মেশিন সপ প্র্যাকটিস

শিষয়শিশিক ব্যিহাশিক শিলস মেশনিং

ক্রাফট ইন্সোক্টি মেশনিং মপ্র্াগ্রাে

মেকাশনকযাল মটকননানলাশি
ঢাকা পশলনটকশনক ইন্সটিটিউট
মেিগাঁও, ঢাকা -১২০৮।
1
CONTENTS

SL No. TITLE PAGE NO.

1 GENARAL INFORMATION 03
2 GENERAL INSTRUCTIONS & SAFETY RULES 04
3 MACHINING PROCESSES 05-07
4 PERFORM BENCH WORK (TO MAKE A MATCHING PARTS 08-10
OF DOVETAIL JOINT).
5 TOOL GEOMETRY (TO MAKE A SINGLE POINT CUTTING) 11-14
6 LIST THE MAIN LATHE MACHINE OPERATIONS 15-17

7 STEP TURNING AND TAPER TURNING 18-20

8 KNURLING AND THREAD CUTTING 21-22
9 DRILLING AND TAPPINNIG 23-24
10 V- BLOCK (BY USING SHAPER MACHINE) 25-26
11 SLOT MAKING (KEY WAY BY USING MILLING MACHINE) 27-28
12 SLOT MAKING (KEY WAY BY USING SHAPER MACHINE) 29-30
13 SPUR GEAR CUTTING-1 31-34
14 SPUR GEAR CUTTING-2 35-37
15 HELICAL CUTTING 38-39

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 GENERAL INFORMATION

This laboratory is aimed at providing an introduction to the Know-how of common

processes used in industries for manufacturing parts by removal of material in a
controlled manner. Auxiliary methods for machining to desired accuracy is covered.
The emphasis throughout the laboratory course will be on understanding the basic
features of the processes rather than details of constructions of machine, or common
practices in manufacturing or acquiring skill in the operation of machines. Evidently,
acquaintance with the machine is desirable and the laboratory sessions will provide
adequate opportunity for this.

3
 GENERAL INSTRUCTIONS AND SAFETY RULES

1. Trainees should wear the uniform and closed foot wear. Trainees inappropriately
dressed for lab, at the instructor’s discretion, be denied access).
2. When you handle chemicals wear eye protection (chemical splash goggles or full
face shield).
3. When you work with furnaces for heat treatment procedures or other thermally
activated equipment you should use special gloves to protect your hands.
4. To protect clothing from chemical damage or other dirt, wear a lab apron or lab
coat. Long hair should be tied back to keep it from coming into contact with lab
chemicals or flames.
5. In case of injury (cut, burn, fire etc.) notify the instructor immediately.
6. In case of a fire or imminently dangerous situation, notify everyone who may be
affected immediately; be sure the lab instructor is also notified.
7. If chemicals splash into someone's eyes act quickly and get them into the eye wash
station, do not wait for the instructor.
8. In case of a serious cut, stop blood flow using direct pressure using a clean towel,
notify the lab instructor immediately.
9. Eating, drinking and smoking are prohibited in the laboratory at all times.
10. Never work in the laboratory without proper supervision by an instructor.
11. Never carry out unauthorized experiments. Come to the laboratory prepared. If you
are unsure about what to do, please ask the instructor.
12. Except the scientific calculator, any other electronic devices are not permitted to
use inside the Laboratory.
13. Any damage to any of the equipment/instrument/machine caused due to
carelessness, the cost will be fully recovered from the individual (or) group of
students.

