MT-II LAB

MANUFACTURING TECHNOLOGY LAB – II SVHEC, GOBI

INDEX

Sl.No Name of the Experiment Page No.

1 Study of special machines

2Cutting force calculation on single point cutting tool using lathe tool dynamometer

3 Shear angle measurement

4 Dovetail in shaper

5 V- block using a shaper

6 Internal key way in slotter

7 Round to square in planner

8 Drilling, Reaming and Tapping

9 Spur gear milling in Universal milling machine

10 Surface grinding in Horizontal surface grinding machine

11 Cylindrical grinding in Center grinding machine

12 Assembly of Machined components for checking clearance fit

13 Assembly of Machined components for checking interference fit

14 Multiple operations in Capstan lathe

15 Key way milling in Vertical milling machine

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.

Fig (1.0) Radial drilling machine

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1. Base

2. Column

3. Radial arm

4. Motor for elevating the arm

5. Elevating screw

6. Guide ways

7. Motor for driving the drill

8. Carriage

9. Spindle

10. Table

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1. STUDY OF DRILLING, MILLING, SHAPER, GRINDING MACHINEGEAR HOBBING MACHINES AND SLOTTING MACHINE

1. DRILLING MACHINEThe drilling machine is one of the most important machine tools in a workshop. In a

drilling machine holes may be drilled quickly and at a low cost. The hole is generated by the rotating edge of a cutting tool known as the drill, which exerts large force on the work clamped on the table. The different parts of a radial drilling machine have been illustrated in Fig (1.0). They are as follows:

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1. Base2. Column3. Radial arm

4. Drill head5. Spindle speed and feed mechanism

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1.1 BASEThe base of a radial drilling machine is a large rectangular casting that is finished on its

top to support a column on its one end and to hold the work table at the other end. In some machines T-slots are provided on the base for clamping work when it serves as a table.

1.2 COLUMNThe column is a cylindrical casting that is mounted vertically at one end of the base. It

supports the radial arm which may slide up or down on its face. An electric motor is mounted on the top of the column, which imparts vertical adjustment of the arm by rotating a screw passing through a nut attached to the arm.

1.3 RADIAL ARMThe radial arm that is mounted on the column extends horizontally over the base. It is a

massive casting with its front vertical face accurately machined to provide guide ways on which the drill head may be made to slide. The arm may be swung round the column. In some machines this movement is controlled by a separate motor.

1.4 DRILL HEADThe drill head is mounted on the radial arm and drives the drill spindle. It encloses all the

mechanism for driving the drill at multiple speeds and at different speed. All the mechanisms and controls are housed within a small drill head, which may be made to slide on the guide ways of the arm for adjusting the position of drill spindle with respect to the work.

1.5 SPINDLE DRIVE AND FEED MECHANISMA constant speed motor is mounted at the extreme end of the radial arm, which drives a

horizontal spindle, which runs along the length of the arm, and the motion is transmitted to the drill head through bevel gears. By train of gearing within the drill head, the speed of the spindle may be varied. Through another train of gearing within the drill head, different feeds of the spindle are obtained. In some machines, a vertical motor is fitted directly on the drill head and through gearbox multiple speed and the feed of the spindle can be obtained.

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Fig (2.0) MILLING MACHINE

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1

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4 5

6

7

8

9

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1. Over arm

2. Arbor support

3. Arbor

4. Spindle

5. Table

6. Saddle

7. Knee

8. Elevating screw

9. Column

10. Base

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2. MILLING MACHINE Milling is the process of removing metal by feeding the work piece through a rotating multipoint cutter. Milling machine can be used for machining flat surfaces, complex and irregular areas, surface of revolution, external and internal threads, gear cutting, helical surface of cross sections. The different parts of a Milling machine have been illustrated in Fig (3.0). They are as follows:

1. Base 2.Column 3.Knee 4.Saddle 5.Table 6.Spindle 7.ArborFig (2) shows the parts of a standard Milling Machine.

2.1. BASE: It is the foundation of the machine and is that part upon which all parts are mounted. It gives the machine rigidity and strength.

2.2. COLUMN: It is the main supporting frame. The motor and other driving mechanisms are contained with in it.

2.3 KNEE: The knee projects from the column and slides up and down on its face. It supports the saddle and table and partially supported by the elevating screw which adjusts its height.

