DEPARTMENT OF MECHANICAL ENGINEERINGsmec.ac.in/sites/default/files/lab1/MTLAB MANUAL.pdf ·...

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St.MARTIN’S ENGINEERING COLLEGE

DEPARTMENT OF

MECHANICAL ENGINEERING

MACHINE TOOLS LAB

III YEAR I SEM

A.Y.2016-17

Document No:

SMEC/ME/LAB/

MANUAL/MT

DATE

OF

ISSUE:

01-07-2016

COMPLIEDBY:

Prof.P.P.C.PRASAD

VERIFIED BY:

PROF.S.VEERMANI

AUTHORISED BY

D.V.SRIKANTH

HEAD OF THE DEPARTMENT

2

LAB EXERCISE-1-FACING AND STEP TURNING ON LATHE MACHINE

1.1 OBJECTIVE:

Learning the skill in Facing & Step turning operations on Lathe Machine

1.2 RESOURCES:

Sl.No Name of the equipment Range Type Qty

1 Lathe Machine Medium General 1

2 Work Piece Φ32X105mm MS 1

3 Tool Single point HSS/CAR 1

4 Spanner 3-Jaw chuck square 1

5 Spanner Tool Post Box 1

6 Vernier Calipers 0-200mm LC20µ 1

1.3 PRECAUTIONS

a) Follow the safety rules & Check the power connections.

b) Clamp the component in Chuck firmly and take out the spanner.

c) Select the required cutting parameters

d) Set the tool & tool post for the given operation

1.4 OPERATIONAL DESCRIPTION

Major parts of Lathe Machine: Head stock/ spindle with gear box, Tail stock,

Carriage/feed gear box, Bed with guide ways. For other details refer the sketch

KINEMATICS: Engine Lathe consists of work/job rotation by spindle & Motor with

3-Jaw/4Jaw chuck. The single point Tool is clamped in square tool post with

carriage having the linear, cross travels.

OPERATION: Turning and step turning operations are done by selecting the

single point tool (HSS/Carbide) for the given work material. The selection of spindle RPM/Cutting speed and manual/auto longitudinal feed for the tool.

Facing Operation: Work/job rotation tool feed by cross slide perpendicular to the

spindle axis from outer diameter to center of the component. If the tool is not set at center of the component then a dimple of material left out.

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Turning Operation: The chip removal process goes with job rotation and linear

feed movement of the tool. The major power consumed by the spindle rotation in the form of cutting speed.

Operation Drawing

1.5 PROCESS PROCEDURE:

a) Take the MS blank Φ30x105mm and clamp in the 3Jaw chuck on Face A

b) Face side B’ to 102.5mm and Plain turn Φ30x180mm from face B’

c) Reload the component and Face side A’ 100±0.1mm

d) complete the turning Φ30x100,step turn Φ22x70mm and Φ16x15mm

1.6 TIME CALCULATION CHART

Operation Dimension Side Tool

C-Cutting

Speed

R

RPM

S-

Feed/rev

FM-

Feed/Min

T-

Tool travel

Time

Tx60/FM

Tool&Job

setting

Time

Units mm HSS/CAR Meters/Min Mm/rev S x R mm Sec Sec Sec

Facing 102.5 B HSS 24 250 0.1 25 20 48 30+30 108

Turning Φ30 B HSS 24 250 0.1 25 70 168 30 198

Facing 100 A HSS 24 250 0.1 25 20 48 30+30 108

Turning Φ30 A HSS 24 250 0.1 25 40 96 30 126

Turning Φ22 A HSS 24 250 0.1 25 80 192 30 222

Turning Φ16 A HSS 24 250 0.1 25 20 48 30 78

Total Time = 840Sec=~14 min 840

4

1.7 INSPECTION CHART

Dimension&Tol Reading-1 Reading2 Reading3 Average Remark

MS Blank

Φ32X105±1

100±0.1

Φ30

Φ22

Φ16

1.8 RESULTS:

The machined component is inspected as per the drawing dimensions

Accepted / Accepted with permissible deviations / Rejected

1.9 PRE LAB QUESTIONS :

1. Learn about Blank/work piece selection

2) Learn about Tool selection

4) Work out the Process planning

1.10 LAB ASSIGNMENT

1. What is the composition of Work Material?

2. What is the composition of Tool Material?

Prepared by P.P.C.Prasad

5

ST.MARTIN’S ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGG. MACHINE TOOLS LAB

