Production_Technology Lab Manual 181903

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

SHREE SARASWATI EDUCATION SANSTHAN’S GROUP OF INSTITUTIONS

Faculty of EngineeringDepartment of Mechanical Engineering

SUB: Production Technology ( 181903)

Experiment List

Sr.No. Title

1 STUDY OF SINGLE POINT AND MULTI POINT CUTTING TOOL

GEOMETRY

2 STUDY OF VARIOUS CUTTING TOOL MATERIALS

3 CHIP THICKNESS ANALYSIS

4 TO OBSERVE THE EFFECT OF CUTTING PARAMETERS ON TYPES

OF CHIP PRODUCED

5 STUDY OF PLAN LAYOUT OF CAPSTAN AND TURRET LATHE

6 STUDY OF UNCONVENTIONAL MACHINING PROCESS

7 NC AND CNC MACHINES

8 MANUFACTURING OF GEAR

9 JIGS AND FIXTURES


PRACTICAL NO. 1

SINGLE POINT AND MULTI POINT

CUTTING TOOL GEOMETRY

SINGLE POINT AND MULTI POINT CUTTING TOOL GEOMETRY


AIM:

To study of tool geometry of single point and multi point cutting tool.

THEORY:

INTRODUCTION:

It is an instrumental media which helps to remove material from the work piece, and to give

desired shape and size with the help of single point contact tool or multi point cutting tool. The

relative motion is established between work and the cutting tool to undergo cutting process.

CUTTING TOOL CLASSIFICATION:

According to different methods

According to method of manufacturing-

Forged tool, Tipped tool brazed to the carbon steel shank,

Tipped tool fastened mechanically to the carbon steel shank.

According to the method of holding the tool- Solid tool, Tool bit inserted in the tool

holder.

According to the method of using the tool- Turning, Chamfering, Thread cutting,

Facing, Grooving, Forming, Boring, Internal thread cutting, parting off.

According to the method of applying the feed- Right hand, Left hand, Round nose.


SINGLE POINT CUTTING TOOL GEOMETRY

MULTI POINT CUTTING TOOL GEOMETRY


MULTI POINT CUTTING TOOLS

REVIEW QUESTIONS:

1. Define a cutting tool.

2. How the tools are classified?

3. Name at least 10 single point cutting tools and 10-multi point cutting tools.

4. Explain with sketch the difference between tool holders used for

a) Brazed carbide

b) Clamp on type

c) Solid high-speed steel insert bit.

5. Differentiate between tool signature, tool geometry and tool nomenclature with sketch.

6. Write a short note on tool angles and effect of tool angles on cutting process.

7. Explain briefly the design factors affecting tool life.

SIGNATURE:

GRADE:


PRACTICAL NO.2

CUTTING TOOL MATERIALS


CUTTING TOOL MATERIALS

AIM:

To study of various Cutting Tool Materials.

THEORY:

INTRODUCTION:

Selection of cutting Tool material is among the most important factor for machining ooperation.

Cutting Tool is subjected to

a) High Temperature

b) Contact Stress

c) Sliding along the Tool Chip Interface and along machined surface

Consequently it possesses following characteristics

1. Hardness

2. Toughness

3. Wear Resistance

4. Chemical Stability

CLASSSIFICATION OF CUTTING TOOL MATERIALS:

1. Carbon and medium alloy steel

2. High speed steel

3. Cast cobalt alloys

4. Carbides (Cemented or Sintered Carbides)

5. Coated Tools

6. Cubic Boron Nitride

7. Ceramics

8. Diamond


REVIEW QUESTIONS:

1. State the factors responsible for the development of newer Tool materials.

2. Enlist commonly used cutting Tool materials stating their types, compositions, Red Hot

Hardness Temperature, Permissible Cutting Speeds and Applications.

3. Discuss the basic requirements of materials for Cutting Tools.

4. State the desirable properties of Cutting Tool materials and differentiate between

Cemented Carbide Tool and Cemented Oxide Tool with respect to the above Properties.

5. List out the important characteristics of Ceramic Tool materials and stating its

advantages.

6. Enumerate some precaution while working with Diamond.

SIGNATURE:

GRADE:


PRACTICAL NO. 3

CHIP THICKNESS ANALYSIS

CHIP THICKNESS ANALYSISAIM:

To study effect of cutting parameters on chip thickness

APPARATUS/INSTRUMENTS:

Lathe with a three-jaw chuck, Vernier Caliper, Ø20; 20 mm long M.S. rod.

PROCEDURE: Set up the lathe and machine the MS rod for different set of cutting parameters.

