ME6311-MT_I__LAB

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II YEAR, III SEMESTER

SUB.CODE:- ME6311

SUB. NAME:

MANUFACTURING TECHNOLOGY LAB MANUAL-I

Lab incharg:

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ME6311 MANUFACTURING TECHNOLOGY LABORATORY

OBJECTIVES:

• To Study and practice the various operations that can be performed in lathe, shaper,

drilling, Milling machines etc. and to equip with the practical knowledge required in the

core industries.

LIST OF EXPERIMENTS

Machining and Machining time estimations for:

1. Taper Turning

. !"ternal Thread cutting

#. $nternal Thread %utting

&. !ccentric Turning

'. (nurling

). Square *ead Shaping

+. *e"agonal *ead Shaping

TOTAL: 45 PERIODS

OUTCOMES:

• pon completion of this course, the students can able to demonstrate and fabricate

different types of components using the machine tools.

LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS

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S NO NAME OF THE EQUIPMENT Q!"

1 %entre -athes + os.

*ori/ontal Milling Machine 1 o

# 0ertical Milling Machine 1 o

& Shaper 1 os.

GENERAL INFORMATION

In this laboratory you will be exposed to the common manufacturing

processes such as Metal cutting, Metal casting, metal forming, and metal

joining.You are required to submit the lab record on each laboratory session in

the following that session.

You will be proided with a question ban! and qui" will be based on the

questions contained in the ban!. You hae to refer to the textboo!s for

appropriate answers to the questions in the question ban!.

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GENERAL INSTRUCTIONS

1. $ery student should obtain a copy of %aboratory Manual.

2. &ress 'ode( )tudents must come to the laboratory wearing *i+ %ab niform

*ii+ %eather )hoes. -alf pants, loosely hanging garments and slippers are

not allowed.

#. o aoid injury, the student must ta!e the permission of the laboratory

sta/ before handling any machine.

0. )tudents must ensure that their wor! areas are clean and dry to aoid

slipping.

. leather apron will be issued to each student during 3elding $xercise.

)tudents not wearing the apron will not be permitted to wor! in the

laboratory. )tudents are required to clear o/ all tools and materials from

machine4wor! place.

5. t the end of each experiment, students must clear o/ all tools and

materials from the wor! area.

6. 'areless handling of machines may result in serious injury.

7. %aboratory record must be submitted in standard form in the subsequent

lab class. 8eports on ordinary sheet and computer papers will not be

accepted.

9. he %ab report should only contain( *i+ itle of the experiment, *ii+ wo to

three lines stating the objecties *im+, *iii+ :ame of all equipments4tools

used, *i+ ;rocedure and *+ 8esult. he report should be neat and sweet.

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INDE!

S.N

OE!".NAME

"AGE.N

O

DATE OF

SUBMISSIO

N

SIGNATUR

E

1 FACING PLAIN TURNING AND

STEP TURNING

2 TAPER TURNING BY USING

COMPOUND REST METHOD

# TAPER TURNING BY USING

TAILSTOCK SET OVER METHOD

0 ECCENTRIC TURNING

SINGLE AND MULTI START V

EXTERNAL THREAD CUTTING

AND KNURLING

5 BORING AND INTERNAL

THREAD CUTTING

6 ROUND TO SQUARE USING

SHAPER MACHINE

7 ROUND TO HEXAGON USING

SHAPER MACHINE

91<1112

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LATHE

INTRODUCTION:

%athe is the father of all machine tool. It is a basic machine tool

probably the most important one of all, lathe was actually the =rst

machine tool.

%athe is a particular type of machine tool in which the wor! is held and

rotated against a suitable cutting tool for the purpose of producing surface

of reolution in any material.

LATHE SPECIFICATIONS:

In order to specify a lathe, a number of parameters could be used

on the speci=c applications. -oweer, the major elements used for

speci=cations should inariably be based on the components that would

be manufactured in the lathe. he sum of lathe speci=cations is,

%>&istance between centers.

>)wing diameter oer bed.

?>)wing diameter oer carriage.

8>8adius.

->-eight of center from bed

DISTANCE BET#EEN CENTERS $L%:

his would be specifying the maximum length of the job that can be

turned in the lathe.

S#ING DIAMETER OVER BED $A%:

his speci=es the maximum diameter of the job that can be turned in

the lathe machine generally restricted to small length jobs.