LAB EXERCISE-2-CENTER DRILLING ON LATHE MACHINE

1.1 OBJECTIVE:

Learning the skill in Center Drilling operation on Lathe Machine

1.2 RESOURCES:




3 Center Drill Φ2.5x600 HSS/A 1

4. Drill Chuck 0 to 10mm Morse taper-0 1



1.3 PRECAUTIONS

a) Follow the safety rules & Check the power connections.

b) Check the power connections.

c) Clamp the component in Chuck firmly and take out the spanner.

d)Select the required cutting parameters

e) Set the Tailstock with Drill Chuck and Center Drill for the given operation


Major parts of Lathe Machine: Head stock/ spindle with gear box, Tail stock, Carriage/feed gear box, Bed with guide ways. For other details refer the sketch


3-Jaw/4Jaw chuck. The single point Tool is clamped in square tool post with carriage having the linear, cross travels. Tail stock is used for center support of job

and for Center drilling and drilling operations

OPERATION: Center Drilling operation is done by fixing the center Drill in Drill Chuck and the morse taper shank is inserted into the Tail stock. The selection of

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spindle RPM/Cutting speed and manual feed for the Drill by Tail stock. The Drilling

operation has to be done with job rotation and inline feed for the tool.

Operation Drawing


a) Take the Turned and faced blank Φ30x100mm and clamp in the 3Jaw chuck on Face A

b) Fix the Center Drill Φ2.5x600 into the Drill Chuck fix the Morse taper shank

into the Tail stock’

c) Set the Tail stock near to the job face

d) Switch on the Lathe for Clock wise rotation and feed the drill manually by

rotating the Tail stock end wheel

e) Replace the Tap Drill size Φ4.1 and enlarge the center drilled hole to M5 tap drill size Φ4.1



C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time


Center Drilling

Φ2.5 B HSS 5 600 0.1 60 20 20 30+30 80

Drilling Φ4.1 B HSS 5 600 0.1 60 20 20 30+30 80


7



Φ2.5

Φ4.1x12

1.8 RESULTS:




1. Learn about Types of Center Drills, nomenclature and geometry

2) Learn about Morse taper shank

1.10 LAB ASSIGNMENT

1. List out the Tap Drill sizes?

2. Study about Drilling accuracies.


8



LAB EXERCISE-3-GROOVING, KNURLING AND TAPER TURNING OPERATIONS ON LATHE MACHINE

1.1 OBJECTIVE:

Learning the skill in Grooving, Knurling and Taper Turning operations on Lathe

Machine

1.2 RESOURCES:




3 Grooving Tool 5mm HSS/CAR 1

4 Taper Turning Tool Single point HSS/CAR 1

5 Knurling Medium Double Roller 1




1.3 PRECAUTIONS

f) Check the power connections.

g) Clamp the component in Chuck firmly and take out the spanner.

h) Select the required cutting parameters

i) Set the tool & tool post for the given operations




3-Jaw/4Jaw chuck. The single point Taper turning & Grooving Tools are clamped in square tool post with carriage having the linear and compound slide cross travels.

9

OPERATION: Grooving: Grooving Tool is fixed in the tool post and job is fixed in

the 3-Jaw Chuck. Start the Lathe Machine and set for clockwise rotation. Set the Grooving Tool at the required position and move across till Φ18 forms.

Knurling: Fix the Knurling tool in the tool post. Position the Knurling tool by moving the carriage. Apply the Pressure against the rotating component and move

the tool linearly for the completion of the Knurling operation.

Taper Turning operation: Single point tool fixed in square tool post and set the angle with the compound slide. Position the carriage longitudinally and feed the

single point tool for taper turning operation. Take the number of passes to get the required taper surface as per the drawing dimensions.

