ANNA UNIVERSITY - COIMBATORE THE KAVERY ENGINEERING

COLLEGEM.KALIPATTI, METTUR (TK), SALEM (DT) – 636453

DEPARTMENT OF MECHANICAL ENGINEERING

MANUFACTURING TECHNOLOGY – II LABORATORY MANUAL

IV SEMESTER MECHANICAL ENGINEERING

Name of the student: ______________________________________________

Register Number : ______________________________________________

Prepared By

K.NALLATHAMBIDepartment of Mechanical Engineering

INDEX

Ex. No Date Name of the experiment Page No Marks

ObtainedStaff

signature Remarks

1 Study of Shaping Machine

2 Study of Slotting Machine

3 Study of Planing Machine

4 Study of Drilling Machine

5 Study of Milling machine

6 Study of grinding Machine

7 Study of a turret Lathe

8 Shaping of Round Job to Square

9 Shaping of Dovetail Joint

10 Internal keyway cutting using Slotter

11 Planing of Round Job to Square

12 Drilling and Taping

13 Gear Milling

14 Keyway Milling

15 Milling of Round Job to Square

16 Surface Grinding

17 Cylindrical Grinding

18 Multiple Machining

19 Assembly of Parts

Ex. No Date Name of the experiment Page No Marks

ObtainedStaff

signature Remarks

SHAPING MACHINE AND ITS PARTS

Exp. No: 1 Study of Shaping MachineDate :

AIM:

To study the construction and operation of a shaping machine.

REQUIREMENTS:

1. Shaping Machine.

PARTS:

Important parts of the machine are:1. Frame (Machine Column)2. Ram3. Machine Table with table support4. Saddle5. Ram Head with Tool Slide and Tool Post with Clapper Box Block6. Main Gearing (Gear Train and oscillating slider crank mechanism)7. Drive (Electro Motor)

INTRODUCTION:

The shaper is a machine tool used primarily for:1. Producing a flat or plane surface which may be in a horizontal, a vertical or an angular plane.2. Making slots, grooves and keyways3. Producing contour of concave/convex or a combination of these

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.

CONSTRUCTION:

The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column), Cross rail, Ram and tool head (Tool Post, Tool Slide, Clamper Box Block).

Base: The base is a heavy cast iron casting which is fixed to the shop floor. It supports the body frame and the entire load of the machine. The base absorbs and withstands vibrations and other forces which are likely to be induced during the shaping operations.

Body (Pillar, Frame, Column): It is mounted on the base and houses the drive mechanism compressing the main drives, the gear box and the quick return mechanism for the ram movement. The top of the body provides guide ways for the ram and its front provides the guide ways for the cross rail.

PRINCIPLE OF PRODUCING FLAT SURFACE IN SHAPING MACHINE

Cross rail: The cross rail is mounted on the front of the body frame and can be moved up and down. The vertical movement of the cross rail permits jobs of different heights to be accommodated below the tool. Sliding along the cross rail is a saddle which carries the work table.

Ram and tool head: The ram is driven back and forth in its slides by the slotted link mechanism. The back and forth movement of ram is called stroke and it can be adjusted according to the length of the work piece to be-machined.

OPERATIONS:

Shaping is a technique with straight-lined motion (cutting and feed motion).

The feed motion takes place in steps.

The work piece clamping fixture (compound slide) consists of saddle and machine table.

The machine table is additionally supported.

The ram carries the ram head consisting of swivel-head plate, tool slide, clapper box with tool block and tool holder (tool post).

During the working stroke the tool block rests on the clapper box (as a result of the cutting pressure), during the return stroke it is lifted. In this way the tool tip is protected. With older shaping machines the tool is dragging over the work-piece during the return stroke. The working position is reached by the dead weight and, thus, by falling back.

Modern machines have an automatic tool lifter. For shaping oblique surfaces the tool slide can be swiveled on the swivel-head plate. In order to maintain the mobility of the tool block, it is also possible to set the clapper box on the tool slide at an angle, i.e. to swivel it in the circular slot.

SLOTTING MACHINE AND ITS PARTS

Exp. No: 2 Study of Slotting MachineDate :

AIM:

To study the construction and operation of a Slotting machine.

REQUIREMENTS:

1. Slotting Machine.

PARTS:

Important parts of the machine are:1. Base2. Column3. Ram4. Tool Holder5. Table6. Drive (Electro Motor)

INTRODUCTION:

The slotting machine is a reciprocating machine tool in which, the ram holding the tool reciprocates in a vertical axis and the cutting action of the tool is only during the downward stroke.

WORKING PRINCIPLE:

Slotting machines are very similar to shaping machines in respect of machining principle, tool-work motions and general applications. Slotting machines are characterized by : Vertical tool reciprocation with down stroke acting

Longer stroke length Less strong and rigid An additional rotary feed motion of the work table Used mostly for machining internal surfaces.