S#ING DIAMETER OVER CARRIAGE $B%:

his speci=es the maximum diameter of job that can be turned in the

lathe machines with the job across the cross slide.

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@ther factors should also be speci=ed to fully describe the lathe machine.

1. -orse power of the motor

2. Aeed range

#. ccuracy achieed

0. 'utting speed range

. )crew cutting capacity

5. )pindle nose diameter

PARTS OF ENGINE LATHE OR CENTER LATHE:

he principal parts of an engine lathe are,

1. ?ed,

1. -ead stoc!,

2. ail stoc!,

#. 'arriage,

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#.1. )addle,

1.1. 'ross slide,

#.2. 'ompound rest,

#.#. ool post,

#.0. pron.

0. Aeed Mechanism,

. hread cutting mechanism.

CARRIERS AND CATCH PLATES:

'arriers and catch plates are used to drie a wor! piece when it is held

between two centers. 'arriers or driing dogs are attached to the end of the

wor! piece by a setscrew, and catch plates are either screwed or bolted to

the nose of the headstoc! spindle.

CHUC&:

chuc! is one of the most important deices for holding and rotating a

piece of wor! in a lathe. 3or! piece of short length, and large diameter or

irregular shapes, which cannot be coneniently mounted between centers,

are held quic!ly and rigidly in a chuc!.

TYPES OF CHUC&S:

1. Aour jaw independent chuc!

2. hree jaw uniersal chuc!

#. ir or hydraulic operated chuc!

0. Magnetic chuc!

. 'ollet chuc!

5. 'ombination chuc!

6. &rill chuc!

FACE PLATE:

faceplate consists of a circular dis! bored out and threaded to =t the

nose of the lathe spindle. his has the radial, plain and slots for holding

wor! by bolts and clamps.

ANGLE PLATE:

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his is a cast iron plate haing two faces machined to ma!e them

absolutely at right angles to each other. -oles and slots are proided on both

faces so that it may be clamped on a faceplate and can hold the wor! piece

on the face by bolts and clamps.

MANDRELS:

mandrel is a deice for holding and rotating a hollow piece of wor!

that has been preiously drilled or bored. he wor! reoles with the mandrel

which is mounted between two centers.

PLAIN MANDREL:

he plain mandrel this type of mandrel is most commonly used in shops

and =nds wide application where a large number of identical pieces haing

standard si"e holes are required to be mounted on it.

STEP MANDREL:

step mandrel haing steps of di/erent diameters may be employed to

drie di/erent wor! pieces haing di/erent si"es of holes without replacing

the mandrel each time. his type of mandrel is suitable for turning collars,

washers and odd si"e jobs used in repairing wor!shops.

COOLER MANDREL:

cooler mandrel haing solid coolers is used for turning wor! pieces

haing holes of larger diameter, usually aboe 1<< mm. his construction

reduces weight and =ts better than a solid mandrel of equal si"e.

SCRE#ED MANDREL:

screwed mandrel is threaded at one end with a collar. 3or! pieces

haing internal threads are screwed on to it against the collar for machining.

CONE MANDREL:

cone mandrel consists of a solid attached to the one end of the body,

and a sliding cone, which can be adjusted by turning a nut at a threaded end.

GANG MANDREL:

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his has a =xed collar at one end and a moable collar at the threaded

end, which may be adjusted, to this position by a nut. he mandrel is used to

hole a set of hollow wor! piece between two collars by tightening the nut.

EXPANSION MANDREL:

here are di/erent types of expansion mandrels. he mandrel consists

of tapered pin, which is drien into a sleee that is parallel outside and

tapered inside the sleee has three longitudinal slots, two of which are cut

nearly through, and the third splits it completely.

RESTS:

rest is a mechanical deice which supports a long slender wor! piece,

which is turned between centers or by a clutch, at some intermediate point to

preent bending of the wor! piece due to its own weight and ibrations set up

due to the cutting force that acts on it.

STEADY REST:

steady rest shown in Aig consists of a cast iron base, which may be

made to slide on the loath bed ways and clamped at any desired position

where a support is necessary.

FOLLO#ER REST:

follower rest consists of a B'C li!e casting two adjustable jaws which

support the wor! piece. he rest is bolted to the bac! end of the carriage and

moes with it.