Operation Drawing


a) Take the MS blank(Turned & Step turned) Φ30/ Φ22/ Φ16x100mm and clamp in the 3Jaw chuck on Face B

b) Set the Grooving tool at the position and on the spindle rotation clockwise

and feed the grooving tool across till Φ18 achieved.

c) Set the knurling tool in position and

d) Set the taper turning tool with the required angle. Use the compound

slide for making the taper turning operation from face A side till Φ20/ Φ22x20mmlong.

10


Operation

Dimension Side

Tool

C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time

Units mm HSS/CAR

Meters/Min

Mm/rev S x R mm Sec Sec Sec

Grooving Φ18/5 A HSS 15 250 0.1 25 10 24 30+30 84

Knurling Φ30/30 B HSS 20 250 0.1 25 30+30 144 30+30 204

Taper

Tturning

Φ20/ Φ/22 x20

3xpasses

A HSS 16 250 0.1 25 30 3x72

=216

30+30 276




MS Blank

105±1

Φ18x5

Φ30knurling

Φ22/ Φ20

Taper angle

1.8 RESULTS:




1. Why grooving operation is required

2) Calculation of Taper angle.

3) Applications of knurling

1.10 LAB ASSIGNMENT

1. Give the Grooving tool geometry

2. What is the composition of Tool Material? Prepared by P.P.C.Prasad

11



LAB EXERCISE-4-DRILLING, TAPPING AND SQUARE CUTTING

1.1 OBJECTIVE:

Learning the skill in Drilling, Tapping and Square cutting operations to complete

the 3-Jaw Chuck spanner.

1.2 RESOURCES:


1 Drilling Machine 25mm Radial 1

2 Work piece Φ30x100mm MS 1

3 Drill Φ10 HSS 1

4. Tap M5 HSS 1

5 File Medium Carbon Steel 1

5 Spanner Drill chuck Bevel 1


1.3 PRECAUTIONS

a) Check the power connections of Radial Drilling Machine.

b) Ensure the proper clamping of the component in the Radial drilling Vice


Major parts of Radial Drilling Machine: Spindle Head / Arm/Pillar/ Work Vice.

For other details refer the sketch

KINEMATICS: Radial Drilling Machine consists of Tool rotation by spindle & Motor with Morse taper spindle & sleeve adaptors. The Drill head is moved on the arm

and the Radial arm can be adjusted up down (Manual/Power) on the fixed pillar. The drilling operation can be performed with rotating tool and manual feed down

against fixed work piece.

OPERATION: Drilling operation is done by fixing the Drill in Drill Chuck and the morse taper shank is inserted into the spindle. The drill point is adjusted by

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moving uptown and linearly on the arm with rotational adjustment. Power on for

the drilling spindle and feed into the fixed job at the Vice.

Tapping: Manual tapping operation has to be performed with three tap set. The

first Tap is having long chamfer to form the threads of less depth. The second Tap forms the full threads. The third tap gives the finish for the thread formation.

Filling: Filling is a manual operation comes under fitting trade. Many machines

requires manual fitting exercise to get the final required fit for the 3-Jaw square spanner.

Operation Drawing


a) Take the Turned and faced blank Φ30x100mm and clamp in the Vice

b) Fix the Drill Φ10 into the Drill Chuck and fix the Morse taper shank of the Drill chuck into the drilling machine spindle.

c) Set the Drill point at the required position on to the job. Power the

spindle rotation and feed the drill into the work by manual.

d) Unload the component and hold it on the Vice up down and perform the

tapping operation M5 with three manual tap set.

e) Reload the component and do by fitting operation for the square formation at Face A’

f) Insert the Φ10mmxx100mm long MS rod into the Φ10 hole and grub it

with M5x10mm Grub screw.