The cutting parameters are speed, feed and depth of cut. In the first set up vary the depth of cut,

keeping the speed and feed constant. In the second set up vary the speed, keeping the feed and

depth of cut constant. In the third setup, vary the feed, keeping the speed and depth of cut

constant. Collect the chips and measure the thickness at four different points along the length.

OBSERVATIONS:


1. Material: MS, Ø20 and 20 mm long2. Parameters: Speed

TABLE A: Speed = 250rpm; Feed = 0.12mm/rev

Depth of

cut

(mm)

Chip Thickness

(mm)

T1 T2 T3 T4 Average

0.5

1.0

1.5

TABLE B: Feed = 0.12mm/rev; Depth of cut = 0.5 mm

Speed

(rpm)

Chip Thickness

(mm)

T1 T2 T3 T4 Average

0.06

0.12

0.24

TABLE C: Speed = 350 rpm; Depth of cut = 1 mm


Feed

(mm/rev)

Chip Thickness

(mm)

T1 T2 T3 T4 Average

0.06

0.12

0.24

GRAPHS:

TABLE A: Depth of cut Vs Chip Thickness

TABLE B: Speed Vs Chip Thickness

TABLE C: Feed Vs Chip Thickness

CONCLUSION:

SIGNATURE:

GRADE:


PRACTICAL NO. 4

MECHANICS OF METAL CUTTING AND

CHIP FORMATION


MECHANICS OF METAL CUTTING AND CHIP

FORMATIONAIM: TO STUDY OF MECHANICS OF METAL CUTTING AND CHIP FORMATION.

THEORY:

INTRODUCTION:

Every convectional machining process involves the formation of chips. Chip formation is

a complex phenomenon where a force is applied to work piece to remove the material from the

work piece. The metal is sheared along the shear plane, which makes an angle Ø with the

direction of tool travel because of shearing action.

CHIP FORMATION:

The shape and size of the chips obtained depends on the types of the material to be cut

and other cutting conditions. It also indicates the type and quality of pieces. The following three

basic types of the chips are produced in any convectional machining process.

I. Segmental or Discontinuous chip.

II. Continuous chip.

III. Continuous chip with built-up edge.

I. Segmental Chip:

This type of chips consist of separate, plastically deformed segments which loosely

where to each other or …………………………..which are produced by actual frature of the

metal ahead of the cutting edge. The fracture of the metal take place when the magnitude of the

compression forces reaches the fracture limits of the metal.

Facture affecting the segmental chip:

1.) Brittle material (C.I., Brass, Casting etc)

2.) Low speed and high depth of cut. while cutting ductile material.

3.) Small rake angles too ductile material, segmental chips.

II. Continuous Chip:

This type of chips produced when material ahead of the too continuously deforms

without fracture and flows off the rake face in the form of nibbeu. The following

factors are responsible for the continuous chip……

1. Ductile material Steel Copper Aluminum etc.


2. High cutting speed.

3. Large rake angle.

4. Sharp cutting edge.

5. Efficient cutting fluid.

6. Low friction between tool face & chips.

III. Continuous chip with Built Up Edge:

This type of chip is similar to continuous chip except that a built up edge is formed on

the nose of the tool. The built of edge is formed


PRACTICAL NO.5

PLAN LAYOUT OF CAPSTAN AND

TURRET LATHE

PLAN LAYOUT OF CAPSTAN AND TURRET LATHE

AIM:


To study of Plan layout of Capstan and Turret lathe.

THEORY:

INTRODUCTION:

The Capstan (C) & Turret (T) lathes are developed for the purpose of producing mass identical

parts with more production rates and at the same time very less rejection rates.

A - HeadStock C - Capstan Slide B - Capstan D - Adjustment For Capstan Stops E - BED

CAPSTAN LATHE PARTS


TURRET LATHE

MAIN PARTS:

Bed, All geared headstock, Saddle, Multi station tool post. Here, tailstock is replaced by

hexagonal turret sliding on the machine bed. Six faces of turret holds six different operation

tools, either with auto indexing or manual indexing. By indexing the operator brings tool in the

axis of lathe, keeping in view the sequence of operations. The job is clamped either in chucks or

collets and all feed movements are regulated with the help of adjustable stops, for specific

operations.

WORKING PRINCIPLE OF SEMI AUTOMATS AND FULL AUTOMATS:

CONSTRUCTION DETAILS—EVALUATION PROCESS OF WORKING:

1. For properly setting up a turret, skill is necessary in the selection, mounting, and

adjustment of the tools.

