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LABORATORY MANUAL MEC224 MECHANICAL ENGINEERING WORKSHOP

TABLE OF CONTENTS S. No. 1 2 3 4 5 6 7 8 Title of the Experiment To perform taper turning using tailstock offset method To make a job of eccentric turning on lathe machine. To make a job with drilling and boring operation on lathe machine To prepare a job on Surface Grinder / Cylindrical Grinder and measure the various parameters of the finished piece. To make a job on lathe machine with internal threading and external threading Exercise on milling machine to produce a spur gear Graph plotting of variation in hardness at different zones of job after welding with TIG and MIG welding To join two metal sheets of 1.5 mm thickness through the spot welding Page No. 3 7 10 14 17 21 24 27

JOB 1:- To perform taper turning using tailstock offset method. MACHINES/EQUIPMENTS/TOOLS USED:MACHINE USED: - Lathe machine MATERIAL USED: - M.S round bar 25mm diameter. TOOLS USED: - Marking block, facing tool, steel rule, vernier calipers and out side caliper. LEARNING OBJECTIVE: - To learn taper turning operation on lathe machine using tail stock offset method

OUTLINE OF PROCEDURE:1. Take a circular bar of diameter 25mm and 65mm length and hold it in 4 jaw chuck. 2. Turn diameter as 22mm and according to dimensions given turn required diameters. 3. For taper turning set the tail stock off-center (adjusting the axis of rotation)

REQUIRED RESULTS:1. To know the nomenclature of single point cutting tool. 2. To analyze the turning operation on lathe machine.

CAUTIONS:1. Do not change the gear while running the machine. 2. Concentrate on job while machining. 3. Do not check the size of job while machine is running. 4. Set the speed as per required. LEARNING OUTCOME:- to be written by the students in 50-70 words.

Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

JOB 2:-To make a job of eccentric turning on lathe machine. MACHINES/EQUIPMENTS/TOOLS USED:- Machine used: - Centre lathe MATERIAL USED: - Mild steel TOOL USED: - Surface gauge, steel foot rule, odd leg calliper, turning tool, smooth file, dot punch LEARNING OBJECTIVE: - To learn eccentric turning on lathe machine.

BEFORE MACHINING

AFTER MACHINING

PROCEDURE:Take MS round piece of 32mm and cut the piece of 62mm. Face & turn the job 30mm &length 60 mm. Now mark the dot punch at the centre of the faced side and paste the chalk on that side and with the help of divider make a circle of 15mm at side of chalk paste. Now hold the job in four jaw chuck lathe for eccentric turning aligns it with help of surface gauge and scribe around the dotted circle. Now turn the work piece at the centre of work piece i.e up to 30mm. SCOPE OF RESULTS TO BE REPORTED:1. To know the operation of eccentric turning on lathe machine. PRECAUTIONS 1. 2. 3. 4. 5. 6. Align the job properly in the 4 jaw chuck. Set the cutting tool in the centre height of job. The depth of cut should be minimum; it should not be more than 0.5 mm. Do not change gear while lathe is running. Lock the compound slide for the threading operations. Clean the machine after the completion of job.

LEARNING OUTCOME:- to be written by the students in 50-70 words.

Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

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JOB3:- To make a job with drilling and boring operation on lathe machine. MACHINES/EQUIPMENTS/TOOLS USED: - Lathe machine MATERIAL USED: - M.S round bar 25mm diameter. TOOLS USED: - Marking block, facing tool, steel rule, vernier calipers, out side caliper, drill (12.7mm), boring bar and depth gauge LEARNING OBJECTIVE: - To learn about drilling and boring operation on lathe machine.