13



C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time


Drilling Φ10 B HSS 5 250 0.1 60 20 20 30+30 80

Tapping ΦM5 B HSS Manual - - - - 300 30+30 360

Square

filling

11±0.05 A Medium File

Manual - - - - 4X300

=1200

4x30

=120

1320




Φ10

M5

11±0.05

1.8 RESULTS:




1. Give the twist Drill nomenclature and geometry

2) Learn the Process planning

1.10 LAB ASSIGNMENT

1. Importance of fitting and accuracies

2. Tap Drill sizes?

3. Drilling accuracies.

14




LAB EXERCISE-5-FACING,STEP TURNING,GROOVING AND THREAD

CUTTING ON LATHE MACHINE

1.1 OBJECTIVE:

Learning the skill in Facing, Step Turning, Grooving and Thread cutting operations on Lathe Machine

1.2 RESOURCES:



2 Work Piece Φ30X 85mm MS 1

3 Tool Single point HSS/CAR 1

4 Threading Tool Metric HSS 1




1.3 PRECAUTIONS

a) Check the power connections.

b) Clamp the component in Chuck firmly and take out the spanner.





3-Jaw/4Jaw chuck. The single point Tool is clamped in square tool post with carriage having the linear, cross travels.

OPERATION: For Turning and grooving operations follow the previous exercises.

Threading Operation: Threading operation set at low cutting speeds and high feed

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rates equal to pitch of thread/rev. set the feed gears for the given pitch and

engaging the auto feed by half nut lever

Operation Drawing


a) Take the MS blank Φ30x105mm and clamp in the 3Jaw chuck and follow

the previous exercises process procedures for turning & grooving operations.

b) Set the Thread cutting tool (metric) start the spindle rotation and the tool

keep near to the face of the component. Engage the half nut and disengage at the groove. Take back the tool by cross slide and bring back

to the face of the component and set the depth of cut and repeat the operation till to get the full thread formation.



C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time


Facing 87.5 B HSS 20 250 0.1 25 20 48 30+30 108

Turning Φ25 B HSS 20 250 0.1 25 70 168 30 198

Facing 85 A HSS 20 250 0.1 25 20 48 30+30 108

Turning Φ25 A HSS 20 250 0.1 25 40 96 30 126

Turning Φ10 A HSS 24 250 0.1 25 80 192 30 222

Grooving Φ8 A HSS 7 250 0.1 25 20 48 30 78

Threading M10x1.5 A HSS 7.5 250 1.5 375 25 5X4=20 30+30 84

Total Time = 924Sec=~15.4 min 924

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MS Blank

Φ25x85 ±1

85±0.1

Φ25x35±0.1

Φ10x50

Φ8x5

M10X1.5

1.8 RESULTS:



1.9 PRE LAB QUESTIONS:

1. Learn the types of Threads and its applications.

2.How to use the Thread Vernier calipers?

1.10 LAB ASSIGNMENT

1. What is the care to be taken for Thread cutting?

2. What is the geometry of threading tools?


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LAB EXERCISE-6-FACE MILLING OPERATION ON KNEE TYPE MILLING MACHINE

1.1 OBJECTIVE:

Learning the skill of face milling operation for making the Bearing Block housing

part.

1.2 RESOURCES:


1 Milling Machine Medium Knee 1

2 Work Piece 32x32x32mm MS Cube 1

3 Face Mill End Mill HSS/CAR 1

4 Vice 0-200mm flat 1


1.3 PRECAUTIONS


b) Clamp the component in Vice firmly.


d) Set the tool for the given operation


Major parts of Milling Machine: Spindle Head with gear box, Carriage/feed gear box, Bed & Column with guide ways. For other details refer the sketch

KINEMATICS: Knee type Milling machine consists of rotating spindle work/job is

fixed wit a Vice or T-slots on longitudinal table compound table. The table is having linear (feed-x), cross (feed/setting-Y) and up down motions (Depth of cut

setting-Z)

OPERATION: Face milling operation is done by selecting the different face milling cutters/End Mills inserted into the spindle (ISO/Morse taper). Fix the work piece in

the Vice, and set by adjusting Cross table (Y-axis) and the depth of cut by up down (z-axis). Ensure proper setting of the work and tool for the milling operation

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and start the spindle rotation with correct spindle speed. Give the longitudinal feed

(X-axis) Manual/power. After the above operation if the face is not complete again set the cross position of table and repeat the facing operation.