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 MACHINING PROCESSES

MACHINING PROCESSES Machining is one of the processes of manufacturing in

which the specified shape to the work piece is imparted by removing surplus material.
Conventionally this surplus material from the work piece is removed in the form of chips
by interacting the work piece with an appropriate tool. This mechanical generation of
chips can be carried out by single point or multi point tools or by abrasive operations
these are summarized below:

Machining Processes
Single point tool operations Multi-point tool operations Abrasive operations
1. Turning 1. Milling 1. Grinding
2. Boring 2. Drilling 2. Lapping
3. Shaping 3. Tapping 3. Honing
4. Planing 4. Reaming 4. Super-finishing
5. Hobbing
6. Broaching
7. Sawing

The process of chip formation in metal cutting is affected by relative motion between
the tool and the work piece achieved with the aid of a device called machine tool. This
relative motion can be obtained by a combination of rotary and translatory movements
of either the tool or the workpiece or both. The kind of surface that is produced by the
operation depends on the shape of the tool and the path it traverses through the
materials. When the workpiece is rotated about an axis and the tool is traversed in a
definite path relative to the axis, a surface of revolution is generated. When the tool
path is parallel to the axis, the surface generated is a cylinder as in straight turning
(Fig.1.) or boring (Fig.2.) operations. Similarly, planes may be generated by a series
of straight cuts without rotating the work piece as in shaping and planning operations
(Fig.3). In shaping the tool is reciprocating and the work piece is moved crosswise at
the end of each stroke. Planning is done by reciprocating the work piece and
crosswise movement is provided to the tool. Surface may be machined by the tools
having a number of cutting edges that can cut successively through the work piece

5
materials. In plane milling, the cutter revolves and moves over the work piece as
shown (Fig.4). The axis of the cutter is parallel to the surface generated. Similarly in
drilling, the drill may turn and be fed into the work piece of the workpiece may revolve
while the drill is fed into it (Fig.5). The machine tools, in general, provide two kinds of
relative motions. The primary motion is responsible for the cutting action and absorbs
most of the power required to perform the machining action. The secondary motion of
the feed motion may proceed in steps or continuously and absorbs only a fraction of
the total power required for machining. When the secondary motion is added to the
primary motion, machine surfaces of desired geometric characteristics are produced.
. Consider a situation where both the cutting motions as well as the feed motion
(provided at the end of each stroke) are rectilinear but perpendicular to each other.
Here the machined surface produced is a plane. The line generated by the primary
motion (cutting motion) is called the generatrix, while the line representing the
secondary motion (feed motion) is called the directrix (Fig. 6a). Depending upon the
shapes of the generatrix and the directrix and their relative orientation various
geometries can be produced on the workpiece. Consider another case when the
generatrix is a circle and the directrix is a line perpendicular to the plane of the
generatrix. It is clear that in this situation the surface produced will be a cylinder (Fig.
6b). A tapered surface can be produced by merely changing the angle that the directrix
makes with the plane of the generatrix. When the directrix is in the plane of the circular
generatrix (Fig. 6c), lines are generated which results in a plain surface when a number
of generatrices and directrices are placed side by side in the direction perpendicular
to the plane of the generatrix. In actual practice, the cutting is performed by cutting
edge and not a point. Thus, a series of generatrix directrix combinations are involved
and the relative motion produces a surface rather than a line. Basically there are two
methods of producing new surfaces, the tracing method and the generation method.
In the tracing method the surface is obtained by direct tracing of the generatrices and
when the surface produced is the envelope of the generatrics the process is known
as generation. Figs. 6(a) & 6{b), the plane and the cylindrical surfaces are obtained
by direct tracing, while in Fig. 6(c) the final surface geometry is the envelope of the
generatrices.

6
Fig. 1 Straight turning Fig. 2 Straight boring

Fig. 3 Shaping and planning Fig. 4 planning

Fig. 5 Drilling

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 Experiment No. Date:

PERFORM BENCH WORK (TO MAKE A MATCHING PARTS OF DOVETAIL JOINT).

AIM:
To fabricate the fitting model as per the drawing given below.

MATERIAL:
Mild Steel (M.S)

TOOLS REQUIRED:
1. Scriber.
2. Steel rule.
3. Dot Punch
4. Hacksaw frame with hacksaw blade.
5. Bench vice
6. Rectangular and triangular rough file.
7. Rectangular and triangular smooth file.
8. L- Square.