2.4. SADDLE: The saddle supports and carries the table and is adjustable transversely on ways on top of the knee. It is provided with graduations for exact movement and operated by power or hand.

2.5. TABLE:

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The table rests on ways on the saddle and travels longitudinally in a horizontal plane. It supports the works piece, fixtures and all other equipments.

2.6. SPINDLE: The spindle obtains its power from the motor through motors. Cutters are mounted directly in the spindle nose.

2.7. ARBOR:

The arbor is an accurately machined shaft for holding and driving the arbor cutter.

It is tapered at one end to fit the spindle nose and two slots to fit the nose keys for locating and

driving it

Fig (3.0) Shaper

1. Table support

2. Table

3. Clapper box

4. Apron clamping bolts

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10.

11.

12.

13.

14.

15.

3.

SHAPERThe shaper is a reciprocating type of machine tool intended primarily to produce flat

surfaces. These surfaces may be horizontal, vertical, or inclined.The different parts of typical shaper are shown in fig (3.0).

The principal parts of a standard shaper are:1. Base2. Column3. Cross rail4. Saddle

5. Table6. Ram 7. Tool head

3.1 BASEThe base is the necessary bed or required for all machine tools. The base may be rigidly

bolted to the floor of the shop or on the bench according to the size of the machine. It is so designed that it can take up the entire load of the machine and the forces set up by the cutting tool over the work. It is made of cast iron to resist vibration and take up high compressive load.

3.2 COLUMNThe column is a box like casting mounted upon the base. It encloses the ram driving

mechanism. Two accurately machined guide ways are provided on the top of the column on which the ram reciprocates. The front vertical face of the column, serves as the guide ways for the cross rail. The lid on the left side of the column may be opened for inspection and oiling of the internal mechanism.

3.3 CROSSRAIL The crossrail is mounted on the front vertical guide ways of the column. It has two

parallel guide ways on its top in the vertical plane that is perpendicular to the ram axis. The table may be raised or lowered to accommodate different sizes of jobs by rotating elevating screw, which causes the cross rail to slide up and down on the vertical face of the column. A horizontal cross feed screw, which is fitted within the cross rail and parallel to the top guide ways of the cross rail actuates the table to move in a crosswise direction.

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3.4 SADDLEThe saddle is mounted on the crossrail, which holds the table firmly on its top. Crosswise

movement of the saddle by rotating the cross feed screw by hand or power causes the table to move sideways.

3.5 TABLEThe table is bolted to the saddle receives crosswise and vertical movements from the

saddle and cross rail. It is a box like casting having T-slots both on the top and sides for clamping the work. In a universal shaper the table may be swiveled on a horizontal axis and the upper part of the table may be tilted up or down.

3.6 RAMThe ram is the reciprocating member of the shaper. This is semi cylindrical in form and

heavily ribbed inside to make it more rigid. It slides on the accurately machined dovetail guide ways on the top of the column and is connected to the reciprocating mechanism contained within the column. It houses a screwed shaft for altering the position of the ram with respect to the work and holds the tool head at the extreme forward end.

FIG 4.0. Horizontal spindle surface grinder

1. Column,

2. Wheel head

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3. Table

4. Wheel

5. Saddle

6. Base

3.7 TOOLHEADThe toolhead of a shaper holds the tool rigidly, provides vertical and angular feed

movement of the tool and allows the tool to have an automatic relief during its return stroke. The vertical slide of the toolhead has a swivel base, which is held on a circular seat on the ram. The swivel base is graduated in degrees, so that the vertical slide is set perpendicular to the work or at any desired angle.

4. GRINDING MACHINE Grinding is metal cutting operation performed by means of a rotating abrasive wheel that acts as a tool. This is used to finish work pieces, which must show a high surface quality, accuracy of shape and dimension.

4.1 SURFACE GRINDERSurface grinding machines are employed to finish plane or flat surfaces.The different parts of a horizontal spindle reciprocating table surface grinder are

shown in fig 4.0.The principal parts of a horizontal spindle reciprocating table surface grinder are:

1.Base2.Table3.Wheel head

4.1.1 BASEThe base has a column at the back for supporting the wheel head. The base also

contains the drive mechanisms.

4.1.2 TABLEThe table is fitted to the saddle on carefully machined ways. It reciprocates along

ways to provide the longitudinal feed. T- slots are provided in the table surface for clamping work pieces directly on the table or for clamping grinding fixtures or a magnetic chuck.