CONSTRUCTION:

The slotter can be considered as a vertical shaper and its main parts are:1. Base, column and table2. Ram and tool head assembly3. Saddle and cross slide4. Ram drive mechanism and feed mechanism.

MACHINING OPERATIONS OF SLOTING MACHINE

The base of the slotting machine is rigidly built to take up all the cutting forces. The front face of the vertical column has guide ways for Tool the reciprocating ram. The ram supports the tool head to which the tool is attached. The work piece is mounted on the table which can be given longitudinal, cross and rotary feed motion.

The slotting machine is used for cutting grooves, keys and slotes of various shapes making regular and irregular surfaces both internal and external cutting internal and external gears and profiles The slotter machine can be used on any type of work where vertical tool movement is considered essential and advantageous.

The different types of slotting machines are:

1. Punch slotter: a heavy duty rigid machine designed for removing large amount of metal from large forgings or castings

2. Tool room slotter: a heavy machine which is designed to operate at high speeds. This machine takes light cuts and gives accurate finishing.

3. Production slotter: a heavy duty slotter consisting of heavy cast base and heavy frame, and is generally made in two parts.

OPERATIONS:

The usual and possible machining applications of slotting machines are : Internal flat surfaces Enlargement and / or finishing non-circular holes bounded by a number of flat surfaces as

shown in Fig. 4.4.11 (a) Blind geometrical holes like hexagonal socket as shown in Fig. 4.4.11 (b) Internal grooves and slots of rectangular and curved sections. Internal keyways and splines, straight tooth of internal spur gears, internal curved surface

of circular section, internal oil grooves etc. which are not possible in shaping machines.

PLANING MACHINE AND ITS PARTS

Exp. No: 3 Study of Planing MachineDate :

AIM:

To study the construction and operation of a Planing machine.

REQUIREMENTS:

1. Planing Machine.

PARTS:

Important parts of the machine are:1. Base and table with Rack and pinion2. Column3. Cross Beam4. Cross Rail5. Tool heads (Vertical, Side)6. Drive (Electro Motor)

INTRODUCTION:

Planing machines are basically used for producing flat surfaces in different planes. They are similar to Shapers but bigger in size and capacity but the tool moves instead of the job. Planer is a very large reciprocating machine tool. The work is mounted on the table by one of the work holding devices. Twor vertical columns with vertical guideways are provided on both sides of the bed and connected by cross rail to mount the tool heads and also connected by cross beam on the top. These tool heads are used to hold the

WORKING PRINCIPLE:

Planing machines are basically used for producing flat surfaces in different planes. However, the major differences between planing machines from shaping machines are : Planing machines produce flat surface by the combined actions of the Generatrix and Directrix and nstead

of the tool, the workpiece reciprocates giving the fast cutting motion and instead of the job, the tool(s) is given the slow feed motion(s).

Planing machines are much larger and more rugged and generally used for large jobs with longer stroke length and heavy cuts. In planing machine, the workpiece is mounted on the reciprocating table and the tool is mounted on the horizontal rail which, again, can move vertically up and down along the vertical rails.

Planing machines are more productive (than shaping machines) for longer and faster stroke, heavy cuts (high feed and depth of cut) possible and simultaneous use of a number of tools.

In planing machines The length and position of stroke can be adjusted Only single point tools are used The quick return persists Form tools are often used for machining grooves of curved section Both shaping and planing machines can also produce large curved surfaces by using

suitable attachments.

MACHINING OF A MACHINE BED IN PLANING MACHINE

CONSTRUCTION:

The major parts of the planer are Bed, Table, Columns, Cross Rail and Tool Heads.

BED:The bed is very strong and rigid of box type which is made by casting process. The bed length is made twice the length of the table with V guide ways. The table is mounted over the bed which houses various mechanisms. Cross ribs are used to increase the strength of the bed.

TABLE:Table is a box type structure which reciprocates on the bed guideways. It is having T Slots [reamed holes at regular intervals, stop pins and troughs] as that of the shaper for clamping the workpiece.

COLUMNS:The two long structural member along with the guideways provided on both the sides of the member. The two long columns connected by a cross rail and cross beam. The cross rail slides on these guide ways. It carries the feed mechanism and power transmission links.

CROSS RAIL:It is rigid structural member mounted between two columns and slides on the guideways provided on the columns. The cross rail can be set or clamped at any height. It carries toolheads.

TOOL HEADS:Maximum four tool heads can be mounted on the planer. Two are on the cross rail and another two are on the guideways of both the columns. It may tilt to any required angle.

TYPES OF PLANING MACHINE:1. Double Housing planer2. Open side Planer3. Pit Planer4. Edge Planer5. Divided table planer.

OPERATIONS:

The common machining work done in shaping machines Machining Guideways, Beds and tables of various machines like lathes, milling machines, grinding

machines and planing machines itself, broaching where the several parallel surfaces of typical machine bed and guideway are surfaced by a number of single point HSS or carbide tools.