OUTLINE PROCEDURE:1. Hold the job in 4 jaw chuck and align it properly. 2. Set the facing tool and maintain the job length as 40mm. 3. Set the drill in tail stock and start drilling operation. 4. Make a hole throughout the job and set the boring tool and start boring operation. 5. Maintain size as per drawing. REQUIRED RESULTS:1. To know the nomenclature of single point cutting tool. 2. To analyze the turning operation on lathe machine. CAUTIONS:1. Do not change the gear while running the machine. 2. Concentrate on job while machining. 3. Do not check the size of job while machine is running. 4. Set the speed as per required. LEARNING OUTCOME:To be written by the students in 50-70 words.

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Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

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Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

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JOB4: - To prepare a job on Surface Grinder / Cylindrical Grinder and measure the various parameters of the finished piece. MATERIAL USED: - M S sq. 65mm X 16mm X 16mm. MACHINES/EQUIPMENT/TOOLS USED: - Surface grinder, Micrometer, diamond dresser, vernier caliper. LEARNING OBJECTIVES: - To perform different operations on surface grinder Machines, cutting of specimen, measuring marking and product finishing on grinder Machines. Sketch:-

OUTLINE PROCEDURE: - Hold the job in the center of magnetic chuck and take a sketch of the specimen and work upon it by measuring the dimensions as per sketch. List down the steps of operations and then used different tools as per the requirement. SCOPE OF RESULT TO BE REPORTED:i. Observed dimensions as per sketch. ii. To know how to perform different operations on Machines. PRECAUTI ONS:i. ii. iii. iv. v.

Clean the magnetic chuck before starting the operation. Set the job firmly in the center of the magnetic chuck. Depth of cut should be minimum 0.02mm. Sprinkle the coolant at tool and wok piece interface. During working, never wear loose clothes.

LEARNING OUTCOME: - Student will know how to perform different operations on surface grinder machines.

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Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

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Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

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JOB 5:- To make a job on lathe machine with internal threading and external threading. MACHINES/EQUIPMENTS/TOOLS USED:-Lathe machine MATERIAL USED- M.S. pipe 50 mm, and M.S. round 25 mm TOOL USED:- Surface gauge, facing tool, boring tool, threading tools, screw pitch gauge, steel foot rule, and vernier calliper. LEARNING OBJECTIVE: - To learn internal and external threading on lathe machine

BEFORE MACHINING PROCEDURE

AFTER MACHINING

Take a MS. pipe 2*40 mm. Hold in 4 jaw chucks and align it properly with the help of surface gauge. Set the boring tool and maintain the size mm. Set the threading tool and leaver of lead screw at 11 T.P.I (B.S.W). Set the depth of cut and threading is done until you get the required depth. Unload the job. Reset the job from face side and mark of length 35mm. Face the job up to length 35mm.

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FOR EXTERNAL THREADS: -

PROCEDURE:Take a MS Round . 25mm*115 mm. Hold in 4 jaw chucks and align it properly with the help of surface gauge. Set the turning and maintain the size as per drawing and set the drill chuck in tail stock spindle and do centering operation . Set the threading tool and leaver of lead screw at 8 T.P.I (square). Set the depth of cut and threading is done until you get the required depth. Unload the job. SCOPE OF RESULTS TO BE REPORTED:1. To know geometry of boring tool. 2. To know internal and external threading operation on lathe machine PRECAUTIONS 1. Align the job properly in the 4 jaw chuck. 2. Set the cutting tool in the centre height of job. 3. The depth of cut should be minimum; it should not be more than 0.5 mm. 4. Do not change gear while lathe is running. 5. Lock the compound slide for the threading operations. 6. Clean the machine after the completion of job.