THEORY:
Marking: The marking is the first step in fitting. Marking on the work can be done by
setting out dimensions with the help of a working drawing. The measuring instruments
used
in fitting are scale, Calipers, vernier caliper, micrometer, height gauge etc. Marking
tools
used in fitting are Scriber, Dot punch, Scribing gauge etc..
Filing: Filling is the process of removing burrs from cuts, clean the face of cuts and to
give the final shape to a work piece. The flatness and squareness of the surfaces
finished by
filing are checked with try square.
Sawing: It is the method of removing excess material quickly with the help of hand
hack
–saw.

8
SKECTH

PROCEDURE
1. Check the dimensions of the given work piece with respect to the given model.
2. File the one edge of the given work piece to straightness and checked with Try
square.
3. File the adjacent edge so that it is square with first edge filed and checked with Try
square. File the upper and bottom surfaces of work piece.
4. Paste white color on the upper surface of the work piece (with chalk powder and
water).
5. By marking gauges (Scale, Try square, Scriber, Divider), mark the dimensions on
the
given work pieces.
6. Using Dot punch and Hammer, make the punch marks (dots) on the marked
dimensions on the given work piece.
7. By using hacksaw remove the extra material from the work piece and use cold
chisel,
if necessary to remove the material. Removing small amount (1 mm to 2mm) of
material Files can be used.
9
SKETCH OF THE FINISHED MODEL

PRECAUTIONS

1. Wear shoes to protect your feet.

2. Do not wear wrist watch while working.
3. Beware of the live electrical wires don’t attempt or try to touch
them.
4. Use hand glows / Welding shield.
5. Handle the tools / machines as per the instruction given by the

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Experiment No. Date:

TOOL GEOMETRY (TO MAKE A SINGLE POINT CUTTING).

AIM
To perform single point cutting tools on a given material made of Mild steel.

MATERIAL REQUIRED
A mild steel Square bar.

APPARATUS

1. Grinding Machine with standard accessories 2.

Work piece

CUTTING TOOLS

There are basically two types of cutting tools:

• Single point (e.g. turning tools).
• Multiple point (e.g. milling tools).
In general Single Point Cutting Tool is used which is made of H S S( high speed steel).
The main alloying elements in H S S are l8-4-l (i.e.; l8% Tungsten, 4% chromium and
l% vanadium, it has 0.75% carbon and l2% cobalt).Figure 2 shows the terminology of
single point cutting tool.

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12
SKECTH

The figure 2 shows a typical cutting tool and the terminology used to describe it.

Shank: The shank is the portion of the tool bit which is not ground to form cutting
edges and is rectangular in cross-section.
Face: The face of the cutting tool is that surface against which the chip slides upward.
Flank: The lank of a cutting tool is that surface which face the work piece.
Heel: The heel of a single point tool is the lowest portion of the side cutting edges.
Nose: The nose of a tool is the conjunction of the side-and end-cutting edges. A nose
radius increases the tool life and improves surface finish.
Base: The base of a tool is the underside of the shank.

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Rake: The rake is the slope of the top away from the cutting edge. The larger the rake
angle, the larger the shear angle and subsequently the cutting force and power
reduce.
End cutting edge angle: It is the angle between face of the tool and a plane
perpendicular to the side of the shank. It varies from 5 to l5 degrees.
The actual geometry varies with the type of work to be done. The standard cutting tool
shapes are shown in figure 3.

• Facing tools are ground to provide clearance with a center.

• Roughing tools have a small side relief angle to leave more material to support the
cutting edge during deep cuts.
• Finishing tools have a more rounded nose to provide a finer finish. Round nose tools
are for lighter turning. They have no back or side rake to permit cutting in either
direction.
• Left hand cutting tools are designed to cut best when traveling from left to right.
• Aluminum is cut best by specially shaped cutting tools (not shown) that are used
with the cutting edge slightly above center to reduce chatter.

TOOL ANGLES
There are three important angles in the construction of a cutting tool rake angle,
clearance angle and plan approach angle.

