MTM Final

1|Page Machine Tools and Machining
Lab session #01

Study of lathe machine, its parts, its tools and different
operations (Facing, turning, taper turning)
Lathe Machine:
Lathe machine is a machine which is used to convert a round work-piece
into a desire Object by rotating it along its own axis and performing various operations
(facing, turning, threading etc.) on it which is symmetrical around its axis of rotation
according to the need.
LATHE MACHINE
Parts of Lathe Machine:

The Parts of the machine are labeled in above diagram and their explanation is
given below
Bed:
It is made of a cast iron and is the main
component of the Lathe machine on which all
other components are mounted. It is shown in
the figure below
Head Stock:
It is mounted on the Left side of the
bed. It contains Gear box inside which is connected
to Heavy duty Motor and a Chuck which is
connected to spindle coming out of Headstock on its
right, in which work piece is grasped.
Tail stock:
It fits on the inner ways of the bed at the
right most of the bed and it can slide over the bed to
support the work-piece so that during operation it
doesn’t loses its center.
Carriage:
It is mounted on the bed its main purpose is to
move the tool for cutting purpose which is connect
to carriage through Tool post. It has various
components attach to it so that Tool can move in
every possible direction so that almost every type
of cutting can be done on Lathe machine
The components which are attached to it are Tool

Post, Compound Rest, Cross Slide, Apron and
Saddle
Cross slide:
It is mounted on the traverse slide of the carriage
so that tool can be feed in to the work-piece
through the rotation of hand wheel.
Compound rest:
It is mounted to the cross slide, it is
pivoted around the tool post.
Tool post:
It is used to mount Tool Holder which is used to clamp Cutting Tool.
Operation performed on Lathe Machine:

Following are the operations which are performed on the Lathe machine
1) Turning
2) Facing
3) Tapper Turning
4) Threading
5) Knurling
6) Drilling
7) Sanding
Types of Lathe Machine:
Engine Lathe:
Engine lathes are the most common types of lathe machine. It is
designed for low power operations as well as high power operations. Various lengths of
the machine is available. The length can be up to 60 feet. Engine lathe is commonly seen
in every machine shop. Various metals can be machines. The machine can operates at a
wide range of speed ratios.
Tool Room Lathe:

It is a very versatile lathe machine. It can give better accuracy and finishing.
It has wider range of speeds. It can give different types of feeds. It can be a great device to
manufacture die.
Turret Lathe:
It is a great machine for quick operations. It has various types of tool posts
mounted on a single structure. As a number of tools are set up on machine, the job can be
completed very quickly with the help of a single setup. A capstan wheel is used to position
the next tool. A sequential
Machining process can be done by using the turret lathe without moving the work piece. It
eliminates the error that occurs due to misalignment.
Single Point Cutting Tool:

The single point cutting tool is that tool which has only
one cutting point or edge. These tools used for turning,
boring, shaping or planning operations. These tools
used on lathe, boring and shaper machines.
Nomenclature of Single point cutting tool:
A single point cutting tool has different parts
1) Shank: It is the main body of tool.

2) Flank: It is the surface or Surfaces, below the adjacent to cutting edge
3) Face: The surface on which chip slides
4) Heel: It is the intersection of the Flank and Base of the tool
5) Nose: The point where side cutting edge and end cutting edge intersects
6) Cutting Edge: It is the edge on the face of the tool which removes material
from the work piece. The
cutting edge consists of the
side cutting edge which is
“Major cutting edge” and
cutting edge which is
“Minor cutting edge” and
the nose
Cutting Speed:
The rotational speed of the work-piece and the movement of the

tool must be consider relative to the work-piece. Basically, the softer the metal the faster
the cutting. Until you get a feel for the proper speeds, start with relatively low speeds and
work up to faster speeds. One of the great features is that you can adjust the rotational speed
without stopping to change belts or gears. Most cutting operations on the lathe will be done
at speeds of a few hundred RPM - with the speed control set below the 12 O'clock position
and with the HI/LO gear in the LO range. Higher speeds, and particularly the HI range, are
used for operations such as polishing, not cutting.
Lathe Feed:
The distance the cutting tool advances along the length of the work for every revolution of
spindle.
1) FACING EXPERIMENT:
Facing is an operation which is used to decrease the Length of the work piece.
The tool which is used for Facing is “Single Point Cutting Tool”. The tool is moved radially
from edge to center of the work-piece through cross slide.
Procedure:
1) First of all take a key and open a check before that check that machine is switch off
2) After opening the chuck, take work piece and insert a little length of work-piece in
the chuck so that it doesn’t move from center during the operation and tight the
chuck with the key.
3) Now turn on the machine and make the spindle rotate and check if the workpiece is
out of center or not. If it is then slightly loose the chuck strike the piece from where
it is out and again tight the chuck.
4) Now we clamp the Single point cutting tool on the tool post.
5) Next step is to take a reference of the work-piece for this we use both Longitude and
Cross Slide.
6) First we use longitudinal slide and take the tool tip to the end of the work-piece
where we have to perform the facing, Then by using the Cross slide we move the
tool towards the center of the face such that it touches the edge of face of work
piece.
7) Now we move the tool little right to the work-piece by using longitude slide so that
on Switching ON the machine it doesn’t touch the work-piece because it will
produce a thread in it.
8) Now simply by using the both slide we first make the tool tip contact with the face
at its outer edge and then move it towards the center through Cross slide. It will
remove material from the face of work-piece and decrease its length.
OBSERVATION & CALCULATION:
No of Obs Operation Material RPM Feed Cutt Depth

1 Facing Mild steel 590 Manual 1mm
1045
2) TURNING EXPERIMENT:
Turning is the removal of metal from the outer diameter of a rotating

cylindrical workpiece grasped in the chuck to reduce its
diameter, usually to a specified dimension, and to
produce a smooth finish on the metal.
Procedure:
2) After opening the chuck, take work piece and insert a little length of work-piece in
the chuck so that it doesn’t move from center during the operation and tight the
chuck with the key.
3) Now turn on the machine and make the spindle rotate and check if the workpiece is
out of center or not. If it is then slightly loose the chuck strike the piece from where
it is out and again tight the chuck
Cross Slide.
6) The difference between facing and turning is that in turning we remove the material
by rotating the wheel of longitudinal slide and give a cutt depth with cross slide
7) Now we take the tool to the work piece through longitudinal slide handle and give a
cutt depth through cross slide
8) Now simply turn On the Lathe machine and moving the longitudinal slide towards
left will cutt the material and reduce the diameter of the round object.
9) Slowly and smoothly moving longitudinal slide towards the left will not only
remove the material but also produce good surface finish

1 Turning Mild steel 590 Manual 1mm
1045
3) TAPER TURNING:
When the diameter of a piece changes uniformly, from one end to the other, the
piece is said to be tapered. Taper turning as a machining operation is the gradual reduction
in diameter from one part of a cylindrical work-piece to another part Tapers can be either
external or internal.
Methods of Tapper Turning:
There are basic three methods of performing the Tapper turning on the work-piece.
1) Using Compound Rest

2) Offsetting the tail stock
3) Using Tapper attachment
Tapper Attachment:
The taper attachment is used for turning and boring tapers. It is
bolted to the back of the carriage saddle. In operation, it is connected to the cross-slide so
that it moves the cross-slide laterally as the carriage moves longitudinally. This action
causes the cutting tool to move at an angle to the axis of the work-piece to produce a taper.
.
Compound Rest:
The compound rest is generally used for turning or boring short
steep tapers, but it can also be used for longer, gradual tapers, providing the length of the
taper does not exceed the distance the compound rest will move upon its slide. This method
can be used with a high degree of accuracy, but is somewhat limited due to the lack of an
automatic feed and the length of the taper being restricted to the movement of the slide.
.
Offsetting the tailstock:
The tailstock offset method is generally used to cut a taper
when no taper attachment is available. This involves moving the tailstock centre out-of-line
with the headstock centre. However, the amount that the tailstock may be offset is limited.
This method will not permit steep tapers to be turned or standard tapers to be turned on the
end of a long piece of work
Procedure:
1) The Method we are going to use is “Compound rest”
3) After opening the chuck, take work piece and insert a little length of work-piece in the
chuck so that it doesn’t move from center during the operation and tight the chuck with
the key.
4) Now turn on the machine and make the spindle rotate and check if the workpiece is out
of center or not. If it is then slightly loose the chuck strike the piece from where it is
out and again tight the chuck
10 | P a g e Machine Tools and Machining
Cross Slide.
7) Next Step is to Set the compound Slide at an angle which is half of the angle of the
taper for this we unlock the lever at set it to angle and then lock the lever again
8) Now take the tool tip to the work-piece through cross & longitudinal slide and make it
touch slightly with the workpiece
9) Now rotate the handle of the compound rest smoothly and continuously till it reaches
the end up to which you want taper for better surface finish.

