3341901 me ii-lab_manual_prepared by vipul hingu

LAB

MANUAL

Prepared By

Mr. Narsinhbhai Patel

Mr. Vipul Hingu

MENUFACTURING ENGINEERING -II

S.B. P

OLYTECHNIC

LAB PRACTICAL LIST ME-II (3341901)

Prepared By NAP & VHH

LAB PRACTICAL LIST

Practical No. Aim of Practical

1 Preparatory Activity

2 Effect of Varying Cutting Parameters

3 Effect of Varying Work Piece Materials

4 Turning Job

5 Milling Job

6 Shaping and Drilling Job

7 Grinding Job

8 Tool Layout

9 Industrial Visit

S.B. P

OLYTECHNIC

EXPERIMENT NO. 1 S.B. POLYTECHNIC, SAVLI ME-II (3341901)

Prepared By NAP & VHH Page 1 of 2

EXPERIMENT NO. 1

AIM: - Preparatory Activity for Job on Lathe.

In This Experiment We Study about Lathe Machine Tools and its Geometry.

Lathe is the universal metal removal machine for round job. To understand total

manufacturing process on different types of machine, following terminology is must understand for

different machine.

Metal Removal Rate (MRR)

(A) Speed

When metal is cut, the work piece surface is driven with the respect to the

tool or the tool with respect to the surface, at a relatively high rate of speed. This is

called Cutting Speed or Speed. It is defined as the rate at which the uncut surface of

the work piece passes through the cutting edge of the tool. It is expressed in meter

per minute or surface meter per minute.

(B) Depth of Cut

Halt the amount of the diameter which is changed by cutting action in one

pass is called the depth of cut. It is measured in mm.

(C) Feed

Rate of which the tool is feed against work piece for cutting action is called

Feed. Feed is expressed in mm per revolution in turning operation. Feed determines

the time required for metal cutting operation.

The above terminology is show in different type of machine as following

(1) Turning & Boring Operation on Lathe. Show in Fig. 1.1

(2) Operation on Shaper Machine. Show in Fig. 1.2

(3) Operation on Planing Machine. Show in Fig. 1.3

(4) Operation on Milling Machine. Show in Fig. 1.4

(5) Operation on Grinding Machine. Show in Fig. 1.5

(6) Operation on Drilling Machine. Show in Fig. 1.6

(7) Operation on Broaching Machine. Show in Fig. 1.7

Metal Removal Rate (MRR)

The quantity of material removed from the job per second of minute is called MRR. It is

measured in mm3/sec or m3/minute

S.B. P

OLYTECHNIC


Prepared By NAP & VHH Page 1A

(Fig, 1.1)

Turning & Boring Operation on Lathe

(Fig, 1.2) (Fig, 1.3)

Operation on Shaper Operation on Planing Machine

(Fig, 1.4) (Fig, 1.5)

Operation on Milling Operation on Grinding

(Fig, 1.6) (Fig, 1.7)

Operation on Drilling Machine Operation on Broaching Machine

S.B. P

OLYTECHNIC



MRR = 1000

mm3/sec Where, v = Cutting Speed in mm/min

f = feed mm/ rev

d = depth of cut in mm

Tool Material & Tool Geometry for Lathe

Tool geometry and application for lathe machine is show in Fig. 1.8

Tool Property

Main property of cutting tool materials:

(1) Toughness (2) Wear Resistant (3) Red Hardness

Tool Material

Following are commonly used tool material.

(1) High Speed Steel (3) Cemented Carbides (5) Cemented Oxide

(2) Stelites (4) Ceramics (6) Diamond

ISO Classification of Carbide Tigs:

(a) P01, P10, 920, 930, 940, 950, - Ferrous Materials.

(b) M10, M20, M30, M40 – Intermediates.

(c) K01, K10, K20, K30, K40 – Cast Iron.

S.B. P

OLYTECHNIC



(Fig, 1.8) Tool Geometry of Lathe machine

S.B. P

OLYTECHNIC



EXPERIMENT NO. 2

AIM: - To Study Effect of Varying Cutting Parameters.

We are study effect of Speed, Feed, and Depth of Cut on Tool Life and Surface Finish.

Influences of Cutting Variables

When any material is machined on lathe, milling, drilling, or shaping, it produced chips &

give particular finished surface.

Show Fig. 2.1

When we change cutting speed, depth of cut, feed it has effect on

(a) Power Consumption

(b) Accuracy

(c) Production Rate.