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Rake Angle
Rake angle is the angle between the top face of the tool and the normal to the work
surface at the cutting edge. In general, the larger the rake angle, the smaller the
cutting force on the tool. A large rake angle will improve cutting action, but would lead
to early tool failure, since the tool wedge angle is relatively weak. A compromise must
therefore be made between adequate strength and good cutting action.
Clearance Angle
Clearance angle is the angle between the flank or front face of the tool and a tangent
to the work surface originating at the cutting edge. All cutting tools must have
clearance to allow cutting to take place. Clearance should be kept to a minimum, as
excessive clearance angle will not improve cutting efficiency and will merely weaken
the tool. Typical value for front clearance angle is 6° in external turning.

TOOL MATERIALS IN COMMON USE

The different materials 5. Cemented carbides
used for cutting tools
are: 1. High carbon
steel
2. Alloy steels 6. Ceramics
3. High speed steel 7. Diamonds
4. Stellites 8. Abrasives
Cemented Carbides: An extremely hard material made from tungsten powder. Carbide
tools are usually used in the form of brazed or clamped tips. High cutting speeds may
be used and materials difficult to cut with HSS may be readily machined using carbide
tipped tool.

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Experiment No. Date:

LIST THE MAIN LATHE MACHINE OPERATIONS REQUIRED

TO MAKE THE PART shown below: (6 marks)

AIM
To perform various lathe operations such as facing, Centre Drilling, Parallel turning,
taper turning, Grooving, Threading, Drilling, step turning and on a given material made
of Mild steel.

MATERIAL REQUIRED
A mild steel bar of 45 mm diameter and 70 mm length.

TOOLS AND EQUIPMENT USED

H.S.S. single point cutting tool,
Chuck key,
Tool post key,
Outside caliper,
Steel rule.

SEQUENCE OF OPERATIONS
1. Facing H.S.S Single Point tool
2. Rough turning H.S.S Single Point tool
3. Finish turning H.S.S Single Point tool
4. Step turning H.S.S Single Point tool
5. Taper turning H.S.S Single Point tool

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SKECTH

SL No. Name of the part

1 Facing
2 Centre Drilling
3 Parallel Turning
4 Taper Turning
5 Grooving
6 Threading/ Drilling

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1. Define the term “facing operation”?
Facing is to remove a small amount of material (around 1 – 2 mm) from the end of the
workpiece to produce smooth and true face and also to bring the workpiece to the
desired length. The two ends of the workpiece is cut to make it flat, straight and to
reduce the workpiece length to the required size. This operation is called Facing.

2. For what purposes do we need to do center drilling?

Center holes are used either to be used as a seat for the tailstock centers which may
support the workpiece or as start and guide for drilling operation. This operation of
making small conical spot on the end of the workpiece is called center drilling.

3. What is the function of the graduated collars?

Graduated Micrometer Collars:
They assist the lathe operator in setting the cutting tool accurately to remove the
required amount of material from the workpiece.
The cross slide graduated collars may indicate the distance that the cutting tool has
moved toward the work, or the amount that will be removed from the work diameter.

4. Mention one method used to bring the cutting tool tip to the center of the machine?
This means that the lathe tool point should be the same height as the tip of the
tailstock centre. If this is not done and the tool point is either above or below the
centre point - usually the finish to the steel will be poor. Also, a significant amount of
vibration could take place during turning.

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Experiment No. Date:

STEP TURNING AND TAPER TURNING

AIM
To perform various lathe operations such as facing, plain turning, step turning and
taper turning on a given material made of Mild steel.

MATERIAL REQUIRED
A mild steel bar of 25 mm diameter and 100 mm length.

TOOLS AND EQUIPMENT USED

H.S.S. single point cutting tool,
Chuck key,
Tool post key,
Outside caliper,
Steel rule.

SEQUENCE OF OPERATIONS
1. Facing H.S.S Single Point tool
2. Rough turning H.S.S Single Point tool
3. Finish turning H.S.S Single Point tool
4. Step turning H.S.S Single Point tool
5. Taper turning H.S.S Single Point tool

PROCEDURE
 The work piece is fixed in a 3 – jaw chuck with sufficient overhang.
 Adjust the machine to run the job to a required cutting speed.
 Fix the cutting tool in the tool post and centering operation is performed so that the
axis of the job coincides with the lathe axis.
 Give the feed and depth of cut to the cutting tool.
 Facing operation is performed from the center of the job towards outwards or from
the circumference towards the center.