1 Mild steel 590 Manual 1mm
Taper turning 1045
Tool Used:
The tool used for this is Single Point Cutting tool and its type is High speed cutting tool.
Quality control:
To get a better surface finish we need to move the slide smoothly or automatic feed and
need higher RPM.
Drawbacks:
The drawbacks in the Taper turning operation on Lathe is that you cannot move
the slide fast because it cause poor surface finish on the tapered portion
1) Continuous operation heats up the tool tip to certain temperature where it gets damage
2) Human need is always required for these operation in ordinary Lathe machine
3) Speedy work leads to roughness and not proper surface finish
Improvements:
1) Use of cooling agent will reduce the damage of tool tip
2) Moderate RPM and Feed leads to better surface finish
3) Slow & smooth operation give better surface finish
4) Use of CNC Lathe machine reduces the use of human presence all the time
5) Sharping the tool after certain time will increase the production rate
Conclusions and results:

While performing the experiment I observed that there is no surface
finish. Tool wear off due to continuous use as it got heat up. Hot chips may harm while
performing operation so precautionary measures should be observed..
Safety precautions:
 Do not operate a lathe until you fully understand its controls.

 Never operate a machine if safety guards are removed or not closed properly.
 Work area should be clean.
 Gloves should be used for hand protection
 Wear approved safety glasses for eyes protection.
 Operation should be performed carefully.
 Discipline should be maintained for safety from any mishap.
Lab session #02
To perform Drilling, Boring, knurling and Parting on a

Workpiece by lathe machine.
1) DRILLING EXPERIMENT:
Drilling is the operation which is used to create a hole in the face of the
cylindrical workpiece which is mounted on the lathe machine
Frequently, holes will need to be drilled using the lathe before other internal operations can
be completed such as boring, reaming & tapping, Although Lathe is not a drilling machine
but it save time and effort by using lathe for this operation rather than shifting the work-
piece from one machine to another machine.
Before drilling the end of a work-piece on the lathe the end to be drilled must be spotted
(center-punched) and then center-drilled so that the drill will start properly and be correctly
aligned .The Headstock & Tailstock spindles should be aligned for all drilling operations in
order to produce perfect hole and avoid damage to the work and the lathe.
Speed of the spindle should be set according to the material which is to be drilled.
Drilling Methods:
There are two methods to drill using lathe depending.
1) Supporting drill in the tailstock

2) Supporting drill in the headstock
Supporting drill in the Tailstock:
Methods of supporting the twist drill in the tailstock can vary.

Straight shank drills are usually held in a drill chuck, which is placed in the taper socket of
the tailstock spindle. Combination drill and countersinks (center drills), counter-bores,
reamers, taps, and other small shank cutters can also be supported in this way.
Supporting drill in the Headstock:
The drill can also be held and rotated in the headstock with the
work held stationary against the tailstock. Straight shank twist drills are supported in the
headstock by a drill chuck or collet which is mounted in the headstock spindle. A universal
or independent jaw chuck can also be used to hold and turn twist drills if a headstock drill
chuck is not available. Tapered shank twist drills can be mounted in the headstock by using
a special adapter, such as a sleeve with an internal taper to hold the tapered drill, while the
outside of the sleeve is made to fit into the headstock spindle.
Procedure:
1) First of all mount the work-piece into the chuck by closing the jaw of the chuck
while pacing work-piece in it
2) Secondly mount the drill bit in the tailstock and check whether the work-piece and
drill bit are in line. If not adjustment is need to be done so that they become in line
3) To start the drilling operation, compute the correct RPM for the drill and set the
spindle speed accordingly.
4) Ensure the tailstock is clamped down on the lathe ways.
5) The feed is controlled by turning the tailstock handwheel.
6) The graduations on the tailstock spindle are used to determine the depth of cut.

No of Operation Material Drill type Feed RPM Drill
Obs size
1 Drilling Mild steel Straight Manual 375 10mm
1045 shank
BORING EXPERIMENT:
Boring is the enlarging and turing of a hole by removing material
from internal surfaces with a single-point cutter bit. On the lathe, boring is accomplished in
either of these two methods:
1) Mounting the holder and boring

tool bar with cutter bit on the tool
post and revolving the workpiece.
2) Mounting the workpiece in a fixed

position to the carriage and
revolving the boring tool bar and
cutter bit in a chuck attached to the
headstock spindle. (This is a special
process and not used in most
machine shops).
Procedure:
1) First of all open the chuck with the help of the key and mount the work-piece in the
chuck and tight it with the key and check whether it is perfectly aligned or not if it is not
align then make adjustments to make it perfectly align.
2) Mount the boring tool on the tool-post and touch its tip with the work-piece and check
whether it is correctly mounted or not, if not make adjustments
3) Position the cutter bit so that the cutting edge is immediately to the right of the
workpiece and clears the wall of the hole by about 1/1 6 inch
4) Traverse the carriage by hand, without starting the lathe, to move the cutter bit and
boring tool bar into the hole to the depth of the intended boring and out again to
determine whether there is sufficient clearance to prevent the back of the cutter bit and
the boring tool bar from rubbing the inside of the hole. When the clearance is
satisfactory
5) position the cutter bit to the right of the workpiece ready for the first cut. Use the
micrometer carriage stop to control the depth of tool travel.
6) Move the carriage longitudinally by the longitudinal slide to move toolbit into the
workpiece to increase the hole size by removing material.

1 Boring Mild steel 375 Manual 1mm
1024

1 Boring Mild steel 540 automatic 0.5mm
1024
3) KNURLING EXPERIMENT:
Knurling is a manufacturing process, typically conducted on a lathe,

whereby a pattern of straight, angled or crossed lines is cut or rolled into the material.
The operation is performed for producing indentations on a part of a work-piece. Knurling
allows hands or fingers to get a better grip on the knurled object than would be provided by
the originally smooth metal surface. Occasionally, the knurled pattern is a series of straight
ridges or a helix of "straight" ridges rather than the more-usual crisscross pattern.
Knurling Tool:
The tool which is used to produce knurling pattern on the work-piece is

known as knurling tool. It is basically the wheels with the patterns engrave on their surface.
Procedure:
1) First of all mount the work-piece in to the Three Jaw chuck and tight it with the key
and make sure it is aligned if it is not aligned then make adjustment to make it align
2) Second clamp Knurling tool on the tool post such that it is perpendicular to the
work-piece
3) By moving the handles of cross and longitudinal slide take the knurling tool to the
point on work-piece where you want to perform knurling operation
4) Turn on the lathe machine and adjust the spindle speed to minimum because no
cutting is done in this operation
5) Now rotate the handle of cross-slide to the move the tool in the direction of
workpiece, and press the tool gently across work-piece Excesive pressure will
damage tool and also work-piece

1 Knurling Mild steel Minimum Manual No cutting
1024
PARTING EXPERIMENT:
Parting uses a blade-like cutting tool plunged directly into the work-piece to
cut off the work-piece at a specific length. It is normally used to remove the finished end of
a workpiece from the bar stock that is clamped in the chuck. Other uses include things such
as cutting the head off a bolt.
Parting is always done close to the chuck jaws - no more than 1/2" out, and,
preferably, no more than 1/4" out. (Note: this is also relative to the diameter of the work-
piece; 1/4" may be right for a 3/4" diameter work-piece, but would be too far out for a 1/8"
dia. piece.) Parting cuts impose great tangential force on the work-piece that could cause
the work-piece to be forced out of the chuck if you cut too far from the chuck jaws.
Tool used:
It is the tool which is used to perform Parting
operation.
Procedure:
1) First of all mount the work-piece on the chuck by opening its jaw with the help of key
and keep the point of the work-piece near the chuck from where we want to
cut because if the work-piece extends from the chuck more than a few times its diameter,
the end of the work-piece can start to swing in a dangerous arc
2) Now clamp the parting tool on the tool post and make sure it is exactly perpendicular to
the work piece so that it cut the piece accurately with face parallel to other face
3) Now after clamping the tool take the tool-tip to the point where we want to perform
parting with the help of longitudinal and cross slide.
4) Now turn on the lathe machine and adjust the spindle rpm according to the requirement
5) Now simply rotate the handle of the cross-slide such that it touches the workpiece it will
give the mark from where we want to remove.
6) Now slowly and continuously rotate the wheel with Hand or engage automatic feed
lever
7) And move the tool until it reaches the mid and cutt piece off
8) For smooth surface finish we need to increase the rpm and reduce the feed rate

1 Parting Mild steel 230 Manual -
1024
Nomenclature:
Neck: reduced dia, used for assembly purpose
Shank: the part which is used to hold the tool. It may be taper
or straight. Upto 13mm it is straight and beyond that limit it
is taper.
Lead: it is the distance measured parallel to the drill axis
between corresponding points on the flute in one
complete revolution
Tang: It receive and transmit drive feed.

