Lab Manual v1

5/22/2018 Lab Manual v1

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DHANALAKSHMI SRINIVASAN INSTITUTE OF TECHNOLOGY

SAMAYAPURAM - TRICHY

ME2258 MANUFACTURING TECHNOLOGY LAB 2 MANUAL 1

S.No Experiment NameDate of

ExperimentMarks Signature

Metal Cutting experiment

1. Shear angle calculation2. Cutting force calculation

3. Tool wear calculation

Material Removal using Slotter, Milling and Planer machines

4.Internal keyway cutting inSlotter machine

5. Round to square in planer

6.Gear milling in milling

machine

7.Keyway cutting in milling

machine

Grinding

8. Surface grinding

9. Cylindrical grinding

Capstan and turret lathe

10. Study

11.

Drilling, Countersinking and

Reaming in Capstan and

Turret lathe

Gear machining

12.Gear manufacturing using

gear hobbing.


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General Shop Safety

All tools are dangerous if used improperly or carelessly. Working safely is the first

thing the user or operator should learn because the safe way is the correct way. A person

learning to operate machine tools must first learn the safety regulations and precautions

for each tool or machine. Most accidents are caused by not following prescribedprocedures. Develop safe work habits rather than suffer the consequences of an

accident.

Most of the safety practices mentioned in this section are general in nature. Safety

precautions for specific tools and machines are described in detail in the chapters along

with the description of the equipment. Study these carefully and be on the alert to apply

them.

EYE PROTECTION

Using eye protection in the machine shop is the most important safety rule of all.Metal chips and shavings can flyat great speeds and distances and cause serious eye

injury.

Safety glasses must be worn when working with hand cutting tools, since most hand

cutting tools are made of hardened steel and can break or shatter when used

improperly.

There are many different types of safety glasses available in the supply system;

however, the ones that offer the best protection are the safety glasses with side

shields. Safety goggles should be worn over prescription glasses. For specific

information about eye protection, contact the Occupational Health Clinic or refer toTB MED 586.

HAZARDOUS NOISE PROTECTION

Noise hazards are very common in the machine shop. High intensity noise can cause

permanent loss of hearing. Although noise hazards cannot always be eliminated,

hearing loss is avoidable with ear muffs, ear plugs, or both. These are available

through the local supply system or from the Occupational Health Clinic. Ear plugs

must be properly fitted by qualified personnel. For specific information on hearing

protection, refer to TB MED 501.

FOOT PROTECTION

The floor in a machine shop is often covered with razor-sharp metal chips, and heavy

stock may be dropped on the feet. Therefore, safety shoes or a solid leather shoe must

be worn at all times. Safety shoes are available in the supply system. These have a

steel plate located over the toe and are designed to resist impact. Some safety shoes

also have an instep guard.

GRINDING DUST AND HAZARDOUS FUMES

Grinding dust from abrasive wheels is made up of extremely fine particles of themetal and the wheel. Some grinding machines are equipped with a vacuum dust


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collector. When operating a grinder without a vacuum, wear an approved respirator to

avoid inhaling the dust. Whenever possible, use coolant when grinding. This will aid

in dust control. Grinding dust can be very dangerous to your health, especially

beryllium or parts used in nuclear systems. These materials require careful control of

grinding dust.

Metals such as zinc give off toxic fumes when heated above their boiling point.

Inhaling these fumes may cause temporary sickness, or death. The fumes produced

from lead and mercury are very harmful, as their effect is cumulative in the body and

can cause irreversible damage. When unsure of the materials being machined, it is

advisable to wear a respirator.

For more specific information on respirator safety, refer to TBMED 502.

PROPER LIFTING PROCEDURES

Using improper lifting procedures may result in a permanent back injury. Back injurycan be avoided if the correct lifting procedures are followed. When lifting heavy or

large objects, get some assistance or use a hoist or forklift.

Objects within your ability can be lifted safely as long as the following procedures are

followed:

Keep your back straight. Squat down, bending at the knees. Use the leg muscles to do the work and lift slowly. Do not bend over the load as this

will put excessive strain on your spine.