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4.1.3 WHEEL HEADThe wheel head is mounted on the column secured to the base. It has ways for the

vertical slide, which can be raised or lowered with the grinding wheel only manually by rotating a hand wheel to accommodate work pieces of different heights and to set the wheel for depth of cut. Horizontal, cross wise movement of the wheel slide with the wheel, actuated by hand or by hydraulic drive, accomplishes the cross feed of the wheel. The grinding wheel rotates at constant speed; it is powered by a special built- in motor.

4.2. CYLINDRICAL CENTRE- TYPE GRINDER

Cylindrical centre- type grinders are intended primarily for grinding Plain cylindrical parts, although they can also be used for grinding contoured cylinders, fillets and even cams and crank shafts.

FIG 4.1 Cylindrical centre- type grinder

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1. Headstock, 2. Grinding wheel3. Wheel head4. Tailstock

5. Upper table6. Lower table7. Base.

The different parts of a cylindrical centre- type grinder are shown in fig 4.1.The principal parts of a cylindrical centre- type grinder are:1. Base2. Tables3. Head stock

4. Tailstock5. Wheel head6. Cross-feed

4.2.1 BASEThe base or bed is the main casting that rests on the floor and supports the parts

mounted on it. On the top of the base are precision horizontal ways set at right angles for the table to slide on. The base also houses the table- drive mechanism.

4.2.2 TABLESThere are two tables – lower table and upper table. The lower table slides on

ways on the bed provides traverse of the work past the grinding wheel. It can be moved by hand or power within desired limits.

The upper table that is provided at its center is mounted on the top of the sliding table. It has T- Slots for securing the headstock and tailstock and can be positioned along the table to suit the length of the work. The upper table can be swiveled and clamped in position to provide adjustment for grinding straight or tapered work as desired.

4.2.3 HEADSTOCKThe headstock supports the work piece by means of a dead center and drives it by

means of a dog, or it may hold and drive the work piece in a chuck.

4.2.4 TAILSTOCK The tailstock can be adjusted and clamped in various positions to accommodate

different lengths of work pieces.

4.2.5 WHEEL HEAD

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The wheel head carries a grinding wheel and its driving motor is mounted on a slide at the top and rear of the base. The wheel head may be moved perpendicularly to the table ways, by hand or power, to feed the wheel to the work.]

4.2.6 CROSS-FEEDThe grinding wheel is fed to the work by hand or power as determined by the

engagement of the cross – feed control lever.

4.3 CENTRELESS GRINDERCentreless grinding is a method of grinding exterior cylindrical, tapered and formed

surfaces on work pieces that are not held and rotated between centers. The principal elements of an external centreless grinder are the grinding wheel, regulating wheel and the work rest. Both the wheels are rotated in the same direction. The work rest is located between the wheels. The work is placed upon the work rest, and the latter, together with the regulating wheel, is fed forward, forcing the work against the grinding wheel

FIG 5.0 Gear Hobbing

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FIG 6.0 Gear Hobbing5.0 GEAR HOBBING

Gear Hobbing is a technique that is employed to create gear teeth configurations that are

ideal for use in a wide range of machinery components. In cases where the gear hobbing takes

place in a mass producing environment, gear hobbing is accomplished through the use of

precision gear hobbing machines that ensure that the cut of each tooth on each gear produced

meets the specifications set by the producer.

Generally, a gear hobbing machine will make use of a series of customized bits that help

to create the specific types of cutting and shaping necessary to create gears those posses

exactly the right pitch and circle to work in various types of equipment. A customized bit is

used for a particular size and type of gear hobbing, which helps to ensure that the cuts that are

made into the blank surface of the circle of metal are relatively smooth and uniform.

6.0 Slotting machine

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Slotting machines can simply be considered as vertical shaping machine where the single

point (straight or formed) reciprocates vertically (but without quick return effect) and the

workpiece, being mounted on the table, is given slow longitudinal and / or rotary feed as can

be seen in Fig. 6.0. In this machine also the length and position of stroke can be adjusted. Only

light cuts are taken due to lack of rigidity of the tool holding ram for cantilever mode of

action. Unlike shaping and planing machines, slotting machines are generally used to machine

internal surfaces (flat, formed grooves and cylindrical).