TYPES:

1. )peed lathe

a. 3oodwor!ing

b. 'entering

c. ;olishing

d. )pinning

2. $ngine lathe

a. ?elt drie

b .Indiidual motor drie

c. Dear head lathe

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#. ?ench lathe

0. ool room lathe

. 'apstan and turret lathe

5. )pecial purpose

a. 3heel lathea. . %athe

b. Dap. ?ed lathe

c. &uplicating lathe

6. utomatic lathe

THE ENGINE LATHE OR CENTER LATHE:

he term BengineC lathe is associated with the lathe owing to the fed

that early lathe was drien by steam engines It has all parts.

THE BENCH LATHE:

his is a small lathe usually mounted on bench it has similarly all the

parts of an engine lathe or speed lathe and it only di/erence is being in the

si"e. his is used for small and precision wor!.

THE TOOL ROOM LATHE:

tool room lathe haing the features similar to an engine lathe is much

more accurately built and has wide range of spindle speed ranging from a

ery few to quite high speed unto 2<< rpm. his lathe is mainly used for

precision wor!s on tools, dies, and gauges and in machinery wor!.

THE CAPSTAN AND TURRET LATHE:

hese lathes are deeloped of the engine lathe and are used for

product on wor!. he distinguishing features of this type of lathe is that the

tailstoc! of an engine lathe is replaced by a hexagonal turret on the face of

which multiple tools may be =tted and feed into the wor! in the proper

sequence.

SPECIAL PURPOSE LATHE:

s the name implies they are used for special purpose and the jobs,which cannot be accommodated or coneniently machined on a standard

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lathe. he wheel lathe is made for =nishing the journal and turning the

traded on the railroad carriage and locomotie wheel. he gab bed lathe in

which a section of the bed is adjacent to the headstoc! of the bed is

recoerable is used to sluing extra large diameter piece. he lathe a new

member of the lathe family is intended for machining of rotor for jet engines.

AUTOMATIC LATHE: hese are high speed heay duty mass production

lathe with complete automatic controls once the tools are set and the

machine started it performs automatically all the operation to =nish the

job.

TOOLS:

cutting tool may be used either for cutting a part as with a !nife or for

remaining the chips parts are produced by remoing the metal mostly in the

form of small ships remoal in the metal cutting process may be performed

wither by cutting tools haing distinct cutting edges or by abrasiely stic!s

abrasie cloth etc,

ll cutting tools can be diided into 2 groups

1. )ingle point cutting tool

2. Multi point cutting tool

SINGLE POINT CUTTING TOOLS:

)ingle point cutting tool has a sharpened cutting part its point and

shaftE the point of the too bounded by the base. he side Fan! or major Fan!

or end slan! or minor Fan! or and it base. he side cutting edges of a tool is

form by the interaction of the base and the side Fan!. he end cutting edge,

a tool into form by the intersection of the base and the Fan!, the chip and cut

from the wor! piece by the side cutting edges. he paint a where the end

and side cutting edge met is called nose of tool.

LATHE OPERATIONS:

TURNING:

urning is the further most generally used operation is the lathe. In ties

the wor! held in spindle is rotated which the tool is fed part the wor! piece in

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a direction parallel in the axis of rotation. he surface generated is the

cylindrical shape

FACING:

Aacing is the operation of machining the ends of a piece of wor! to

produce Fat )urface )quare with the axis. he operation inoles feeding the

tool parallel to the axis of rotation of the wor! piece.

TAPER TURNING:

aper may be turned in a lathe by feeding the tool at an angle to the

axis of the wor! piece. 3hich taper is essential that the tool cuttings edge

should be accurately on the centre line of the wor! piece otherwise correcttaper will not be obtained

?y a broad nose form tool ?y setting oer to the tailstoc! center

?y swieling the compound rest ?y a taper turning attachment.

?y combing longitudinal and cross feed in a lather.

THREAD CUTTING:

hread cutting is one of the most important operations performed in alathe. 3hen the job is reduced between centers or by a chuc!. he

longitudinal feed should be equal to the pitch of the thread to be cut per

reolution of the wor! piece.

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FACING, "LAIN TURNING AND STE" TURNING

DRA#ING:

ll &imensions are in mm

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FACING "LAIN TURNING AND STE" TURNING

E$. N%:Da&:

AIM:

o machine the gien cylindrical rod as per the s!etch by using lathe.

MATERIALS SU""LIED:

'ylindrical wor! piece of diameter GGGGGGGmm and lengthGGGGGGGGG mm

mild steel rod.