(d) Economy

(e) Surface Finish

(f) Tool Life

(a) Power Consumption

The product of cutting speed, feed and depth of cut is the metal removal rate. In

order to achieve higher metal removal rate V.d.f/power should be minimum. In other

words the power available for metal removal must be utilized at its best and without any

waste.

(b) Accuracy

Regarding the selection of cutting tool in order to maintain the standard of

quality the tool angle may be varied from positive to negative or the tool profile may be

suitably modified. The cost can be reduced, Selection optimum cutting speed according

to work piece tool combination.

(c) Production Rate

To increase the production rate, all variable factors such as speed, feed, and

depth of cut should be suitably optimized to increase the metal removal rate. Under

special circumstances if the production cost increases cutting tool with carbide tool bit,

ceramics or even diamond may be used to increase metal removal rate.

(d) Economy

When speed, feed rate and depth cut are increased, the production time is

decreased and production becomes economical.

S.B. P

OLYTECHNIC



(Fig. 2.1)

(Fig. 2.2)

S.B. P

OLYTECHNIC



No. Parameter Effect on Tool Life Effect on Surface Finish

1. 2. 3.

Increase in Speed Increase in Feed Decrease in Depth of Cut

Decrease in tool life Decrease in tool life Increase in tool life

Increase in surface finish Decrease in surface finish Increase in surface finish

Conclusion

(1) Increase in speed will give more production, good finish but decrease tool life.

(2) Increase in feed will give more production but decrease in surface finish & tool life.

(3) Increase in depth of cut will give more production but increase in power consumption,

decrease tool life & surface finish.

S.B. P

OLYTECHNIC



EXPERIMENT NO. 3

AIM:- To study about Interpret Surface Finish, Tool Life and Type of Chip Formation

on varying Cutting Parameters of Different Material.

We are study about effect of surface finish, tool life and type of chip formation on varying

cutting parameters of different material

Process of Chip Formation

When a tool cuts metal it is driven by a force necessary to overcome friction and the

forces that hold the metal together. The metal that the tool first meets is compressed and

caused to flow up the face of the tool. The pressure against the face of the tool and the

friction force opposing the metal flow build up to large amount. At that time the material

may be shared by the advancing tool or torn by the bending of the chip to start a crack.

Types of Chips

The Following variables are influence the type of chip.

(1) Properties of the material cut.

(2) Rake angle

(3) Cutting Speed

(4) Depth of Cut

(5) Feed Rate

(6) Type and quality of cutting fluid

Classification of Chips:

i. The Discontinuous or Segmental Chip.

ii. The Continuous or Ribbon Chip.

iii. The Continuous with Built Up Edge.

(i) The Discontinuous or Segmental Chip.

Factors for discontinuous chip:

(a) Brittle material or low ductility

(b) Low cutting speed

(c) Small rack angle

(ii) The Continuous or Ribbon Chip.

Factors for continuous chip

(a) Ductile materials.

(b) Large rack angle.

(c) Small depth of cut

(d) Sharp cutting edge

S.B. P

OLYTECHNIC



(Fig. 3.1) Different Types of Chips

(Fig. 3.2)

S.B. P

OLYTECHNIC



(iii) The Continuous With Built Up Edge.

Factors for continuous chip with build-up edge

(a) Ductile Material.

(b) High feed.

(c) High depth of cut

(d) Improper cutting fluid

Varying Cutting Parameters of Different Material

A. MATERIAL – M.S

Take the M.S rod as a work piece and the hold the w/p on a lathe machine.

No. Spindle Speed in RPM Feed inch/rev Type of Chip Surface Finish

1. 240 0.285 Discontinuous Rough

2. 400 0.285 Discontinuous Fine

3. 575 0.285 Continuous Fine

B. MATERIAL – C.I

Take the C.I rod as a work piece and the hold the w/p on a lathe machine. Take the

sample turning operation on lathe m/c.





C. MATERIAL – ALUMINIUM

Take the aluminium rod as a work piece and the hold the w/p and bolt cost on a lathe

machine





S.B. P

OLYTECHNIC



EXPERIMENT NO. 4

AIM: - Preparation of Job on Lathe Machine.

To perform various lathe operations such as Plain turning, Taper turning, Threading,

Grooving, Chamfering and Knurling on a given material made of Mild steel.

Working Principle of Lathe Machine

The work piece is held in either chuck or between two centres and rotated. Suitable cutting tool is held in tool post and by selecting suitable cutting parameters and with relative working motions between work piece and cutting tool. Block Diagram of Lathe Machine Show in Fig. 4.1.