Shaping machines and slotting machines, for their low productivity, are generally used,

instead of general production, for piece production required for repair and maintenance. Like

shaping and slotting machines, planing machines, as such are also becoming obsolete and

getting replaced by plano-millers where instead of single point tools a large number of large

size and high speed milling cutters are used.

TABULATION :

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S. NO.

DEPTH HORIZONTAL VERTICAL RESULTANTAVERAGE

OF CUT COMPONENT COMPONENT P = Sqrt (Px2 + Pz

2)

(mm) Px (kg) Pz (kg) (Kg) (Kg)1 0.50 2 0.50 3 0.50 4 0.50

1 0.75 2 0.75 3 0.75 4 0.75

NOTE :

1. Pz – the main or tangential component, determines the torque on main drive mechanism, the deflection of the tool and the required power. This component acts in the direction of the cutting speed.

2. Px – the axial component, acts in the direction of the tool traverse and it is at right angles to Pz. It contributes very little to the power consumption.

3. Py – the radial component, acts along the tool shank and perpendicular to the other two components. It has no share in the power consumption.

2. CUTTING FORCE CALCULATION ON SINGLE POINT CUTTING TOOL USING LATHE TOOL DYNAMOMETER

AIM :

To measure the cutting forces for the given cutting conditions.

TOOLS AND EQUIPMENTS REQUIRED :

Lathe

Tool Dynamometer

PROCEDURE :

1. The Lathe Tool Dynamometer is initially set to zero reading.

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2. The known depth of cut is given and take the readings of Px and Pz force components from the Lathe Tool Dynamometer.

3. Calculate the resultant cutting force P = Sqrt (Px

2 + Pz2)

4. Repeat the same procedure to get few more readings and calculate the mean cutting force.

5. Repeat the same procedure for different depth of cuts.

RESULT :

Thus the cutting forces are measured for different depth of cuts.

CHIP THICKNESS :LC = Least Count

S. NO.

DEPTH PITCH SCALE HEAD SCALE HEAD SCALE CHIPOF CUT READING COINCIDENCE READING THICKNESS

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t1 (mm) (PSR) (HSC) HSR = HSC*LC t2 = PSR + HSR1 0.25 2 0.25 3 0.25 4 0.25 1 0.50 2 0.50 3 0.50 4 0.50

SHEAR ANGLE :

S. NO.

UNCUTCHIP

THICKNESSt1 (mm)

CHIPTHICKNESS

t2 (mm)

CHIPTHICKNESS

RATIOrc = t1 / t2

SHEARANGLE

AVERAGESHEAR ANGLE

1 0.25 2 0.25 3 0.25 4 0.25 1 0.50 2 0.50 3 0.50 4 0.50

3. SHEAR ANGLE MEASUREMENT

AIM :To measure the shear angle to the given conditions.

TOOLS AND EQUIPMENTS REQUIRED :LatheSingle point turning toolMicrometer.

PROCEDURE :

1. The workpiece is held in the chuck.

2. The known depth of cut is given (uncut chip thickness, t1).

3. The chip is taken for thickness inspection. Find the mean chip thickness, t2.

4. Calculate the chip thickness ratio, rc = t1 / t2

5. Calculate the shear angle for the given rake angle of the tool. rc cos

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tan = ----------- 1 - rc sin where, - rake angle.

6. Repeat the same procedure to get few more readings and calculate the mean shear angle.

7. Repeat the experiment for different depth of cuts.

NOTE :

1. The value of Shear angle depends on the cutting conditions, tool geometry, tool material and work material.

2. If the Shear angle is small, the plane of the shear is large, the chip is thicker, more force is required to remove the chip.

If the shear angle is large, the plane of shear will be shorter and the chip is thin. Hence, less force is required to remove the chip.

RESULT :

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

GIVEN WORK PIECE FIG (1)

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FINISHED WORK PIECE FIG (2)

4. MACHINING THE DOVE-TAIL SLOT ON A WORK PIECE USING A SHAPER

AIM: To machine a work piece and provide a Dove - Tail slot using a shaper

MATERIALS REQUIRED:Cast iron cube – 80 X 80 X 80 mm

TOOLS REQUIRED:1. Shaper2. Hammer3. Shaping tool4. Steel Rule5. Scriber6. Try Square7. Center punch8. Spanner

PROCEDURE:

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1. The given work piece is held firmly in a shaper vice.