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Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

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Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

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JOB-6 Exercise on milling machine to produce a spur gear. MATERIAL USED:- Cast iron. MACHINES/EQUIPMENTS/TOOLS USED: Horizontal milling machine with dividing head, Involute cutter 16 DP -o3, Vernier caliper, Dog carrier, Spanner set, Depth gauge. LEARNING OBJECTIVES:-To produce gear teeth using milling machine

OUTLINE PROCEDURE:- Hold the job in mandrel and adjust the table in the centre of slotting cutter then set the depth of cut, feed the job against rotating cutter and take a sketch of the specimen and work upon it by measuring the dimensions as per sketch. List down the steps of operations and then used different tools as per the requirement. SCOPE OF RESULT TO BE REPORTED:Observed dimensions as per sketch. To know how to perform different operations on milling m/c. PRECAUTIONS:Do not carry tool in your pockets. Follow the operative instructions given strictly. Always remove chips by brush, Do not remove by hand. During working, never wear loose clothes. Always wear fitting clothes. Always use correct speed & feed. LEARNING OUTCOME:- To perform gear cutting operation on milling machine.

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Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

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Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

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JOB 7:- Graph plotting of variation in hardness at different zones of job after welding with TIG and MIG welding EQUIPMENT REQUIRED: MIG and TIG welding machines, Hardness tester MATERIAL REQUIRED: M.S flat LEARNING OBJECTIVES: The objective of this work is to identify the part of a weld joint that exhibited irradiated weld joint tensile specimen and investigate the mechanisms occurring by analyzing the corresponding microstructure. PROCEDURE AND OUTLINES a First of all we will take the mild steel pieces and weld the mild steel pieces with the TIG and MIG welding. b The various effects will be read out with welding in the different zones. c Then take the readings at different zones. d Then again check the regions after the welding.their are various HAZ after welding with TIG and MIG we check the hardness at various regions. e Then plot the variations of hardness at different zones. SCOPE OF THE RESULTS TO BE REPORTED: To understand the working of various operations by TIG and MIG and analyze the hardness at various levels. CAUTIONS: a Always wear shoes while performing the practical. b Do not wear bangles, bracelets, rings, chains, and even neck tie. c Turn off all equipment when not in use. d Do not drape cables over your body.

LEARNING OUTCOMS: To be written by the students in 50-70 words.

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Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

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Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

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JOB 8:- To join two metal sheets of 1.5 mm thickness through the spot welding MACHINES/EQUIPMENTS:- Spot welding machine. MATERIAL USED: - Two metal sheet of thickness 1.5 mm and length 100 mm. TOOLS USED: - Marking block, Hammer, Chisel, , and sand paper LEARNING OBJECTIVE: - To learn spot welding a sheet metal OUTLINE OF PROCEDURE:1. Initially cut two mild steel sheets of length 100 mm each using a hammer and chisel. 2. Clean using a hammer and chisel. 3. The face surface of the sheet are being finally rubbed with a sand paper. 4. Then the welding parameters according to the thickness of the sheet are calculated. 5. Then the two sheets are made to overlap up to correct length and finally the overlap region is placed between the electrodes. 6. As the electrodes are being pressed with the help of paddle the circuit gets completed and a nugget is ground due to heat offered due to resistance between the sheets. REQUIRED RESULTS:The mild steel sheets have been perfectly joined by the spot welding process. CAUTIONS:1. Welding parameters play an important role in deciding the quality of weld, so must be calculated properly. 2. The paddle faces at the sheet must be properly cleaned with the help of sand paper 3. The paddle must be kept pressed until whole of the nugget formation takes place. LEARNING OUTCOME:- to be written by the students in 50-70 words.

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Process Sheet

Workshop Name: Name of Student: Roll No.: Job: Drawing:

Date: Section: Registration No.:

S. No.

Job Operations Specification / Dimension

Tools Used

Equipment/Machine Remark Used

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Learning Outcome:

To be filled in by Faculty Parameter (Scale from 1-10, 1 for very poor and S.No. 10 Marks excellent) obtained Understanding of the student about the 1 procedure/apparatus. (process sheet) Dimensional Accuracy, Finishing and Learning Outcome. Completion of experiment/job, Discipline and Cleanliness Signature of Faculty Total marks obtained

Max. Marks 20

2 3

20 10

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