Machine Required

Lathe Machine

Specification of Lathe Machine Used for Making Job

(1) Height of the Centre: _______________ (2) Swing Diameter over Bed: _______________ (3) Length between Centres: _______________ (4) Swing Diameter over carriage: _______________ (5) Maximum bar Diameter: _______________ (6) Length of Bed: _______________ (7) Diameter of Spindle Nose: _______________ (8) Pitch of Lead Screw: _______________ (9) Capacity of Motor: _______________

Material Required

A mild steel bar of ____ mm diameter and ____ mm length

Tools & Equipment Used

(1) H.S.S. single point cutting tool,

(2) Parting tool,

(3) Grooving tool,

(4) Knurling tool,

(5) Threading tool,

(6) Chuckey,

(7) Tool post key,

(8) Outside calliper,

(9) Thread Gauge,

(10) Steel rule,

(11) Cutting Fluid.

S.B. P

OLYTECHNIC



(Fig. 4.1) Block Diagram of Lathe

Tool Geometry

S.B. P

OLYTECHNIC



Drawing of the Job

Fig. No. 4.14

Operation Chart

Sr. No. Sequence of Operations Cutting Tool Used

1 Facing H.S.S Single Point Tool

2 Rough Turning H.S.S Single Point Tool

3 Finish Turning H.S.S Single Point Tool

4 Step Turning Parting Tool

5 Threading Threading Tool

6 Taper Turning H.S.S Single Point Tool

7 Grooving Grooving Tool

8 Knurling Knurling Tool

9 Chamfering H.S.S Single Point Tool

S.B. P

OLYTECHNIC



Lathe Operation

(Fig. 4.2) Straight turning (Fig. 4.3) Taper Turning (Fig. 4.4) Profiling

(Fig. 4.5) Turning (Fig. 4.6) Facing (Fig. 4.7) Face Grooving

(Fig. 4.8) Form Tool (Fig. 4.9) Boring (Fig. 4.10) Drilling

(Fig. 4.11) Grooving (Fig. 4.12) Threading (Fig. 4.13) Knurling

S.B. P

OLYTECHNIC



Types of Operations

(1) Facing Operation

Facing is the operation of machining the ends of a piece of work to produce a flat surface square with the axis. The operation involves feeding the tool perpendicular to the axis of rotation of the work piece.

A regular turning tool may be used for facing a large work piece. The cutting edge should be set at the same height as the centre of the work piece. The tool is brought into work piece from around the centre for the desired depth of cut and then is fed outward, generally by hand perpendicular to the axis of rotation of the work piece. Show Fig. No.

(2) Rough Turning Operation

Rough turning is the operation of removal of excess material from the work piece in a minimum time by applying high rate of feed and heavy depth of cut. The depth of cut for roughing operations in machining the work ranges from 2 to 5 mm and the rate of feed is from 0.3 to 1.5 mm per revolution of the work.

(3) Finish Turning Operation

It requires high cutting speed, small feed, and a very small depth of cut to generate a smooth surface. The depth of cut ranges from 0.5 to 1 mm and feed from 0.1 to 0.3 mm per revolution of the work piece.

(4) Step Turning Operation

Is the operation of making different diameters of desired length? The diameters and lengths are measured by means of outside calliper and steel rule respectively.

(5) Threading Operation

Principle of Thread Cutting

The principle of thread cutting is to produce a helical groove on a cylindrical or conical surface by feeding the tool longitudinally when the job is revolved between centres or by a chuck. The longitudinal feed should be equal to the pitch of the thread to be cut per revolution of the work piece. The lead screw of the lathe, through which the saddle receives its traversing motion, has a definite pitch. A definite ratio between the longitudinal feed and rotation of the head stock spindle should therefore be found out so that the relative speeds of rotation of the work and the lead screw will result in the cutting of a screw of the desired pitch.

This is affected by change gears arranged between the spindle and the lead screw or by the change gear mechanism or feed box used in a modern lathe.

S.B. P

OLYTECHNIC



Calculation of change-wheels, metric thread on English lead screw

To calculate the wheels required for cutting a screw of certain pitch, it is necessary to know how the ratio is obtained and exactly where the driving and driven wheels are to be placed. Suppose the pitch of a lead screw is 12 mm and it is required to cut a screw of 3 mm pitch, then the lathe spindle must rotate 4 times the speed of the lead screw that is

Spindle turn

Lead screw turn = Means that we must have

Driver teeth

Driver teeth = Since a small gear rotates faster than a larger

One with which it is connected.