Flutes: helical grooves on the body of drill. Provide clearance to
the chips produced at their cutting edge.
Quality Check:
To get a better surface finish we need to move the slide smoothly or use
automatic feed and need higher RPM.
Drawbacks:
Continuous operation heats up the tool tip to certain temperature where it gets
damage
Improvements:
Sharping the tool after certain time will increase the production rate

While performing the experiment I observed that there is less surface finish.
Tool wear off due to continuous use as it got heat up during drilling and boring which may
lead to imperfect dimensions. Hot chips may harm while performing operation so
precautionary measures should be observed. Parting operation is mainly used to cut off the
end of the work piece that is clamped in the chuck. Parting can be very accurately and
efficiently performed on the lathe machine.
Safety precautions:
 Always wear safety glasses.

 Roll up your sleeves and tuck in loose clothing.
 Never wear a ring or a watch.
Lab session #03
To study and perform Threading Operation on a lathe machine.
Threading:
Threading is the process of creating a screw thread over the cylindrical work-piece which
is rotated about its own axis.
Types of threads:
There are two types of thread according to standard
1) UNF (unified fine thread)

2) UNC (unified coarse thread)
UNF (unified fine thread):
It has more threads and more depth so they are widely used in automobile UNC
(unified coarse thread):
It has somewhat less thread and depth so used in nut and bolt and other applications.
Nomenclature:
In the nomenclature of threads we discuss geometry related terms

 Major (nominal) diameter – This is the largest diameter of a screw thread, touching the
crests on an external thread or the roots of an internal thread.
 Minor (core) diameter – This is the smallest diameter of a screw thread, touching the
roots or core of an external thread (root or core diameter) or the crests of an internal thread.
 Pitch diameter – This is the diameter of an imaginary cylinder, passing through the
threads at the points where the thread width is equal to the space between the threads.
 Pitch – It is the distance measured parallel to the axis, between corresponding points on
adjacent screw threads.
 Lead – It is the distance a screw advances axially in one turn.
 Flank – Flank is the straight portion of the surface, on either side of the screw thread.
 Crest – It is the peak edge of a screw thread,that connects the adjacent flanks at the top.
 Root – It is the bottom edge of the thread that connects the adjacent flanks at the bottom.
 Thread angle – This is the angle included between the flanks of the thread, measured in
an axial plane.
Tool used:
The tool used for making thread is a single point cutting tool which is also
called thread milling tool. It is a form tool.
Automatic feed:
The threads are formed on lathe through the automatic feed they cannot be
produce manually because the lathe has lead screw and gear system through which no of
TPI (no of threads per inch) can be varied. Table is given on each Lathe machine on which
there is mentioned the adjustment of lever for required TPI.
Procedure:
1) First of all mount the work-piece on the chuck by opening its jaw with the help of
key and keep the work-piece length slight larger in the chuck so that it don’t lose its
center during the operation and tight the chuck
2) Now clamp the single point cutting tool or threading tool on the tool post and make
sure it is slightly tilted towards the work piece so that it cut the threads on the work-
piece and donot touch the chuck on linear movement towards the chuck
3) Now set the levers to the required position for setting the TPI from the table. (Make
sure to set the lever while the machine is switched off)
4) Now move the tool by moving the carriage and touch the tip of the tool to the work-
piece so that it will touch the work-piece during automatic feed now keep the
touching position of the tooltip and mark the position and move the tool along the
bed towards the tailstock little away from the tool
5) Now give the depth of cutt through cross slide i.e 0.5mm
6) Now switch ON the lathe machine and engage the automatic feed lever and engage
the forward movement (anticlock-wise movement) lever
7) Keep the lathe running forward up to that point where we want the thread, soon that
point reach switch off the machine and use cross slide and move the tool away
8) Now engage the lever to reversed movement (clockwise movement) and let the tool
move to the starting point again NOTE donot move the tool with the longitudinal
slide because if you do so the thread will start from other point and will destroy the
first one
9) Repeat the same procedure with another depth of cutt of 0.5mm

1 Threading Mild steel 95 12 TPI 0.5
1024
Quality control:
In order to maintain quality we should go for multiple cuts to make threads at
the same automatic fees rate. And the tool should be in good working condition.
Drawbacks:
1) he drawbacks in the Threading operation on Lathe is that you cannot move the slide
fast because it has an automatic feed
2) Continuous operation or large depth of cutt heats up the tool tip to certain
temperature where it gets damage
3) Large depth of cut will lead to failure of tool tip and also work-piece
Improvements:


Sharping the tool after certain time will increase the production rate
Conclusions and Results:

For the better surface finish and precise dimension operation
must be performed slow and steady.
Safety Precautions:
 Always wear safety glasses.

 Roll up your sleeves and tuck in loose clothing.
 Be sure that chuck or face plate is mounted securely before starting the lathe.
Lab session #04:
To study Shaper Machine, its parts and the operations.
Shaper Machine:
Shaper is a machine which is used for planning the surface by the moving single
point cutting tool riding on the ram which moves above the stationary work-piece and chip
of the material from the surface. The Ram moves back and forth typically by a crank inside
a coloumn
Quick return mechanism:

Shaper machine works on whit worth quick return mechanism to
convert rotary motion into reciprocating motion.
As it is clear by diagram that forward stroke

is slower and reverse stroke is faster.
Cutting is only done in forward stroke,
reverse stroke is idle stroke. Forward stroke
is also known as power stroke.
Stroke length is adjusted by crank pin.
Parts of Shaper Machine:

Following are the main parts of a shaper machine
Base:
The base of shaper supports the column or pillar which supports all working parts such
as ram, work table, drive mechanism etc. Base is a heavy cast iron body.
Column:
Pillar or Body: The shaper has a column which is a ribbed casting of cellular
construction. The top of the column carries the ram slide ways, whilst the table slide ways
are machined on the front of the casting. The crank and slotted link mechanism that drives
the ram is contained within the column. The driving motor, the variable speed gearbox,
levers, handles and other controls of shaper are also contained in the column.
Cross rail:
The cross rail carries the horizontal table slide ways and is mounted on the vertical
slide ways of the column. The cross rail can be raised or lowered by means of an elevating
screw in order to compensate for different thick nesses of work. The cross rail is a, heavy
casting and it also carries the table cross feed screw together with the pawl and ratchet
intermittent drive mechanism.
Saddle:
Saddle is gibed to the cross rail and supports the table. If the table is removed, the
work can be bolted or clamped to the T-slots in front of the saddle. Crosswise movement of
the saddle causes the work table to move sideways.
Table:
The work table is a box shaped casting with T-slots in its upper surface and down
one side. It also has a v machined in the vertical side to carry cylindrical work.
The upper surface of the work table is machined in situ after assembly to ensure that
the working surface of the table is a true datum for work setting. The work table is bolted to
the saddle and can be moved vertically and crosswise with the help of saddle and cross rail.
Ram:
Ram is a rigidly braced casting and is located on the top of column. The ram is driven
back and forth in its slides by the slotted link mechanism. The ram contains a stroke positioning
mechanism and the down feed mechanism.
Tool head:
The tool head slides in a dovetail at the front of the ram by means of T-bolts. It
can swivel from 0° to 90° in a vertical plane: The tool head can be raised or lowered by
hand feed for vertical cuts on the workpiece. The tool head holds the tool. The tool head
imparts the tool, the necessary vertical and angular feed movements. The tool slide controls
the in feed of the cutting tool into the work piece. In other words, it controls the depth of
cut and is adjusted by a lead screw.
Clapper box:
It allows the cutting tool to lift on the return or idle stroke so that the tool is not
dragged back through the uncut work piece and gets damaged. The tool post carries the
cutting tool.
Applications:
There are many applications of the shaper machine some of which are mentioned below:
1) Dove tail slides

2) Internal splines
3) Key ways cutting
4) T-slotting
5) Facing
6) Flat surfaces with specific reference Flat angular surfaces.
Procedure:
1) First of all take rough piece whose surface is not plane and hold it in vice in such a
way that its surface is parallel to the table
2) Use the head tool lever and adjust the cut of depth
3) Turn on the machine and hold the clutch lever and also set the cross slide
4) Now engage the clutch the tool will move on the stationary work-piece and remove
the material
5) With every stroke work-piece moves due to cross slide next portion is removed
6) As soon the tool runs over all the surface increase the depth of cut by stopping the
tool with the clutch lever
7) And give a further depth of cut and repeat te process until required dimensions are
not achieved

Operation Material RAM Table Feed Tool
No of Obs speed Cutt Depth material
1 Surface Mild steel 0.5mm HHS
34.5 m/min 0.3
planning 1024 mm/stroke
Quality check:
To get a better surface finish and result perform experiment with low depth of
cut and speed
Drawbacks:
1) Continuous operation heats up the work-piece and tool
2) Not proper alignment can cause adverse effect to dimensions

4) Larger depth of cut can cause tool tip to break
5) Great material removal rate but with less surface finish
Improvements:
1) As it is such an old machine conversion to NC and CNC can have a good
impact on the result of operation
2) We didn’t use the coolant while working on this machine. So, we must use the
proper coolant to increase the life of tool.

