Manufacturing Process-II Lab Manual

[ Manufacturing Process-II lab.
Manual]
Manufacturing Process-II
Lab Manual
Student Name
ITEZAZ AHMED RANJHA
Registration #
2018-IM-132
Name of Subject
IME-222 Manufacturing Process-II
Department of Industrial and Manufacturing Engineering, UET

Lahore(RCET)
List of experiments
Page 1
[ Manufacturing Process-II lab. Manual]
1. To construct the layout of Machine Tool Lab.

2. Introduction to a Engine Lathe.
3. To perform different operations on Lathe Machine.
4. To determine Material Removal Rate of a turning operation on a Lathe
Machine.
5. Investigate the effects of spindle speed on surface roughness and dimensional
accuracy of machined parts with visual inspection method.
6. Investigate the effects of depth of cut on surface roughness and dimensional
7. Investigate the effects of feed rate on surface roughness and dimensional
8. Introduction to a Drilling Machine and to Study the parts of an Upright Drill
Machine.
9. To determine the Material Removal Rate (MMR) for a drilling operation.
10. To study the parts of a Vertical Milling Machine.
11. To Determine the Material Removal Rate (M.R.R) of a Vertical Milling
Machine.
12. To study the milling cutters and their functions.

13. Introduction to a universal grinding machine.
14. To perform the external cylindrical grinding operation on a rod by using the
universal grinding machine.
15. To grind the different tool angles on Tool and Cutter Grinder
Page 2
LAB SESSION # 01
Page 3
Objective
To construct the layout of Machine Tool Lab.
Page 4
LAB SESSION # 02
Objective
Page 5
Introduction to a Lathe Machine
Apparatus
Lathe machine, Mild steel bar, Cutting tools etc.
Theory
Lathe Machine
The lathe is a machine tool used in metal cutting operations called "turning." The work piece
is rotated as tooling is applied to it to remove material. Lathes can be manually operated or operated
by computer numerical control (CNC).
The Bed
The lathe bed is a mounting and aligning surface for the other machine components. Viewed
from the operating position in front of the machine, the headstock is mounted on the left end of the
bed and the tailstock on the right. The bed must be bolted to a base to provide a rigid and stable
platform.
Headstock
The headstock holds the spindle and drive mechanism for turning the work piece. The spindle
is a precision shaft and bearing arrangement rotated directly by a motor or through a motor-driven
belt. Gears or sliding pulleys mounted at the rear of the headstock allow spindle speed adjustment.
Tailstock
The tailstock supports long work that would otherwise sag or flex too much to allow for
accurate machining. Without a tailstock, long pieces cannot be turned straight and will invariably
have a taper. Some tailstocks can be intentionally misaligned to accurately cut a taper if needed.
The tailstock has a centering device pressed into a shallow, specially drilled hole in the end of the
work piece. The center can be either "live" or "dead.
Carriage
The carriage provides mounting and motion control components for tooling. The
carriage moves left and right, either through manual operation of a hand wheel, or it can be driven
by a lead screw. At the base of a carriage is a saddle that mates and aligns with the bed ways.
Cross Slide
The cross-slide is mounted to the top of the carriage to provide movement perpendicular to
the length of the bed for facing cuts. An additional motion assembly, the compound rest, with an
adjustable angle, is often added to the top of the cross slide for angular cuts.
Lead Screw
The lead screw provides automatic feed and makes thread cutting possible. It is a precision-
threaded shaft, driven by gears as the headstock turns. It passes through the front of the carriage
apron and is supported at the tailstock end by a bearing bracket.
Page 6
Guide ways
Guideways are linear bearings for translator movement between two members of a machine
tool such as carriage and bed in a lathe. The requirements of guideways are high accuracy, high
surface finish, low value of frictional force and low wear rate.
Types of Guide ways
The type of guideways may be classified as guideways with sliding friction also termed as
slideways and guideways with rolling friction also termed as anti-friction guideways. The shape of
the slideway basically depends upon the function it is expected to serve. There are some guidelines
in identifying the shape of a slideway.
 Load carrying capacity
 Ease of manufacture
 Ease of chip disposal
 Effective lubrication
 Position of slideway
1. Slideways
 V-slideways
They can adjust clearances under the weight of the moving member. Machining accuracy is not
greatly affected by the wear of guideways. The chips would not clog the slideways. They are
difficult to manufacture and provide very small bearing area.
There are two types of V ways.
 Symmetrical V- slideways
 Asymmetrical V-slideways
Symmetrical V ways Symmetrical V ways
 Flat Slideways
These ways are easier to manufacture and are able to provide a large amount of bearing area.
However locational accuracy is less than v-slideways. They are mostly used in conjunction with V-
slideways. The most common arrangement is found in lathes.A similar arrangement is also used in
planers & horizontal boring machine.
Page 7
Flat Slideways
 Round Slideways
Round slideways are kinematically sound since the constrain all possible motions except the
direction requiredbut are only used in vertical types of machines such as drilling (radial &
pillar). The main reason for their low usage is low rigidity and difficulty in manufacturing.
Round Slideways
 Dovetail Slideways
Thay are compact but difficult to manufacture. They are generally used for vertical
movement and where space is at a premium. However they provide good rigidity &
alignment. They are generally used in carriage of lathes.
Dovetail Slideways
2. Antifriction Guideways
They involve intermediate rolling members (balls or rollers) between the sliding members
thus reducing the friction as shown in fig. They are used mainly because of low friction during
motion, very high stiffness and consequent high velocities possible for slideway movement.
They are generally used in high precision machine tools.
Page 8
Antifriction Guideways
Questions
 How many linear & rotating axis a Lathe Machine has?