Carry the object where it is comfortable, and pay close attention to where you arewalking and object around you.

When placing the object back on the floor, use the same procedures as when it waslifted.

ELECTRICAL SAFETY

Exposure to electrical hazard will be minimal unless the operator becomes involved

with machine repair. The machine operator is mostly concerned with the on and offswitch on the machine tool. However, if adjustments or repairs must be made, the

power source should be disconnected. If the machine tool is wired permanently, the

circuit breaker should be switched off and tagged with an appropriate warning

statement. Most often the power source will not be disconnected for routine

adjustment such as changing machine speeds. However, if a speed change involves a

belt change, make sure that no other person is likely to turn on the machine while the

operators hands are in contact with belts and pulleys.


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SAFETY RULES FOR MACHINE TOOLS

Since different cutting tools and machining procedures are used on various machine

tools, the safety precautions for each may vary. The following are general safety rules

for any machine tool:

Gears, pulleys, belts, couplings, ends of shafts having keyways, and other revolvingor reciprocating parts should be guarded to a height of 6 feet above the floor.

The guards should be removed only for repairing or adjusting the machine and mustbe replaced before operating it.

Safety setscrews should be used in collars and on all revolving or reciprocatingmembers of the machine tool or its equipment.

Do not operate any machine tool without proper lighting. Never attempt to operate any machine tool until you fully understand how it works

and know how to stop it quickly.

Never wear loose or torn clothing and secure long hair, since these items can becomecaught in revolving machine parts. Ties should be removed and shirt sleeves should

be rolled up above the elbow.

Gloves should never be worn when operating machinery except when absolutelynecessary.

Always stop the machine before cleaning it or taking measurements of the workpiece. Do not lubricate a machine while it is in motion. Injury to the operator and damage to

the machine may result from this practice.

Never remove metal chips, turnings, or shavings with your hands; they may cause aserious cut. If the shavings are long, stop the machine and break them with pliers or a

bent rod, and then brush chips off the machine. Remove cast-iron chips, which break

into small pieces, with a brush. Never wipe away chips when the machine is

operating.

Always wear safety glasses or goggles while operating machine tools. Also, wearrespiratory protection if operation creates hazardous dust. All persons in the areawhere power tools are being operated should also wear safety eye protection and

respirators as needed.

Know where tire extinguishers are located in the shop area and how to use them. Never wear jewellery while working around machine tools. Rings, watches, or

bracelets maybe caught in a revolving part which could result in the hand being pulled

into the machine.

Avoid horseplay. Tools are very sharp and machines are made of hard steel. Anaccidental slip or fall may cause a serious injury.


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Never use compressed air without a safety nozzle to clean machines or clothing. Itwill blow sharp, dangerous metal chips a long distance.

Keep the floor around machines free of tools, stock, oil, grease, and metal chips.Tripping over metal on the floor, especially round bars, can cause dangerous falls.

Wipe up all oil, grease, and cutting fluid spills on the floor as soon as possible toprevent a fall. Metal chips are very sharp and can easily become embedded in the

soles of shoes, making them very slippery, especially when walking on concrete floor.

Never place tools or other materials on the machine table. Cluttering up a machinewith tools or materials creates unsafe working conditions. Use a bench or table near

the machine for this purpose.

Always use a rag when handling sharp cutters such a smiling cutters and end mills. Do not expose power tools to rain or use in damp or wet locations. Always secure the work piece. Use clamps or a vise. It is safer than using your hands,

and it frees both hands to operate the tool

Do not abuse electrical cords. Never carry a tool by its cord or yank it to disconnect itfrom a receptacle. Keep electrical cords away from heat, oil, and sharp edges.

Have damaged or worn power cords and strain relievers repaired or replacedimmediately.

Remove adjusting keys and wrenches. Form a habit of checking to see that keys andwrenches are removed from tools before turning them on.

Do not operate any machine tool while under the influence of drugs, alcohol, or anymedication that could cause drowsiness.