Machining of long parallel T-slots, Vee and inverted Vee type guideways helical grooving on large rods, long and wide 2-D curved surfaces, repetitive oil grooves

DRILLING MACHINE AND ITS PARTS

Exp. No: 4 Study of Drilling MachineDate :

AIM:

To study the construction and operation of a Drilling machine.

REQUIREMENTS:

1. Drilling Machine.

PARTS:

Important parts of the machine are:1. Base2. Column3. Table4. Drill Head5. Spindle, Quill, Quill Support6. Drive (Electro Motor)

INTRODUCTION:

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.

WORKING PRINCIPLE:

The rotating edge of the drill exerts a large force on the workpiece and the hole is generated. The removal of metal in a drilling operation is by shearing and extrusion.

CONSTRUCTION:

The machine has only a hand feed mechanism for feeding the tool into the workpiece. This enables the

operator to feel how the drill is cutting and accordingly he can control the down feed pressure. Sensitive

drill presses are manufactured in bench or floor models, i.e., the base of machine may be mounted on a

bench or floor.The main operating parts of a sensitive machine/drill press are Base, Column, Table, and

Drill Head.

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 workpiece 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.

MACHINING OPERATIONS OF DRILLING MACHINE

3. Table: The table, either rectangular or round. Drill machine/press in shape supports the workpiece 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 workpiece. Slots are

provided in most tables to allow the jigs, fixtures or large workpieces 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 different types of drilling machines are:

1. Portable drilling machine: It is a small light weight, compact and self contained unit that can drill holes

upto 12.5 rnrn diameter. The machine is driven by a small electric motor operating at high speed. The

machine is capable of drilling holes in the workpieces in any position.

2. Sensitive drill machine/press: This is a light weight, high speed machine designed for drilling small holes in light jobs. Generally the machine has the capacity to rotate drills of 1.5 to 15.5 rnrn at high speed of 20,000 rev/min.

OPERATIONS:

The operations done by drilling machine are:

1. Drilling2. Reaming3. Boring4. Counterboring5. Countersinking6. Tapping

VERTICAL MILLING MACHINE

Exp. No: 5 Study of Milling MachineDate :

AIM:

To study the construction and operation of a Milling machine.

REQUIREMENTS:

1. Milling Machine.

PARTS:

Important parts of the machine are:1. Base2. Column3. Knee, Table and Saddle4. Overarm / Ram5. Swivel (Turret)6. Quill, Quill Feed Lever and Handwheel7. Drive (Electro Motor)

INTRODUCTION:

Milling is the cutting operation that removes metal by feeding the work against a rotating, cutter having single or multiple cutting edges. Flat or curved surfaces of many shapes can be machined by milling with good finish and accuracy. A milling machine may also be used for drilling, slotting, making a circular profile and gear cutting by having suitable attachments.

WORKING PRINCIPLE:

The work piece is holding on the worktable of the machine. The table movement controls the feed of work

piece against the rotating cutter. The cutter is mounted on a spindle or arbor and revolves at high speed.

Except for rotation the cutter has no other motion. As the work piece advances, the cutter teeth remove

the metal from the surface of work piece and the desired shape is produced.

CONSTRUCTION:The main part of machine is base, Column, Knee, Saddle, Table, Column, Over arm / Ram.

1. Base: It gives support and rigidity to the machine and also acts as a reservoir for the cutting fluids.

2. Column: The column is the main supporting frame mounted vertically on the base. The column is box

shaped, heavily ribbed inside and houses all the driving mechanisms for the spindle and table feed.

3. Knee: The knee is a rigid casting mounted on the front face of the column. The knee moves vertically

along the guide ways and this movement enables to adjust the distance between the cutter

HORIZONTAL MILLING MACHINE:

MACHINING OPERATIONS OF MILLING MACHINE

and the job mounted on the table. The adjustment is obtained manually or automatically by operating the

elevating screw provided below the knee.

4. Saddle: The saddle rests on the knee and constitutes the intermediate part between the knee and the

table. The saddle moves transversely, i.e., crosswise (in or out) on guide ways provided on the knee.

5. Table: The table rests on guide ways in the saddle and provides support to the work. The table is made

of cast iron, its top surface is accurately machined and carriers T-slots which accommodate the clamping

bolt for fixing the work. The worktable and hence the job fitted on it is given motions in three directions:

a). Vertical (up and down) movement provided by raising or lowering the knee.

b). Cross (in or out) or transverse motion provided by moving the saddle in relation to knee.

c). Longitudinal (back and forth) motion provided by hand wheel fitted on the side of feed screw.

In addition to the above motions, the table of a universal milling machine can be swiveled 45° to either

side of the centre line and thus fed at an angle to the spindle.

6. Over arm: The Over arm is mounted at the top of the column and is guided in perfect alignment by the

machined surfaces. The Over arm is the support for the arbor.

7. Arbor support: The arbor support is fitted to the Over arm and can be clamped at any location on the

Over arm. Its function is to align and support various arbors. The arbor is a machined shaft that holds and

drives the cutters.