2. The shaping tool is set firmly on a tool head.

3. After adjusting the length of stroke and position of stroke of the ram, machine is

switched on.

4. By giving cross feed and longitudinal feed to the tool head the all sides of work

piece is machined as per the given drawing.

5. The machine is switched off and the work piece is removed from the vice.

6. The work piece is marked and punched as per the given drawing.

7. Again the work piece is held on the vice and the machine is switched on.

8. By giving angular feed to the tool through the tool slide the Dove-tail shape is

machined.

9. The machine is switched off.

10. The work piece is removed and is measured & checked for all the dimensions as

per the given drawing.

RESULT:

The shaping operation was done on the given work piece as shown in fig (1) and Dove

– Tail slot was provided as per the dimensions shown in fig (2).

GIVEN WORK PIECE (FIG: 1)

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FINISHED WORK PIECE (FIG: 2)

5. MACHINING V- BLOCK USING A SHAPER

AIM: To machine V- block using a shaper

MATERIALS REQUIRED:Cast iron cube – 78 X 78 X 78 mm

TOOLS REQUIRED:1. Shaper2. Hammer3. Shaping tool4. Steel Rule5. Scriber6. Try Square7. Center punch8. Spanner

PROCEDURE:

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1. The given work piece is held firmly in a shaper vice.

2. The shaping tool is set firmly on a tool head.

3. After adjusting the length of stroke and position of stroke the machine is switched on.

4. By giving cross feed to the work piece through the table the shaping operation is done on

all the work surfaces.

5. The machine is switched off and the work piece is removed from the vice.

6. The work piece is marked and punched as per the given drawing.

7. Again the work piece is held on the vice and the machine is switched on.

8. By giving angular feed to the tool through the tool slide the V- shape is machined.

9. The machine is switched off.

10. The work piece is removed and is measured & checked for all the dimensions as per the

given drawing.

RESULT:

The given work piece as shown in fig(1) is subjected to shaping operations to become a

finished work piece as shown in fig (2).

GIVEN WORKPIECE (FIG: 1)

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6. INTERNAL KEY WAY CUTTING IN SLOTTER

AIM:

To obtain the required dimensions of the given gear block by performing slotting

operation

TOOLS REQUIRED: 1 .Toolbar with key way cutting tool 2 Steel rule 3. Vernier caliper 4 Spanner 5 .Dot punch 6. Scriber 7 Hammer

PROCEDURE:

1 .The work piece is cut for the required dimensions.

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2. After making proper marking and punching, the work piece is fitted on the fixture

tightly.

3. The stroke length of the ram is adjusted according to the length of the work piece.

4. The power switched ON.

5. The operation is done by giving small depth of cut for 3 to 4 part of the

reciprocating motion.

6. Coolant may be applied if it is necessary.

7. The operation is again performed until the required dimensions are obtained.

8. The machined work piece is checked for the required dimensions using vernier

caliper.

9. All the safety precautions are to be followed.

RESULT:

Thus the required dimensions of the given work piece was obtained by Slotting

operation.

GIVEN WORK PIECE FIG (1):

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7. MACHINING WORK PIECE A ROUND TO SQUARE IN PLANNER

AIM: To obtain the square from round by performing planning operation in planning machine.

TOOLS REQUIRED: 1. Vernier caliper 2. Cutting tool 3. Spanner 4. Scriber 5. V-Block 6. Marking gauge 7. Dot punch 8. Hammer

PROCEDURE:

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1. The Diameter of the M.S Round shaft by performing planning operation in planning

machine.

2. Side of the square is measured with the help of Diameter of the shaft.

3. Marking and punching both sides the shaft.

4. The work piece is fitted in the vice and checking the marked line straight.

5. Tool is fitted in the tool head to required height position.

6. Switched ON the Planning machine and the depth of cut be given to the work piece.

7. After one side is completed we have to setting the other side and checking the line.

8. The operation is repeated up to other three sides machining.

9. The machined work piece is checking the sides of the square with the help of vernier

caliper.

10. All the safety precautions are to be followed while doing the operations.

RESULT: Thus the Square is made on the given M.S. Round shaft by planning operation.

GIVEN WORK PIECE (FIG: 1)

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8. MACHINING A WORK PIECE BY DRILLING, REAMING AND TAPPING USING A DRILLING MACHINE

AIM:

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To obtain the required model on the mild steel flat by performing the drilling, reaming and tapping operations .