TOOLS ' INSTRUMENTS RE(UIRED:


2. ;arting tool

#. )teel rule

0. Hernier caliper

SE(UENCE OF O"ERATIONS:

1. 'hec!ing of 3or! piece

2. ob setting

#. ool setting

0. Aacing

. ;lain urning

5. )tep turning

6. 'hamfering

#OR)ING STE"S:

1. he mild steel rod is cut approximately to the gien dimensions.

2. hen the wor! piece is held in the chuc! such that no eccentricity

and run out occurs. It is done by using the mar!ing bloc!.

#. hen the wor! piece is =tted tightly with the help of chuc! !ey in

the chuc!.

0. he single point cutting tool is placed on tool post and it is always

aligned such that it coincides with the axis of the dead centre

. he tool is =xed tightly with the help of tool post !ey

5. :ow the constant speed is applied to the wor! piece

6. hen the tool tip is brought to the centre of wor! piece

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7. he facing operation is done by giing cross feed by moing carriage

and tool post by moing from centre and the turning operation is

done by giing longitudinal feed.he chamfering is done to the

edges of wor! piece.

9. he wor! piece is clamped on the other side for machining.

1<. he operations are repeated to ma!e step turning to the gien

si"e.

11. hen the wor! piece is chec!ed for required dimensions with the

help of ernier caliper.

RESULT:

hus the required si"e and shape of the gien wor! piece is

obtained.

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TA"ER TURNING BY USING COM"OUND REST METHOD

DRA#ING:

aper angle calculation (

an J > *&Kd+ 4 2 %

J > anK1 * &Kd + 4 2 %

3here J > aper angle in degrees

& > Major diameter in mm

& > Minor diameter in mm

% > %ength of job


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TA"ER TURNING BY USING COM"OUND REST METHOD

E$. N%: Da&:

AIM:

o obtain the required shape and si"e of the wor! piece by taper turning

operation using compound rest.

MATERIALS SU""LIED:

'ylindrical wor! piece of diameterGGGGGGGGGmm and lengthGGGGGGGGG mm

mild steel rod.



2. ;arting tool

#. )teel rule

0. Hernier caliper



2. ob setting

#. ool setting

0. Aacing

. ;lain urning

5. aper turning

6. 'hamfering

#OR)ING STE"S:

1. he gien wor! piece is chec!ed for its dimension.

2. he wor! piece is held in the chuc!. 'huc! !ey is used to tighten the job =rmly, ensuring centering of wor! piece.

#. he single point cutting tool is held in the tool post and tightens the

nuts using ool post !ey.

0. Aacing is done with cutting tool moing from the centre of wor! piece

towards outside. It is one until the required length of the job is

obtained.

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. urning is done to reduce the diameter of the job. )uLcient depth of

cit is gien and it is done until the required diameter of the job is

obtained.

5. :ext step taper turning is done on the wor! piece, as per the taper

angle already calculated. hen the compound rest base is swieled

and set at half taper angle. 'utting tool is moed at an angle to the

lathe axis. ool is moed by the compound rest hand wheel.

6. Aor chamfering to be done at the end of the wor! piece, the tool is

held at 0< to the lathe axis and is fed against the rotating wor!

spice.

7. Ainally the dimension of wor! piece is again chec!ed.

RESULT:


obtained.

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TA"ER TURNING BY USING TAILSTOC) SET O*ER METHOD

DRA#ING:

ail stoc! set oer calculation(

)et oer ) > % x an J

> % x *&Kd+ 4 2 %

3here % > otal length of job

& > Major diameter in mm

& > Minor diameter in mm

% > %ength of tapered portion


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TA"ER TURNING BY USING TAILSTOC) SETO*ER METHOD

E$. N%: Da&:

AIM:

o obtain the required shape and si"e of the wor! piece by taper turning

operation using tailstoc! set oer.

MATERIALS SU""LIED:


mild steel rod.



2. ;arting tool

#. )teel rule

0. Hernier caliper



2. ob setting

#. ool setting

0. Aacing

. ;lain urning

5. aper turning

6. 'hamfering

#OR)ING STE"S:


2. he wor! piece is held in the chuc!. 'huc! !ey is used to tighten

the job =rmly, ensuring centering of wor! piece.

#. he single point cutting tool is held in the tool post and tightens

the nuts using ool post !ey.

