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Manufacturing Technology - I
Manufacturing Technology - I
Manufacturing Technology - I
LABORATORY RECORD
Name
: ______________________________
Register No.
: ______________________________
Branch
: ______________________________
Semester
: ______________________________
DEPARTMENT OF
Faculty In-charge
Internal Examiner
External Examiner
SYLLABUS
ME6311
LTPC
0032
OBJECTIVE
To study and practice the various operations that can be performed in lathe, shaper,
drilling, milling machines etc., and to equip with the practical knowledge required in the
core industries
LIST OF EXPERIMENTS
Machining and Machining time estimations for :
1. Taper Turning
2. External Thread cutting
3. Internal Thread Cutting
4. Eccentric Turning
5. Knurling
6. Square Head Shaping
7. Hexagonal Head Shaping
INDEX
EX.NO
DATE
NAME OF EXPERIMENT
MARK
SIGNATURE
Study of LATHE
INTRODUCTION:
Lathe is the father of all machine tool. It is a basic machine tool probably the
most important one of all, lathe was actually the first machine tool.
Lathe is a particular type of machine tool in which the work is held and rotated
against a suitable cutting tool for the purpose of producing surface of revolution in
any material.
LATHE SPECIFICATIONS:
In order to specify a lathe, a number of parameters could be used on the
specific applications. However, the major elements used for specifications should
invariably be based on the components that would be manufactured in the lathe.
The sum of lathe specifications is,
L=Distance between centers.
A=Swing diameter over bed.
B=Swing diameter over carriage.
R=Radius.
H=Height of center from bed
Distance between Centers (L):
This would be specifying the maximum length of the job that can be turned in
the lathe.
Swing Diameter over Bed (A):
This specifies the maximum diameter of the job that can be turned in the lathe
machine generally restricted to small length jobs.
Swing Diameter over Carriage (B):
This specifies the maximum diameter of job that can be turned in the lathe
machines with the job across the cross slide.
Other factors should also be specified to fully describe the lathe machine.
1. Horse power of the motor
2. Feed range
3. Accuracy achieved
4. Cutting speed range
5. Screw cutting capacity
6. Spindle nose diameter
PARTS OF ENGINE LATHE OR CENTER LATHE:
The principal parts of an engine lathe are,
1. Bed,
2. Head stock,
3. Tail stock,
4. Carriage,
4.1. Saddle,
4.2. Cross slide,
4.3. Compound rest,
4.4. Tool post,
4.5. Apron.
5. Feed Mechanism,
6. Thread cutting mechanism.
Carriers and Catch Plates:
Carriers and catch plates are used to drive a work piece when it is held between
two centers. Carriers or driving dogs are attached to the end of the work piece by a
setscrew, and catch plates are either screwed or bolted to the nose of the headstock
spindle.
Chuck:
A chuck is one of the most important devices for holding and rotating a piece of
work in a lathe. Work piece of short length, and large diameter or irregular shapes,
which cannot be conveniently mounted between centers, are held quickly and rigidly in
a chuck.
Types of chucks:
1.
2.
3.
4.
5.
6.
Face Plate:
A faceplate consists of a circular disk bored out and threaded to fit the nose of
the lathe spindle. This has the radial, plain and T slots for holding work by bolts and
clamps.
Angle plate:
This is a cast iron plate having two faces machined to make them absolutely at
right angles to each other. Holes and slots are provided on both faces so that it may be
clamped on a faceplate and can hold the work piece on the face by bolts and clamps.
Mandrels:
A mandrel is a device for holding and rotating a hollow piece of work that has
been previously drilled or bored. The work revolves with the mandrel which is mounted
between two centers.
Plain mandrel:
The plain mandrel this type of mandrel is most commonly used in shops and
finds wide application where a large number of identical pieces having standard size
holes are required to be mounted on it.
Step mandrel:
A step mandrel having steps of different diameters may be employed to drive
different work pieces having different sizes of holes without replacing the mandrel each
time. This type of mandrel is suitable for turning collars, washers and odd size jobs
used in repairing workshops.
Cooler mandrel:
A cooler mandrel having solid coolers is used for turning work pieces having
holes of larger diameter, usually above 100 mm. This construction reduces weight and
fits better than a solid mandrel of equal size.
Screwed mandrel:
A screwed mandrel is threaded at one end with a collar. Work pieces having
internal threads are screwed on to it against the collar for machining.
