VSA SCHOLL OF ENGINEERING

MANUFACTURING TECHNOLOGY II LABORATORY MANUAL

IV SEMESTER MECHANICAL ENGINEERING

Name of the student: ______________________________________________ Register Number : ______________________________________________

INDEX Ex. No 1 2 3 4 5 6 7 8 9 10 11 12 Date Name of the experiment

Shaping of Round Job to Square Shaping of Dovetail Joint Internal keyway cutting using Slotter Planing of Round Job to Square Drilling and Taping Gear Milling Keyway Milling Milling of Round Job to Square Surface Grinding Cylindrical Grinding Multiple Machining Assembly of Parts

Page No

Marks Obtained

Staff signature

Remarks

Exp. No: 1 Date AIM: :

Shaping of Round Job to Square

To study the construction of a shaping machine and to shape the given round MS raw material into a square as per given dimension. REQUIREMENTS: 1. Shaping Machine 2. Polished HSS tool. 3. Raw Material 50 x 50mm Mild Steel Rod. 4. Marking gauge. 5. Try square. 6. Steel rule. 7. Tool holder. CONSTRUCTION OF A SHAPING MACHINE:
Mechanical shaping machines consist of the following major components: 1 - machine column (frame) 2 - main gearing (gear train and oscillating slider crank mechanism) 3 - ram 4 - ram head with tool slide and tool post 5 - machine table 6 - saddle 7 - table support 8 - drive (electro-motor)

PROCEDURE: 1. The maximum square dimension is marked on the job using scriber steel rule on the diameter of the work piece. 2. The markings are punched by using punch hammer. 3. The work piece is clamped on the vice which is on the shaper table such that the marking is parallel to the table surface. 4. The tool holder with the tool is fixed rigidly on the clapper box. 5. The stroke length of the ram is adjusted to our requirements by using hand wheel. 6. First roughing cut is given and the feed is given when the tool return back.

Raw material

7. Depth of the cut for rough and finish is given by the movement of the tool post from top to bottom. 8. Finally finishing cut is given when a small amount of material is left to reach the finish marking. RESULT: Thus the shape the given round raw material into a square as per given dimension is done.

Raw Material

Finished work piece

Exp. No: 2 Date AIM: :

Shaping of Dovetail Joint

To shape the given square MS raw material into a dovetail shape as per given dimension. REQUIREMENTS: 1. Shaping Machine 2. Tool holder. 3. Polished HSS tool. 4. Raw Material - 50 x 50mm Mild Steel Square Rod 5. Marking gauge. 6. Try square. 7. Steel rule. PROCEDURE: 1. The dovetail shape is marked on the job using scriber steel rule on the face of the square work piece. 2. The markings are punched by using punch hammer. 3. The work piece is clamped on the vice which is on the shaper table such that the horizontal marking is parallel to the table surface. 4. The tool holder with the tool is fixed rigidly on the clapper box. 5. The stroke length of the ram is adjusted to our requirements by using hand wheel. 6. First roughing cut is given and the feed is given when the tool return back. 7. Depth of the cut for rough and finish is given by the movement of the tool post from top to bottom. 8. Finally finishing cut is given when a small amount of material is left to reach the finish marking. RESULT: Thus the shape of a dovetail is machined from the given square MS raw material as per the given dimension.

Exp. No: 3 Date AIM: :

Internal keyway cutting using Slotter

To study the construction of a slotting machine and to machine an internal keyway to the given dimension using slotter. REQUIREMENTS: 1. Slotter 2. polished HSS tool. 3. Tool holder. 4. Raw Material Dia 2 x 25mm length 5. Marking gauge. 6. Steel rule. 7. Punch CONSTRUCTION OF SLOTTING MACHINE:

PROCEDURE: 1. Take the raw material make a centre punch on the center of the workpiece and mark the required dimensions on the work piece by applying chalk on it. 2. Remove the material by drilling and boring to 1inch diameter at the center. 3. Place the work piece on the slotter table and mount the tool holder on the tool post.

Raw material

Internal drilling & Boring

Keyway cutting shown in shaded potion

Finished part

4. The work piece is fixed in the table such that the tool holder can pass through the 1 inch diameter hole created 5. Place the tool on the tool holder and roll the ram to see that the tool touches the internal diameter phase. 6. Mark on the work piece the shape of the keyway. 7. Now switch on the motor such that the ram reciprocates to top and bottom. 8. For every cut the feed is given with the help of the horizontal movement movement of the table. 9. Repeat the operation until the required keyway is machined. RESULT: Thus the machining of the internal keyway in a slotter is done to the given dimensions.