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Study of Machine Tools

Various machining purpose used these all type of mechanical machining

machines are Lathe machine, Shaper machine, Slotting machine, Planning machine,

Drilling machine, Boring machine, Milling machine, Grinding machine, Lapping

machine Honing machine and Broaching machine

These machines are to producing various operations like namely Facing,

Chamfering, Step turning, Taper turning, Plain turning, Knurling, Grooving, Thread

cutting, Drilling, Tapping, Precision grinding, Cylindrical grinding, Surface grinding,

grinding of tool angles e.t.c.

Lathe:

Fig 1. Center Lathe

A lathe s a machine tool which rotates the workpiece on its axis to perform various

operations such as cutting, sanding, knurling, drilling, or deformation with tools that

are applied to the workpiece to create an object which has symmetry about an axis of

rotation.


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SHAPER MACHINE:

Fig 2 Shaper machine

A shaper is a type of machine tool that uses linear relative motion between the

workpiece and a single-point cutting tool to machine a linear tool path. Its cut is

analogous to that of a lathe, except that it is linear instead of helical. (Adding axes of

motion can yield helical tool paths, as also done in helical planning.) A shaper is

analogous to a planer, but smaller, and with the cutter riding a ram that moves above a

stationary workpiece, rather than the entire workpiece moving beneath the cutter. The

ram is moved back and forth typically by a crank inside the column; hydraulically

actuated shapers also exist.

PLANNING MACHINE:

A planer is a type of metalworking machine tool that uses linear relative motion

between the workpiece and a single-point cutting tool to machine a linear tool path. Its

cut is analogous to that of a lathe, except that it is linear instead of helical. (Adding axes

of motion can yield helical tool paths; see "Helical planing" below.) A planer is

analogous to a shaper, but larger, and with the entire workpiece moving on a table

beneath the cutter, instead of the cutter riding a ram that moves above a stationary

workpiece. The table is moved back and forth on the bed beneath the cutting head either

by mechanical means, such as a rack and pinion drive or a leadscrew, or by a hydrauliccylinder.


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Fig 3 Planer machine

DRILLING MACHINE:

A drill or drill motor is a tool fitted with a cutting tool attachment or driving

tool attachment, usually a drill bit or driver bit, used for drilling holes in various

materials or fastening various materials together with the use of fasteners. The

attachment is gripped by a chuck at one end of the drill and rotated while pressed against

the target material. The tip, and sometimes edges, of the cutting tool does the work of

cutting into the target material. This may be slicing off thin shavings (twist drills or

auger bits), grinding off small particles (oil drilling), crushing and removing pieces of

the workpiece (SDS masonry drill), countersinking, counterboring, or other operations.Drills are commonly used in woodworking, metalworking, construction and do-it

yourself projects. Specially designed drills are also used in medicine, space missions

and other applications.


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MILLING MACHINE

Fig 4Milling machine

A milling machine (also see synonyms below) is a machine tool used to machine

solid materials. Milling machines are often classed in two basic forms, horizontal and

vertical, which refers to the orientation of the main spindle. Both types range in size

from small, bench-mounted devices to room-sized machines. Unlike a drill press, this

holds the workpiece stationary as the drill moves axially to penetrate the material,

milling machines also move the workpiece radially against the rotating milling cutter,

which cuts on its sides as well as its tip. Workpiece and cutter movement are precisely

controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides

and lead screws or analogous technology. Milling machines may be manually operated,

mechanically automated, or digitally automated via computer numerical control (CNC).


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Fig 1: Hexagonal block


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Ex No: 1

MEASUREMENT OF SHEAR ANGLEDate

Aim:

To measure the shear angle to the given conditions.

Tools and Equipments needed:

Lathe, Single point turning tool, Micrometer.

Procedure:

1. The workpiece is held in the chuck of lathe.2. The known depth of cut is given and cut is made on the workpiece uncut chipthickness, (t1).3. The chip is taken for thickness inspection. And the mean chip thickness is

measured. (t2).

4. Chip thickness ratio is calculated using the formula =

5. For the given tool rake angle the shear angle is calculated using the formulatan =

cos1 sin

6. The same procedure is repeated for few more thickness readings on the samechip and same mean shear angle is calculated.