TOOLS REQUIRED:1. Steel rule2. Vernier caliper3. Drills , Reamer & taps required4. Reamer and Taps5. Drill chuck with Key6. Scriber7. Hammer8. Dot punch

PROCEDURE: 1. Necessary markings are made on the work piece by using surface plate and the scriber. 2. After that the punch marking are formed on the work piece and the flat is fitted on the

vice.3. The drill is hold tightly in the chuck with the help of chuck key and inserted in the

spindle of the drilling machine.4. The spindle with the arm is aligned according to the position of hole required on the

work piece.5. The power is switched on spindle speed is selected according to the diameter of the

drill.6. For higher diameter holes slow speed is given to the spindle through tumbler gear

arrangement. The drill is fed into the work piece manually by rotating the feed handle.7. Coolant should be continuously feed while doing the operations.8. According to the required hole diameter the operation is repeated by changing the

drill9. The drill head is moved to the other punched center and drilling operation is

repeated..10. The drill bit is replaced with reamer and the holes are reamed by feeding the

reamer into the hole like drilling.11. The tapping Operation is done by using the initial. Intermediate, final tap.12. The work piece is checked for diameter with the help of vernier caliper.13. All the safety precautions are followed while doing the operation.

RESULT: The given work piece as shown in fig(1) is subjected to drilling and reaming operations

to become a finished work piece as shown in fig (2).

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GIVEN WORKPIECE: (FIG 1)

FINISHED WORK PIECE: (FIG 2)

9. MACHINING A SPUR GEAR USING A MILLING MACHINE

AIM :To machine gear to the given module and number of teeth in the given workpiece.

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TOOLS AND EQUIPMENTS REQUIRED :Milling machine, Vernier caliper, Mandrel.

PROCEDURE :1. Calculate the gear tooth proportions.

Blank diameter = ( Z + 2 ) mTooth depth = 2.25 mTooth width = 1.5708 m

where, Z = Number of teeth required

m = module2. Indexing calculation

Index crank movement = 40 / Z3. The dividing head and the tail stock are bolted on the machine table. Their axis must be set

parallel to the machine table.4. The gear blank is held between the dividing head and tailstock using a mandrel. The mandrel

is connected with the spindle of dividing head by a carrier and catch plate.5. The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.6. Set the speed and feed for machining.7. For giving depth of cut, the table is raised till the periphery of the gear blank just touches the

cutter. 8. The micrometer dial of vertical feed screw is set to zero in this position.9. Then the table is raised further to give the required depth of cut. 10. The machine is started and feed is given to the table to cut the first groove of the blank. 11. After the cut, the table is brought back to the starting position. 12. Then the gear blank is indexed for the next tooth space. 13. This is continued till all the gear teeth are cut.

CALCULATION :Z = No. of teeth = 23m = module = 2 mmBlank Diameter = (Z + 2) m

= (23 + 2) 2= 50 mm

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

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

RESULT :The given work piece as shown in fig (1) is subjected to gear generating operation to

become a finished work piece as shown in fig (2).

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GIVEN WORKPIECE (FIG: 1)


10. MACHINING A WORK PIECE USING A SURFACE GRINDING MACHINE

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AIM: To machine a work piece using a surface grinding machine.

MATERIALS REQUIRED: Mild steel Flat - 80 X 50 X 10 mm

TOOLS REQUIRED:1. Surface grinding machine2. Vernier Caliper

PROCEDURE:1. The given work piece is held firmly on a magnetic chuck of a surface grinder.2. The machine is started and the grinding wheel is allowed to revolve at a selected speed.3. After giving a depth of cut, the work piece is made to reciprocate under the grinding

wheel.4. The table is fed axially between passes to produce a fine flat surface.5. The process is repeated for grinding another side until the desired dimension is

achieved.6. The dimensions are checked for its given dimensions using a vernier caliper.

RESULT:The given work piece as shown in fig (1) is subjected to surface grinding

operation to become a finished work piece as shown in fig (2).

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11. MACHINING A WORK PIECE USING A CENTRE TYPECYLINDRICAL GRINDING MACHINE

AIM:

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To machine a work piece using a cylindrical grinding machine.