Hence we may say,

Driver teeth

Driver teeth =

Lead screw turn pitch of the screw to be cut

spindle turn pitch of the lead screw

In BRITISH SYSTEM

Driver teeth

Driver teeth =

𝑇ℎ𝑟𝑒𝑎𝑑𝑠 𝑝𝑒𝑟 𝑖𝑛𝑐ℎ 𝑜𝑛 𝑙𝑒𝑎𝑑 𝑠𝑐𝑟𝑒𝑤

𝑇ℎ𝑟𝑒𝑎𝑑𝑠 𝑝𝑒𝑟 𝑖𝑛𝑐ℎ 𝑜𝑛 𝑤𝑜𝑟𝑘𝑤

Often engine lathes are equipped with a set of gears ranging from 20 to 120 teeth in steps of 5 teeth and one translating gear of 127 teeth. The cutting of metric threads on a lathe with an English pitch lead screw may be carried out by a translating gear of 127 teeth.

Driver teeth

Driver teeth =

5 𝑝 𝑛

127

Where,

P= pitch of the thread to be cut and

N=thread per inch on lead screw

𝐷𝑟𝑖𝑣𝑒𝑟 𝑡𝑒𝑒𝑡ℎ

𝐷𝑟𝑖𝑣𝑒𝑟 𝑡𝑒𝑒𝑡ℎ =

pitch of the work

pitch of the lead screw =

𝑝

(1

𝑝) 𝑋 (

127

5) =

5 𝑝 𝑛

127

Since, pitch = 1

No.of thread per inch

S.B. P

OLYTECHNIC



Thread Cutting Operation

In a thread cutting operation, the first step is to remove the excess material from the work piece to make its diameter equal to the major diameter of the screw thread. Change gears of correct size are then fitted to the end of the bed between the spindle and the lead screw.

The shape or form of the thread depends on the shape of the cutting tool to be used. In a metric thread, the included angle of the cutting edge should be ground exactly 600. The top of the tool nose should be set at the same height as the centre of the work piece. A thread tool gauge is usually used against the turned surface to check the cutting tool, so that each face of the tool may be equally inclined to the centre line of the work piece as shown.

The speed of the spindle is reduced by one half to one fourth of the speed require for turning according to the type of the material being machined and the half nut is then engaged. The depth of cut usually varies from 0.05 to 0.2 mm is given by advancing the tool perpendicular to the axis of the work.

After the tool has produced a helical groove up to the desired length of the work, the tool is quickly withdrawn by the use of the cross slide, the half-nut disengaged and the tool is brought back to the starting position to give a fresh cut. Before re-engaging the half-nut it is necessary to ensure that the tool will follow the same path it has traversed in the previous cut, otherwise the job will be spoiled. Several cuts are necessary before the full depth of thread is reached arising from this comes the necessity to “pick-up” the thread which is accomplished by using a chasing dial or thread indicator.

(6) Taper Turning Operation

A taper may be defined as a uniform increase or decrease in diameter of a piece of

work measured along its length. In a lathe, taper turning means to produce a conical surface

by gradual reduction in diameter from a cylindrical work piece. The amount of taper in a

work piece is usually specified by the ratio of the difference in diameters of the taper to its

length. This is termed as the iconicity designated by the letter ‘K’.

K = (𝐷−𝑑)

𝐿 Where,

D= Large diameter of taper in mm

d= Small diameter of taper in mm

L= length of tapered part in mm

A taper may be turned by any one of the following methods:

(a) Form tool method, (b) Tail stock set over method, (c) Swivelling the compound rest and (d) Taper turning attachment

S.B. P

OLYTECHNIC



Taper turning by swivelling the compound rest:

This method employs the principle of turning taper by rotating the work piece on the lathe axis and feeding the tool at an angle to the axis of rotation of the work piece. The tool mounted on the compound rest is attached to a circular base, graduated in degrees, which may be swivelled and clamped at any desired angle. Once the compound rest is set at the desired half taper angle, rotation of the compound slide screw will cause the tool to be fed at that angle and generate a corresponding taper. The setting of the compound rest is done by swivelling the rest at the half taper angle. This is calculated by the equation.