7. The experiment is repeated for different depth of cut.


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Measurement of Chip Thickness LC ____________

S.NoDepth Of Cut

t1 (mm)

Micrometer ReadingChip

Thicknesst2= PSR +

HSR

Pitch scale

reading

Head Scale

Coincidence

(HSC)

Head Scale

Reading

HSR =

HSC*LC

1. 0.25

2. 0.25

3. 0.25

4. 0.25

5. 0.5

6. 0.5

7. 0.5

8. 0.5

Shear Angle calculation

S.No

Uncut Chip

Thickness t1

(mm)

Average shear

angleChip

Thickness t2

Chip

Thickness ratio

r = t1/t2

Shear angle

1. 0.25

2. 0.25

3. 0.25

4. 0.25

5. 0.5

6. 0.5

7. 0.5

8. 0.5


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Calculation

RESULT:

Thus the shear angle is found for different depth of cuts.

Workpiece no: Date of completion Staff signature Marks


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Ex No: 2

Cutting force measurementDate

Aim:

To measure the cutting forces for given cutting conditions.

Tools Required:

Lathe, Lathe tool dynamometer, workpiece of any material.

Procedure:

1. The lathe tool dynamometer is initially set to zero reading.

2. The workpiece to be machined is ensured to have smooth surface and the tool tip

coincides with centre height of workpiece. .

3. Insert the power cable into the 230V, 50Hz, A.C. Main supply.

4. Switch on the instrument by placing the power switch at ON position.

5. Set the switch at read position.

6. Turn back the read switch to read position in X, Y, Z to read the coordinate

values.



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Ex No: 3Tool Wear measurement using Tool Makers

microscopeDate

Aim:

To measure the flank wear of the given single point cutting tool using tool

makers microscope.

Tools Required:

Tool makers microscope Micrometer attachment Single point cutting tool.

Procedure

The tool makers microscope is switched on.

The single point cutting tool is placed on the glass table.

Using the focusing wheel of the microscope the cutting tool is brought under

proper focus.

One of the worn flank end is place on the reference line which is visible through

the microscope.

The table movement is adjusted from one end of the flank wear to the other endusing the micrometer.

From the micrometer reading, the length of the flank wear is noted down.


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50 mm

6mm

3 mm

25

50 mm


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Ex No: 4MACHINING AN INTERNAL KEYWAY

USING SLOTTING MACHINEDate

Aim:

To machine an internal keyway in the given workpiece to the dimensions as

shown in the figure using Slotting Machine.

Tools and materials required:

Slotting Machine, Scriber, Divider, Steel Rule, MS Square plate (50 x 50 x 6

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 therequired shape.

7. The workpiece is now checked for final dimensions.

Result:

Thus, internal keyway is machined in the given workpiece to the dimensions as




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Before Machining

25 mm

53

After Machining

40

40


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Ex No: 5

Cylinder to Square Block using PlanerDate

AimTo machine the workpiece as the given drawing using planer machine.

Tools required:

Single point cutting tool

Double ended spanner

Parallel bar

Lever

Steel Rule

Try square

Vernier height gauge.

Materials required:

Aluminum round (53 x 25 thick)

Procedure

The machine is cleaned and lubricated.

Raw materials size is checked.

Workpiece is fixed in machine vise along with parallels

Marking is done on the job as per given dimensions.

Adjust the stroke length according to job length.

Planning operation is done for required dimension using suitable depth of

cut and number of passes.

Result:

Thus, internal keyway is machined in the given workpiece to the dimensions as




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Ex No: 6

Gear Milling in Milling machine.Date

Aim:

To make a spur gear on the given gear blank using horizontal milling

machine.

Tools Required:

Double end spanner

Vernier Calliper

Gear tooth vernier.

Index plate.

Milling cutter.

Centre.

Mandrel

Universal Milling machine.

Materials Required.