2. In small lot production, it is important that this work can be done quickly, so as not to

consume too much of the total production time, which consists of set up, work piece

handling, machine handling and cutting time.

3. Set up time is reduced by having the tool in up to date condition and readily available.

4. For short run jobs, a permanent set up of the usual bar tools on the turret is a means of

reducing time.

5. The tools selected are standard and when permanently mounted, they may be quickly

adjusted for various jobs.

6. The loading and unloading time, which is the time consumed in mounting or removing

the work, depends largely on the work holding devices used.

7. For bar work, this time is reduced to a minimum by using bar stock collets.

8. The time it takes, to pre position the tools ready for cutting is part of the cycle time.

9. This is reduced by having the tool in proper sequence for convenient use and by taking

10. Multiple or combined cuts whenever possible.

11. The balance of the machine handling time is made up of the time necessary to change the

speeds and feeds.

12. Cutting time is controlled with proper cutting tools, feeds and speeds.


13. Combined cuts refer to the simultaneous use of both slide and turret tools.

14. In bar work, combined cuts are especially desirable, as an additional support is given, to

the work piece, thereby, reducing spring and chatter.

15. In chucking work, internal operations such as drilling or boring may frequently be

combined with turning or facing cuts from the square turret.

16. Time is also saved, by taking multiple cuts, that is, having two or more tools mounted on

one tool station.

17. For outside turning, a single cutter turner or box tool has been developed As bar stock is

supported only at the collets, additional support must be provided for heavy cuts to be

taken.

18. This is done by means of two rollers that contact the turned diameter of the stock to

counter the thrust of the cutting tool.

MAJOR OPERATIONS TO BE CARRIED OUT USING AUTOMATES:

Turning, Drilling, Boring, Threading, Reaming, Necking, Chamfering and cutting off or parting

off. Other specialized operations are possible with specialized tools.

REVIEW QUESTIONS:

1. What are the main parts of capstan and turret lathes? Where they differ?

2. Explain step-by-step procedure of part you already made using Capstan & Turret lathe in

your workshop.

3. Write down different types of turret lathes and their applications.

4. Compare engine lathe with automats.

5. Compare and differentiate between capstan and turret lathe.

6. Explain with sketch the function of bar feeding mechanism.

SIGNATURE:

GRADE:


PRACTICAL NO. 6

UNCONVENTIONAL MACHINING

PROCESS


UNCONVENTIONAL MACHINING PROCESS

AIM:

To study of Unconventional Methods of Machining.

THEORY:

INTRODUCTION:

Last few decades have witnessed a rapid growth in the development of harder and difficult to

machine metals and alloys. It has been realized that such materials are difficult to machine by

conventional methods, and therefore their machining is not only costly but also results into poor

surface finish and shorter tool life. To overcome these difficulties a number of newer machining

methods have been developed. These methods are not convectional in the sense that material

removal does not occur due to plastic deformation and with the formation of the chips.

These methods have found successful applications in several important industries for machining

of components having complicated shapes made of hard materials like tungsten carbides, super

alloys, ceramics, refractory materials etc. Today unconventional machining techniques play an

important role in manufacturing industries.

CLASSIFICATION:

Newer machining methods can be classified on the basis of the type of energy they employ for

purpose of metal removal. Broadly, speaking they can be classified as below:

1. Mechanical metal removal processes.2. Electro-chemical metal removals processes.3. Thermal Metal Removal processes

Mechanical methods are characterized by the fact that material removal is due to the application

of mechanical energy in the form of high frequency vibrations or kinetic energy of an abrasive

jet. Practical machining methods that employ mechanical energy are:

I. Ultra Sonic Machining (USM)II. Abrasive Jet machining (AJM), and

III. Water Jet machining (WJM)


ULTRA SONIC MACHINING

Electro chemical methods are based on electrochemical dissolution of materials by an electrolyte under the influence of an externally applied electric potential. The practical methods that utilize this principle are:

(a) Electro Chemical machining (ECM)

(b) Electro Chemical grinding (ECG)

ELECTRO CHEMICAL MACHINING

In thermal method, the material is removed due to controlled, localized heating of the work piece. This results into material removal by melting and evaporation. The source of heat generation in such cases can be widely different. Practical machining method based on this principal are

(a) Electro Discharge Machining (EDM)

(b) Plasma Are Machining (PAM)

(c) Electron beam machining (EBM) and

(d) Laser Beam Machining (LBM)


ELECTRO DISCHARGE MACHINING

LASER BEAM MACHINING

REVIEW QUESTIONS:

1. Differentiate between convectional and unconventional machining. State the advantages of unconventional machining.

2. Give the classification of unconventional machining method. Why they are developed.

3. Describe the below mention process in detail with neat sketch.

(a) Ultra Sonic Machining

(b) Electric Discharge Machining

(c) Abrasive Jet Machining

(d) Electro Chemical Grinding and Electro Chemical Machining

(e) Laser Beam Machining

SIGNATURE:

GRADE:


PRACTICAL NO.7

MANUFACTURING OF GEAR

MANUFACTURING OF GEAR


AIM:

To study manufacturing of a gear on milling machine.