8. Elevating screw: The upward and downward movement to the knee and the table is given by the elevating screw that is operated by hand or an automatic feed.

OPERATIONS:

The operations done by drilling machine are:

1. Face Milling2. Plain or Slab Milling3. Angular Milling4. Form Milling5. Special Operations like Sawing, Slotting, Gear cutting

GRINDING MACHINE AND ITS PARTS

Exp. No: 6 Study of Grinding MachineDate :

AIM:

To study the construction and operation of a Grinding machine.

REQUIREMENTS:

1. Grinding Machine.

PARTS:

Important parts of the machine are:1. Base2. Table3. Column4. Wheel Head5. Grinding Wheel

INTRODUCTION:

Grinding is metal removing process in which the metal is removed with the help of rotating grinding wheel. Grinding wheels are made of fine grains of abrasive materials held together with bonding materials.

WORKING PRINCIPLE:

In grinding the wheel is rotated and the work is fed against the wheel. The abrasive grains which project on the surface of the grinding wheel moving with high velocity and shear off small metal particle from the work piece. During machining, the blunt abrasive grains are released from the wheel surface. In their place, new abrasive grains project from the surface of the wheel, known as sharpening of grinding wheel.

CONSTRUCTION:

Types of Grinding MachinesBased on operations: Tool Grinder, Cut off GrinderBased on Surface finish Quality: Precision grinder, Rough GrindersType of the surface generated: Cylindrical grinders, Internal Grinders, Surface grinders, Tool grinders, Special purpose grinding machines and Surface finishing grindersThe Surface grinders have the major parts like Base, table, column, wheel head and grinding wheel.

BASE:The base is the main casting that rests on the floor and supports the parts mounted on it. On top of the base, horizontal guide ways are set on which the table slides to give motion to the work piece. The table drive mechanism is incorporated in the base itself.

MACHINING OPERATIONS OF GRINDING MACHINE

TABLEThere are two tables such as upper table and lower table. The lower table slides on the guide ways of the bed and provides traverse feed or longitudinal feed of the work past the grinding wheel. It can be moved by hand and power within the limits. Adjustable dogs are provided at the side of the lower table. The dogs can be set in proper place to reverse the table at the end of the stroke.Upper table is mounted on the lower table ad it carries the head stock and tailstock. The head stock and tail stock can be adjusted according to the length of the work piece. The upper table can be swiveled and clamped in position over the power table. The maximum angle of the swivel is 10 degree on either side. The swiveling is used for grinding tapers.

COLUMN:Column is the supporting frame mounted vertically on the base. It houses the wheel head on the guide ways.

WHEEL HEAD:The wheel head carries a grinding wheel and rotated by a motor housed in the headstock. The wheel head is placed over the bed at its backside. The wheel head can be moved perpendicular to the table ways by hand or power. This movement is called cross feed.

GRINDING WHEEL:Grinding wheels are made up of small abrasive particles held together by bonding material. It is a multi edge cutter.Abrasive is a hard material. It can be used to cut or wear away other materials. Small abrasive particles called abrasive grains are used in grinding wheels. Abrasives may be Natural abrasives or artificial abrasives.

OPERATIONS:

The grinding is mainly used for the following purposes:a. To remove small amount of metal from the work piece and finish to close tolerancesb. To obtain better surface finishc. To machine hard surfaces that cannot be machined by high speed steelsd. Sharpening of cutting toolse. Grinding of threads

TURRET LATHE AND ITS PARTS:

Exp. No: 7 Study of Turret LatheDate :

AIM:

To study the construction and operation of a Turret Lathe.

REQUIREMENTS:

1. Turret Lathe

PARTS:

Important parts of the machine are:1. Bed2. Headstock3. turret Head and Saddle4. Cross Slide

INTRODUCTION:In ordinary lathe, changing and setting of tools take more time. The production rate is low due to which the cost is increased. Semi automatic and automatic lathes are used to reduce the changing and setting time of the tools. More than one tool can be used at a time to perform specific task. It reduces the tool changing time, unloading time and increases the rate of production.

WORKING PRINCIPLE:The working principle of the Turret lathe is similar to Lathe. Turret Lathe is a type of semi automatic lathe which carries multiple tools mounted on the Turret head. Turret lathes are used for heavy jobs. In turret lathe all the machining operations are performed automatically. But, loading, unloading of the jobs, bringing the tools in correct positions, coolant on or off and selection of the spindle are carried out manually.

CONSTRUCTION:

The major parts of the Turret Lathe are Bed, Headstock, turret Head and Saddle and Cross Slide

BED:Bed is the base part of the lathe. It is a box type construction which is made of Cast Iron. Guide ways on the top of the bed has been provided accurately. Cross slide and turret head are mounted on these guideways. The bed should be strong and rigid to withstand heavy loads, force and vibrations during machining work.