Therefore, Z axis is -Z toward the chuck of the lathe, and X axis is moving in the direction
of the turret, so that the direction in which the workpiece becomes smaller is -X. In addition
to the XYZ three linear axis, there are three other rotating axis and three auxiliary axis.
 Write down the design criteria of the bed of a Lathe Machine.

The main requirement of a lathe bed is to provide a guide for continued accurate
longitudinal movement of the carriage and tailstock. It has one or more slide ways cast as an
integral part.
 Residual Stresses:
 Nature of the cast material.
 Design of casting.
 Foundry techniques.
 Heat treatment.
 Machining operations.
 More amount of friction is present in

(a) Live center (b) Dead center
Page 9
 What are the elements of a Lathe Machine responsible for the movement of cutting
tool?
The feed rod, which is powered by a set of gears from the headstock, rotates during the
operation of the lathe and provides movement to the carriage and the cross slide. The
leadscrew is especially useful to accurately machine threads on a workpiece. It is engaged
with the carriage by a closing split nut.
 Setup time in Turret Lathe is less than Engine Lathe. How?

On turret lathes the machining time is saved by the parallel action of the cutting tools set in
the turret and on the cross slide, by the use of combination type tools, and by work with
holders that carry several tools acting simultaneously.
 Write down the applications of V-slideways, Flat slideways, Round slideways & Anti-
friction guideways.
Flat slideways
The advantages of flat slideways are that they require devices for adjusting the clearances, have
tendency to accumulate dust, and their retention of lubricating oil is poor for lathe bed, both flat and
inverted slideways, which are simple to manufacture and easily escaped when wear has taken place,
are used.
Anti-friction guideways
Dove tail type slideways are preferred when the location of the moving parts is considered essential.
These are generally used for milling machine tables, saddles and knees. In dovetail type slideways,
adjustment for wear can be made by parallel blocks pushed by set screws.
Round slideways
Cylindrical slide fulfils the conditions of kinematic principles being fully constrained. These guides
are used in the pillar or radial drilling machines.
Clearance between mating surfaces of slideways are inevitable because of wear and manufacturing
imperfections. Clearance between flat ways may be controlled periodically by means of three gibs
or strips.
Comments
 Tool holders are used to hold lathe cutting tools.
Page 10
• To install, clean the holder and tighten the bolts.
• The lathe’s tool holder is attached to the tool post using a quick release lever.
• The tool post is attached to the machine with a T-bolt.
LAB SESSION # 03
Objective
To perform different operations on Lathe Machine
Theory
Facing
Page 11
Facing is the process of removing metal from the end of a workpiece to produce a flat
surface. Most often, the workpiece is cylindrical, but by using 4- jaw chuck we can face rectangular
or odd-shaped work to form cubes and other non-cylindrical shapes.
When a lathe cutting tool removes metal it applies considerable tangential (i.e. lateral or
sideways) force to the workpiece. To safely perform a facing operation the end of the workpiece
must be positioned close to the jaws of the chuck. The workpiece should not extend more than 2-3
times its diameter from the chuck jaws unless a steady rest is used to support the free end.
Straight turning
In this operation the work is held in the spindle and is rotated whole the tool is fed past the
work piece in a direction parallel to the axis of rotation. The surface generated is a cylindrical
surface.
Design Considerations for Turning Operations

• Parts should be designed so that can be fixtured and clamped in the work holding devices.
• Dimensional accuracy and surface finish specified should be as wide as possible.
• Avoid sharp corners, tapers, and major dimensional variations in the part.
• Use near-net-shape forming.
• Cutting tools should be able to travel across workpiece without obstruction.
• Standard cutting tools, inserts, and toolholders should be used.
• Materials should be selected for their machineability.
Taper Turning
A taper may be defined as a uniform increase or decrease in diameter of a work piece
measured along its length. In a Lathe taper turning is an operation to produce a conical surface by
gradual reduction in diameter from a cylindrical job.
Contour turning
Page 12
Instead of feeding the tool along a straight line parallel to the axis of rotatation as in turning,
the tool follows a contour that is other than straight, thus creating a tapered cylinder or conical
shape.
Form turning
In this operation, sometimes called forming, the tool has a shape that is imparted to the work
by plunging the tool radially into the work.
Chamfering
The cutting edge of the tool is used to cut an angle on the corner of the cylinder, forming
what is called a "chamfer."
Cutoff
The tool is fed radially into the rotating work at some location along its length to cut off the
end of the part. This operation is sometimes referred to as parting.
Threading
A pointed tool is fed linearly across the outside surface of the rotating workpart in a
direction parallel to the axis of rotation at a large effective feed rate, thus creating threads in the
cylinder.
Boring
A single-point tool is fed linearly, parallel to the axis of rotation, on the inside diameter of
an existing hole in the part.
Drilling
Drilling can be performed on a lathe by feeding the drill into the rotating work along its axis.
Reaming can be performed in a similar way.
Knurling
This is not a machining operation because it does not involve cutting of material. Instead, it
is a metal forming operation used to produce a regular cross hatched pattern in the work surface.
Page 13
Machining operations other than turning that are performed on a lathe: (a) facing, (b) taper
turning, (c) contour turning, (d) form turning, (e) chamfering, (f) cutoff, (g) threading, (h)
boring, (i) drilling and (j) knurling
Questions
 What type of guide ways are present in Lathe Machine.
 v-slide ways
 Flat slide ways
 Dove tail slide ways
 Round slide ways
 Differentiate the following processes as generating or forming.