Cone mandrel:
A cone mandrel consists of a solid attached to the one end of the
body, and a sliding cone, which can be adjusted by turning a nut at a threaded end.
Gang mandrel:
This has a fixed collar at one end and a movable collar at the threaded end,
which may be adjusted, to this position by a nut. The mandrel is used to hole a set of
hollow work piece between two collars by tightening the nut.
Expansion mandrel:
There are different types of expansion mandrels. The mandrel consists of
tapered pin, which is driven into a sleeve that is parallel outside and tapered inside the
sleeve has three longitudinal slots, two of which are cut nearly through, and the third
splits it completely.
Rests:
A rest is a mechanical device which supports a long slender work piece, which is
turned between centers or by a clutch, at some intermediate point to prevent bending
of the work piece due to its own weight and vibrations set up due to the cutting force
that acts on it.
Steady rest:
A steady rest shown in Fig consists of a cast iron base, which may be made to
slide on the loath bed ways and clamped at any desired position where a support is
necessary.
Follower rest:
A follower rest consists of a C like casting two adjustable jaws which support
the work piece. The rest is bolted to the back end of the carriage and moves with it.
TYPES OF LATHE:
1.
Speed lathe
a. Woodworking
b. Centering
c. Polishing
d. Spinning
2. Engine lathe
a. Belt drive
b .Individual motor drive
c. Gear head lathe
3. Bench lathe
4. Tool room lathe
5. Capstan and turret lathe
6. Special purpose
a. Wheel lathe
b. T. Lathe
c. Gap. Bed lathe
d. Duplicating lathe
7. Automatic lathe
ii.
iii.
iv.
v.
THREAD CUTTING:
LATHE EXERCISES
Ex. No:
Date:
AIM:
To obtain the required shape and size of the work piece by turning and facing
operation.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter _______mm and length_________ mm mild
steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece
3. Tool setting
4. Facing
5. Turning
6. Chamfering
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the job
firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts
using spanner.
4. Facing is done with cutting tool moving from the centre of work piece
towards outside. It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cit is
given and it is done until the required diameter of the job is obtained.
6. Finally the dimension of work piece is again checked.
RESULT:
Thus the required size and shape of the given work piece is obtained.
ECCENTRIC TURNING
Ex. No:
Date:
AIM:
To obtain the required shape and size of the work piece by turning and facing
operation.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter _______mm and length_________ mm mild
steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece
3. Tool setting
4. Facing
5. Turning
6. Chamfering
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the job
firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts
using spanner.
4. Facing is done with cutting tool moving from the center of work piece
towards outside. It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is
given and it is done until the required diameter of the job is obtained.
6. Finally the dimension of work piece is again checked.
RESULT:
Thus the required size and shape of the given work piece is obtained.
Ex. No:
Date:
AIM:
To obtain the required shape and size of the work piece by turning and facing
operation.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter _______mm and length_________ mm mild
steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece
3. Tool setting
4. Facing
5. Turning
6. Chamfering
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the job
firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts
using spanner.
4. Facing is done with cutting tool moving from the center of work piece
towards outside. It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is
given and it is done until the required diameter of the job is obtained.
6. Finally the dimension of work piece is again checked.
RESULT:
Thus the required size and shape of the given work piece is obtained.
Date:
AIM:
To obtain the required shape and size of the work piece by step turning and
knurling.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter________ mm and length__________mm mild
steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
7. Knurling tool
SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Turning
6. Knurling
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the job
firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts
using spanner.
4. Facing is done with cutting tool moving from the centre of work piece
towards outside. It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cit is
given and it is done until the required diameter of the job is obtained.
6. Fix the knurling tool in the tool post.
7. Move the carriage outward, and then move it longitudinally, and give a small
cross feed. Repeat this step until knurling of required length is done.
8. Finally the dimension of work piece is again checked.
RESULT:
Thus the required size and shape of the given work piece is obtained.
Date:
AIM:
To obtain the required shape and size of the work piece by taper turning
operation using compound method.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_________mm and length_________ mm mild
steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Turning
6. Taper turning
WORKING STEPS:
Taper turning:
The angle is determined by using the formula,
Tan = (D-d)/2L
Where,
D=Larger diameter of the work piece
d=smaller dia of the work piece
L=taper length of the work piece
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly,
ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts using Tool
post key.