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 Plain turning operation is performed until the diameter of the work piece reduces
to 23 mm.
 Check the dimensions by using vernier calipers.
 Perform the plain turning operation on the same work piece for the required length
in order to reduce the diameter to 18 mm so as to get the step turning.
 Using a V – cutting tool grooving operation is performed according to the given
dimensions and finishes the groove using parting tool. Swivel the compound slide to
the required angle and perform taper turning operation by rotating the compound slide
wheel.
 The angle can be measured by using the formula tanα = (D – d) / 2L.
 Finally check the dimensions by using vernier calipers.

PRECAUTIONS
 The work piece should be held rigidly in the chuck before operating the machine.
 Tool should be properly ground, fixed at correct height and properly secured, and
work also be firmly secured.
 Before operating the machine see whether the job and tool is firmly secured in
devices or not.
 Optimum machining conditions should be maintained.
 Chips should not be allowed to wound around a revolving job and cleared as often
as possible
 Apply cutting fluids to the tool and work piece properly.

MODEL CALCULATIONS

The amount by which the compound rest has to be swivel is estimated using the taper
angle. Taper angle is calculated as follows.
Taper angle (α) = tan-1(D-d)/2L
Where,

D = Diameter of bigger end, mm

d = Diameter of smaller end, mm
L = Length of taper, mm

20
SKECTH

21
Experiment No. Date:

KNURLING AND THREAD CUTTING

AIM
To perform Thread cutting and Knurling operation on the given work piece.

MATERIAL REQUIRED
Mild Steel rod of 25 mm diameter and 100 mm long

TOOLS REQUIRED
Vernier calipers,
Steel rule,
Spanner,
Shuck spanner
H.S.S. single point cutting tool

PROCEDURE
 The work piece is fixed in a 3 – jaw chuck with sufficient overhang.
 Adjust the machine to run the job to required cutting speed.
 Fix the cutting tool in the tool post and centering operation is performed so that the
axis of the job coincides with the lathe axis.
 Facing is performed by giving longitudinal depth of cut and cross feed.
 Perform plain turning operation until the diameter of the work piece reduced to
20mm.
 Using V-cutting tool and parting off tool perform grooving operation to the required
dimensions.
 Reduce speed of the spindle by engaging back gear and use Tumbler feed reversing
mechanism to transmit power through the lead screw.
 And calculate the change gears for the required pitch to be made on the work piece.
 Using half nut mechanism perform thread cutting operation (right hand threading)
according to the given dimensions and continues it until required depth of cut is
obtained.
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 At the same speed knurling operation is performed using knurling tool.

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 For every operation check the dimensions using vernier calipers.

PRECAUTIONS
 Before starting the spindle by power, lathe spindle should be revolved by one
revolution by hand to make it sure that no fouling is there.
 Tool should be properly ground, fixed at correct height and properly secured, and
work also be firmly secured.
 Chips should not be allowed to wind around a revolving job and cleared as often
as possible.
 Before operating threading operation, V-tool should be properly ground to the
required helix angle.
 Apply cutting fluids to the tool and work piece property.
 No attempt should be made to clean the revolving job with cotton waste.
 On hearing unusual noise, machine should be stopped.

SKECTH

24
Experiment No. Date:

DRILLING AND TAPPING

AIM
To perform drilling, and tapping operations on the given M.S Flat work piece.

APPARATUS

1. Drilling Machine with standard accessories 2.

Work piece

MATERIAL

Mild Steel flat plate 50 mm × 50 mm ×10 mm

PROCEDURE

 The given work piece is first filed to get required length, breadth and thickness wet chalk is applied
on four sides and with the scriber lines are drawn to get center hole at required location.

 The centers are punched with a Punch and hammer.

 The work piece is fixed firmly in the vice of the Drilling Machine

 3/8” drill bit is fixed firmly in the chuck and drilling is performed giving uniform depths.

 The drill bit is removed from the drill chuck and is replaced by a reamer.