HEADSTOCK:Head stock of Turret lathe is similar to that of the ordinary centre lathe. It is bigger in size and heavier in construction. It houses spindle and driving mechanism. A motor or speed 30 to 2000 rpm is fitted. There are various types of head stocks depending on the driving mechanism.

MACHINING OPERATIONS OF TURRET LATHE:

Types of Lathe operations:

TURRET HEAD AND SADDLE:Turret head has a hexagonal block having six faces with a bore for size or more than six tools at a time. The four threaded holes on these faces are used to accommodate the tool holders. The turret head is mounted on the ram fitted with turret slides longitudinally on a saddle. The ram is actuated either by hand or power. The forward movement of the ram is controlled by the preset or adjustable stop. To index the cutting tool, the ram or turret is returned to its starting position for tripping the stops. The tripping stops are locked in position by locking nuts. Each tool is indexed 60 degrees by the roation of a circular plate. The circular plate is indexed automatically along with the turret head. Bringing the next tool into the cutting position is known as Geneva mechanism.

CROSS SLIDE:Cross slide is attached to the saddle. Cross slide is carries two tool posts. Each tool can be indexed by 90 degrees. the compound rest and tool post. The cross slide can be moved either by power or by hand. Stop bars are provided for controlling the motion of each tool which can be indexed automatically with square turret for next machining operation.

OPERATIONS:

The operations that can be performed by Turret lathe are:

1. Drilling, Boring, reaming, counter boring, turning and threading2. Forming, Chamfering, knurling, necking, Parting

Raw material

Exp. No: 8 Shaping of Round Job to SquareDate :

AIM:To study the construction of a shaping machine and to shape the given round MS raw material into a square as per given dimension.

REQUIREMENTS:1. Shaping Machine2. Polished HSS tool.3. Raw Material Ø50 x 50mm Mild Steel Rod.4. Marking gauge. 5. Try square. 6. Steel rule. 7. Tool holder.

PROCEDURE:

The maximum square dimension is marked on the job using scriber steel rule on the diameter of the work piece.

The markings are punched by using punch hammer.

The work piece is clamped on the vice which is on the shaper table such that the marking is parallel to the table surface.

The tool holder with the tool is fixed rigidly on the clapper box.

The stroke length of the ram is adjusted to our requirements by using hand wheel.

First roughing cut is given and the feed is given when the tool return back.

Depth of the cut for rough and finish is given by the movement of the tool post from top to bottom.

Finally finishing cut is given when a small amount of material is left to reach the finish marking.

RESULT:

Thus the shape the given round raw material into a square as per given dimension is done.

Raw Material

Finished work piece

Exp. No: 9 Shaping of Dovetail JointDate :

AIM:To shape the given square MS raw material into a dovetail shape as per given dimension.

REQUIREMENTS:1. Shaping Machine2. Tool holder. 3. Polished HSS tool. 4. Raw Material - 50 x 50mm Mild Steel Square Rod 5. Marking gauge. 6. Try square. 7. Steel rule.

PROCEDURE:

The dovetail shape is marked on the job using scriber steel rule on the face of the square work piece.

The markings are punched by using punch hammer.

The work piece is clamped on the vice which is on the shaper table such that the horizontal marking is parallel to the table surface.

The tool holder with the tool is fixed rigidly on the clapper box.

The stroke length of the ram is adjusted to our requirements by using hand wheel.

First roughing cut is given and the feed is given when the tool return back.

Depth of the cut for rough and finish is given by the movement of the tool post from top to bottom.

Finally finishing cut is given when a small amount of material is left to reach the finish marking.

RESULT:

Thus the shape of a dovetail is machined from the given square MS raw material as per the given dimension.

Raw material

Internal drilling & Boring

Keyway cutting shown in shaded potion Finished part

Exp. No: 10 internal keyway cutting using SlotterDate :

AIM:To study the construction of a slotting machine and to machine an internal keyway to the given dimension using slotter.

REQUIREMENTS:

1. Slotter2. ¾” polished HSS tool.3. Tool holder. 4. Raw Material Dia 2” x 25mm length 5. Marking gauge. 6. Steel rule. 7. Punch

PROCEDURE:

Take the raw material make a centre punch on the center of the work piece and mark the required dimensions on the work piece by applying chalk on it.

Remove the material by drilling and boring to 1inch diameter at the center.

Place the work piece on the slotter table and mount the tool holder on the tool post.

The work piece is fixed in the table such that the tool holder can pass through the 1 inch diameter hole created

Place the tool on the tool holder and roll the ram to see that the tool touches the internal diameter phase.

Mark on the work piece the shape of the keyway.

Now switch on the motor such that the ram reciprocates to top and bottom.

For every cut the feed is given with the help of the horizontal movement movement of the table.

Repeat the operation until the required keyway is machined.

RESULT:

Thus the machining of the internal keyway in a slotter is done to the given dimensions.

Raw material

Exp. No: 11 Planing of Round Job to SquareDate :

AIM:To study the construction of a planing machine and to shape the given round MS raw material into a square as per given dimension.