For the better surface finish and precise dimension operation must be
performed slow and steady.
Precautions:
 Always use the safety glasses during operation

 Do not exceed the maximum speed.
 Always cover the body because hot chip can fall on skin
 Be sure that work piece on the vice is mounted securely
before starting the machine.
 Stop the machine before measuring the work.
Lab session #05:
To study Milling Machine, its parts and the operations.
Milling:
Milling is a machining operation in which a workpart is fed past a rotating
cylindrical too with multiple cutting edges (in rare cases, a tool with one cutting ege called
a fly-cutter is used). The axis of rotation of the cutting tool is perpendicular to the direction
of feed. This orientation between the tool axis and the feed direction is one of the features
that distinguishes milling from drilling. The cutting tool in milling is called a milling cutter
and the cutting edges are called teeth. The machine tool that traditionally performs this
operation is a milling machine.
The geometric form created by milling in a plane surface. Other work geometries can be
created either by means of the cutter path of the cutter shape.
TYPES OF MILLING:
Milling can be divided into two basic types:
1) Peripheral milling
2) Face milling
Peripheral Milling:
Peripheral milling is also known as plain milling. In this type of
milling the axis of tool is parallel to the surface being machined, and the operation is
performed by cutting edges on the outside periphery of the cutter.
Types of peripheral milling:
In peripheral milling, the rotation direction of the cutter
distinguishes two forms of milling:
Up milling:
In up milling, also called conventional milling, the direction of motion of
the cutter teeth is opposite the feed direction when the teeth cut into work. It is milling
“against the feed”.
Down milling:
In down milling, also called climb milling, the direction of cutter motion
is the same as the feed direction when the teeth cut the work. It is milling “with the feed”.
Difference between Peripheral and Face Milling:

In peripheral milling, cutting is accomplished by the peripheral
teeth of the milling cutter and the tool axis is parallel to the work surface; in face milling,
cutting is accomplished by the flat face of the cutter whose axis is perpendicular to the work
surface.
Types of Milling Machine:

Following are the types of milling machine
1) Vertical Milling Machine:

A vertical milling machine with its different parts is shown below:
Base:
It gives support and rigidity to the machine and acts as a reservoir for the
cutting fluids.
Column:
It is often cast integrally with the base. The machined face of the column provides
the ways for vertical movement of the knee. The upper part of the column is machined to
receive a turret, on which the overarm is mounted.
Overarm:
It is round, or of the ram type. It may be adjusted toward or away from the
column to increase the capacity of the machine.
Head:
It is attached to the end of the ram. Provision is made to swivel the head in one
plane. On universal-type machines, the head may be swiveled in two planes.
Mounted on top of the head is the motor, which provides drive to the spindle, usually
through V-belts. Spindle speed changes are effected by means of a variable-speed pulley
and crank or by belt changes and a reduction gear. The spindle may be fed by means of a
hand lever or a handwheel, or by automatic power feed. Most machines are equipped with
a micrometer quill stop for precision drilling and boring to depth.
Knee:
It moves up and down on the face of the column and supports the saddle and the
table. Most cutting on the vertical milling machine is done by end mill cutters; therefore,
it is not necessary to swing the table even when cutting a helix. As a result, vertical
milling machines are equipped with plain tables only.
Horizontal Milling Machine
The base and column are the same as described above
Saddle:
It is fitted on top of the knee and may be moved in or out either manually by means of the
cross feed hand wheel or automatically by the cross feed engaging lever.
Swivel table:
The swivel table housing, fastened to the saddle on a universal milling machine, enables
the table to be swiveled 45° to either side of the centerline.
Table:
The table rests on guideways in the saddle and travels longitudinally in a
horizontal plane. It supports the vise and the work. The cross feed hand wheel is used to
move the table toward or away from the column. The table hand wheel is used to move
the table horizontally left and right in front of the column. The feed dial is used to
regulate the table feeds.
Overarm:
The overarm provides for correct alignment and support of the arbor and
various attachments. It can be adjusted and locked in various positions, depending on the
length of the arbor and the position of the cutter.
Arbor support:
The arbor support is fitted to the overarm and can be clamped at any
location on the overarm. Its purpose is to align and support various arbors and
attachments.
Elevating screw:
The elevating screw is controlled by hand or an automatic feed. It gives
an upward or downward movement to the knee and the table.
The spindle speed dial is set by a crank that is turned to regulate the spindle speed. On
some milling machines, the spindle speed changes are made by means of two levers.
When making speed changes, always check to see whether the change can be made when
the machine is running or if it must be stopped.
Procedure:
1) Remove all burrs from all edges of the work with a mill file.
2) Clean the vise and workpiece.
3) Align the vise to the column face of the milling machine using a dial indicator. Set the
work in the vise using parallels and paper feelers under each corner to make sure that the
work is seated on the parallels.
4) Tighten the vise securely by hand.
5) Tap the work lightly at the four corners with a soft faced hammer until the paper feelers
are tight between the work and the parallels.
6) Select a plain helical cutter wider than the work to be machined.
7) Mount the cutter on the arbor for conventional milling.
8) Set the proper speed for the size of cutter and the type of work material.
9) Set the feed to approximately .003 to .005 in. (0.08 to 0.13 mm) chip per tooth (CPT).
10) Start the cutter and raise the work, using a paper feeler between the cutter and the work.
11) Stop the spindle when the cutter just cuts the paper.
12) Raise the knee .002 in. (0.05 mm) for paper thickness.
13) Set the graduated collar on the elevating screw hand wheel to zero.
14) Move the work clear of the cutter and set the depth of cut using the graduated collar.
15) For roughing cuts, use a depth of not less than 0.125 in. (3 mm) and .010 to .025 in.
(0.25 to 0.63 mm) or finish cuts.
16) Set the table dogs for the length of cut. Engage the feed and cut side 1.
Tooling:
High-speed steel, consisting of iron with various amounts of carbon, tungsten,
chromium, molybdenum, and vanadium, is used for most solid milling cutters, since it
possesses all the qualities required for a milling cutter.
Quality check:
To get a better surface finish and result perform experiment with low depth of cut and high
speed
Drawbacks:

2) Not proper alignment can cause adverse effect to dimensions
4) Lubrication is required for better result
5) Larger depth of cut can cause damage to tool
Improvements:
2) Higher speed and sharp tool must be used for the better result

For the better surface finish and precise dimension operation must be performed
with low depth of cut and at higher rpm with continuous lubrication
Safety Precautions:
 Avoid performing a machining operation on the milling machine until you are
thoroughly familiar with how it should be done.
 Maintain cutting fluids properly. Discard them when they become contaminated.
 Be sure cutter rotates in the proper direction.
 Carefully read instruction when using the new synthetic oils, solvents and adhesives.
Lab session #06
To study cylindrical grinding, its tool and operation.
Cylindrical grinding:
The cylindrical grinder is a type of grinding machine used to shape the
outside of an object. The cylindrical grinder can work on a variety of shapes, however the
object must have a central axis of rotation. This includes but is not limited to such shapes as
a cylinder, an ellipse, a cam, or a crankshaft
Cylindrical grinding is defined as having four
essential actions:
1. The work (object) must be constantly
rotating
2. The grinding wheel must be constantly
rotating
3. The grinding wheel is fed towards and
away from the work
4. Either the work or the grinding wheel is
traversed with respect to the other.
Types of cylindrical grinding:

1. outside diameter (OD) grinding,
2. inside diameter (ID) grinding,
3. Plunge grinding.
4. creep feed grinding
5. Centerless grinding.
Outside diameter grinding:
OD grinding is grinding
occurring on external surface a of an object
between the centers. The centers are end units with
a point that allow the object to be rotated. The
grinding wheel is also being rotated in the same
direction when it comes in contact with the object.
This effectively means the two surfaces will be
moving opposite
Directions when contact is made which allows for a smoother operation and less chance of a
jam up.
Inside diameter grinding:
ID grinding is
grinding occurring on the inside of an object. The
grinding wheel is always smaller than the width
of the object. The object is held in place by
a collet, which also rotates the object in place.
Just as with OD grinding, the grinding wheel and
the object rotated in opposite directions giving
reversed direction contact of the two surfaces
where the grinding occurs.
Plunge grinding:
A form of OD grinding, however the major difference is that the grinding
wheel makes continuous contact with a single point of the object instead of traversing the
object.
Creep feed grinding:
Creep Feed is a form of
grinding where a full depth of cut is removed in a
single pass of the wheel. Successful operation of
this technique can reduce manufacturing time by
50%, but often the grinding machine being used
must be designed specifically for this purpose.
This form occurs in both cylindrical and surface
grinding.
Centerless grinding:
It is a form of grinding
where there is no collet or pair of centers
holding the object in place. Instead, there is a
regulating wheel positioned on the opposite
side of the object to the grinding wheel. A
work rest keeps the object at the appropriate
height but has no bearing on its rotary speed.
The work blade is angled slightly towards the
regulating wheel, with the workpiece
centerline above the centerlines of the
regulating and grinding wheel.
Procedure:
The step-by-step procedure for grinding a straight shaft is given below. The shaft has been
roughly turned prior to grinding.
1) Check and grind headstock and tailstock centers if necessary.