 Turning
Page 14
 Chamfering
 Boring
 What is the level of labour skill in different operation on Lathe.
 Form turning
 Contuour turning
 Taper turning
There should be skilled labour for these process.
Comments:
The operating principle of the lathe machine is to use the spindle rotation and the movement of the
bed to turn the material into the required work piece. A lathe is a kind of machine tool, which fixes
the work piece on the main shaft and rotates at high speed to process the cutting tool in feed motion.
LAB SESSION #04
Page 15
Objective
To determine Material Removal Rate of a turning operation on a Lathe Machine.
Apparatus
Lathe machine, Mild steel bar, Vernier caliper, Cutting tool etc.
Theory
Material Removal Rate (MRR)
It is the volumetric or cubic rate of material removed. MRR can be most conveniently
determined by the following equation.
M.R.R= π×d× ×
Specimen calculation
Where,
=Outer Diameter = 11.4mm
=Final diameter = 10.1mm
= = 11.4+10.1/2=10.75mm
Depth of cut=d=11.4-10.1=1.3mm
L=Li-Lf/2
Initial length=Li=95mm
Final length=40.6mm
L=Li-LF/2, 95-40.6/2=27.2mm
Time=t=160s
= 27.2/160=0.17mm/s
M.R.R= π×d× × =3.1416×1.3×10.75×0.17
M.R.R=7.46mm/s
Questions
Page 16
 Theoratical & actual values of MRR are different. Write down expected reasons of
change in values.
Therotical values does not include all factors (e.g., sparking out, tool overrun), it cannot be
considered as a sufficiently exact parameter in comparing different procedures. In the
calculation of the practical parameter the removed material volume is divided by a certain
time data (T x ) characterizing the production of a surface element/surface/component.
 Energy required to machine Stainless Steel is more than Aluminium. Why?

Materials with good machinability require little power to cut, that’s why stainless steel
required more energy to machine than Aluminium.
Comments:
A machinists’ depth of cut strategy is directly related to the Material Removal Rate. Using the
proper RDOC and ADOC combination can boost MRR rates, shaving minutes off of cycle times
and opening the door for greater production. Utilizing the right approach for your tool can also
result in prolonged tool life, minimizing the rate of normal tool wear.
LAB SESSION #05
Page 17
Objective
Investigate the effects of spindle speed on surface roughness and dimensional accuracy
of machined parts.
Apparatus
Lathe machine, Mild steel bar, Vernier calipers, Cutting tools etc.
Theory
Cutting speed
Cutting speed is the speed at the outside edge of the part as it is rotating. This is also known
as surface speed. Surface speed, surface footage, and surface area are all directly related.
Surface speed is measured in surface feet per minute (SFPM). All cutting speeds work on
the surface footage principle. Again, cutting speeds depend primarily on the kind of material you
are cutting and the kind of cutting tool you are using. The hardness of the work material has a great
deal to do with the recommended cutting speed. The harder the work material, the slower the
cutting speed. The softer the work material, the faster the recommended cutting speed.
Calculating RPM
The RPM setting depends on the cutting speed and the diameter of the part. The RPM
setting will change with the diameter of the part. As the diameter of the part gets smaller, the RPM
must increase to maintain the recommended surface footage. Again, take the case of the wheel.
Think of the part as a wheel and the cutting speed as a distance. A larger wheel (part) will need to
turn fewer revolutions per minute to cover the same distance in the same amount of time than a
smaller wheel (part). Therefore, to maintain the recommended cutting speed, larger diameter parts
must be run at slower speeds than a smaller diameter part.
The lathe must be set so that the part will be operating at the proper surface speed. Spindle
speed settings on the lathe are done in RPMs. To calculate the proper RPM for the tool and the
workpiece, we must use the following formula:
1000  V
N (rpm) 
 D
This simplified version of the RPM formula is the most common formula used in machine
shops. This RPM formula can be used for other machining operations as well.
Spindle Speed
It is calculated by using this formula from cutting speed and size of the work piece.
1000  V
N (rpm) 
 D
Page 18
Surface roughness:
Surface Roughness is a measure of the texture of a surface. It is quantified by the vertical
deviations of a real surface from its ideal form. If these deviations are large, the surface is rough; if
they are small the surface is smooth. Roughness is typically considered to be the high frequency,
short wavelength component of a measured surface.It is measured by using the “Surface Texture
Measuring Instruments.”
Dimensional Accuracy:
The Vernier caliper will be used to measure the dimensions of the machined parts then it
will be compared with the exact one to find the error.
Observations & Calculations:
No. of Cutting Surface Dimensional