Tan α = (𝐷−𝑑)

𝐿

Where,

α = Half taper angle

(7) Grooving Operation

Grooving is reducing work piece diameter across a very small length. In majority of cases grooving is done after thread cutting is over or by the side of shoulders to provide margin. In grooving, the work piece is rotated at half the turning speed and the grooving tool is fed at right angle to work piece axis.

(8) Knurling Operation

Knurling is the process of embossing a diamond shaped pattern of the surface of a

work piece. The purpose of knurling is to provide an effective gripping surface on a work

piece to proven it from slipping when operated by hand. Knurling is performed by a special

knurling tool which consists of a set of hardened steel rollers in a holder with the teeth cut

on their surface in a definite pattern. The tool is held rigidly on the tool post and the rollers

are pressed against the revolving surface of work piece to squeeze the metal against the

multiple cutting edges, producing depressions in a regular pattern on the surface of the

work piece.

Knurling is done at the slowest speed and oil is flowed on the tool and work piece.

Knurling is done at the slowest speed and oil is flowed on the tool and work piece to

dissipate heat generated during knurling. The feed varies from 1 to 2 mm per revolution.

(9) Chamfering Operation

Chamfering is the operation of bevelling the extreme end of a work piece. This is

done to remove the burrs, to protect the end of the work piece from being damaged and to

have a better look. The operation may be performed after the completion of all operations.

It is an essential operation after thread cutting so that the nut may pass freely on the

threaded work piece.

S.B. P

OLYTECHNIC



Metal Cutting Parameters

The cutting speed of a tool is the speed at which the metal is removed by the tool from the

work piece. In a lathe, it is the peripheral speed of the work past the cutting tool expressed in

meters/minute

I. Cutting speed (V) = 𝝅 𝑫 𝑵

𝟏𝟎𝟎𝟎 m/min Where,

D= Diameter of the work in mm N= RPM of the work

II. Feed

The feed of a cutting tool in a Lathe work is the distance the tool advances for

each revolution of the work. Feed is expressed in mm/rev.

III. Depth of Cut

The depth is the perpendicular distance measured from the machined

surface to the uncut surface of the work piece.

Depth of Cut = (𝐷1−𝐷2)

2

Where,

D1= Diameter of the work surface before machining

D2= Diameter of the work surface after machining

While using HSS tool for turning mild steel work piece. The following parameters are to be chosen. IV. Rough Turning Operation

Cutting speed (V) = 25m/min,

Feed (f) = 0.2 mm/rev,

Depth of cut (t) = 1 mm

V. Finish Turning Operation

Cutting speed (V) = 40m/min,

Feed (f) = 0.1 mm/rev,

Depth of cut (t) = 0.2 mm

VI. Tool Geometry

Back rake angle = 7°,

End relief angle = 6°,

Side relief angle = 6°,

End cutting edge angle = 15°,

S.B. P

OLYTECHNIC



Side cutting edge angle = 15°,

Nose radius = 2 mm

Procedure

1) The work piece and HSS single point cutting tool are securely held in the chuck and tool post

respectively.

2) Operations such as facing, rough turning and finish turning are performed on a given mild

steel bar one after the other in sequence up to the dimensions shown. Then the step

turning is performed using parting tool.

3) HSS single point cutting tool is replaced by a threading tool. Right hand and left hand metric

threads are cut on the work piece up to the required length at 1/4th of the normal speed of

the spindle.

4) Then the compound rest is swivelled by calculated half taper angle and taper is generated

on the work piece. Rotation of the compound slide screw will cause the tool to be fed at the

half-taper angle.

5) HSS single point cutting tool is replaced by the Grooving tool and Grooving operation is

performed at half of the normal spindle speed.

6) HSS single point cutting tool is replaced by the Knurling tool and knurling operation is

performed at the slowest speed of the spindle.

7) After, the chamfering is done at the end of the work piece.

8) Finally, the work piece is removed from the chuck. Work piece is ready.

Precautions

1) Operate the machine at optimal speeds.

2) Do not take depth of cut more than 2 mm.

3) Knurling should be done at slow speeds and apply lubricating oil while knurling

4) Care should be taken to obtain the required accuracy

Result

Required specimen obtained according to specified operations (plane turning, tapper turning,

threading. Knurling and chamfering) with given dimensions.

S.B. P

OLYTECHNIC



EXPERIMENT NO. 5

AIM: - Preparation of Job on Milling Machine.

To perform plane milling operation on the given specimen (mild steel) & get to its correct

dimensions.