REQUIREMENTS:1. Planing Machine2. Tool holder. 3. Polished HSS tool. 4. Raw Material Φ75 x 75mm Mild Steel Rod.5. Marking gauge. 6. Try square & Scriber. 7. Steel rule.

PROCEDURE:

The maximum square dimension is marked on the job using scriber steel rule on the diameter of the work piece.

The markings are punched by using punch hammer.

The work piece is clamped on the vice which is on the planer table such that the marking is parallel surface to the table.

The tool holder with the tool is fixed rigidly on the clapper box of the tool post.

The stroke length of the ram is adjusted to our requirements by using hand wheel.

First roughing cut is given and the feed is given when the tool return back.

Depth of the cut for rough and finish is given by the movement of the tool post from top to bottom.

Finally finishing cut is given when a small amount of material is left to reach the finish marking.

RESULT:

Thus the given round raw material is machined into a square as per given dimension.

Finished piece

Exp. No: 12 Drilling and TapingDate :

AIM: To study the construction of a drilling machine and to perform an operation of drilling, reaming, and tapping in the given work piece.

REQUIREMENTS:1. Drilling Machine2. Drill bit 12mm3. Reamer 12 mm 4. Tap set M12 & coconut oil as coolant.5. Raw Material 100 x 50 x 6mm MS plate.6. Scriber & Steel rule7. Centre punch

PROCEDURE:DRILLINGThe markings as per the given drawing are done on the raw material using scriber and steel rule.

Center punch is used to produce an identification of the centre where the holes have to be drilled and a circle of the given size is marked on the raw material using divider.The drill is fixed in the drilling machine and the adjustment of the vice where the raw material is fixed is aligned with the circle previously draw.

Now the drilling machine is switched on the hole is made.

REAMING:1. It has multi cutting edge. 2. It cannot originate a hole.

3. The reamer is fixed in the spindle of the drilling machine and soft finishing is made in the work piece.

4. The accurate hole is accepted within 0.0125 mm.

TAPPING:It has multi cutting edges.

M12 tap is fixed on the spindle of the drilling machine and the spindle speed is adjusted such that it runs in a lesser rpm.

Tapping, a hole is slowly done on the reamed hole. This tapping operation can be done by fixing the work piece on the machine vice also.

Care should be taken such that the work piece is exactly perpendicular to the tap in the spindle such that the thread formation is done exactly.

RESULT:

Thus the operation of drilling, Reaming and tapping are done according to the given dimensions.

GEAR MILLING PRINCIPLE

Exp. No: 13 Gear MillingDate :

AIM:To study the construction of a milling machine and to produce the gear from the given work piece by using milling machine.

REQUIREMENTS:1. Universal Milling Machine with Indexing Mechanism and Universal dividing head.2. Modular cutter 3. Mandrel 4. Turning tool 5. Outside caliper.6. Spanner set. 7. Steel rule 8. Drill bit 19.5”

PROCEDURE:The given raw material is held on a lathe in a 3- jaw chuck and facing is done on both sides of the work piece.

The work piece is drilled through 19.5” drill bits which is fitted taper of tailstock sleeve.

The inner diameter of the work piece is based on single point cutting tool according to the mandrel which direction is same as the size of the vertical gear shaping machine.

Then the job is fitted in the mandrel and outer diameter of work piece is turned with single point turning tool.

The given gear blank is lined to the required addendum diameter to gear blank.

This is held in universal dividing head with mandrel.

Indexing calculation are performed and the required size of the hole is selected in the given disc plate.

Then the material is removed from the work piece by passing the work piece over the lathe cutter.

RESULT:

Thus the gear is produced in the work piece using the milling machine.

Exp. No: 14 Keyway MillingDate :

AIM:To machine a internal keyway of given dimensions in a Vertical milling machine.

REQUIREMENTS:1. Vertical Milling Machine2. End mill cutter.3. Raw material4. Scriber5. Steel rule

PROCEDURE:

Take the required piece and check it for the given dimensions.

Mark the required dimensions on the work piece by applying chalk on it.

Place the work piece horizontally in the vice.

Fix the end mill cutter on the vertical milling machine spindle.

Raise the table where the work piece is held in the vice such that it reaches nearer to the cutter face.

Switch on the spindle and raise the table such that the required depth of cut is given for the first pass.

Move the table horizontally such that the feed is given until the marking required for the keyway.

Repeat the pass number of times by increasing the depth of cut until the required keyway is cut.

RESULT:

Thus internal keyway in a milling machine is done to the given dimensions.

Raw material

Exp. No: 15 Milling of Round Job to SquareDate :

AIM:To perform a round to square machining operation to the given dimensions in a Vertical milling machine.

REQUIREMENTS:1. Vertical Milling machine2. Multi point milling cutter.3. Raw Material4. Scriber5. Steel rule6. Try square

PROCEDURE:

Take the required piece and check it for the given dimensions.

Mark the required dimensions on the work piece by applying chalk on it.