0. Aacing is done with cutting tool moing from the centre of wor!

piece towards outside. It is one until the required length of the job

is obtained.

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. urning is done to reduce the diameter of the job. )uLcient depth

of cit is gien and it is done until the required diameter of the job

is obtained.

5. :ext step taper turning is done on the wor! piece, as per the

tailstoc! setoer already calculated. hen the tailstoc! is made to

slide on its base towards or away from the operator by a setoer

screw. 'utting tool is moed parallel to the lathe axis by rotating

the carriage hand wheel.

6. Aor chamfering to be done at the end of the wor! piece, the tool

is held at 0< to the lathe axis and is fed against the rotating wor!

spice.


RESULT:


obtained.

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ECCENTRIC TURNING

DRA#ING

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ECCENTRIC TURNING

E$. N%: Da&:

AIM:

o obtain the required shape and si"e of the wor! piece by $''$:8I'

8:I:D operation.

MATERIALS SU""LIED:


mild steel rod.


. )ingle point cutting tool

5. ;arting tool

6. )teel rule

7. Hernier caliper



9. ob setting

1<. ool setting

11. Aacing

12. ;lain urning

1#. aper turning

10. 'hamfering

#OR)ING STE"S:


1<. he wor! piece is held in the chuc!. 'huc! !ey is used to

tighten the job =rmly, ensuring centering of wor! piece.11. he single point cutting tool is held in the tool post and

tightens the nuts using ool post !ey.

12. Aacing is done with cutting tool moing from the centre of

wor! piece towards outside. It is one until the required length of

the job is obtained.

1#. urning is done to reduce the diameter of the job. )uLcient

depth of cit is gien and it is done until the required diameter of the job is obtained.

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10. :ext step taper turning is done on the wor! piece, as per

the tailstoc! setoer already calculated. hen the tailstoc! is

made to slide on its base towards or away from the operator by a

setoer screw. 'utting tool is moed parallel to the lathe axis by

rotating the carriage hand wheel.

1. Aor chamfering to be done at the end of the wor! piece, the

tool is held at 0< to the lathe axis and is fed against the rotating

wor! spice.


RESULT:


obtained.

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SINGLE AND MULTI START * THREAD

CUTTING AND )NURLING

DRA#ING:

%% &IM$:)I@:) 8$ I: MM

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SINGLE AND MULTI START * THREAD

CUTTING AND )NURLING

E$. N%:

Da&:

AIM:

o obtain the required shape and si"e of the wor! piece by turning and thread

cutting.

MATERIALS SUPPLIED:

'ylindrical wor! piece of diameterGGGGGGGGGmm and lengthGGGGGGGGGGmm

mild steel rod.



2. hread cutting tool

#. nurling tool

0. Hernier caliper

. ;itch gauge



2. ool setting

#. Aacing

0. ;lain urning

. hread cutting

5. 'hamfering

#OR&ING STEPS:


2. he wor! piece is held in the chuc!. 'huc! !ey is used to tighten the

job =rmly, ensuring centering of wor! piece.


nuts using spanner.

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obtained.



obtained.

5. Aor chamfering to be done at the end of the wor! piece, the tool is

held at 0< to the lathe axis and is fed against the rotating wor!

spice.

6. he cutting tool in the tool post is ta!en out. hread cutting tool is

held in the tool post and tightened the nuts.

7. he gear ration is calculated and the suitable si"e gears are =tted in

the change gear train.

9. Aor right hand thread the lead screw rotates in cloc! wise direction

and for left thread, it rotates in anti cloc! wise direction.

1<. he half nut is engaged after giing suitable depth of cut.

11. he tool is moed towards headstoc! in helical path and thread is

produced.

12. t the end of each cut tool is withdrawn. hen the spindle of the

machine is reersed and the tool is moed towards tailstoc!.

1#. fter the tool reaches the starting position the machine is

stopped.

10. he required depth of cut is gien and the cycle is repeated to

obtain the required depth.

1. he dimension of wor! piece and pitch of the thread are again

chec!ed.

15. hen the !nurling tool is =xed and required pattern of !nurling is

made on the job.

16. Ainally both ends of the job are chamfered by using chamfering

tool.

RESULT:

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obtained.

