. Cross rail

5. Tool head




PLANER - SPECIFICATIONS

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

PLANER OPERATIONS

• Planing horizotal surface

• Planing of an angle

• Planing vertical surface

• Planing curved surface


PLANER VS SHAPER

• Tool stationary – work piece reciprocates

• Large & heavy work piece

• More accuracy – tool rigidly supported

• Production time more

• Work setting more skill

• Heavy cut , strong base, strong tools

RESULT:

Thus the working principle and operations done in planning machine have been

studied.


EX.NO: 13 CUTTING KEY WAYS USING SHAPER/PLANER

DATE:

AIM:

To cut external key to the required dimensions in Shaping Machine to

accommodate key.

MATERIALS REQUIRED:

Work piece -shaft as per the required diameter

TOOLS REQUIRED:

Steel rule, Tipped tool, Scriber, Dot punch, Anvil, Surface gauge, Steel rule

SKETCH:


PROCEDURE:

1. The dimensions of the given work piece are checked as per the

requirements.

2. Key and key way dimensions in proportionate to shaft diameter found.

3. Key way dimensions are marked over the shaft then permanent mark

are made using dot punch.

4. Key way is machined in shaper machine to the required dimensions.

RESULT:

Thus external key to the required dimensions in Shaping Machine is cut to

accommodate key.


EX.NO: 12 DOVE TAIL MACHINING IN SHAPER/PLANER

DATE:

AIM:

To perform a dove tail fitting on the given work piece by shaper machine.

MATERIALS REQUIRED:

Rectangular Slab work piece as per the required dimension.

TOOLS REQUIRED:

Steel rule, Scriber, Dot punch, Try square, Parting tool

SKETCH:


PROCEDURE:

1. Initially the given work piece is checked for its dimensions.

2. The dove tail surfaces are marked using scriber to given dimensions, then

punched.

3. The job is fixed on a vice of the shaper to name external dove tail.

4. The vertical slide of the tool head is swiveled to the required angle from

vertical position.

5. The apron is further swiveled away from the work so that the tool will clear the

work during return stroke.

6. The angular down feed is given to the required depth of cut and length of

stroke is adjusted.

7. The above procedure is respected to obtain an internal dove tail part.

8. Then the work piece is removed and assembled for dove tail fit.

RESULT:

Thus the dove tail [internal and external] part were made to the given dimensions

and assembled to obtain dove tail fit assembly.


EX.NO: 15 ESTIMATION OF MACHINING TIME FOR THE LATHE

OPERATIONS

DATE:

AIM: To Determine the Machining Time Requirement For Lathe Operations.

PROCEDURE:

The factors that govern machining time will be understood from a simple case of

machining. A steel rod has to be reduced in diameter from D1 to D2 over a length L by

straight turning in a centre lathe as indicated in Figure.

Actual cutting or machining time =TC

Where, t = depth of cut in one pass, mm.


But practically the value of t and hence np is decided by the machining

allowance kept or left in the preformed blanks. Usually, for saving time and material,

very less machining allowance is left, Hence, number of passes used is generally one or

maximum two : one for roughing and one for finishing.

The Equation clearly indicates that in turning to a given diameter and length, the cutting

time, TC is governed mainly by the selection of the values of cutting velocity, VC and

feed, so. This is true more or less in all machining operations being done in different

machine tools.

ESTIMATION OF MACHINING TIME:

In case of turning in lathes

a. Determine the length of cut by proper selection of amount of

approach, A (2 ~ 5 mm) and over run, O (1 to 3 mm).

b. Select the approximate values of VC and so based on the tool –work

materials and other factors.

c. Determine the spindle speed, N using equation then fix N as well as so

from the chart giving the lists of N and so available in that lathe

d. Finally determine TC using equation


The machining time for facing, grooving, taper turning, threading, parting etc. in lathes

can also be determined or estimated following the same principle and method.

CALCULATION:

How much machining time will be required to reduce the diameter of a cast iron rod

from 120 mm to 116 mm over a length of 100 mm by turning using a carbide insert?

Reasonably select values of VC and so.

RESULT:

Thus the machining time for lathe operations can be determined by this method.


VIVA QUESTIONS

1. What is a lathe?

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

3. What are principle parts of the lathe?

4. What are the types of headstock?

5. State the various parts mounted on the carriage?

6. What are the four types of tool post?

7. What is an apron?

8. State any two specification of lathe?

9. List any four types of lathe?

10. What is a semi-automatic lathe?

11. What is copying lathe?

12. State the various feed mechanisms used for obtaining automatic feed?

13. List any four holding devices?

14. Define the term ‘Conicity’?

15. What is shaper?

16. List any four important parts of a Shaper?

17. How the feed & depth of cut is given to the shaper?

18. Mention any four-shaper specification?

19. Define cutting stroke?

20. Why the time for forward stroke is greater than return stroke?

21. How the planer differs from the shaper?

22. State the use of planer?

23. List the various types of planners?

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

25. Mention any four specification of planer?

26. What is meant by drilling?

27. What is gang -drilling machine?

28. Mention any four specification of drilling machine?

29. List any four machining operations that can be performed on a drilling machine?

30. What are the different ways to mount the drilling tool?

31. What are the specifications of the milling machine?

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

33. State any two comparisons between plain &universal milling machine?

34. What are the cutter holding devices?

35. List the various type of milling attachment?

36. Write any six specifications in milling machine?

37. Write any ten nomenclature of plain milling cutter?

38. What are the advantages of milling process?


39. What are the down milling processes?

40. List out the various milling operations?

41. What are the types of milling cutter?

42. What does term indexing mean?

43. What are the three types dividing heads?

44. What is cam milling?

45. What are the different types of thread milling?

46. What are the other forming methods for manufacturing gears?

47. List the gear generating process?

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

49. What is tool signature?

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

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

52. What are all the conditions for using positive rake angle?

53. When will the negative rake angles be used?

54. Define orthogonal & oblique cutting?

55. Define machinability of metal?

56. What are the factors affecting the machinability?

me6465 manufacturing technology manual

Education

lathe operations total

work piece materials

tool path

study of milling machine

study of lathe date

machining processes

planning operations

appropriate tool