Working Principle of Milling Machine

The working principle, employed in the metal removing operation on a milling machine, is

that the work is rigidly clamped on the table of the machine, or held between centres, and

multiteeth cutter mounted either on a spindle or on arbor. Revolves at a fairly high speed and the

work fed slowly past the cutter. Block Diagram of Milling Machine Show in Fig. 5.1.

Machine Required

Milling Machine

Specification of Milling Machine Used for Making Job

The milling machine is specified by its table working surface, its longitudinal, cross and

vertical transverse, knee movement in degrees, range and number of spindle speeds, available

power of the machine and machine type.

Material Required

Mild Steel Specimen.


(1) Plane (Face) Milling Cutter,

(2) Vernier Calipers,

(3) Steel rule,

(4) Scriber,

(5) Work Holding Fixtures: Work Piece Supporting Fixtures,

(6) Miscellaneous Tools: Hammer, Brush, Allen keys,

(7) Cutting Fluid (If needed).

Theory

Milling machine is a machine tool in which metal is removed by means of a revolving cutter

with many teeth (multipoint), each tooth having a cutting edge which removes the metal from the

work piece. The work may be fed to the cutter, longitudinally, transversely or vertically, the cutter

is set to a certain depth of cut by raising the table. This machine is very much suitable in tool room

work due to its variety of operations, better surface finish and accuracy.

S.B. P

OLYTECHNIC



(Fig. 5.1) Block Diagram of Milling Machine

S.B. P

OLYTECHNIC



Drawing of the Job

Fig. 5.10

Sequence of Operation

I. Measuring of specimen

II. Fixing of specimen in the milling m/c.

III. Giving the correct depth and automatic feed cut the specimen

IV. Check the specimen with Vernier caliper at the end.

S.B. P

OLYTECHNIC



(Fig. 5.2) Plain Milling Operation (Fig. 5.3) Face Milling Operation

(Fig. 5.4) Gang Milling Operation (Fig. 5.5) Form Milling Operation

(Fig. 5.6) Angular Milling Operation

(Fig. 5.7) Woodruff Keyway Milling Operation

S.B. P

OLYTECHNIC



Procedure

1) The dimensions of the given job are checked with the steel rule.

2) The given job is fixed in the vice provided on the machine table such a, one end of it is

projected outside the jaws of the vice.

3) A face milling cutter is mounted on the horizontal milling machine spindle and one end of

the job is face milled, by raising the table so that the end of the job faces the cutter.

4) The job is removed from the vice and fitted in the reverse position.

5) The other end of job is face milled such that, the length of the job is exactly 100 mm.

6) The table is lowered and the job is removed from the vice and refitted in it such that, the

top face of the job is projected from the vice jaws.

7) The face milling cutter is removed from the spindle and the arbor is mounted in the spindle;

followed by fixing the plain milling cutter.

8) The top surface of the job is slab milled; first giving rough cuts followed by a finish cut.

9) The job is removed from the vice and refitted in it such that, the face opposite to the above,

comes to the top and projects above the vice jaws.

10) The top surface of the job is milled in stages; giving finish cuts towards the end such that,

the height of the job is exactly 40 mm.

11) The burrs if any along the edges are removed with the help of the flat file.

Precautions

1) The milling machine must be stopped before setting up or removing a work piece, cutter or

other accessory

2) Never stop the feeding of job when the cutting operation is going on, otherwise the tool will

cut deeper at the point where feed is stopped.

3) All the chips should be removed from the cutter. A wiping cloth should be placed on the

cutter to protect the hands. The cutter should be rotated in the clockwise direction only for

right handed tools.

4) The work piece and cutter should be kept as cool as possible (i.e. coolant should be used

where necessary to minimize heat absorption).

5) The table surface should be protected with a wiping cloth.

6) Tool must be mounted as close to the machine spindle as possible.

Result

The rectangular block of 50 x 40 x 100 mm, is thus obtained, by the stages described above. S.B

. POLY

TECHNIC



(Fig. 5.8) Work Piece Holding Devices (Vise)

(Fig. 5.9) Various Mounting Work piece

S.B. P

OLYTECHNIC



EXPERIMENT NO. 6

AIM: - Preparation of Job on Shaping Machine & Drilling Machine.

Shaping Machine

To perform V and Dovetail machining & U-cut on the given work piece.

Working Principle of Shaping Machine

A shaper has a reciprocating ram that carries a cutting tool. The tool cuts only on the

forward stroke of the ram. The work is held in a Vise or on the worktable, which moves at a right

angle to the line of motion of the ram, permitting the cuts to progress across the surface being

machined. Block Diagram of Milling Machine Show in Fig. 6.1.