Obs. Speed Roughness Accuracy
(mm/min) %
1 Fast Low 80
2 Medium Medium 60
3 Low Fast 40
Table 5.1
Results & Conclusions
Surface roughness depend on cutting speed if cutting speed is low surface roughness will be
low and vice versa.
Questions
 What is the difference b/w cutting speed and spindle speed.
The angular velocity of the workpiece (rev/min) is called the "spindle speed" by machinists.
Its tangential linear equivalent at the workpiece surface (m/min or sfm) is called the "cutting
speed", "surface speed", or simply the "speed" by machinists. ... This velocity is called the
"feed" by machinists.
Page 19
 What is the role of vibration in the surface finish of a part.

Radial vibration influence more on surface roughness than tangential direction.
The result shows that vibration and material of the tool holder plays a
secondary role in surface finish
Comments
The study reveals that the surface roughness is directly influenced by the spindle speed and
feed rate. It is observed that the surface roughness increases with increased feed rate and is higher at
lower speeds and vice versa for all feed rates.
LAB SESSION #06

Objective
Investigate the effects of depth of cut on surface roughness and dimensional accuracy of
machined parts.
Page 20
Apparatus
Lathe machine, Mild steel bar, Vernier calipers, Cutting tools etc.
Observations & Calculations
No. of Depth of Surface Dimensional

Obs. cut Roughness Accuracy
(mm) %
1 0.2 Good 80
2 0.5 Normal 60
3 0.8 Low 40
Table 6.1
Questions
 Write down some methods to reduce the level vibration.
Limit the time spent by workers on a vibrating surface. Mechanically isolate the vibrating
source or surface to reduce exposure. Ensure that equipment is well maintained to avoid
excessive vibration. Install vibration damping seats.
Comments:
If depth of cut of tool is less surface finish will be good.The dimensional accuracy is also
proportional.
LAB SESSION #07

Objective
Investigate the effects of feed rate on surface roughness and dimensional accuracy of
machined parts.
Apparatus
Lathe machine, Mild steel raw material, Vernier calipers, Cutting tools etc.
Page 21
Observations & Calculations:
No. of Feed rate Surface Dimensional

Obs. Roughness Accuracy
(mm/min)
%
1 Good 40
2 Normal 60
3 Low 80
Table 7.1
Questions
 What is the difference b/w feed & feed rate?
The feed of a lathe is the distance the cutting tool advances along the length of the work for
every revolution of the spindle.While Feed rate is defined as the distance the tool travels
during one revolution of the part.
Comments
If feed rate is high we get poor surface finish.similarly if we increase the feed rate dimensional
accuracy of tool will be good.
LAB SESSION #08
Objective
Introduction to a Drilling Machine and to Study the parts of an Upright Drill Machine.
Apparatus:
Drilling Machine, Mild steel raw material, Vernier caliper, Drills etc.
Theory
Page 22
Drill Press
A drill press is a piece of machinery that uses a motor-driven, rotating tool to drill holes in
workpieces. Workpieces are generally metals and wood. A drill press is an upright-standing fixed
drill that can be mounted on a cabinet or to the floor. Drill presses come in different styles and
types.
Parts of Upright Drill Machine
Base
The base is that part of a machine on which the column is mounted. In the belt driven
drilling machines both the fast and loose pulley and cone pulley are also mounted on the base.
Column
The column is the most important part which is mounted on the base and acts as a support
and holding device for all the other parts of an upright drilling machine. It acts as a support for table
and all feed mechanisms.
Table
Table is the part on which the work piece is mounted. This is held up by fixing it to a
column. A table can have rectangular geometry or circular in shape.
Head
The drill head is the one which holds all the feed mechanisms and spindle drive motion.
Drill head is mounted on the column. In some drilling machines provision is made for the
movement of the drill head so as the facilitating easy machining over the work piece.
Spindle and drill head assembly
Spindle is the part to which the driller is connected. It acts as a linking pin in transfer of
energy form top shaft to the tool through the usage of bevel gears. A sliding key is engaged in
connection of bevel gears and the spindle. The spindle is surrounded by a non rotating sleeve which
is called as a quill. The vertical movement of the spindle is obtained by engaging a rack teeth which
are cut on the outer surface of the quill.
Spindle drive mechanism
Spindle drive mechanism is the sole reason for obtaining multiple speeds of spindle.
These multiple speeds of the spindle are obtained by three types.
1) Step cone pulley drive
2) Step cone pulley drive with one or more back gears
3) Gearing
In a step cone pulley drive the multiple speeds are obtained by the step cone which
consists of various pulley sizes.
Feed mechanism
Page 23
In general the feed mechanism is by hand feed or in some cases automatic feed is
also given the automatic feed is given by two different ways,
1. Quick traverse hand feed
2. Sensitive hand feed
Fig. 6.1 The complete description of parts as shown in diagram.
Operations on drilling machine