2) Check drilled centers of workpiece for accuracy.
3) Place a grinding wheel of the proper grain, grade, structure, and bond on the wheel
spindle.
4) Place wheel guards in position to cover the wheel adequately.
5) Set the proper wheel speed on grinding machine (Table 5-2 in Appendix A).
6) Place the diamond dresser and holder on the machine table and true and dress the
grinding wheel.
7) Mount the headstock and footstock on the table.
8) Attach the proper size drive dog on the headstock end of the workpiece.
9) Mount the workpiece between headstock and tailstock centers. Use lubricant (oil and
white lead mixture) on tailstock center. Make sure centers fit drill center holes correctly
with no play.
10) Set the proper rotational work speed on the wheel head. The general range of work
speed for cylindrical grinding is 60 to 100 SFPM. Heavy rough grinding is sometimes
performed at work speeds as low as 20 or 30 SFPM. Soft metals such as aluminum are
sometimes ground at speeds up to 200 SFPM.
11) Position the table trip dogs to allow minimum table traverse. The wheel should overlap
each end of the workpiece not more than one-half the wheel width to assure a uniform
straight cut over the length of the workpiece.
12) Calculate the table traverse feed using this formula.
TT = (WW x FF x WRPM) + 12
Where
TT = Table travel in feet per minute
WW = Width of wheel
FF = Fraction of finish
WRPM = Revolutions per minute of workpiece
Quality check:
To get a better surface finish grinding wheel of smaller grain size should be used along with
the lubrication.
Drawbacks:
1) It can only be used for cylindrical objects it cannot perform its function on a flat surface.
2) The grinding wheel needs maintenance regularly if the accurate dimensions are to be
achieved.
3) It is very expensive machine.
4) Continuous operation heats up the work-piece and grinding wheel
5) Not proper alignment can cause adverse effect to dimensions.
Improvements:
1) Use of cooling agent will increase the surface which and control the heat
2) Maximum RPM and smaller depth of cut leads to better surface finish
4) Use of CNC surface grinding machine reduces the errors and increase precision
5) Planning the surface of grinding wheel is necessary for better result
Conclusion and Results:

Cylindrical grinding is an efficient method of surface finish of cylindrical objects.
Various types of cylindrical grinding has made it possible to grind any length of the
cylindrical objects. Anyhow this method cannot be used to grind flat surfaces which is a big
limitation. For better results it should be perform slowly.
Safety precautions:
 Check the Speed it should be in range.
 Check Grinding wheel and Grinding Guard
 Ensure assembly of flanges and other parts.
 Use Right Wheel Dimension
 Always Test Before Running
 Always Wear Personal Protective Equipment
 Carry out Maintenance at Regular Intervals of Time
Lab session #07:

To study NC-Surface Grinder and its Opertion.
Surface grinding:
Surface grinding is used to produce a smooth finish on flat
surfaces. It is a widely used abrasive machining process in which a spinning wheel covered
in rough particles (grinding wheel) cuts chips of metallic or nonmetallic substance from a
workpiece, making a face of it flat or smooth.
Surface grinding is the most
common of the grinding operations. It is a
finishing process that uses a rotating
abrasive wheel to smooth the flat surface of
metallic or nonmetallic materials to give
them a more refined look by removing the
oxide layer and impurities on work piece
surfaces. This will also attain a desired
surface for a functional purpose.
Surface grinder:
A surface grinder is a machine tool used to provide precision ground
surfaces, either to a critical size or for the surface finish. Following are the few main types of
the surface grinder.
1) Horizontal-spindle (peripheral) surface grinders:

The periphery (flat edge) of the wheel
is in contact with the workpiece, producing the flat surface. Peripheral grinding is used in
high-precision work on simple flat surfaces; tapers or angled surfaces; slots; flat surfaces
next to shoulders; recessed surfaces; and profiles.
2) Vertical-spindle (wheel-face) grinders:

The face of
a wheel (cup, cylinder, disc, or segmental wheel) is used
on the flat surface. Wheel-face grinding is often used for
fast material removal, but some machines can accomplish
high-precision work. The workpiece is held on a
reciprocating table, which can be varied according to the
task, or a rotary-table machine, with continuous or
indexed rotation. Indexing allows loading or unloading
one station while grinding operations are being
performed on another.
3) Disc grinders and double-disc grinders:

Disc grinding is similar to surface
grinding, but with a larger contact area between disc and workpiece. Disc grinders are
available in both vertical and horizontal spindle types. Double disc grinders work both sides
of a workpiece simultaneously. Disc grinders are capable of achieving especially fine
tolerances.
Abrasive Materials:
The abrasive grains are the cutting took of a grinding wheel. They
actually cut small pieces or chips off the work as the wheel rotates. The shape of each grain is
irregular with several sharp cutting edges. When these edges grow dull, the forces acting on the
wheel tend to fracture the abrasive grains and produce new cutting edges.
Most grinding wheels are made of silicon carbide or aluminum oxide,
both of which are artificial (manufactured) abrasives. Silicon carbide is extremely hard but
brittle. Aluminum oxide is slightly softer but is tougher than silicon carbide. It dulls more
quickly, but it does not fracture easily therefore it is better suited for grinding materials of
relatively high tensile strength.
Abrasive Grain Size:
Abrasive grains are selected according to the mesh of a sieve through

which they are sorted. For example, grain number 40 indicates that the abrasive grain passes
through a sieve having approximately 40 meshes to the linear inch. A grinding wheel is
designated coarse, medium, or fine according to the size of the individual abrasive grains making
up the wheel.
Bonding Materials:
The abrasive particles in a grinding wheel are held in place by the
bonding agent. The percentage of bond in the wheel determines, to a great extent, the “hardness”
or “grade” of the wheel. The greater the percentage and strength of the bond, the harder the
grinding wheel will be. “Hard” wheels retain the cutting grains longer, while “soft” wheels
release the grains quickly. If a grinding wheel is “too hard” for the job, it will glaze because the
bond prevents dulled abrasive particles from being released so new grains can be exposed for
cutting. Besides controlling hardness and holding the abrasive, the bond also provides the proper
safety factor at running speed. It holds the wheel together while centrifugal force is trying to tear
it apart. The most common bonds used in grinding wheels are given below;
 Vitrified.
 Silicate.
 Shellac.
 Resinoid
 Rubber.
Markings:
Every grinding wheel is marked by the manufacturer with a stencil or a small tag. The
manufacturers have worked out a standard system of markings, shown in Figure 5-9.
For an example use a wheel marked A36-

L5-V23. The A refers to the abrasive
which is aluminum oxide. The 36
represents the grain size. The L shows the
grade or degree of hardness, which is
medium. The 5 refers to the structure of
the wheel and the V refers to the bond
type.
Quality check:
To get a better surface finish grinding wheel of smaller grain size should be used along with
the lubrication.
Procedure:
1) The surface grinder is composed of an abrasive wheel, a work holding device known as
a chuck, and a reciprocating or rotary table. The chuck holds the material in place while it
is being worked on. It can do this one of two ways: ferromagnetic pieces are held in place
by a magnetic chuck, while non-ferromagnetic and nonmetallic pieces are held in place
by vacuum or mechanical means.
2) A machine vise (made from ferromagnetic steel or cast iron) placed on the magnetic
chuck can be used to hold non-ferromagnetic workpieces if only a magnetic chuck is
available.
3) Factors to consider in surface grinding are the material of the grinding wheel and the
material of the piece being worked on.
4) Typical workpiece materials include cast iron and mild steel. These two materials don't
tend to clog the grinding wheel while being processed. Other materials are aluminum,
stainless steel, brass and some plastics.
5) When grinding at high temperatures, the material tends to become weakened and is more
inclined to corrode. This can also result in a loss of magnetism in materials where this is
applicable.
6) The grinding wheel is not limited to a cylindrical shape and can have a myriad of options
that are useful in transferring different geometries to the object being worked on. Straight
wheels can be dressed by the operator to produce custom geometries.
7) When surface grinding an object, one must keep in mind that the shape of the wheel will
be transferred to the material of the object like a reverse image.
8) Spark out is a term used when precision values are sought and literally means "until the
sparks are out (no more)". It involves passing the workpiece under the wheel, without
resetting the depth of cut, more than once and generally multiple times. This ensures that
any inconsistencies in the machine or workpiece are eliminated
Drawbacks:
1) The machine is very expensive so every cannot afford it although it has excellent surface
finish.
2) It can only grind horizontal, vertical and angular flat surface on table in a precise way.
3) The wheel has to be dressed every now and then in order to attain great accuracy.
4) A lot of precautions must be carries out in order to perform with machine in safe way.
5) Continuous operation heats up the work-piece and grinding wheel
6) Not proper alignment can cause adverse effect to dimensions.
Improvements:
1. Use of cooling agent will increase the surface which and control the heat
2. Maximum RPM and smaller depth of cut leads to better surface finish
3. Slow & smooth operation give better surface finish
4. Use of CNC surface grinding machine reduces the errors and increase precision
5. Planning the surface of grinding wheel is necessary for better result
Safety Precautions:
1. Check the Speed:
The speed of the grinder must always be monitored. Grinder should not
rotate faster than the maximum RPM stated on the wheel.
2. Check Grinding wheel and Grinding Guard:
Never use a grinder without the grinding wheel guard which is
provided for protection. Check the grinding wheel for any kind of crack or damage before
using the grinder.
3. Ensure proper assembly of flanges and other parts:

Grinding wheel consists of several smaller parts which should be
properly assembled and tightened together. Make sure that the right flanges are used and
attached properly for a smooth movement. Ensure that there are no traces of burr or flash.
4. Use Right Wheel Dimension:
Using the right dimension of grinding wheel plays an important
role in ensuring safety and achieving higher efficiency. Using the right dimension wheel also
helps in achieving the maximum allowed rotation speed of the grinding wheel.
5. Always Test Before Running:
Grinders must always be tested before beginning any kind of
work. Test run the grinder in a safe enclosed area such as beneath the workbench to detect
any kind of damage or fault in the wheel or the grinder.
6. Always Wear Personal Protective Equipment:
Never use the grinder without wearing all the personal protective
equipment and clothing such as goggles, helmets, masks, ear protection, gloves, leather
aprons etc. Also ensure that the personal protective equipment and tools are in proper
condition before using them.
7. Carry out Maintenance at Regular Intervals of Time

Carry out maintenance of grinders at regular intervals of time and as stated by the
manufacturer. Never use a faulty device and carry out all possible preventive maintenance
for safe operation of the grinder.
Conclusion:
A surface grinding operation might give us a smooth and a shiny surface but it
has its own limits. And the machine is very expensive. So we go for surface grinding of the
materials that are needed very much.
Lab session #08:
To study the working of a Vertical Grinding Machine
Vertical Drilling Machine:

The drilling machine or drill press is one of the most common and useful machine
employed in industry for producing forming and finishing holes in a workpiece. The unit
essentially consists of:
1. A spindle which turns the tool (called drill) which can be advanced in the workpiece
either automatically or by hand.
2. A work table which holds the workpiece rigidly in position.
Working Principal:
The rotating edge of the drill exerts a large force on the workpiece
and the hole is generated. The removal of metal in a drilling operation is by shearing and
extrusion.
Parts of Vertical Drilling Machine:

The machine has only a hand feed
mechanism for feeding the tool into the workpiece.
This enables the operator to feel how the drill is
cutting and accordingly he can control the down feed
pressure. Sensitive drill presses are manufactured in
bench or floor models, i.e., the base of machine may
be mounted on a bench or floor. The main operating
parts of a sensitive machine/drill press are Base,
Column, Table, and Drill Head.
Base:
The base is a heavy casting that supports the
machine structure; it provides rigid mounting for the
column and stability for the machine. The base is usually
provided with holes and slots which help to Bolt the base
to a table or bench and allow the work-holding device or
the workpiece to be fastened to the base.
Column:
The column is a vertical post that Column holds the worktable and the head
containing the driving mechanism. The column may be of round or box section.
Table:
The table, either rectangular or round. Drill machine/press in shape supports the
workpiece and is carried by the vertical column. The surface of the table is 90-degree to the
column and it can be raised, lowered and swiveled around it. The table can be clamp/hold the
required the workpiece. Slots are provided in most tables to allow the jigs, fixtures or large
workpieces to be securely fixed directly to the table.
Drilling Head:
The drilling head, mounted close to the top of the column, houses the driving
arrangement and variable speed pulleys. These units transmit rotary motion at different
speeds to the drill spindle. The hand feed lever is used to control the vertical movement of the
spindle sleeve and the cutting tool.
Operations on a Drilling Machine:

The following operation can be performed on this machine.
a) Drilling
b) Countersinking
c) Reaming
d) Boring
e) Spot facing
f) Tapping
g) Counter boring
Nomenclature:
Neck: reduced diameter used for

assembly purpose
Shank: the part which is used to hold the

tool. It may be taper or straight. up to 13mm it is straight and beyond
that limit it is taper.
Lead: it is the distance measured parallel to the drill axis between
corresponding points on the flute in one complete revolution
Tang: It receive and transmit drive feed.

Flutes: helical grooves on the body of drill. Provide clearance to the chips
produced at their cutting edge.
Procedure:
1) Work piece is mounted on the table.
2) Tool is tightened in the chuck according to your operation
3) Spotting of work piece has done earlier
4) Feed lever is manual and by lowering the tool machining is done
5) Drilling is done step wise, if you want a hole of 20mm we achieve it by repeating
procedure.
6) After machining clean the work piece
TABLE
Max. RPM Min. RPM Working RPM Feed Least
Count
1200 77 800 ¼ inch
Quality check:
To get a finished hole start from small hole size to the required size and use reaming
operation at the end.
Drawbacks:

2) Not proper alignment can drill a hole other than required location
4) Lubrication is required for better result
5) Larger holes cannot be directly drilled.
Improvements:
2) Higher speed and sharp tool must be used for the better result
3) Reaming operation should be performed to get the required dimensions

For the better surface finish and precise dimension operation must be
performed with at higher rpm with continuous lubrication and further perform reaming
operation
Safety precautions:
 Do not support the work piece by hand – use work holding device.
 Use brush to clean the chip
 No adjustments while the machine is operating
 Ensure for the cutting tools running straight before starting the operation.
 Never place tools on the drilling table
 Avoid loose clothing and protect the eyes.
 Ease the feed if drill breaks inside the work piece.
Lab session #09:
To study and Perform the Wire Electric Discharge Machining.
Electric Discharge Machining:

(EDM) is a process of metal machining in which a tool
discharges thousands of sparks to a metal workpiece. A non-conventional process, EDM
works on parts resistant to conventional machining processes, but only if these parts are
electrically conductive; usually, they are non-ferrous, and include steel, titanium, super
alloys, brass, and many other metals. Instead of cutting the material, EDM melts or
vaporizes it, leaving little debris and providing a very accurate line. Industry-wide
acceptance has led to a wide variety of EDM applications, as it is highly versatile, can cut
hard metals, and utilizes a relatively compact amount of workspace.
Electric discharge machining has the following types;
1. Die Sinker or “Ram” EDM

2. Wire or “Cheese Cutter” EDM
3. Hole Drilling or “Hole Popper” EDM
Wire EDM Working Principle:

CNC wire cut EDM machine puts impulse voltage between electrode wire
and workpiece through impulse source, controlled by servo system, to get a certain gap, and
realize impulse discharging in the working liquid between electrode wire and workpiece.
Numerous tiny holes appears due to erosion
of impulse discharging, and therefore get
the needed shape of workpiece as show in
figure.
Electrode wire is connecting to cathode of

impulse power source, and workpiece is
connecting to anode of impulse power
source. When workpiece is approaching
electrode wire in the insulating liquid and
gap between them getting small to a certain value, insulating liquid was broken through;
Very shortly, discharging channel forms, and

electrical discharging happens. And release huge
high temperature instantaneously, up to more than
10000 degree centigrade, the eroded workpiece is
cooling down swiftly in working liquid and flushed
away. As show in figure 1-2
Three basic conditions that wire cut EDM work