MATERIALS REQUIRED:Mild steel polished round rod - 25 X 150 mm

TOOLS REQUIRED:1. Centre type cylindrical grinder2. Vernier Caliper3. Spanners

PROCEDURE:

1. The given work piece is held between centers.

2. The machine is switched on and the grinding wheel is allowed to revolve at a selected speed.

3. By giving longitudinal and cross feeds the work piece is ground for the required dimensions.

4. The work piece is removed from the machine and is checked for the given dimensions.

RESULT:

The given work piece as shown in fig (1) is subjected to external cylindrical grinding

operation by centre type cylindrical grinder to become a finished work piece as shown in fig

(2).

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12. MACHINING A COMPONENTS FOR LEARENCE FIT ASSEMBLY

AIM:

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To machine the components for clearance fit assembly using lathe.

MATERIALS REQUIRED:Mild steel polished round rod - 30 X 110 mm

TOOLS REQUIRED:1.Turning tool2. Parting off tool3. Drill bit4. Vernier caliper5. Outside caliper6. Inside caliper

PROCEDURE:1. The given work piece is held between rigidly in the chuck.2. The single point cutting tool is set on the tool post. 3. The machine is switched on.4. The straight turning and facing operation are done on the one half of the work piece as per

the given dimensions.5. Then the drill bit of required drill size is held in tailstock and drilling is done for the

required depth in the work piece.6. After finishing the one half of the work piece then another half is also finished as per the

drawing.7. The machine is switched off.8. The parting tool is fixed and by parting off operation the work piece is cut in to two parts

as per the dimensions.9. The two parts are assembled for getting a clearance fit assembly.

RESULT:The given work piece as shown in fig (1) is subjected to machining operations to become

a finished work piece as shown in fig (2).

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13. MACHINING THE COMPONENTS FOR INTERFERENCE FIT ASSEMBLY

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AIM: To machine the components for interference fit assembly using lathe and drilling

machine.

MATERIALS REQUIRED:1. Mild steel polished round rod - 30 X 110 mm2. Mild steel plate – 50 X 50 X 10 mm

TOOLS REQUIRED:1. Lathe machine2. Drilling machine3.Turning tool4. Drill bit5. Parting tool

6. Vernier caliper

PROCEDURE:1. The component – 1 is machined by straight turning and facing operations as per the

dimensions using a lathe.2. The component – 2 is machined by drilling operation as per the dimensions using a

drilling machine.3. After that both the components are assembled to get an interference fit assembly.

RESULT:The given work piece as shown in fig (1) is subjected to turing and drilling operations to

become a finished work piece as shown in fig (2).

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14. MACHINING A WORK PIECE BY TURNING, DRILLING

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AND PARTING USING A CAPSTAN LATHE

AIM :

To machine the workpiece to the given dimensions using capstan lathe.

TOOLS AND EQUIPMENTS REQUIRED :

Capstan Lathe

Stopper

Drill chuck

Counter sink bit

Drill bit

Turning tool

Parting off tool

Vernier Caliper

PROCEDURE :

1. Prepare the tooling layout for the given workpiece.

2. Set the tools in their respective positions of the tool stations.

3. The workpiece is chucked and checked for the rotation.

4. The adjustment to the length of feed for each tool is adjusted by rotating the adjustment

screws.

5. Feed the tools in the required sequence to machine the given workpiece.

RESULT :

The given work piece is subjected to machining operations to become a finished work

piece as shown in fig (1) using capstan lathe.

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GIVEN WORK PIECE FIG (1):


15. CONTOUR MILLING OPERATION ON A WORK PIECE USING45


A MILLING MACHINE

AIM: To perform a contour milling operation on the given work piece using a milling machine

MATERIALS REQUIRED:

Square aluminum plate-100x80x10

TOOLS REQUIRED:1. Vertical Milling machine2. Contour milling cutter3. Outside Caliper4. Steel Rule5. Vernier Caliper

PROCEDURE:1. The given work piece is fixed in a table.2. The form milling cutters are used for contoured milling. 3. The machine is switched on to revolve the cutter at the selected speed.4. By giving Cross feed and longitudinal feed to the work table, the contour operations are done respectively. The profile of the cutter coincides with that of the work piece. 5. After the work piece is milled as per the given drawing machine is switched off.6. The work piece is removed from the work table and all the dimensions are measured and checked.

RESULT:The contour milling operation was done on the given work piece as shown in fig (1) as

per dimensions shown in fig (2).

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Documents

MT-II LAB