 Drilling
 Boring
 Countersinking
 Counter-boring
 Reaming
Page 24
 Spot-facing
Drilling Time Estimation:

The cutting speed in drilling is the surface speed of the twist drill. Thus spindle speed is
calculated as follows:
1000  V
N (rpm) 
 D
Where;
V = Cutting speed
D = Diameter of the drill
N = Rotational speed of the Twist drill
Break through distance is

D
A
2 tan 
Total length of travel is
L = l + A +2mm
Where;
l = length of hole
Time for drilling the hole is
L
T = fN Where f = feed rate
Questions
 What is the difference b/w Multispindle and Gang Drill Machine.
A radial drilling machine is a single post floor mounted with an arm holding a drill head that
can be moved around the post and up and down the post.while A ganged head drill is usuallt
used for some kind of mass production where either several holes need to be drilled at once
or different processes that require a drill head can hold the cutters for the process saving
continuous tool changing and setup checking.
 For bolts which operation is to be used.

Counter sinking Counter boring
Page 25
 ______________________ is a finishing operation

(Reaming/ Spot Facing/ Tapping)
 Write down the motion axis system present in drilling machine.
This invention comprises a control for moving a headstock longitudinally on a radial arm of
a radial drilling machine and for moving the radial arm angularly about the axis of rotation,
by moving the headstock a predetermined distance along an X--X axis and also moving said
headstock a predetermined distance along a Y--Y axis at right angles to the X--X axis, for
bringing the axis of the drill spindle on the headstock from one drilling position to another
drilling position. One Servo motor moves the headstock on the X--X axis and another motor
moves it on the Y--Y axis. The motors may be programmed to move said headstock
automatically. When the headstock is moved on the radial arm along the Y--Y axis, angular
movement of the radial arm is accompanied by movement of the headstock longitudinally of
the radial arm. Thus, the movement of the headstock along X--X and Y--Y axes, also moves
the radial arm angularly.
Comments
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
In rock drilling, the hole is usually not made through a circular cutting motion, and the presence of
burrs on the exit side (unless they have been removed).
LAB SESSION #09
Objective
To determine the material removal rate (MMR) for drilling operation.
Apparatus
Drilling machine, Mild steel raw material, Vernier calipers, Drills etc.
Theory
Page 26
The material removal rate is indicated by the total of the material in the hole. MRR is given by the
area of cross-section of the hole times the tool travel rate through the material. Thus
M.R.R= × ×
=L/T= 16.2/78=0.207mm/s
Observations & Calculations
No. of Dia of Tool Feed rate Spindle Speed MRR

Obs. (mm) (mm/min) (rev/min) (mm3/min)
1 10 0.207 16.3
2 10 0.162 12.723
3 10 0.2125 16.689
Table 9.1
Comments
The parameters namely the spindle speed and feed rate are varied at three level to study their effect
on material removal rate (MRR), surface roughness (SR).
LAB SESSION #10

Objective
To study the parts of a Vertical Milling Machine.
Apparatus:
Vertical milling machine, Mild steel plate, Milling cutters etc.
Theory
Milling Machine
A milling machine is a machine tool used for the shaping of metal and other solid material.
Unlike a drill press, in which the workpiece is held stationary and the drill is moved vertically to
Page 27
penetrate the material, milling also involves movement of the workpiece against the rotating cutter,
the latter which is able to cut on its flanks as well as its tip. Milling machines may be manually
operated, mechanically automated, or digitally automated via computer numerical control (CNC).
Types of Milling Machines
1. Horizontal 2. Vertical
Horizontal milling machine:
Horizontal mill has the same sort of x–y table, but the cutters are mounted on a horizontal
arbor across the table. While end mills and the other types of tools available to a vertical mill may
be used in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side and face
mills, which have a cross section rather like a circular saw, but are generally wider and smaller in
diameter. Because the cutters have good support from the arbor, quite heavy cuts can be taken,
enabling rapid material removal rates.
Uses:
These are used to mill grooves and slots. Plain mills are used to shape flat surfaces. Several
cutters may be ganged together on the arbor to mill a complex shape of slots and planes. Special
cutters can also cut grooves, bevels, radii, or indeed any section desired. These specialty cutters tend
to be expensive. Simplex mills have one spindle, and duplex mills have two. It is also easier to cut
gears on a horizontal mill.
Vertical milling machine:
Vertical milling machine is so named because spindle is at right angle to the surface of the table.
Parts of Vertical Milling Machine
The vertical knee mill is the most common milling machine found in machine shops today.
Therefore it will be used as an example to describe the general parts of all mills.
Page 28
Fig. 10.1 The complete description of parts as shown in diagram