Machine Required

Shaper Machine.

Specification of Shaping Machine Used for Making Job

A shaper is identified by the maximum size of a cube it can machine; thus, a 24-inch shaper

will machine a 24-inch cube.

(1) Maximum ram stroke ________ mm

(2) Work table surface (Width: ________mm) (Length: ________mm)

(3) No. of stroke per min ________ st/min

(4) Motor power ________ KW

Material Required

Mild steel / Cast iron / Cast Aluminium.


(1) H.S.S tool bit,

(2) V tool,

(3) Plain tool,

(4) Grooving tool.

(5) Vernier calipers,

(6) Vernier height gauge,

(7) Dial indicator,

(8) Required steel ball.

Theory

The shaper also called shaping machine, is a reciprocating type of machine tool in which the

ram moves the cutting tool backward and forward in a straight line to generate the flat surface. The

flat surface may be horizontal, inclined or vertical.

S.B. P

OLYTECHNIC



(Fig. 6.1) Block Diagram of Shaper Machine

(Fig. 6.2) Block Diagram of Drilling Machine

S.B. P

OLYTECHNIC



Drawing of the Job

Fig. 6.3

Sequence of Operation

I. Measuring of specimen.

II. Fixing of specimen in the machine vice of the shaping machine.

III. Giving the correct depth and automatic feed for the slot is to be made.

IV. Check the slot with the Vernier calipers & precision measurement by slip gauges at the end.

S.B. P

OLYTECHNIC

EXPERIMENT NO. 6 ME-II (3341906)


(Fig. 6.4) Tool head assembly position in various operation

(Fig. 6.5) Quick Return Mechanism

S.B. P

OLYTECHNIC



Principle of Quick return motion

These types of machine tool are of rectilinear cutting motion therefore, the rotary motion of the

drive is converted into reciprocating motion.

The metal is removed in the forward cutting stroke, while the return stroke goes idle and no metal

is removed during this period.

The cutting mechanism is so designed that it moves at a comparatively slower speed during

forward cutting stroke, whereas during the return stroke it allow the ram to move at a faster speed

to reduce the idle return time.

This mechanism is known as quick return mechanism. Show in Fig. 6.4

Hence we may say,

Cutting Ratio =

=

=

=

The length of the stroke is reduced the crank return action (inverse proportional)

Procedure

1) The dimensions of the given job are checked with the steel rule.

2) The given job is fixed in the vice provided on the machine table such a, one end of it is

projected outside the jaws of the vice.

3) A tool is mounted on the tool holder of shaper machine.

4) Machine power start and interval of after some times check surface finishing.

5) After many stroke and times the job is ready.

Precautions

1) The shaping machine must be stopped before setting up or removing the work piece

2) All the chips should be removed from the cutter.

Result

Required specimen obtained according to specified operations (shaping and grooving operations)

with given dimensions.

S.B. P

OLYTECHNIC

EXPERIMENT NO. 6 ME-II (3341906)


(Fig. 6.6) Drilling (Fig. 6.7) Reaming (Fig. 6.8) Boring

(Fig. 6.9) Counter boring (Fig. 6.9) Counter shinking (Fig. 6.9) Spot facing

(Fig. 6.10) Tapping (Fig. 6.11) Trepanning

S.B. P

OLYTECHNIC



Drilling Machine

To perform drill operation and create throughout hole on given work piece. .

Working Principle of Drilling Machine

The rotating edge of the drill exerts a large force on the work piece and the hole is

generated. The removal of metal in a drilling operation is by shearing and extrusion Block Diagram

of Milling Machine Show in Fig. 6.2.

Machine Required

Radial Drilling Machine.

Specification of Drilling Machine Used for Making Job

(1) Capacity of Machine __________ mm diameter hole

(2) Spindle speed range __________ R.P.M.

(3) Feed Range __________ mm per revolution

(4) Number of Spindle Speed __________

Material Required

Mild steel specimen, coolant (oil and water mixture), lubricant oil


(1) Button pattern stock,

(2) Drill bids,

(3) Vernier calipers,

(4) MARKING TOOLS : Dot punch,

(5) Work holding fixtures: Bench vice, V-Block,

(6) Miscellaneous tools: Brush, Allen Keys.

Procedure

1) Set required diameter tool on drilling spindle.

2) After complete shaping operation set work piece on drilling machine.

3) Mark the centre of hole and centre punching.