 The reaming operation is performed on the hole which has been previously drilled.

 The work is removed from the vice for performing tapping operation.

 The job is fixed firmly in a bench vice.

 Tap is fixed in the tap handle and pressure applied on the taps to obtain internal thread.

PRECAUTIONS

 Reaper should be free from moisture

 Marking is done without parallax error

 Care should be taken while cutting and drilling.

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 While performing drilling and tapping operations lubricant should be used to minimize the friction.

26
SKECTH

27
Experiment No. Date:

V- BLOCK (BY USING SHAPER MACHINE)

AIM
To make a V Block as per the given sketch and dimension by Shaper operations.

MATERIAL REQUIRED

A Mild steel block of size 50x60x60mm

MACHINNE REQUIRED

Shaper machine

CUTTING TOOLS

Steel rule, surface gauge, vernier caliper, vernier height gauge, try-square, single point ‘V’ HSS
cutting tool with tool holder, etc.

SEQUENCE OF OPERATIONS

1 .Marking,.

2 .Fix the specimen in the machine vice

3..By giving the required feed and depth of cut, the required cut is being made progressively.

PROCEDURE

Held the work piece in the shaper machine table and rigidly clamped.

Held the single point ‘V’ HSS cutting tool in the tool post.

Check whether the work piece surface is perpendicular to the cutting tool.

Arrange the ram in suitable position and adjust the stroke length.

Start the shaper machine by turn the power switch and clutch lever.

To be machined all six faces neatly, considering the faces are perpendicular to each other and
check the dimensions.

Rotate and fix the apron in suitable angle in both sides and machine the inclined surface.
28
 By using a form tool, make the two slots as per the drawing.

Clean the machine and remove all scraps from the tray.

PRECAUTION:

 Choose proper feed and depth of cut.

 Feed should be controlle4d to avoid to any damage to the cutting tool.

 Fix the work piece is properly into the vice.

 During cutting to supply coolant in between to the work piece and tool.

29
 Adjust the stroke length properly.

SKECTH

30
Experiment No. Date:

SLOT MAKING (KEY WAY BY USING MILLING MACHINE)

AIM
To make a slot on the given work piece.

MATERIALS REQUIRED
M.S Round Bar

MACHINE REQUIRED
Milling machine

MEASURING INSTRUMENTS
Vernier calipers slip gauges.

CUTTING TOOLS
H.S.S. Tool bit of the required slot size.

SEQUENCE OF OPERATIONS
 Fix the specimen in the three-jaw chuck of the slotting machine
 By giving the required feed and depth of cut, the required slot is being made
progressively

PROCEDURE
 Fix the work piece in the head stock chuck firmly
 Turning tool is fixed in the tool post and centering is to be done
 Turn the job to get a diameter of required length
 Facing is to be done on one side of the job
 Drill bit of 8 mm diameter is fixed on tail stock and centering of work
Piece is to be done by feeding through tail stock.
 Drill bit of 25 mm diameter is fixed in tail stock
 Drill through a hole of 25 mm diameter in the work piece feeding the
tailstock. Boring tool is the fixed on tail stock to perform boring operation to get
a hole of required diameter
 Fit the job in reverse position in the chuck

31
 Facing of other side of the work piece is to be done to get the required
length of the job
 Drilled work piece is fixed on slotting machine.
 A slot of required depth is made
 Slowly cross and longitudinal feed is given to obtain slots as per
requirement.

PRECAUTIONS
 Choose proper feed and depth of cut.
 Feed should be controlled to avoid any damage to the cutting tool
 Lock the index table before starting the operation.
 Care has to be taken so as to maintain the right feed of the material.
 Work-wheel interface zone is to be flooded with coolant

SKECTH
-

32
Experiment No. Date:

SLOT MAKING (KEY WAY BY USING SHAPER MACHINE)

AIM
To make a key way in the given hollow cylindrical work piece.

MATERIAL REQURED
Cylindrical work piece.