Operation Drawing


a) Take the MS blank Φ32x32x32mm and clamp in the Vice on.

b) Set the table Y &Z and give the manual/power feed to the

longitudinal feed

c) Repeat the setting and operation to complete the face

d) Reload the component for other face milling operation and repeat the

same.



C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time


Facing 31 A Φ32/2th

Car

50 500 0.1 50 50 60 30+30 120

Facing 31 B Φ32/2th

Car

50 500 0.1 50 50 60 30+30 120


19



MS Blank

32x32x32mm

30±0.1

1.8 RESULTS:




1. Learn about types of milling operations

2) Learn the milling tool selection

1.10 LAB ASSIGNMENT

1. Give the tool geometry of milling cutter

2. What is the composition of Work & Tool Materials?


20



LAB EXERCISE-7-BORING OPERATION ON LATHE MACHINE

1.1 OBJECTIVE:

Learning the skill of Boring operation for the Bearing block component on Lathe

Machine

1.2 RESOURCES:



2 Work Piece 32x32x32mm MS 1

3 Boring Tool Single point HSS/CAR 1




1.3 PRECAUTIONS

j) Check the power connections.

k) Clamp the component in Chuck firmly and take out the spanner.

l) Select the required cutting parameters

m) Set the tool & tool post for the given operation


Major parts of Lathe Machine: Head stock/ spindle with gear box, Tail stock,

Carriage/feed gear box, Bed with guide ways. For other details refer the sketch

KINEMATICS: Engine Lathe consists of work/job rotation by spindle & Motor with 3-Jaw/4Jaw chuck. The single point Boring Tool is clamped in square tool post with

carriage having the linear, cross travels.

OPERATION: Boring operation is done by selecting the single point Boring tool (HSS/Carbide) for the given work material. The selection of spindle RPM/Cutting

speed and manual/auto longitudinal feed for the tool. The Boring operation is carried out with a pre Drill hole (Ref: previous exercises for drilling operation)

21

Operation Drawing


a) Take the Milled cube 30x30x30mm and clamp in the4Jaw chuck and

average the center of component.

b) Face side B’ with skin cut & center drill and enlarge the hole to Φ25thro’

c) Clamp the boring tool in the tool post and set in to the Φ25hole and set

the depth of cut 0.1mm by moving the cross slide do the boring operation with carriage longitudinal feed. Carefully perform the boring operation till

the Φ26K7x10mm deep.

d) Reload the component for Face A’ Boring operation Φ26K7x10mm



C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time


Facing 30mm B HSS 20 250 0.1 25 20 48 60 108

C.Drilling Φ2.5 B HSS 3 250 0.1 25 5 12 60 72

Drilling Φ12thro B HSS 10 250 0.1 25 40 96 60 156

Drilling Φ25thro B HSS 20 250 0.1 25 40 96 60 156

Boring Φ26 B HSS 20 250 0.1 25 3x15 108 120 228

Boring Φ26 A HSS 20 250 0.1 25 3x15 108 120 228

Total Time =948Sec=~16 min 948

22



MS Blank

30x30x30

Φ25H13 Thro’

Φ26K7x10

Φ26K7x10

1.8 RESULTS:




1. Learn the use of Component averaging in 4-Jaw Chuck

2) Learn the limitations of Boring operation

1.10 LAB ASSIGNMENT

1. What is the importance of Boring accuracies?

2. Give the Boring tool geometry


23



LAB EXERCISE-8-SHAPING OPERATION ON SHAPER

1.1 OBJECTIVE:

Learning the skill of shaping operation for making the Bearing Block housing part.

1.2 RESOURCES:


1 Shaper Machine Medium Horizantal 1


3 Tool Single point HSS 1



1.3 PRECAUTIONS

e) Check the power connections.

f) Clamp the component in Vice firmly.

g) Select the required cutting parameters

h) Set the tool for the given operation


Major parts of Shaping Machine: Ram head with quick return mechanism, gear box, cross feed mechanism, work holding vice with compound table adjustment.

For other details refer the sketch.