4) Start power and give feed and complete drilling operation.

Precautions

1) Coolant has to be sued while drilling.

2) Lubricating oil has to be used to get smooth finish while tapping.

Result

Required specimen obtained according to specified operations (drilling operations) with given

dimensions.

S.B. P

OLYTECHNIC



EXPERIMENT NO. 7

AIM: - Preparation of Job on Grinding Machine.

Grind a single point cutting tool as per given tool signature / nomenclature..

Machine Required

Surface Grinding Machine.

Material Required

H.S.S. square bar: 15 mm Width, 150 mm Length, 15 mm Thick


(1) Gauge

(2) Vernier calipers

(3) Micrometre

(4) CUTTING TOOLS: Diamond point dressing block

(5) WORK HOLDING FIXTURES: Magnetic chuck

(6) Wire brush (for cleaning the formed chips)

(7) Lubricant(coolant)

(8) Required steel ball.

Procedure

1) Before grinding operation, check the condition and availability of following.

A. The protection screen

B. Tool rest

C. The grinding wheels

D. The bath (containing coolant liquid)

E. The exhaust fan

F. Start-stop push buttons.

2) Always observe safety

3) Use the vernier bevel protector for measuring tool angle.

4) Grind the carbide-tipped right hand shank tool on the main flank.

5) Stop the grinding wheel and measure the clearance angle.

6) Grind the tool’s auxiliary flank.

7) Measure the tool angle.

8) Grind the face of the tool.

9) Check the accuracy of the rake angle by the lip angle.

10) Grind the main and auxiliary flanks.

11) Grind the land of the main flank.

12) Grind the land with respect to the face.

13) Round off the tool nose.

14) Make a slope angle of the cutting edge with respect to the tool nose.

S.B. P

OLYTECHNIC



(Fig. 7.1) Cutting Tool Geometry

S.B. P

OLYTECHNIC



15) Tool grinding machine with diamond and abrasive wheels.

16) Dress the land and the nose point of the tool.

17) Lap the rough ground carbide tipped tools.

Precautions

1) Coolant usage is compulsory as the speeds employed are very high and continuous

application of coolant is necessary for ductile materials like steel etc.

2) The grinding tools are first dressed properly.

3) Care has to be taken so as to maintain the right feed of the material.

4) Work-wheel interface zone is to be flooded with coolant

5) Dressing of grinding wheel to be done before commencement of cutting action, intermittent

dressing also to be done if wheel is loaded

Result

Required specimen obtained according to specified operations(surface grinding operation) with

given dimensions

S.B. P

OLYTECHNIC



EXPERIMENT NO. 8

AIM: - Prepare a tool layout of a given component for capstan and turret lathe.

To prepare a tooling layout on capstan and turret lathe

Machine Required :- Capstan and Turret Lathe

Material Required :- Mild steel round bar 40 mm diameter and 60 mm length


(1) Collet chuck

(2) Various tools and tool holder

(3) Micrometre

(4) Varnir calipers

(5) Wire brush (for cleaning the formed chips)

(6) Lubricant(coolant)

Procedure for prepare Tool Layout

1) List the operation to be performed to complete the component from the given work

material.

2) Sequence the operations and combine where ever possible.

3) Select suitable tool holder and tool for each operation. Prepare operation sheet.

4) Prepare line sketch of each operation.

5) Prepare complete tooling layout on hexagonal turret and square turret.

6) Select the proper spindle speed, feed and depth of cut for each operation.

7) Set the work and tools on machine according to planned chart.

Example for prepare Tool Layout

Draw the tool layout for the components shown in Fig. 8.1

Fig. 8.2 shows the tool layout. And the operation sequence is given below.

1) Feed the bar stock to combined stock stop and start drill. Close the collet. The end of bar is

then centred by advancing the start towards it-turret.

2) Drill the internal diameter-turret.

3) The thread diameter is bored to correct size, boring bar in a slide tool-turret.

4) Ream the drilled hole, reamer-turret.

5) Make the recess, slide tool-turret.

6) Cut the internal threads, tap-turret.

7) Cut-off, parting tool rear cross slid.

Result

Required Tool Layout is Ready.

S.B. P

OLYTECHNIC



(Fig. 8.1) Component Drawing

(Fig. 8.2) Tool Layout

S.B. P

OLYTECHNIC

3341901 me ii-lab_manual_prepared by vipul hingu

Engineering

Transcript of 3341901 me ii-lab_manual_prepared by vipul hingu