Head
The head (drive) is that part of the drive system that transforms electrical power from a
motor to mechanical power in the spindle. The drive system also allows the machinist to change the
speed of the spindle (RPM) and therefore the cutting tool. The quill moves vertically in the head
and contains the spindle in which cutting tools are installed.
Column
The column is the most important part which is mounted on the base and acts as a support
and holding device for all the other parts of a milling machine. It acts as a support for table and all
feed mechanisms. The column should be rigid enough to sustain all the forces produced due to the
drilling action of the tool. The head and worktable are mounted with column.
Work table
It gives the motion in X-direction.
Saddle
It gives the motion in Y-direction.
Knee
Page 29
It gives the motion in Z-direction.
The saddle sits on the knee and allows translation of the worktable. Sitting on the base is the
column whose main function is to hold the turret. The turret allows the milling head to be rotated
around the column's center. The over arm (ram) slides on the turret and allows the milling head to
be repositioned over the table.
Base
The whole machine is mounted on this part. The base is that part of a machine on which
the column is mounted. In the belt driven milling machines both the fast and loose pulley and cone
pulley are also mounted on the base. In general the base is of a circular cross section when viewed
from top. The base also has T-slots on it facilitating holding of large pieces for machining.
Questions
 Differentiate between up milling and down milling.
In up milling, cutter rotates against the direction of table feed. In down milling, cutter rotates
along the direction of table feed. Chip load on teeth (or uncut chip thickness) increases
gradually from zero at the point of engagement to maximum at the point of disengagement.
 Down milling provides more surface finish than up milling. How?

Each time a milling edge enters a cut, it is subjected to a shock load. The right type of
contact between the edge and material at the entry and the exit of a cut must be considered
for successful milling. In a milling operation, the workpiece is fed either along or against the
direction of the cutter rotation, which affects the start and finish of the cut, as well as if
down milling or up milling method is used.
 Write down some methods to increase the production rate in case of machining
thousand of parts on a milling machine.
You can do so not only during the day, but also at night or during the weekend. That way
you increase the number of spindles hours of your lathe or milling machine, thus better
utilizing the capacity of your machine park. By implementing CNC automation, you can
therefore manage to produce more at a lower cost.
Comments
Milling is the process of machining using rotary cutters to remove material by advancing a cutter
into a work piece. This may be done varying direction on one or several axes, cutter head speed, and
pressure.
Page 30
LAB SESSION #11
Objective
To Determine the M.R.R of a Vertical Milling Machine.
Page 31
Apparatus:
Vertical milling machine, Mild steel plate, Milling cutters etc.
Theory
Material Removal Rate;

M.R.R = w×d
Specimen calculation
Width of cut = w =12mm
Depth of cut =d= 0.8mm
Length= 43mm
Time= t = 161
Feed rate = Length/machining time
=L/t=43/161=0.26708mm/s
M.R.R=12×0.8×0.267=2.56mm/s
Questions
 How many motion axis are present in milling machine in your lab. Also tell the type of
Milling Machine.
There are three axis of milling machine that is present in our lab
Comments
Milling covers a wide variety of different operations and machines, on scales from small individual
parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes
for machining custom parts to precise tolerances. Milling can be done with a wide range of machine
tools.
LAB SESSION # 12
Objective
To study the milling cutters and their functions.
Theory
Page 32
Helix angle:
The flutes of a milling cutter are almost always helical. If the flutes were straight, the whole
tooth would impact the material at once, causing vibration and reducing accuracy and surface
quality. Setting the flutes at an angle allows the tooth to enter the material gradually, reducing
vibration. Typically, finishing cutters have a higher rake angle (tighter helix) to give a better finish.
Roughing or Finishing:
Different types of cutters are available for cutting away large amounts of material, leaving a
poor surface finish (roughing), or removing a smaller amount of material, but leaving a good
surface finish (finishing). A roughing cutter may have serrated teeth for breaking the chips of
material into smaller pieces. These teeth leave a rough surface behind. A finishing cutter may have
a large number (4 or more) teeth for removing material carefully. However, the large number of
flutes leaves little room for efficient swarf (chip) removal, so they are less good for removing large
amounts of material.
For roughing cycles generally choose up milling operation, less number of teeth, more space
between teeth, smaller rake or helix angles, higher depth of cuts, large diameter milling cutter, high
feed rate and less cutting speed.
For finishing operations generally choose down milling operation, large number of teeth on
milling cutter with small diameter milling cutters, small depth of cuts, higher rake or helix angles,
low feed rates and high cutting speed.
Selecting a milling cutter

Selecting a milling cutter is not a simple task. There are many variables & opinions to
consider, but essentially the machinist is trying to choose a tool which will cut the material to the
required specification for the least cost. The cost of the job is a combination of the price of the
tool, the time taken by the milling machine, and the time taken by the machinist.
Often, for jobs of a large number of parts, and days of machining time, the cost of the tool is
lowest of the three costs.
Page 33
Material: High speed steel (HSS) cutters are the least-expensive and shortest-lived cutters. Cobalt
steel is an improvement on HSS and generally can be run 10 faster. Carbide tools are more
expensive than steel, but last longer, and can be run much faster, so prove more economical in the
long run. HSS tools are perfectly adequate for many applications. The progression from HSS to
cobalt steel to carbide could be viewed as very good, even better, and the best.
Diameter: Larger tools can remove material faster than small ones, therefore the largest possible
cutter that will fit in the job is usually chosen.
Coating: Coatings, such as Titanium nitride, also increase initial cost but reduce wear and
increase tool life.
Helix angle: High helix angles are typically best for soft metals, and low helix angles for hard or
tough metals.
Swarf Removal
Another important quality of the milling cutter to consider is its ability to deal with the swarf
generated by the cutting process. If the swarf is not removed as fast as it is produced, the flutes
will clog and prevent the tool cutting efficiently, causing vibration, tool wear and overheating.
Several factors affect swarf removal, including the depth and angle of the flutes, the size and shape
of the chips, the flow of coolant, and the surrounding material. It may be difficult to predict, but a
good machinist will watch out for swarf build up, and adjust the milling conditions if it is
observed.
Types of Milling Cutters:

Plain Milling Cutters
These are used for peripheral or slab milling. They are cylinder shaped with several rows of teeth
on periphery. These are generally used for flat surfaces. The cutting edges are usually oriented at
a helix angle to reduce impact on entry into the work and these cutters are called helical milling
cutters.
Page 34
Tool Geometry
FIGURE: Tool geometry element of an 18-tooth plain milling cutter
Face Milling Cutters

These are designed with teeth that cut on both sides as well as the periphery of the cutter. Face
milling cutters can be made of HSS or cemented carbide inserts,
Face Milling Cutters

End Milling Cutters
These are actually designed for cutting with its peripheral teeth rather than its end. End mills are
designed with square ends, ends with radii and ball ends. End mills can be used for face milling,
profile milling and pocket milling.
Page 35
End Milling Cutters
Ball nose cutter

Ball nose cutters (lower row in image) are similar to slot drills, but the end of the cutters are
hemispherical. They are ideal for machining 3-dimensional contoured shapes in machining centres,
for example in moulds and dies. They are sometimes called bail mills in shop-floor slang, despite
the fact that that term also has another meaning. They are also used to add a radius between
perpendicular faces to reduce stress concentrations.
Experiment
No.13
Objective
Page 36
Introduction to a universal grinding machine.
Apparatus
Universal grinding machine, Mild steel rod.
Theory
Grinding:
Grinding is a process carried out with a grinding wheel made up of abrasive grains for removing
very fine quantities of material from the work piece surface. The required size of abrasive grains are
thoroughly mixed with the bonding material and then pressed into a disc shaped of given diameter
and thickness. Grinding process is used for two reasons
(i) Higher value of surface finish and accuracy that cannot be provided with the machining
process.
(ii) Hard and brittle materials that cannot be machined or it is uneconomical to use machining
Grinding wheel
A grinding wheel is made of abrasive grains held together by a bond. These grains cut like teeth
when the wheel is revolved at high speed and is brought to bear against a work piece. The properties
of a wheel that determine how it acts are the ginding parameters including the kind and size of an
abrasive matereial, how closely the grains are packed together and the type and amount of the
bonding material.
Grinding Parameters
(i) Abrasive materials
Different abrassive materials are appropriate for grinding different work material. Abrasives are
hard substances used in various forms as tools for grinding and other surface finishing operations.
They are also able to cut materials which are too hard for other tools and give better finishes and
hold closer tolerances.Commonly used abrasive materials are Al2O3, SiC etc
(ii) Grain size
It is an important parameter in determining surface finish and material removal rate. Small grit sizes
produce better finishes, larger grit sizes permit larger material removal rates. Also, harder materials
need smaller grain sizes to cut effectively, while softer materials require larger grit size. Larger
grains produce less surface finish and smaller grains produce poor finish.
Page 37
(iii) Bonding material
A strong bond is required for the good performance of a grinding wheel. Different bonding
materials serve the purpose.
(iv) Wheel Structure and Wheel Grade
A grinding wheel contains the proportion of the bonding materials, pores and abrasive material.
Wheel structure represents the relative amount b/w the abrasive material and pores. While wheel
grade represents the strength of the bonding materials. Amount of the bonding material represents
the wheel grade.
Types of Grinding Machines

Grinding machine is employed to obtain high accuracy along with very high class of surface finish
on the work piece. However, advent of new generation of grinding wheels and grinding machines,
characterized by their rigidity, power and speed enables one to go for high efficiency deep grinding
(often called as abrasive milling) of not only hardened material but also ductile materials. General
types of grinding machines are:
(i) Surface Grinding
(ii) Cylindrical Grinding
(iii) Center less Grinding
(iv) Creep feed Grinding
Surface Grinding
This machine may be similar to a milling machine used mainly to grind flat surface. However, some
types of surface grinders are also capable of producing contour surface with formed grinding wheel.
Basically there are four different types of surface grinding machines characterized by the movement
of their tables and the orientation of grinding wheel spindles as follows:
I. Horizontal spindle and reciprocating table
II. Vertical spindle and reciprocating table
III. Horizontal spindle and rotary table
IV. Vertical spindle and rotary table
Page 38
Various form of surface grinding
Grinding Parameters
Page 39
A: rotation of grinding wheel