Exp. No: 4 Date AIM: :

Planing of Round Job to Square

To study the construction of a planing machine and to shape the given round MS raw material into a square as per given dimension. REQUIREMENTS: 1. Planing Machine 2. Tool holder. 3. Polished HSS tool. 4. Raw Material 75 x 75mm Mild Steel Rod. 5. Marking gauge. 6. Try square & Scriber. 7. Steel rule. CONSTRUCTION OF A PLANING MACHINE:

PROCEDURE: 1. The maximum square dimension is marked on the job using scriber steel rule on the diameter of the work piece. 2. The markings are punched by using punch hammer. 3. The work piece is clamped on the vice which is on the planer table such that the marking is parallel surface to the table.

4. 5. Raw material 6. 7.

8. 9.

10.

11. The tool holder with the tool is fixed rigidly on the clapper box of the tool post. 12. The stroke length of the ram is adjusted to our requirements by using hand wheel. 13. First roughing cut is given and the feed is given when the tool return back. 14. Depth of the cut for rough and finish is given by the movement of the tool post from top to bottom. 15. Finally finishing cut is given when a small amount of material is left to reach the finish marking. RESULT: Thus the given round raw material is machined into a square as per given dimension.

Exp. No: 5 Date AIM: :

Drilling and Taping

To study the construction of a drilling machine and to perform an operation of drilling, reaming, and tapping in the given work piece. REQUIREMENTS: 1. Drilling Machine 2. Drill bit 12mm 3. Reamer 12 mm 4. Tap set M12 & coconut oil as coolant. 5. Raw Material 100 x 50 x 6mm MS plate. 6. Scriber & Steel rule 7. Centre punch CONSTRUCTION OF A RADIAL DRILLING MACHINE

PROCEDURE: DRILLING 1. The markings as per the given drawing are done on the raw material using scriber and steel rule. 2. Center punch is used to produce an identification of the centre where the holes have to be drilled and a circle of the given size is marked on the raw material using divider. 3. The drill is fixed in the drilling machine and the adjustment of the vice where the raw material is fixed is aligned with the circle previously draw.

Finished piece

4. Now the drilling machine is switched on the hole is made. REAMING: 1. It has multi cutting edge. 2. It cannot originate a hole. 3. The reamer is fixed in the spindle of the drilling machine and soft finishing is made in the work piece. 4. The accurate hole is accepted within 0.0125 mm. TAPPING: 1. It has multi cutting edges. 2. M12 tap is fixed on the spindle of the drilling machine and the spindle speed is adjusted such that it runs in a lesser rpm. 3. Tapping, a hole is slowly done on the reamed hole. This tapping operation can be done by fixing the work piece on the machine vice also. 4. Care should be taken such that the work piece is exactly perpendicular to the tap in the spindle such that the thread formation is done exactly.

RESULT: Thus the operation of drilling, Reaming and tapping are done according to the given dimensions.

Exp. No: 6 Date AIM: :

Gear Milling

To study the construction of a milling machine and to produce the gear from the given work piece by using milling machine. REQUIREMENTS: 1. Universal Milling Machine with Indexing Mechanism and Universal dividing head. 2. Modular cutter 3. Mandrel 4. Turning tool 5. Outside caliper. 6. Spanner set. 7. Steel rule 8. Drill bit 19.5 CONSTRUCTION OF A MILLING MACHINE:

PROCEDURE: 1. The given raw material is held on a lathe in a 3- jaw chuck and facing is done on both sides of the work piece. 2. The work piece is drilled through 19.5 drill bits which is fitted taper of tailstock sleeve. 3. The inner diameter of the work piece is based on single point cutting tool according to the mandrel which direction is same as the size of the vertical gear shaping machine. 4. Then the job is fitted in the mandrel and outer diameter of work piece is turned with single point turning tool. 5. The given gear blank is lined to the required addendum diameter to gear blank. 6. This is held in universal dividing head with mandrel. 7. Indexing calculation are performed and the required size of the hole is selected in the given disc plate. 8. Then the material is removed from the work piece by passing the work piece over the lathe cutter. RESULT: Thus the gear is produced in the work piece using the milling machine.

Exp. No: 7 Date AIM: :

Keyway Milling

To machine a internal keyway of given dimensions in a Vertical milling machine. REQUIREMENTS: 1. Vertical Milling Machine 2. End mill cutter. 3. Raw material 4. Scriber 5. Steel rule PROCEDURE: 1. Take the required piece and check it for the given dimensions. 2. Mark the required dimensions on the work piece by applying chalk on it. 3. Place the work piece horizontally in the vice. 4. Fix the end mill cutter on the vertical milling machine spindle. 5. Raise the table where the work piece is held in the vice such that it reaches nearer to the cutter face. 6. Switch on the spindle and raise the table such that the required depth of cut is given for the first pass. 7. Move the table horizontally such that the feed is given until the marking required for the keyway. 8. Repeat the pass number of times by increasing the depth of cut until the required keyway is cut. RESULT: Thus internal keyway in a milling machine is done to the given dimensions.