THEORY:

INTRODUCTION:

Gears are commonly used to transmit power or rotary motion from one shaft to another. They

have the advantage over friction and belt drives that they are positive in action. To meet the

stringent service conditions the gear should be fatigue free, free from noise and chatter, should

ensure high load carrying capacity at constant velocity ratio. Gear cutting is a very complex

process.

CLASSIFICATION OF GEAR MANUFACTURING METHODS:

1. Casting

2. Stamping

3. Extrusion

4. Forging

5. Roll forming

6. Powder metallurgy

7. Machining methods:

Copying / Forming:

By disc type milling cutter on milling machine

By end mill on milling machine

By single point cutting tool on shaper

By broach on broaching machine

Generating / Rolling:

By rack in gear cutter

By pinion in gear cutter

By hob in gear cutter


Forming method:

In this method single point or multi point cutting tool can be used. The shape of the tool tip corresponds to the shape of tooth space of the gear to be manufactured. According to ‘gear theory’ different gears with different number of teeth but same module differ to some extent in tooth profile. So produce exact profile of tooth on the gear blank, one cutter for each number of teeth is required. So it is costly practice. To reduce this cost separate set of cutters are used to range of teeth.

Generating method:

In this method when two cylinders are rolled one acts as cutter and the other acts as blank and the gear teeth are generated on the blank. Single cutter can have different number of teeth provided the module is same.

Gear finishing methods:

Gear shaving

Gear burnishing

Gear grinding

Gear honing

Gear lapping

REVIEW QUESTIONS:

1. Explain the forming and generating methods of gear manufacturing.

2. Explain the gear finishing methods.

3. Explain the method that you used for the manufacturing of gear

SIGNATURE:

GRADE:


PRACTICAL NO. 8

JIGS AND FIXTURES

JIGS AND FIXTURES

AIM:

To study different jigs and fixtures available in workshop.


THEORY:

INTRODUCTION:

Work piece control is biggest issue for a process planner. Because loss of work piece control will

result in work pieces having out of dimension condition. Once the drawing for a part is

completed it is sent to process planning department where method and sequence of manufacture

are finalized. This department also floats the requirements for different tooling needed for the

completion of job. Jigs and fixtures are tooling needed for the satisfactory work piece control, in

simple terms work holding devices.

Fixtures are used to hold and locate the work piece. Fixtures are heavier in construction. Turning,

milling, shaping, planning, grinding, broaching etc. operation require fixtures to hold and job.

Jigs are used to guide and control the tool; hold and locate the work piece. Jigs are required in

drilling, reaming, tapping etc. operations.

Locator locates the job in jig and fixture body. Locating device are listed below:

1. Jack pin, jack screw

2. Cylindrical locator

3. Conical locator

4. Diamond locator

5. Vee locator

Clamps in jigs and fixtures are used to provide holding force to the work piece.

Clamps are of different types:

1. Strap clamp

2. Screw clamp

3. Hinged clamp

4. Wedge clamp.

5. C- clamp

6. Toggle clamp


7. Cam operated clamp

Bushes in jig dose the function of guiding the tool.

1. Fixed bush

2. Liner bush

3. Renewable bush

4. Slip bush.

5. Screw bush

6. Special bush

Different types of jigs are:

1. Template jig

2. Plate jig

3. Channel jig

4. Leaf jig

5. Universal jig

6. Index jig

7. Turn over jig etc.

Fixtures are mainly classified on base of method of manufacture.

1. Milling fixture

2. Turning fixture

3. Grinding fixture

4. Boring fixture

5. Broaching fixture

6. Welding fixture

7. Assembly fixture


OBSERVATION:

Analyze each and every jig and fixture in our workshop in context of function location and

clamping facility.

REVIEW QUESTIONS:

1. Explain the principle of 3-2-1 locations.

2. Differentiate between jigs and fixtures.

3. List out different types of clamps.

4. List out different types of bushes.

5. Explain various types of jigs.

6. What considerations are taken while designing a clamp?

SIGNATURE:

GRADE:

Documents

Production_Technology Lab Manual 181903