correctly:
1) The gap between electrode wire and workpiece should be certainly maintained in a
required range. Within this range, not only impulse power can break through insulating
liquid to create spark discharging, but also the eroded workpiece can be flushed away
after discharging process. If gap is too big, insulating liquid can’t be break through,,
and there will be no spark discharging; if gap is too small, short circuit is easy to
happen, no spark discharging neither.
2) The procedure should happen in the liquid with insulate capacity, for example
saponification and deionized water, the liquid could act as medium of discharging
channel and provide cooling and flushing.
3) Electrical discharging should be short time impulse discharging,. As with short
discharging time, the released heat won’t affect inside material of workpiece, and
limits energy to a tiny field and keep characteristics of cool machining of wire
cut EDM machine.
Dielectric Fluid:
One of the most important factors in a successful EDM operation is the
removal of the particles (chips) from the working gap. Flushing these particles out of the gap
with the dielectric fluid will produce good cutting conditions, while poor flushing will cause
erratic cutting and poor machining conditions. The dielectric fluid used in the wire-cut EDM
process serves several functions:
• It helps to initiate the spark between the wire (electrode) and the work-piece.
• It serves as an insulator between the wire and the work-piece.
• It flushes away the particles of disintegrated wire and work-piece to prevent
shorting.
Tooling:
The tool used in the EDM wire cut machine is the wire of different material usually brass wire
Procedure:
1) The conductive work piece is mounted to the machine and the work piece is secured to
the table in such way that the electrode can make the desired cut path without interference
either from the work piece, or the work holding device.
2) The material needs to be removed and the part should be tightly fastened to table to
ensure that it remains in place during the process.
3) The work piece must be aligned relative to the machine axis that consists of X, Y, Z, U
and V axes.
4) The ball indicator is usually attached and the work piece is adjusted until it is vertical
and parallel within the desired tolerance.
5) The machine coordinate system has to be set to the appropriate position after the work
piece is secured to the machine table and aligned to machine axes.
6) The Wire electrode is positioned to work piece.
7) The brass electrode while being spooled off and under tension is brought within a close
proximity of the work piece edge.
8) The edge position command and designate is executed to the appropriate axis.
9) The process for the cutting had been program using G and M codes.
Quality check:
If we want to obtain a very good surface roughness, the electrical current and the
pulse duration should be decreased, so that the electrical discharges between the wire
electrode and the work piece are smaller, with a higher frequency.
Drawbacks:
1) The slow rate of material removal.
2) Potential fire hazard associated with use of combustible oil based dielectrics.
3) The additional time and cost used for creating electrodes for ram/sinker EDM.
4) Reproducing sharp corners on the workpiece is difficult due to electrode wear.
5) Specific power consumption is very high.
6) Power consumption is high.
7) "Overcut" is formed.
8) Excessive tool wear occurs during machining.
9) Electrically non-conductive materials can be machined only with specific set-up of the
process
Improvements:
1) Reduce the time between intervals.
2) Use a wire of high conducting materials.
3) Reduce the diameter of the wire as much as it is possible in order to reduce the over
cut.

1) Wire EDM, or electrical-discharge wire cutting process is based on the principal energy
mode is thermal with the electrical discharge. It is also similar to contour cutting with a
band saw, a slowly moving wire travels along a prescribed path, cutting the workpiece,
with the discharge sparks acting like cutting teeth.
2) This process is used to cut plates as thick as 300 mm (12 in.), and for making punches,
tools, and dies from hard metals. It can also cut intricate components for the electronics
industry.
3) Special brass wires are typically used and usually performed in a bath of water.
4) As technology advances in speed, workpiece size and geometry complexity, accuracy,
ease of use, unattended operation, industry education and affordability. In the case of
complicated shapes requiring cuts or angled, conical, or other unusual surfaces, the upper
and lower wire guide systems carry out differing movements accordingly.
Safety Precautions:
The safety issues of when handling EDM-Cut are pre-machining condition. Such safety
issues are like;
 The setup of the machine must be right such the clamp of the workpiece is tighten
securely and firmly.
 Since the machine is supplied by high current therefore carelessness will result to injury
or worst fatality.
 If the machine suddenly hanged or running awkwardly press the emergency button to
stop it immediately and shut down the power supply. Report to the technician.
Lab session #10

To perform the Die Sinking Operation.
EDM Die Sinking:

The sinker EDM machining (Electrical Discharge Machining)
process uses an electrically charged electrode that is configured to a specific geometry to
burn the geometry of the electrode into a metal component. The sinker EDM process is
commonly used in the production of dies and molds.
Two metal parts submerged in an

insulating liquid are connected to a source of
current which is switched on and off
automatically depending on the parameters
set on the controller. When the current is
switched on, an electric tension is created
between the two metal parts.
If the two parts are brought together to

within a fraction of an inch, the electrical
tension is discharged and a spark jumps across. Where it strikes, the metal is heated up so
much that it melts.
Innumerable such sparks spray, one after the other (never simultaneously) and gradually
shape the desired form in the piece of metal, according to the shape of the electrode. Several
hundred thousand sparks must fly per second before erosion takes place.
Tooling:
Any one if the following can be used as a electrode depending upon the need of
the hour.
Brass:
It is an alloy of copper and zinc. Brass materials are used to form EDM wire and small
tubular electrodes. Brass does not resist wear as well as copper or tungsten, but is much easier to
machine and can be die-cast or extruded for specialized applications. EDM wire does not need to
provide wear or arc erosion resistance since new wire is fed continuously during the EDM wiring
cutting process.
Copper:
Copper alloys have better EDM wear resistance than brass, but are more difficult to
machine than either brass or graphite. It is also more expensive than graphite. Copper is,
however, a common base material because it is highly conductive and strong. It is useful in the
EDM machining of tungsten carbide, or in applications requiring a fine finish.
Copper tungsten:
Materials are composites of tungsten and copper. They are produced using
powder metallurgy processes. Copper tungsten is very expensive compared to other electrode
materials, but is useful for making deep slots under poor flushing conditions and in the EDM
machining of tungsten carbide. Copper tungsten materials are also used in resistance welding
electrodes and some circuit breaker applications.
Graphite:
It provides a cleaning action at low speeds. Carbon graphite was one of the first brush
material grades developed and is found in many older motors and generators. It has an
amorphous structure.
Molybdenum:
It is used for making EDM wire. It is the wire of choice for small slot work and for
applications requiring exceptionally small corner radii. Molybdenum exhibits high tensile
strength and good conductivity, making it ideal where small diameter wire is needed for
demanding applications.
Silver tungsten:
Material is tungsten carbide particles dispersed in a matrix of silver. Silver
offers high electrical conductivity and tungsten provides excellent erosion resistance and good
anti-welding characteristics in high-power applications. This composite is thus the perfect choice
for EDM electrode applications where maximizing conductivity is crucial.
Tellurium copper:
It is useful in EDM machining applications requiring a fine finish. Tellurium
copper has a machinability that is similar to brass and better than pure copper.
Dielectric Fluid:
One of the most important factors in a successful EDM operation is the
removal of the particles (chips) from the working gap. Flushing these particles out of the gap
with the dielectric fluid will produce good cutting conditions, while poor flushing will cause
erratic cutting and poor machining conditions. The dielectric fluid used in the wire-cut EDM
process serves several functions:
• It helps to initiate the spark between the wire (electrode) and the work-piece.
• It serves as an insulator between the wire and the work-piece.
• It flushes away the particles of disintegrated wire and work-piece to prevent
shorting.
• It acts as a coolant for both the wire and the work-piece.
Procedure:
1. Die sinking EDM work steps
1. The main switch is open

2. Die sinking EDM controller switches open and the safety button is released the use of
machines
3. Home panels, manual (F2) is pressed
4. coordinates X, Y and Z coordinates are adjusted to adjust the position of the electrodes
5. cycle start switch is pressed to heat the engine system
2. Step work PROGRAMMING
1. Oil pump is opened to drain the liquid (oil) which aims to

reduce sparks during cutting.
2. G54 Work coordinate;
3. Absolute coordinate G90
4. Position Z 50.0
5. Position X 50.0, Y 50.0
6. Position Z 0.5
7. Line 3-axis Z I1 B1 -0.5
8. NG position Z 50.0
9. Oil pump off
Step work EDIT

1. F1 Edit, input
2. F8 file, input
3. F1 load, input
4. Yes, input
5. Enter the name
of data file, input
6. Enter, input
7. F10 exit, input
8. F2 Dialogue, input
9. Key in program, input
10. Exit, input
3. Step work for EDGING (auto)

1. Manual, input
2. Exit center, F6 input, input
3. Column X, Y, Z, input. Using a ruler, the distance between the axes at work things are
included. Electrodes are moved automatically to adjust the center position of work objects
4. Ix, the input
5. Ly, the input
6. LZ, input
7. Cycle start
Drawbacks:
 The slow rate of material removal.
 Potential fire hazard associated with use of combustible oil based dielectrics.
 The additional time and cost used for creating electrodes for ram/sinker EDM.
 Reproducing sharp corners on the workpiece is difficult due to electrode wear.
 Specific power consumption is very high.
 Power consumption is high.
 "Overcut" is formed.
 Excessive tool wear occurs during machining.
 Electrically non-conductive materials can be machined only with specific set-up of the
process.
Conclusion:
The desired objectives have been successfully implemented. We have
successfully used Die sinking EDM machine with skill and know how to enter the
program and run machine for the design of the products made. In addition, we also know
how to apply the program to form the G-code to get the result as above. All that was taught
to us was really helpful to our advantage as we go into the working world later.
Safety precautions:
 Make sure there are no leaks in the tank dielectric liquid tank hose and pipe connections.
 Make sure a fire extinguisher near the machine for use in emergencies.
 Make sure the materials are installed in areas where the right job.
 Make sure the electrodes are not touching the thing work.
 Make sure the cutting wire is not touching things work
 Make sure each cable there is no leakage.
Lab session #11