KINEMATICS: Horizontal Shaping Machine consists of linear motion (feed-X) Ram head with quick return mechanism is the major part of cutting action. The tool is

held in the tool post having the facility for vertical (depth of cut), and linear stroke positional adjustments. The work is held with a heavy duty vice having cross

indexing synchronized mechanism with ram movement. The component is firmly held in the vice having the positional adjustments both vertical (Z) and cross(Y)

axes.

OPERATION: Shaping machine is mainly used for prismatic components for plain surface machining, external chamfering, slotting operations etc.The job is

24

stationary and the tool generates by linear movement of ram. At the end of the

ram stroke the job is indexed automatically.

Operation Drawing


SHAPING:

a) Take the MS blank Φ30x30x30mm and clamp in the Vice. Set the required tool stroke and cross indexing auto mechanism.

b) Set the work table Y &Z and give the power feed to the Ram head

c) Give the depth of cut for the tool till the operation completed.

d)Set the component for other face operation/ chamfering/ slotting etc.


Operation D-Dimension

Side Tool

C-Cutting

Speed

Stroke length

S-cross Feed/stk

N-No of strokes

Time

Nx60/C

Tool&Job setting

Time

Units mm HSS/CAR strokes/Min mm Mm/stroke D/S Sec Sec Sec

Facing 30 A HSS 50 50 0.1 300 360 60+60 480

CHF 2x450 B HSS 50 50 0.1 20 24 30+30 84

Total Time =564 Sec=~ 9.4 min 564

25



MS Blank

30x30x30mm

30x30x30

2x450

1.8 RESULTS:




1. Give the difference between Shaping, Palnning & Milling operations

2) Learn about Quick return mechanism

1.10 LAB ASSIGNMENT

1. What is the difference between single point tools & multi point tools?

2. What is the composition of Work & Tool Materials?


26



LAB EXERCISE-9 SLOTTING OPERATION ON SLOTTING MACHINE

1.1 OBJECTIVE:

Learning the skill of Slotting operation for making the Bearing Block housing part.

1.2 RESOURCES:


1 Slotting Machine Medium Vertical





1.3 PRECAUTIONS

i) Check the power connections.

j) Clamp the component in Vice firmly.

k) Select the required cutting parameters

l) Set the tool for the given operation


Major parts of Slotting Machine: Vertical Ram head with quick return mechanism, gear box, work holding vice with compound table adjustment. For

other details refer the sketch.

KINEMATICS: Vertical Slotting Machine consists of linear motion (feed) with quick return mechanism, against a fixed work piece. The work is held in a vice/

indexing table/T-slot compound table with strap clamps. The work is moved for depth of cut.

OPERATION: Slotting operation is mainly used for Key ways on gears and

shafts.The job is stationary and the tool generates by linear movement of ram.

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Operation Drawing


SLOTTING:

a) Take the MS blank Φ30x30x30mm and clamp in the Vice. Set the

required tool stroke.

b)Set the work table Y &Z and give the power feed to the Ram head


d) Set the component for other face operation/ chamfering/ slotting

etc.


Operation D-Dimension

Side Tool

C-Cutting

Speed

Stroke length

S-cross Feed/stk

N-No of strokes

Time

Nx60/C

Tool&Job setting

Time

Units mm HSS/CAR strokes/Min mm Mm/stroke D/S Sec Sec Sec

Slot 2x4 A 4mm/HSS 50 50 0.1 20 24 60+60 144

Total Time =144 Sec=~ 2.4 min 144



MS Blank

30x30x30mm

2x4±0.1

28

1.8 RESULTS:




1. Explain the crank mechanism of Slotting machine

2) Explain the applications of slotting operations.

1.10 LAB ASSIGNMENT

1. Types of slotting operations.

2. Key way accuracies


29



LAB EXERCISE-10-SURFACE GRINDING OPERATION ON SURFACE GRINDING MACHINE

1.1 OBJECTIVE:

Learning the skill of Shaping & Slotting operations for making the Bearing Block

housing part.

1.2 RESOURCES:


1 Surface grinding Machine Medium Horizontal 1


3 Tool Grinding wheel AL2O3 1

4 chuck 0-200mm Magnetic 1


1.3 PRECAUTIONS

m) Check the power connections.

n) Clamp the component in Vice firmly.

o) Select the required cutting parameters

p) Set the tool for the given operation


Major parts of Surface GRINDING Machine: Grinding Spindle headwork holding magnetic Chuck with compound table for longitudinal (X) feed and cross

setting(Y). Vertical fine adjustment of compound slide (Z). For other details refer the sketch.