Place the work piece horizontally in the vice.

Fix the multi point milling cutter on the vertical milling machine spindle.

Raise the table where the work piece is held in the vice such that it reaches nearer to the cutter face.

Switch on the spindle and raise the table such that the required depth of cut is given for the first pass.

Move the table horizontally such that the feed is given and complete one pass

Repeat the pass number of times by increasing the depth of cut until the required marking has been reached.Remove the workpiece from the vice and rotate it to 90 deg to machine the adjacent side.Similarly the operation is repeated on the 4 sides until the required square is achieved.

RESULT:Thus the square in a milling machine is done to the given dimensions.

Exp. No: 16 Surface GrindingDate :

AIM:To perform surface grinding operation on the given work piece for the given dimensions.

PRINCIPLE:The principle involved in this process is to make flat surface on the given work piece. The cutter is moved perpendicular to the work piece and the grinding is done.

REQUIREMENTS:Grinding MachineWork Piece 100x50x6 mm MS PlateGrinding Wheel

PROCEDURE:

At first work piece is placed in the magnetic chuck.

The work piece should be light weight so that it cannot be removed from the magnetic chuck easily.

Various arrangements regarding the positions of work piece is done.

Grinding wheel and grinding spindle are kept in position with the work piece.

Before switching on the motor, necessary steps should taken. For proper grinding process wheel speed, work speed, transverse speed of the wheel in feed, area of contact is to be noted.

While running the area of contact is adjusted accordingly to the spindle in order to remove the surface.

It is done slowly to remove the materials on the both sides.

In surface grinding the stock removal rate is given by Q = bdy Where d =depth of cut (m) b =width of cut (m) y =work velocity (m/s)q =rate of stroke (m3/s)

RESULT:

Thus the surface grinding is done for the given dimensions.

Exp. No: 17 Cylindrical GrindingDate :

AIM:To grind the cylindrical surface of the given materials as per the given dimensions.

REQUIREMENTS:1. Grinding Machine2. Grinding Wheel3. Work Piece4. Steel rule. 5. Outside calipers. 6. Cutting tool.

PROCEDURE:

The given work piece is first fitted in the chuck of the lathe.

By fitting the tool in tool post the work piece will be reduced to given dimensions.

First reduce the diameter to 23mm size then reduced the diameter to 15mm and 18mm at the middle.

By facing the work piece to the tool work piece is reduced to 70mm.

After the preliminary lathe operation, the work piece is held in the ends of the cylindrical grinder.

The grinding wheel is turned on and it is moved towards the work piece such that the surfaces of the cylindrical position are grinded to +-0.2mm.

RESULT:

Thus the required dimension of cylindrical surface is obtained.

Exp. No: 18 Multiple Machining using Turret LatheDate :

AIM:To study the construction of a turret lathe and to perform multiple machining operations in a single setup using turret lathe

REQUIREMENTS:1. Turret Lathe2. Work Piece3. Steel rule. 4. Cutting tools – RH Cutting Tool, drill bit, Boring tool, Parting tool

PROCEDURE:

The given work piece is first fitted in the chuck of the lathe.

The various tools like drill bit, right hand tool, boring tool, parting off tool is fixed in the turret of the machine in due alignment with the work piece.

First the right hand tool is indexed to be in position with the work piece and facing, turning operations are carried out.

After the operation is over the drill bit fixed in the turret is indexed to the position and the drilling operation is performed.

After the drilling operation similarly the boring tool is indexed to the position to bore the drilled hole and finish to size.

Finally, parting tool is indexed to the position and the required bush piece is parted off.

RESULT:

Thus multiple machining operations is carried out in single setup using turret lathe to the required dimensions.

Exp. No: 19 Assembly of partsDate :

AIM:To perform an assembly of parts which are previously machined.

REQUIREMENTS:1. Machined parts2. Vernier Caliper3. Vice4. Hammer

PROCEDURE:

The machined work pieces are measured using vernier calipers and their sizes are noted.

The internal key way cut work piece from slotter and the external key way cut work piece from the milling machine are joined together by a key.

The bush which was prepared from the turret lathe is fitted into one end of the work piece which was assembled previously.

The various fit and tolerance values for different types of fits are studied and the corresponding process of machining operations for various fits is studied.

RESULT:

Thus assembly of various parts which are machined earlier are assembled and various assembly parameters are studied.

some Machining OperationsMachining Operations

Word Meaning Context More Information

boring

Boring is an operation to enlarge and finish holes accurately. This may be done on a lathe or a milling machine. Boring is a machine operation in

which the work is in contact with a single point tool.

A work piece may be held in a 3, 4, or 6 jaw chuck and collets.

broaching

Broaching is an operation that completes the cutting in one stroke or cut.

Broaching can be done on both internal and external surfaces.

The teeth of a broaching tool are equally spaced so that as the tool advances into the workpiece, each tooth removes a specified amount of metal.

drilling

Drilling is an economical way of removing large amounts of metal to create semi-precision round hole or cavity. Drilling allows a person to make

holes through boards, metals, and other materials.