Raw material

Exp. No: 8 Date AIM: :

Milling of Round Job to Square

To perform a round to square machining operation to the given dimensions in a Vertical milling machine. REQUIREMENTS: 1. Vertical Milling machine 2. Multi point milling cutter. 3. Raw Material 4. Scriber 5. Steel rule 6. Try square PROCEDURE: 1. Take the required piece and check it for the given dimensions. 2. Mark the required dimensions on the work piece by applying chalk on it. 3. Place the work piece horizontally in the vice. 4. Fix the multi point milling cutter on the vertical milling machine spindle. 5. Raise the table where the work piece is held in the vice such that it reaches nearer to the cutter face. 6. Switch on the spindle and raise the table such that the required depth of cut is given for the first pass. 7. Move the table horizontally such that the feed is given and complete one pass 8. Repeat the pass number of times by increasing the depth of cut until the required marking has been reached. 9. Remove the workpiece from the vice and rotate it to 90 deg to machine the adjacent side. 10. Similarly the operation is repeated on the 4 sides until the required square is achieved. RESULT: Thus the square in a milling machine is done to the given dimensions.

Exp. No: 9 Date AIM: :

Surface Grinding

To perform surface grinding operation on the given work piece for the given dimensions. PRINCIPLE: The principle involved in this process is to make flat surface on the given work piece. The cutter is moved perpendicular to the work piece and the grinding is done. REQUIREMENTS: 1. Grinding Machine 2. Work Piece 100x50x6 mm MS Plate 3. Grinding Wheel CONSTRUCTION OF A GRINDING MACHINE:

PROCEDURE: 1. At first work piece is placed in the magnetic chuck. 2. The work piece should be light weight so that it cannot be removed from the magnetic chuck easily. 3. Various arrangements regarding the positions of work piece is done. 4. Grinding wheel and grinding spindle are kept in position with the work piece. 5. Before switching on the motor, necessary steps should taken. For proper grinding process wheel speed, work speed, transverse speed of the wheel in feed, area of contact is to be noted. 6. While running the area of contact is adjusted accordingly to the spindle in order to remove the surface. 7. It is done slowly to remove the materials on the both sides. 8. In surface grinding the stock removal rate is given by Q = bdy Where RESULT: Thus the surface grinding is done for the given dimensions. d =depth of cut (m) b =width of cut (m) y =work velocity (m/s) q =rate of stroke (m3/s)

Exp. No: 10 Date AIM: :

Cylindrical Grinding

To grind the cylindrical surface of the given materials as per the given dimensions. REQUIREMENTS: 1. Grinding Machine 2. Grinding Wheel 3. Work Piece 4. Steel rule. 5. Outside calipers. 6. Cutting tool. PROCEDURE: 1. 2. The given work piece is first fitted in the chuck of the lathe. By fitting the tool in tool post the work piece will be reduced to given dimensions. 3. 4. First reduce the diameter to 23mm size then reduced the diameter to 15mm and 18mm at the middle. By facing the work piece to the tool work piece is reduced to 70mm. 5. 6. After the preliminary lathe operation, the work piece is held in the ends of the The grinding wheel is turned on and it is moved towards the work piece such that cylindrical grinder. the surfaces of the cylindrical position are grinded to +-0.2mm. RESULT: Thus the required dimension of cylindrical surface is obtained.

Exp. No: 11 Date AIM: :

Multiple Machining using Turret Lathe

To study the construction of a turret lathe and to perform multiple machining operations in a single setup using turret lathe REQUIREMENTS: 1. Turret Lathe 2. Work Piece 3. Steel rule. 4. Cutting tools RH Cutting Tool, drill bit, Boring tool, Parting tool CONSTRUCTION OF A TURRET LATHE

PROCEDURE: 1. The given work piece is first fitted in the chuck of the lathe. 2. The various tools like drill bit, right hand tool, boring tool, parting off tool is fixed in the turret of the machine in due alignment with the workpiece. 3. First the right hand tools is indexed to be in position with the work piece and facing, turning operations are carried out. 4. After the operation is over the drill bit fixed in the turret is indexed to the position and the drilling operation is performed. 5. After the drilling operation similarly the boring tool is indexed to the position to bore the drilled hole and finish to size. 6. Finally, Parting tool is indexed to the position and the required bush piece is parted off. RESULT: Thus multiple machining operations is carried out in single setup using turret lathe to the required dimensions.

Exp. No: 12 Date AIM: :

Assembly of parts

To perform an assembly of parts which are previously machined. REQUIREMENTS: 1. Machined parts 2. Vernier Calipher 3. Vice 4. Hammer PROCEDURE: 1. The machined work pieces are measured using vernier caliphers and their sizes are noted. 2. The internal key way cut work piece from slotter and the external key way cut work piece from the milling machine are joined together by a key. 3. The bush which was prepared from the turret lathe is fitted into one end of the work piece which was assembled previously. 4. The various fit and tolerance values for different types of fits are studied and the corresponding process of machining operations for various fits is studied. RESULT: Thus assembly of various parts which are machined earlier are assembled and various assembly parameters are studied.