KINEMATICS: Horizontal Surface Grinding Machine consists of high speed

rotational Grinding wheel. Component held with magnetic chuck having the linear motion (feed-X). The compound slide is set for cross and up down adjustment by

manually operated wheels.

OPERATION: Grinding operation is one of the finishing operations to correct the geometrical and size inaccuracies and surface roughness.

30

Grinding machine is mainly used for prismatic components for plain surface

finishing machining, The Grinding wheel rotates with high speed and the job is generates the surface by linear movement (X). At the end of the Slide stroke set

the component for next stroke by moving the cross slide. The fine up down adjustment is used for the depth of cut(Maximum 10µ only).

Operation Drawing


SURFACE GRINDING:

a) Take the MS blank Φ30x30x30mm and clamp in the Magnetic

chuck. Set the depth of cut 5µ to 10µ.

b) Slide the table to and fro for two times and set the cross table movement for second cut and repeat the grinding operation.

c) Cover the entire surface for the given depth of cut and set the

depth of cut and repeat the process till we get complete surface for the required surface finish.

d) Reload the other surface and repeat the process


Operation

Dimension

Side

Tool

C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool Job setting

Time

Units mm HSS/CAR Meters/Min


Surface grinding

30±0.01 A Φ250Al2O3

2500 3000

0.01 25 20x50=

240 30+30

300

31

1000

Surface grinding

30±0.01 B Φ250Al2O3

2500 3000

0.01 25 20x50=

1000

240 30+30

300



Dimension&Tool Reading-1 Reading2 Reading3 Average Remark

MS Blank

30x30x30mm

30±0.01

Surface

finish6.3Ra

1.8 RESULTS:




1. Types of grinding operations

2) What is the nomenclature of grinding wheels?

1.10 LAB ASSIGNMENT

1. Grinding accuracies

2. Types of grinding wheels?


32



LAB EXERCISE-11-CYLINDRICAL GRINDING OPERATION ON CYLINDRICAL GRINDING MACHINE

1.1 OBJECTIVE:

Learning the skill of Cylindrical grinding operation

1.2 RESOURCES:


1 Cylindrical grinding Machine Medium Horizontal 1

2 Work Piece Φ25x85mm MS 1

3 Tool Grinding wheel AL2O3 1

4 Center 0-200mm Dead 1


1.3 PRECAUTIONS

q) Check the power connections.

r) Insert the component between the dead centers.

s) Select the required cutting parameters

t) Set the tool for the given operation


Major parts of Cylindrical GRINDING Machine: Grinding Spindle, Table with

dead centers, longitudinal (X) feed, Cross movement for setting the depth of cut(Y)

KINEMATICS: Horizontal Cylindrical Grinding Machine consists of high speed

rotational Grinding wheel. Component held between the centers and rotates by the friction of Grinding wheel rotation,

OPERATION: Grinding operation is one of the finishing operations to correct the

geometrical and size inaccuracies and surface roughness. The Cylindrical grinding is performed for the generation of cylindrical surfaces. Cylindrical grinding can able

to generate accurate surfaces in comparison with Center less Grinder. Generally Spindles are performed to mount them in the bearings.

33

Mount the Component between the centers and move linearly against the rotating

high speed cylindrical grinding wheel.

Operation Drawing


SURFACE GRINDING:

a) Take the MS blank Φ25x85mm and insert between the centers

Set the depth of cut 5µ pressure with the Grinding wheel.

b) Slide the table to and fro for the operation and repeat the grinding operation by increasing the depth of cut till the diameter

10h4 achieves.