Used for last removal of stock on preparation for other operations like boring, reaming, or tapping.

drill press

A machine designed to hold drill bits which will produce cylindrical holes.

Used for producing cylindrical holes, as well as reaming, boring, counter-boring, counter-sinking, honing, lapping and tapping.

There are three major types:- Sensitive drill (light drilling)- Upright drill (heavy duty drilling)- Radial arm drill press (large, heavy work pieces)

facing Facing is a lathe operation in which the cutting tool removes metal from the end of the work piece or a shoulder.

Facing is a machine operation

A work piece may be held in a 3, 4, or 6 jaw chuck, collets or a faceplate.

where the work is rotated against a single point tool.

gang drilling machine

Gang drilling machine performs a number of drilling operations in a sequence.

The gang drilling machine is a series of single spindle drill heads mounted on a long table.

Each head is equipped with a different tool to drill the part being machined as it moves from one station to the next.

grinding

Grinding is an operation in which the cutting is done by the use of abrasive particles.

Grinding processes remove very small chips in very large numbers by cutting the action of many small individual abrasive grains.

The abrasive grains are formed into a grinding wheel.Very smooth surfaces can be accomplished by the use of the proper grinding wheel.

grinding machine

Grinding machine machines metal parts with an abrasive wheel which can grind to close tolerances. Grinding machines can produce

parts of the identical size, shape, and finish quality.

Various types of grinding machines:- Plain Surface grinders- Rotary Surface grinders- Tool & Cutter grinders- Universal grinders- Internal grinders

gun drilling machine

Gun drilling machine is a machine used to produce long, deep holes.The operation is called "Gun drilling".

In some drilling machines, the gun drill is held firm in a machine and the workpiece revolves; in other cases the work is stationary and the tool revolves.

Uses three types of spindles for producing deep holes:- way - quill- fixed-spindle

honing

Honing is an internal cutting technique that uses abrasives on a rotating tool to produce extremely accurate holes that require a very smooth finish.

Honing operation

Similar to lapping where abrasive sticks are mounted in a rotating tool.Capable of accuracies of less than 1/10,000th of one inch.

horizontal milling machine

A horizontal milling machine uses a rotating tool to produce flat surfaces.Used for heavy stock removal. The milling machine provides

cutting action with a rotating tool.The spindle is mounted on a horizontal position. Available in different size tables.

lathe The lathe is used for producing cylindrical work. The workpiece is rotated while the cutting tool movement is controlled by the machine.

The lathe may be used for:boring, drilling, tapping, turning, facing, threading, polishing, grooving, knurling, trepanning

The lathe is primarily used for cylindrical work.

non-precision grinding

Non-precision grinding is a cutting technique used when the grinding does not need to be accurate.

Non-precision grinding is done when accuracy is not important.

Non-precision grinding is a free-hand operation done on a pedestal or bench grinder.

precision grinding

Precision grinding is a cutting technique used when close tolerances and very smooth finishes are required.

Precision grinding as often used as a finish machining process.

Precision grinding allows very small amounts of material to be removed from a workpiece. This is extremely useful in acquiring smooth fnishes.

reaming

Reaming is a sizing operation that removes a small amount of metal from a hole already drilled.

The reamer is the tool used for this operation.

Machinists may use hand or machine reamers depending on the job they are performing.

shaper

Shaper is a machine used for the production of flat surfaces in vertical, horizontal, or angular planes.

The shaper cuts by passing a single point tool by the workpiece.

There are three types of shapers:- Horizontal / plain or universal- Vertical (slotter and key seater)- Special

shaping

Shaping is an operation used to produce flat surfaces.

Shaping

When the cutting tool reciprocates while the work is fed towards the tool removing material on each stroke, it is called shaping.

single point threading

Single point threading is a lathe operation used for creating internal / external precision machined threads with a single point tool.

Single point threading

Uses a special cutting tool that reflects the thread form.There are over 100 thread forms.

sensitive drill press

Sensitive drill press is a high speed machine that drills very small holes.

The sensitive drill press

- it is used for light duty work

- extremely precise quill and spindle

- capable of speeds of over 40,000rpm

- maximum drill size of 1/32 of an inch

tapping

Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be threaded into the hole. Also, it is used to make threads on nuts.

Tapping is done with a tool called a "Tap".

Tapping may be done by:- hand- lathe machine- milling machine- tapping machine

turning

Turning is a lathe operation in which the cutting tool removes metal from the outside diameter of a workpiece.

A single point tool is used for turning.

A workpiece may be held in a 3, 4, or 6 jaw chuck, collets or may also be held between centers.

vertical milling machine

A vertical milling machine uses a rotating tool to produce flat surfaces. A very flexible, light-duty machine.

The milling machine provides cutting action with a rotating tool.

The spindle is mounted on a vertical position. Available in different size tables.