Gear Blank (180 mm)

Procedure

Following calculations are made for gear tooth dimensions:

= ( + 2)

= 2.2.5 = 1.507

Where Z = Number of teeth and

m = module

Following calculations are made for indexing

=4


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Calculations

Gear Dimensions

Z = No. of teeth =

m = module = 2 mm

Blank Diameter = (Z + 2) m

=

=

Tooth Depth =

=

=

Indexing Calculation

= 40 / Z

=

=


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Machine parts are cleaned and lubricated.

Raw material size is checked.

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

axis must be set parallel to the machine table.

The given gear blank in fixed between head and tail stock with a mandrel.

Pitch, depth of cut, addendum, dedundum calculations are made and

corresponding index plate is selected.

The cutter is mounted on the arbor. The cutter is centred accurately with

the gear blank.

Suitable speed is selected and machined is switched on.

Feed is given by the linear movement of the table and it is raised till theperiphery of the gear blank just touches the cutter.

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

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

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

of the blank.

The index plate is rotated for required rotation and the teeth are cut.

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

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

This is continued till all the gear teeth are cut.

Result

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

number of teeth.



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Ex No: 7

Key way Cutting in Milling machineDate

Aim

To make a keyway on a workpiece as per the given drawing using verticalmilling machine.

Tools Required

End milling cutter.

Double end spanner.

Parallel bar

Lever.

Steel Rule.

Spanner.

Try Square.Vernier Height gauge.

Materials:

MS square block (52 x 52 x 52 mm

Procedure.


The raw material size is checked.

As per the given drawing markings are done on the workpiece.

The job is fixed on the milling machine using levers.

Keyway is cut on the job as per the dimensions giving a proper depth of

cut.

Remove the job and clean the machine.

Result

Thus, keyway is cut on workpiece using milling machine.



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Ex No: 8Grinding to the required accuracy by surface

grindingDate

Aim:To perform grinding operation in surface grinding machine.

Equipments and Tools required:

Steel Rule

Try square

Vernier Caliper.

Materials Required:

Mild Steel block (100 x 50 x 60)

Procedure:

The given work piece is taken and checked for its dimensions.

The job is placed on the grinding magnet at opened position.

Then each face is grinded to the required accuracy by constant speed.

The job is removed from the required accuracy. It is checked by using vernier

caliper and squareness is checked by using try square.

Result:

Thus the square section is grinded to the required accuracy in grinding

machine.



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Before Machining

After Machining


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Ex No: 9

Drilling, Tapping and ReamingDate

Aim:

To drill and tap the workpiece as per the given dimensions using radialdrilling machine.

Tools Required:

Drill bit.

Lever

Steel Rule

Sleeve

Vernier height Gauge

12 x 1.75 tap.

Materials Required:MS (102 x 52 x 6 mm)

Procedure:



As per the given drawing markings are done on the workpiece.

The workpiece is fixed on the drilling machine.The required drill bit is fixed in the spindle.

Proper speed is set using gears provided.

The operation is done by lowering the handle and starting the material

removal process.The job is removed from the drilling machine and is fixed in the vice.

Suitable tap is selected and tapping is done.

The workpiece is removed and inspected.

Result

The operations are done on the given workpiece using radial drillingmachine as per the required dimensions.



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Before Machining

After Machining


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Ex No: 9

Capstan and Turret latheDate

Aim

To drill, ream, Countersink on a given workpiece as per the drawing

using capstan and turret lathe.

Tools Required

Spanner

Drill Bit and Reamer

Steel Rule

Vernier Calliper.

Materials Required

MS Round rod dia 25mm x 60 mm

Procedure



The job is fixed in the chuck using chuck key.

The single point cutting tool, start drill bit, 10 mm drill bit, reamer tool,Countersink tool are fixed in the turret head.

Facing operation is done on the job using single point cutting tool.The turret head is indexed and start drill is made on job.

The next tool is indexed and a hole of 10mm dia is drilled in the

workpiece.Next reaming tool is indexed and reaming operation is done on the

workpiece.

Next a hole of 15mm dia is countersunk in the workpiece.

The workpiece is removed from lathe.

Result:

Thus the opbject is made as per the given drawing from the workpiece.


Documents

Lab Manual v1