Operation Dimension

Side

Tool

C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time

Units mm HSS/CAR

Meters/Min


Cylindrical grinding

Φ10h4 A Φ250

Al2O3

Total Time = Sec=~ min

34


Dimension&Tool Reading-1 Reading2 Reading3 Average Remark

MS Blank Φ25x85mm

Φ10h4

Surface

finish6.3Ra

1.8 RESULTS:




1. Learn about Cylindrical Grinding operation

2) Learn about Centerless Grinding operation

1.10 LAB ASSIGNMENT

1. Grinding accuracies

2. Types of grinding wheels?


35



LAB EXERCISE-12-PLANING OPERATION ON PLANER

1.1 OBJECTIVE:

Learning the skill of planning operations.

1.2 RESOURCES:


1 planner Machine 41/2 Horizantal 1





1.3 PRECAUTIONS


b) Clamp the component in Vice firmly.


d) Set the tool for the given operation


Major parts of Shaping Machine: Tool post, over arm bridge, columns, 41/2’ mechanical feed table. For other details refer the sketch.

KINEMATICS: Horizontal Planner machine consists of adjustable (vertically &

horizontally) tool post. The component is firmly held on the planner table. The table feed is by a rack and pinion mechanism with heavy duty gear box & 3Hp

motor. The dual feed drive for vertical movement of the over arm bridge on the dual columns.

OPERATION: Generally planning operation is conducted for longer components.

The latest developments are planomilling operations with an attachment. Planning operation is done with single point tool on the prismatic components, saddles,floor

plates, guide ways, etc.

36

Operation Drawing


SHAPING:

a) Take the MS blank Φ30x30x30mm and clamp in the Vice. Set the

required tool stroke and cross indexing auto mechanism.

b) Set the component on work table and give the feed.


d) Set the component for other face operation/ chamfering/ slotting etc.


Operation

Dimension

Side

Tool

C-Cutting

Speed

S-Stroke length

S-index FM-mm/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time

Units mm HSS/CAR

strokes/Min

mm Mm/stroke

S x R mm Sec Sec Sec

Planning 30mm A HSS

Total Time =Sec=~ min



MS Blank

32x32x32mm

30x30

37

1.8 RESULTS:




1. Learn about types planers.

2) What is the importance of Quick return mechanism?

1.10 LAB ASSIGNMENT

1. Rack and pinion mechanism

2. Plano milling?


38



LAB EXERCISE-13-RE SHARPENING THE TWIST DRILL ON

TOOL & CUTTER GRINDER

1.1 OBJECTIVE:

Learning the skill in re sharpening of twist drill.

1.2 RESOURCES:


1 Tool & Cutter Grinder Medium Floor 1

3 Twist Drill Φ10 HSS 1

6 Tool makers microscope medium optical 1

1.3 PRECAUTIONS

e) Check the power connections of Tool & cutter Grinder

f) Ensure the proper clamping of the drill in the Vice


Major parts of Tool & Cutter Grinder: Spindle Head with grinding wheel / Compound slide/ work holder / twist drill. For other details refer the sketch

KINEMATICS: The grinding wheel rotates at high speeds with spindle & Motor.

The Drill is set with required angles on the compound slide.

OPERATION: Set the face of the twist drill point angle (1180) and do the re sharpening by grinding wheel and set the other face and repeat the grinding

operation

Operation Drawing

39


g) Take the twist drill and fix it in the vice.

h) Set the face with point angle (1180)

i) Grind the flank face till to get sharp edge of flute

j) Set the face other face with point angle (1180)

k) Grind the flank face till to get sharp edge of flute


Operation Dimension

Side

Tool

C-Cutting

Speed

R

RPM

S-Feed/rev

FM-Feed/Min

T-Tool travel

Time

Tx60/FM

Tool&Job setting

Time

Units mm HSS/CAR

Meters/Min


Re sharpening of twist drillDrilling

Φ10x1180 A HSS 900 3000

0.05 150 8 4 30+30 64

Φ10x1180 B HSS 900 3000

0.05 150 8 4 30+30 64

Total Time = 128 Sec=~2.1 min 128



Φ10x1180

1.8 RESULTS:



40


1. Give the twist Drill nomenclature and geometry

2) Learn tool and cutter grinder setting

1.10 LAB ASSIGNMENT

1. Blunt tool analysis

2. Tap Drill sizes?

3. Drilling accuracies.


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