To perform CNC water jet cutting operation.
Water jet cutting:

Waterjet Cutting can be classified as a mechanical method. The
energy of the rapidly moving jet is utilized either in the form of a pure waterjet or abrasive
waterjet and then applied to the workpiece causing micro erosion. The cutting water works
as a cooling agent of cutting edge, thus allowing for a very high quality cut. The one main
component which is without any doubt always necessary to create a waterjet is the high
pressure pump.
There are two types of water jet cutting named as
1) Pure water jet cutting
2) Abrasive water jet cutting
Pure water jet cutting:

Pure waterjet is used mainly for relatively soft materials such as plastic,
textiles, paper, sealing materials, metalic foils, plywood... Fig. 8 Pure water samples cut at
KMT Waterjet, Bad Nauheim These materials can be cut at
very high speeds. The limiting factor is usually not the
cutting power of the cutting head, but the ability of the
movement device to move quick enough. When trying to cut
a material at 20m/min, it is not very likely that the cutting
head will have a chance to accelerate to this high speed
within a small workpiece.
Examples: Paper and plastic foils up to
200 m/min Carpeting: 15 - 30 m/min. For such materials,
waterjet is used for cutting of production runs, where it is
used as an alternatives to blade cutting. A pure waterjet has
the width of a hair at around 0,1 mm- 0,2 mm and is
therefore able to cut very sharp contours. Parts requiring
positive-negative inlays, can be put together without any
problem whatsoever. A company logo embedded in a
floormat is highly desirable from a customer’s standpoint.
Abrasive water jet cutting:

The hydroabrasive application is used for harder materials: Metals,
Glass, Stone, Concrete, Glass composites, Ceramics and hard materials like Aluminum oxide
or Silicone Oxide. Fig. 11 Metal, Stone and plastic materials cut at KMT Waterjet Bad
Nauheim The hydro abrasive method is somewhat more complex. In addition to the supply
of high pressure water, a sand feeding system is necessary. Instead of the nut, a abrasive
cutting head is required – this is where the mixing of the water and sand occurs.
After the high pressure water passes through the water orifice, it flows
into the mixing chamber. Because of the high velocity, the jet causes a vacuum, thus sucking
in the mixture of air and sand through the entry port. The sand quantity is controlled by the
abrasive feeder. In
Order to bring this mixture into alignment, a focusing tube

with a conically shaped inlet of three times the diameter of
the water orifice is required. Even small geometrical
variances have an impact on the cutting parameters. In most
cases, Garnet sand and Olivine are used as abrasive. Both are
natural minerals, which are mined and can be purchased at
relatively reasonable prices (0, 25 to 0, 50 €/kg). One
abrasive cutting head requires 250 –600 g Abrasive per
Minute.
Two types of pumps are used for creating high pressure
Intensifier pump:
The hydraulic pressure is amplified by the ratio of the larger
hydraulic cylinder pushing a smaller piston into a cylinder filled with water, thus creating the
ultra-high water pressure. So if the hydraulic cylinder size is 20 times the size of the water
cylinder, then a 3,000 PSI hydraulic pressure is intensified to 60,000 PSI water pressure, or
with a 30:1 ratio 90,000 PSI water pressure.
High-Pressure Plunger Pumps:

All water pumps for pressures above 10,000 PSI are plunger
pumps. A solid plunger is pushed into a closed chamber, raising the pressure and expelling
the pumped fluid through an outlet check valve. Then, the direction of the plunger motion is
reversed, and low-pressure fluid fills the chamber through an inlet check valve. The
continuously reciprocating plunger provides the pumping action (see Figure 4). Two popular
drive types for moving the plunger are currently available. The crank pump moves the
plunger with a crank similar to the one in an automobile engine. The intensifier pump drives
the plunger with a hydraulic cylinder that usually is operated with oil.
Tooling:
1) High-pressure water inlet.
2) Jewel (ruby or diamond).
3) Abrasive (garnet).
4) Mixing tube.
5) Guard.
6) cutting water jet
7) cut material
Procedure:
1) The pressurized water is delivered to a cutting head by either high pressure
tubing or hose. At the cutting head, the high pressure water is applied to an
orifice with a typical diameter ranging from 0.005” to 0.020”. This orifice is
made in a diamond or sapphire, to resist abrasion of the high pressure water. The
orifice defines and creates the water stream which cuts through the material
2) .After the water stream exits the orifice, an abrasive can be added to the water
stream, to allow it to cut hard materials. When cutting hard materials, including
steel, stainless steel, aluminum, stone, wood, plastic, glass, etc., it is the abrasive
that does the actual cutting using a mechanical sawing type action.
3) The abrasive is usually crushed garnet, the same type of material often used as
the abrasive on sand paper. Some special applications utilize other abrasive
types.
4) When cutting soft materials, such as rubber, leather, cloth, paper, cardboard,
insulation, foam, etc., the high pressure water stream does the cutting, and no
abrasive is used.
5) ESAB manufactures the Hydrocut CNC water jet cutting machines for large and
small cutting applications, and can customize a machine to fit your exact needs.
Drawbacks:
1) Cutting Time – While the waterjet cutter can cut most of the same materials, very
often the cutting takes longer than a traditional cutter. More time cutting means less output.
2) Orifice Failure – Low quality waterjet orifices have a tendency to break downand
disrupt cutting, resulting in lost time and productivity.
3) Greater Thickness, Less Accuracy – The thicker a material the further the stream is
away from the nozzle at its point of impact. A less consistent impact from waterjet changes the
cutting accuracy from top to bottom. Often, the jet can spread and make more of a diagonal cut
than a straight up and down cut.
4) Starting Costs – In the beginning, finding and implementing the additional abrasive
materials, like granite, to increase the efficacy of the cutter can by very expensive compared to a
simple plasma cutter.
Conclusion:
Today abrasive waterjet cutting is a mainstream technology in modern
machine shops. It can cut more and thicker materials than laser and does not produce a heat-
affected zone. It cuts much faster than wire EDM.
Safety precautions:
 Do not put your hands in the tank while the jet is operating.
 Wear safety glasses to keep abrasive particles out of your eyes.
 Use hearing protection when the jet is not submerged during cutting.
 Use ozone or hot tub chemicals to minimize bacteria in the tank.
 Carry a medical alert card to show to any doctor treating a waterjet-related injury.
 Do not walk on material support slats.
 Do not build your own high-pressure parts, unless you are an expert in high-pressure
design.

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1|Page Machine Tools and Machining

Lab session #01

Parts of Lathe Machine:

The components which are attached to it are Tool

Operation performed on Lathe Machine:

Types of Lathe Machine:

Tool Room Lathe:

Single Point Cutting Tool:

Nomenclature of Single point cutting tool:

A single point cutting tool has different parts

1) Shank: It is the main body of tool.

The rotational speed of the work-piece and the movement of the

OBSERVATION & CALCULATION:

No of Obs Operation Material RPM Feed Cutt Depth

Turning is the removal of metal from the outer diameter of a rotating

OBSERVATION & CALCULATION:

No of Obs Operation Material RPM Feed Cutt Depth

Methods of Tapper Turning:

1) Using Compound Rest

OBSERVATION & CALCULATION:

No of Obs Operation Material RPM Feed Cutt Depth

Conclusions and results:

 Do not operate a lathe until you fully understand its controls.

Lab session #02

To perform Drilling, Boring, knurling and Parting on a

There are two methods to drill using lathe depending.

1) Supporting drill in the tailstock

Supporting drill in the Tailstock:

Methods of supporting the twist drill in the tailstock can vary.

Supporting drill in the Headstock:

OBSERVATION & CALCULATION:

1) Mounting the holder and boring

2) Mounting the workpiece in a fixed

OBSERVATION & CALCULATION:

No of Obs Operation Material RPM Feed Cutt Depth

No of Obs Operation Material RPM Feed Cutt Depth

Knurling is a manufacturing process, typically conducted on a lathe,

The tool which is used to produce knurling pattern on the work-piece is

OBSERVATION & CALCULATION:

No of Obs Operation Material RPM Feed Cutt Depth

OBSERVATION & CALCULATION:

No of Obs Operation Material RPM Feed Cutt Depth

Tang: It receive and transmit drive feed.

Conclusions and results:

 Always wear safety glasses.

Lab session #03

To study and perform Threading Operation on a lathe machine.

1) UNF (unified fine thread)

UNF (unified fine thread):

(unified coarse thread):

In the nomenclature of threads we discuss geometry related terms

OBSERVATION & CALCULATION:

No of Obs Operation Material RPM Feed Cutt Depth

1) Use of cooling agent will reduce the damage of tool tip

3) Slow & smooth operation give better surface finish

Conclusions and Results:

 Always wear safety glasses.