MACHINNE REQUIRED
Shaper machine

TOOLS REQUIRED
1.Scriber 2.Punch
3.Hammer

4. Slotting tool 5.Steel

Rule

6.Bolt and nut for holding

7.Spanner set.

SEQUENCE OF OPERATIONS
1 .Fix the specimen in the machine vice

2 .By giving the required feed and depth of cut, the required cut is being made progressively.

PROCEDURE
1.Hold the work piece on the table by using bolt and nut. 2.Set the
tool in the tool post.

3.Arrange for slotting movement.

4.Give 0.1 mm depth of cut. 5.Finish
to dimensions

6. Switch of the machine

7. Check the work piece for dimensions.

33
PRECAUTION:
 Choose proper feed and depth of cut.

 Feed should be controlle4d to avoid to any damage to the cutting tool.

 Fix the work piece is properly into the vice.

 During cutting to supply coolant in between to the work piece and tool.

34
 Adjust the stroke length properly.

SKECTH

35
Experiment No. Date:

SPUR GEAR CUTTING

AIM
To perform plane milling operation on the given specimen (mild steel)

MATERIALS REQUIRED
Mild steel specimen.

MACHINE REQUIRED
Milling machine

MEASURING INSTRUMENTS
Vernier calipers

CUTTING TOOLS
Plane (face) milling cutter

MARKING TOOLS
Steel rule, scriber
a. Work holding fixtures: work piece supporting fixtures
b. Miscellaneous tools: Hammer, brush, Allen keys
SEQUENCE OF OPERATIONS
i. Measuring of specimen
ii. Fixing of specimen in the milling m/c.
iii. Giving the correct depth and automatic feed cut the specimen
iv. Check the specimen with Vernier caliper at the end.

PROCEDURE
 Select and cut a piece of stock to make the blank. Allow at least
1/8 inch excess material on the diameter and thickness of the blank for
cleanup cuts.
 Mount the stock in a chuck on a lathe. At the center of the blank, face
an area slightly larger the than the diameter of the required bore.
 Drill and bore to the required size (within tolerance). Remove the blank
from the lathe and press it on a mandrel.
 Set up the mandrel on the milling machine between the centers of the
36
index head and the footstock. Dial in within tolerance.

37
 Select a involute gear cutter and mount and center it. Set the index
head to index 24 divisions. Start the milling machine spindle and move the table up
until the cutter just touches the gear blank.
 Set the micrometer collar on the vertical feed handwheel to zero, then
hand feed the table up toward the cutter slightly less than the whole depth of the
tooth. Cut one tooth groove.
 Then index the work piece for one division and take another cut.
Check the tooth dimensions with a vernier gear tooth caliper as described
previously.
 Make the required adjustments to provide an accurately “sized” tooth.
Continue indexing and cutting until the teeth are cut around the circumference
of the work piece.
 The top surface of the job is milled in stages; giving finish cuts towards
the end such that, the height of the job is exactly 40 mm.
 The burrs if any along the edges are removed with the help of the flat file.

MODEL CALCULATIONS

Indexing Ratio = 𝒏
𝑵

Where, n = No. of slots on the periphery of the indexing plate.

N = Required number of divisions

Direct Indexing

Indexing Ratio =𝟐𝟒

𝑵

Where N= required number of divisions

Simple Indexing
Number of holes to move =𝟒𝟎
𝑵

Where N= required number of divisions

38
Standard Brown and Sharp Index Plates
No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 31, 33 No.3:
37, 39, 41, 43, 47, 49

Example: It is required to divide the periphery of a job into 60 divisions.

Crank Movement (Indexing Ratio) according to simple Indexing = 40/60 = 2/3
𝟐 𝟐 𝟔 𝟏𝟐
= × =
𝟑 𝟑 𝟔 𝟏𝟖

The crank has to move 12 holes on 18 holes circle.

PRECAUTIONS
 The milling machine must be stopped before setting up or removing a
work piece, cutter or other accessory
 Never stop the feeding of job when the cutting operation is going on,
otherwise the tool will cut deeper at the point where feed is stopped.
 All the chips should be removed from the cutter. A wiping cloth should
b
eplaced on the cutter to protect the hands. The cutter should be rotated in the
clockwise direction only for right handed tools.
 The work piece and cutter should be kept as cool as possible (i.e. coolant
should be used where necessary to minimize heat absorption).
 The table surface should be protected with a wiping cloth.
 Tool must be mounted as close to the machine spindle as possible.