4. Facing is done with cutting tool moving from the centre of work piece towards
outside. It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cit is given
and it is done until the required diameter of the job is obtained.
6. Next step taper turning is done on the work piece, as per the taper angle already
calculated. Then the compound rest base is swiveled and set at half taper angle.
Cutting tool is moved at an angle to the lathe axis. Tool is moved by the compound
rest hand wheel.
7. For chamfering to be done at the end of the work piece, the tool is held at 450 to
the lathe axis and is fed against the rotating work spice.
8. Finally the dimension of work piece is again checked.
RESULT:
Thus the required size and shape of the given work piece is obtained.
Date:
AIM:
To obtain the required shape and size of the work piece by turning and thread
cutting.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_________mm and length___________mm
mild steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Turning
6. Chamfering
7. Thread cutting.
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the job
firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts
using spanner.
4. Facing is done with cutting tool moving from the centre of work piece
towards outside. It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cit is
given and it is done until the required diameter of the job is obtained.
6. For chamfering to be done at the end of the work piece, the tool is held at
450 to the lathe axis and is fed against the rotating work spice.
7. The cutting tool in the tool post is taken out. Thread cutting tool is held in the
tool post and tightened the nuts.
8. For right hand thread the lead screw rotates in clock wise direction and for
left thread, it rotates in anti clock wise direction. The carriage is engaged to
lead screw and automatic feed is given.
9. Suitable depth is given and thread is cut on the work spice.
10. Finally the dimension of work piece and pitch of the thread are again
checked.
RESULT:
Thus the required size and shape of the given work piece is obtained.
Date:
AIM:
To obtain the required shape and size of the work piece by Facing, plain turning,
Boring and internal threading.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_______ mm and length_______ mm mild
steel rod.
TOOLS REQUIRED:
1. Lathe
2. Cutting tool
3. Vernier caliper
4. Try square
5. Scriber
6. Vernier height gauge
7. Boring tool and internal thread cutting tool.
SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Turning
6. Boring
7. Thread cutting.
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the job
firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts
using spanner.
4. Facing is done with cutting tool moving from the centre of work piece
towards outside. It is one until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cit is
given and it is done until the required diameter of the job is obtained.
6. Fix the boring tool in the tail stock.
7. Slowly given the feed by rotating the wheel in the tailstock which moves the
tool longitudinally to producing a boring.
8. Fix the internal threading tool, to cut the internal thread.
9. Finally the dimension of work piece is again checked.
RESULT:
Thus the required size and shape of the given work piece is obtained.
Study of shaper
INTRODUCTION:
The shaper is a reciprocating type of machine tool used to produce
flat surface. The surface may be horizontal, vertical or inclined. Modern shaper can
generate contoured surfaces also. The metal working shaper was developed in the year
1836 by James Nesmyth an English man.
Purposes of the shaping machines are as follows:
The main purpose of shaping machine is to machine plane horizontal surface.
It is possible to form vertical and angular surfaces also. With proper tools and
accessories even irregular surfaces can be formed.
Working Principle.
The job is rigidly fixed on the machine table. The single point cutting tool held properly
in the tool post is mounted on a reciprocating ram. The reciprocating motion of the ram
is obtained by a quick return motion mechanism. As the ram reciprocates, the tool cuts
the material during its forward stroke. During return, there is no cutting action and this
stroke is called the idle stroke. The forward and return strokes constitute one operating
cycle of the shaper.
Types of Shaper.
Shapers are classified as follows:
Ram:
Ram carries the tool head at its flank end. Ram reciprocates on the guide ways. It is
connected to the quick return mechanism; stroke of ram can be adjusted by hand
wheel at the top.
Tool head:
Vertical and angular feed can be given to the tool head, the slide can be moved
vertically by rotating down feed screw. There is swivel base for the tool head graduated
in degrees the tool can be swivelled to any required angle. Apron can be titled to the
right or left and clamped in that position. A tool block is hinged inside the box and is
rigidly placed inside the clapper box. During the return stroke the tool block lifts out of
clapper box. This prevents the rubbing of the tool on the job.
SHAPER EXERCISES
Date:
AIM:
To shape the given work piece to the given shape and dimension.
Machine:
Shaping machine (12" stroke)
Cutting Tools:
Single point cutting tool, Parting tool
Measuring and Marking tools:
Steel rule
Scriber
Divider
Spirit Level
Vernier caliper
Punch
Hammer
Work Piece:
Cast Iron Block
Work holding Device:
Machine vice, V- Block
Working steps:
Measure the work piece for its initial dimension.