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BORING AND INTERNAL THREAD CUTTING

DRA#ING:

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ll &IM$:)I@:) 8$ I: MM

BORING AND INTERNAL THREAD CUTTING

E$. N%:Da&:

AIM:

o obtain the required shape and si"e of the wor! piece by Aacing, plain

turning and ?oring and internal threading.

MATERIALS SUPPLIED:

'ylindrical wor! piece of diameterGGGGGGG mm and lengthGGGGGGG mm

mild steel rod.

TOOLS ' E(UI"MENTS ' INSTRUMENTS RE(UIRED:


2. ;arting tool

#. ?oring tool and internal thread cutting tool.

0. &rill chuc!. &rill bit

5. Mandrel

6. )teel rule

7. Hernier caliper

9. Hernier height gauge

SEQUENCE OF OPERATIONS:

1. 'hec!ing of wor! piece2. 3or! piece setting

#. ool setting

0. Aacing

. urning

5. ?oring

6. hread cutting.

#OR&ING STEPS:1. he gien wor! piece is chec!ed for its dimension.

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2. he wor! piece is held in the chuc!. 'huc! !ey is used to tighten the

job =rmly, ensuring centering of wor! piece.


nuts using spanner.



obtained.



obtained.

5. Aix the boring tool in the tail stoc!.

6. )lowly gien the feed by rotating the wheel in the tailstoc! which

moes the tool longitudinally to producing a boring.

7. Aix the internal threading tool, to cut the internal thread.


RESULT:


obtained.

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SHA"ER MACHINE

)haping among the oldest techniques,

1. )haping is where the wor! piece is fed at right angles to the cutting

motion between successie stro!es of the tool. hese processes

require s!illed operators and for the most part hae been replaced

by other processes.

'lassi=cation of )haper Machine

i. -ori"ontalKpush cut

ii. ;lain *;roduction wor!+

iii. niersal *ool room wor!+

i. -ori"ontalKdraw cut )t. Hertical )lotter ey seater

. )pecial purposeKas for gear cutting

H%ri+%n&a "h C& Sha/r

he shaper is a relatiely simple machine. It is used fairly often in the tool

room or for machining one or two pieces for prototype wor!. ooling is

simple, and shapers do not always require operator attention while cutting.

he hori"ontal shaper is the most common type, and its principal

components are shown below, and described as follows(

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Ra0( he ram slides bac! and forth in doetail or square ways to

transmit power to the cutter. he starting point and the length of the

stro!e can be adjusted.

T%% ha1( he tool head is fastened to the ram on a circular plate

so that it can be rotated for ma!ing angular cuts. he tool bead can

also be moed up or down by its hand cran! for precise depth

adjustments.

Ca//r B%$( he clapper box is needed because the cutter drags oer

the wor! on the return stro!e. he clapper box is hinged so that the

cutting tool will not dig in. @ften this clapper box is automatically raised

by mechanical, air, or hydraulic action.

Tab( he table is moed left and right, usually by hand, to position

the wor! under the cutter setting up. hen, either by hand or moreoften automatically, the table moed sideways to feed the wor! under

the cutter at the end or beginning of each stro!e.

Sa11( he saddle moes up and down *Y axis+, usually manually, to

set the rough

position of the depth of cut. Ainal depth can be set by the hand cran! on

the tool head.

C%0n( he column supports the ram and the rails for the saddle. he

mechanism for moing the ram and table is housed inside the column.

#6

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T%% h%1r( ool holders are the same as the ones used on at engine

lathe, though often larger in si"e. he cutter is sharpened with ra!e and

clearance angles similar to lathe tools though the angles are smaller

because the wor! surface is usually Fat. hese cutters are fastened into

the tool holder. ust as in the lathe, but in a ertical plane.

#%r2 h%1ing...#%r2 holding is frequently done in a ise. he ise is

specially designed for use in. ha/r and has long ways which allow

the jaws to open up to 10N or more, therefore quite large wor! pieces

can be held. he ise may also hae a swiel base so that cuts may be

made at an angle. 3or! that cannot be held in the ise *due to si"e or

shape+ is clamped directly to the shaper table in much the same way as

parts are secured on milling machine tables.

Sha/r Si+: Th si"e of a shaper is the maximum length of stro!e which it

can ta!e. -ori"ontal shapers are most often made with stro!es from 15K to

20N long, though some smaller and larger si"es are aailable. hese shapers

use from 2K to Khp motors to drie the head and the automatic feed.