B: reciprocation of worktable
C: transverse feed
D: down feed
Horizontal spindle reciprocating table surface grinder
Cylindrical Grinding
Cylindrical grinding is used for the rotational parts. A rotating cylindrical work piece is ground by a
rotating grinding wheel. Two types of cylindrical grinding are;
(i) Internal cylindrical grinding (grinding of internal holes)
(ii) External cylindrical grinding (grinding of external cylindrical parts)
Universal Grinding Machine
Page 40
This machine is closely related with cylindrical grinding machine but differs in its configuration. It
has a swivel table and a headstock. It has a wheel head that can be rotated on its base is called a
universal grinding machine. Cylindrical grinding machine has not these swiveling features. Due to
these features, cylindrical parts can be ground at an angle.
Questions
 What is the difference between a cylindrical grinder and a universal grinder?
The principle difference between these two types of cylindrical grinding machines is this:
Both the wheel head and work head can be swiveled in universal type grinders, where plain
grinders don't offer this feature. On the other hand, universal grinding systems are used to
grind the inside diameter of an object.
 What type of grinding parameters will be used to grind hard material with high
surface finish?
To grind hard materials a soft grade, fine-grained wheel should be used, Roughing with
coarse grit wheels can give a surface finish as high as 10.
Comments
Grinding ratios (volume of material removed/volume of wheel wear) depend on For form grinding
wheels are dressed to shape using diamond dressing.
Experiment No.14
Page 41
Objective
Perform the external cylindrical grinding operation on a rod by using the universal grinding
machine.
Apparatus
Universal grinding machine, Mild steel (raw material), Vernier callipers etc.
Theory
Grinding:
Another material removal process, in which abrasive particles are contained in bonded grinding
wheel, that operates at very high surface speed. The grinding wheel is usually in disk shaped and is
precisely balanced for high rotational speeds.
External Cylindrical Grinding

External cylinderical grinding denotes the grinding of rods externally. Shafts are ground externally
for accuracy and surface finish.
Comments
A grinding machine, often shortened to grinder, is one of power tools or machine tools used for
grinding, it is a type of machining using an abrasive wheel as the cutting tool. Each grain of
abrasive on the wheel's surface cuts a small chip from the workpiece via shear deformation.
Experiment No. 15
Page 42
Objective
Grind the different tool angles on Tool and Cutter Grinder
Apparatus
Tool & Cutter grinder, Mild steel raw material, Vernier callipers etc
Practical activity
Draw the sketch of these angles and also make them by using tool and cutter grinder
1) Bake Rake Angle (BRA) = 15 Degree
2) Side Cutting Edge Angle (SCEA) = 8 Degree
3) End Relief Angle (ERA) = 10 Degree
4) Nose Radius = 5mm
Questions
 What is the effect of different tool angles and nose radius on surface finish and
dimensional accuracy?
Therefore, the concavities formed on the machined surface decrease. Thus, a large positive
rake angle can improve the machined surface finish.The cutting force decreases with
increasing rake angle. Furthermore, when the rake angle is negative, the cutting force
decreases rapidly with increasing rake angle.
Comments
The cutting force decreases with increasing rake angle. Furthermore, when the rake angle is
negative, the cutting force decreases rapidly with increasing rake angle.
Page 43

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[ Manufacturing Process-II lab.

ITEZAZ AHMED RANJHA

IME-222 Manufacturing Process-II

Department of Industrial and Manufacturing Engineering, UET

1. To construct the layout of Machine Tool Lab.

12. To study the milling cutters and their functions.

Introduction to a Lathe Machine

Symmetrical V ways Symmetrical V ways

 How many linear & rotating axis a Lathe Machine has?

 Write down the design criteria of the bed of a Lathe Machine.

 More amount of friction is present in

 Setup time in Turret Lathe is less than Engine Lathe. How?

• To install, clean the holder and tighten the bolts.

• The tool post is attached to the machine with a T-bolt.

Design Considerations for Turning Operations

 Differentiate the following processes as generating or forming.

There should be skilled labour for these process.

LAB SESSION #04

=Final diameter = 10.1mm

M.R.R= π×d× × =3.1416×1.3×10.75×0.17

 Energy required to machine Stainless Steel is more than Aluminium. Why?

LAB SESSION #05

Observations & Calculations:

No. of Cutting Surface Dimensional

 What is the role of vibration in the surface finish of a part.

LAB SESSION #06

Observations & Calculations

No. of Depth of Surface Dimensional

LAB SESSION #07

Observations & Calculations:

No. of Feed rate Surface Dimensional

LAB SESSION #08

Fig. 6.1 The complete description of parts as shown in diagram.

Operations on drilling machine

Drilling Time Estimation:

Break through distance is

 For bolts which operation is to be used.

 ______________________ is a finishing operation

 Write down the motion axis system present in drilling machine.

LAB SESSION #09

Observations & Calculations

No. of Dia of Tool Feed rate Spindle Speed MRR

LAB SESSION #10

Fig. 10.1 The complete description of parts as shown in diagram

It gives the motion in Z-direction.

 Down milling provides more surface finish than up milling. How?

LAB SESSION #11

Material Removal Rate;

Selecting a milling cutter

Types of Milling Cutters:

FIGURE: Tool geometry element of an 18-tooth plain milling cutter

Face Milling Cutters

Face Milling Cutters

End Milling Cutters

Ball nose cutter

Introduction to a universal grinding machine.

(i) Abrasive materials