Set the work piece on machine vice with V- block
Fix the cutting tool on tool holder.
Move cutting tool to the work piece to set the initial zero of the feed.
Take the work piece out of the machine vice and mark the dimension on the
work piece to the appropriate dimensions using proper measuring tools.
Fix the parting tool according to the marking.
Give the feed in smaller graduation until the entire groove is made.
Result
Thus the given work piece is shaped to the given dimensions is made.
Introduction:
Milling is the cutting operation that removes metal by feeding the work against a
rotating, cutter having single or multiple cutting edges. Flat or curved surfaces of many
shapes can be machined by milling with good finish and accuracy. A milling machine
may also be used for drilling, slotting, making a circular profile and gear cutting by
having suitable attachments.
The milling machine is classified as follows:
I. Column and knee type:1. Plain milling machine
2. Universal milling machine
3. Omuniversal milling machine
4. Vertical milling machine
II. Planomiller
III. Fixed bed type milling machine
IV. Special type:
1. Rotary table milling machine,
2. Drum type milling machine,
3. Planetary milling machine,
4. Pantograph milling machine.
Milling Machine Construction:
The main part of machine is base, Column, Knee, Saddle, Table, Overarm, Arbor
Support and Elevating Screw.
Base: It gives support and rigidity to the machine and also acts as a reservoir for the
cutting fluids.
Column: The column is the main supporting frame mounted vertically on the base. The
column is box shaped, heavily ribbed inside and houses all the driving mechanisms for
the spindle and table feed.
Knee: The knee is a rigid casting mounted on the front face of the column. The knee
moves vertically along the guide ways and this movement enables to adjust the
distance between the cutter and the job mounted on the table. The adjustment is
obtained manually or automatically by operating the elevating screw provided below the
knee.
Saddle: The saddle rests on the knee and constitutes the intermediate part between
the knee and the table. The saddle moves transversely, i.e., crosswise (in or out) on
guide ways provided on the knee.
Table: The table rests on guide ways in the saddle and provides support to the work.
The table is made of cast iron, its top surface is accurately machined and carriers Tslots which accommodate the clamping bolt for fixing the work. The worktable and
hence the job fitted on it is given motions in three directions:
a). Vertical (up and down) movement provided by raising or lowering the knee.
b). Cross (in or out) or transverse motion provided by moving the saddle in
relation to knee.
c). Longitudinal (back and forth) motion provided by hand wheel fitted on the
side of feed screw.
In addition to the above motions, the table of a universal milling machine can be
swiveled 45 to either side of the centre line and thus fed at an angle to the spindle.
Overarm: The Overarm is mounted at the top of the column and is guided in perfect
alignment by the machined surfaces. The Overarm is the support for the arbor.
Arbor support: The arbor support is fitted to the Overarm and can be clamped at any
location on the Overarm. Its function is to align and support various arbors. The arbor
is a machined shaft that holds and drives the cutters.
Elevating screw: The upward and downward movement to the knee and the table is
given by the elevating screw that is operated by hand or an automatic feed.
MILLING EXERCISES
Date:
AIM:
To machine the hexagonal surface on the given block using horizontal milling
machine.
Machine:
Horizontal milling machine
Cutting tools:
Milling Cutter
Measuring and Marking tools:
Steel rule
Scriber
Divider
Verniercaliper
Punch
Hammer
Work Piece:
CI Round block (100, thickness35mm)
Work Holding Device:
Machine vice
Tool Holding Device:
Indexing Chuck
Procedure:
The given workpieceis checked for its initial dimensions.
The width across the flat is first determined (Across flat = 1.5 S + 3 mm)
A universal dividing head is mounted on the table with its spindle swivelled to
the horizontal position.
The workpiece is mounted at the nose of the dividing head spindle by the help
of a suitable chuck.
The workpiece is centered below the cutter and the first cut is taken.
The workpiece is rotated through one sixth of a revolution by using the
indexing mechanism and then the second cut is taken. It is to be repeated for
six numbers of times to finish six faces of the work piece.
Calculation:
Diameter, D
Depth of cut
2xS
(1.5 x S) + 3mm
Indexing calculation:
For Hexagonal surface,
The number of faces, Z = 6.
Simple Indexing
Result:
Thus the required hexagonal surface is milled using the horizontal milling
machine.