Sha/r #i1&h: Th 0a$i00 3i1&h 3hich can b c& depends on the

aailable moement of the table. Most shapers hae a width capacity equal

to or greater than the length of the stro!e. he maximum ertical heightaailable is about 456 &% 476.

M'-I:$ metal surfaces especially where a large amount ot metal has to be

remoed. @ther machines such as milling machines are much more

expensie and are more suited to remoing smaller amounts of metalE

ery accurately. he reciprocating motion of the mechanism inside the

shaping machine can be seen in the diagram. s the disc rotates the top

of the machine moes forwards and bac!wards, pushing a cutting tool. he cutting tool remoes the metal from wor! which is carefully bolted.

ypes of 3or!( he tool post and the tool slide can be angled as seen below.

his allows the shaper to be used for di/erent types of wor!.

#7

7/18/2019 ME6311-MT_I__LAB


*i+ he tool post has been turned at an angle so that side of the material can be machined.

*ii+ he tool post is not angled so that the tool can be used toleel a surface.

*iii+ he top slide is slowly feed into the material so that a

Orac!O can be machined for a rac! and pinion gear system.

#9

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R%n1 &% S8ar Uing Sha/r Machin

E$. N%:

Da&:

Ai0: -

o ma!e the square shape from the cylindrical wor! piece on a

shaper machine.

T%% r8ir1 (

)ingle ;oint ool *-.).)+, Hernier caliper, djustable spanner, !ey,

hammer, etc...

Ma&ria r8ir1:

cylindrical wor! piece of diameter ............mm and PPPmm

length of cast iron rod.

"r%c1r:

1. he single point cutting tool is clamped in the tool post.

2. he surface of the material to be machined is mar!ed.

#. he wor! piece is =xed in the machine ice, ensuring that it is parallel to the

stro!e of the ram. ?y eleating screw it is brought to the required height.

0. he ram stro!e is adjusted depending on the length of the wor! piece to

account for speed ariation.

. 8am stro!e > length of job Q length of approach Q length of oer trael.

5. he table and the clapper box are moed so that the tip of the tool just

touches the wor! piece.

6. )tart the machine and the let the ram reciprocates, cutting during the

forward stro!e. &uring the return stro!e depth of cut is set by rotating

the handle. Aeed is also set simultaneously by cran!ing table feed

screw. Aeeding can be automated if required.

7. fter machining a grooe on the wor! piece the NHN tool is remoed andthe parting tool is =xed.

7/18/2019 ME6311-MT_I__LAB


9. Ainishing cut is gien on the )quare )hape and 0 sides.

1<.;rocedure is repeated for required si"e and shape.

R&:

hus a square shape from the cylindrical wor! piece on a shaper

machine

7/18/2019 ME6311-MT_I__LAB


R%n1 &% H$ag%n Uing Sha/r Machin

E$. N%:

Da&:

Ai0( K

o ma!e the square shape from the cylindrical wor! piece on a

shaper machine.

T%% r8ir1 ( K

)ingle ;oint ool *-.).)+, Hernier caliper, djustable spanner, !ey,

hammer, etc...

Ma&ria r8ir1:

cylindrical wor! piece of diameter ...........mm and length PPPPmm of cast iron rod.

"r%c1r:

1. he single point cutting tool is clamped in the tool post.

2. he surface of the material to be machined is mar!ed.

#. he wor! piece is =xed in the machine ice, ensuring that it is parallel to the

stro!e of the ram. ?y eleating screw it is brought to the required height.

0. he ram stro!e is adjusted depending on the length of the wor! piece to

account for speed ariation.

. 8am stro!e > length of job Q length of approach Q length of oer trael.

5. he table and the clapper box are moed so that the tip of the tool just

touches the wor! piece.

6. )tart the machine and the let the ram reciprocates, cutting during theforward stro!e. &uring the return stro!e depth of cut is set by rotating

the handle. Aeed is also set simultaneously by cran!ing table feed

screw. Aeeding can be automated if required.

7. fter machining a grooe on the wor! piece the NHN tool is remoed and

the parting tool is =xed. O

9. Ainishing cut is gien on the )quare )hape and 0 sides.

1<.;rocedure is repeated for required si"e and shape.

7/18/2019 ME6311-MT_I__LAB


R&:

hus a square shape from the cylindrical wor! piece on a shaper

machine

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ME6311-MT_I__LAB