39
SKECTH

40
Experiment No. Date:

SPUR GEAR CUTTING

AIM:
To fabricate the spur gear model according to the figure given below.

MATERIAL:
Mild Steel (M.S)

TOOLS REQUIRED:
Milling cutter, Indexing head, vernier caliper etc.

MARKING TOOLS
Steel rule, scriber
a. Work holding fixtures: work piece supporting fixtures
b. Miscellaneous tools: Hammer, brush, Allen keys

SEQUENCE OF OPERATIONS
i. Measuring of specimen
ii. Fixing of specimen in the milling m/c.
iii. Giving the correct depth and automatic feed cut the specimen
iv. Check the specimen with Vernier caliper at the end.

PROCEDURE:
a. Fix the gear blank in milling mandrel between supporting center and Indexing head
centre.
b. Fix the milling cutter in Arbor.
c. Calculate indexing for given blank diameter and find out the number of teeth i.e. Z
.
d. Bring the cutter near the blank and it should touch the work piece.
e. Give depth of cut by knee elevating handle according to the calculations.
f. Continue this indexing procedure for the required number of teeth and complete the
model.

41
MODEL CALCULATIONS

Indexing Ratio = 𝑛
𝑁

Where, n = No. of slots on the periphery of the indexing plate.

N = Required number of divisions

Direct Indexing

Indexing Ratio =24

𝑁

Where N= required number of divisions

Simple Indexing
Number of holes to move =40
𝑁

Where N= required number of divisions

Standard Brown and Sharp Index Plates

No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 31, 33 No.3:
37, 39, 41, 43, 47, 49

42
SKECTH

43
 Helical gear cutting on Milling Machine
AIM:
To make a helical gear from a Aluminum shaft using milling machine

MATERIAL REQUIRED :
Aluminum shaft of Ф50 mm

TOOLS REQUIRED :
1. Turning tool
2. Milling cutter ( 2 mm module )
3. Vernier caliper ( 0- 150 mm)
4. Drilling tool Ф 10 mm ,Ф20 mm
5. Mandrel Ф 20 mm
6. Spanner
7. Gear tooth Vernier

FORMULA :
Outer diameter = (N+2) M,
Module =OD/ (N+2),
No .of teeth = (OD/M) -2
N- Number of teeth
M=module
OD= outer diameter

PROCEDURE OF HELICAL GEAR CUTTING:

1. Turn the given CI bank to required diameter in center lathe.
2. Drill a hole in the blank of diameter equal to mandrel size.
3. Fix the blank between two centers of the dividing head using mandrel.
4. Set the milling cutter on the machine spindle and select the suitable
speed.
5. Raise the table (knee) vertically up until blank touches the cutter.
6. Calculate depth of cut and indexing calculation from module & number
of teeth.
7. Give the depth of cut by raising the knee up.
8. According to index calculation set the dividing head.
9. Switch on the spindle and feed the blank against the rotating cutter by
44
reciprocating the table
10. Move the index arm on the index plate according to the calculated
number of holes.
11. Feed the blank against the rotating cutter to cut the next tooth.
12. Repeat the same for remaining teeth

helical gear calculation

MODEL CALCULATION FOR HELICAL GEAR:

No of teeth(z) = 30

Module(m) = 2 mm

External dia. of blank = (z+2)*m

= (30+2)*2=64

Depth of cut =2.25*m

= 2.25*2
= 4.5 mm

The indexing crank rotation = one complete rotation and move arm holes
in 33 concentric circle.

45
Material :- MS/SS/Forge Steel/Plastic/Aluminum/Brass
Power Transmission Shaft :- Solid Round Shaft
Load bearing : Torque- HP- N(rpm)-
Data : Formula :
1. Module (m) = 2.75mm Pitch Dia = m x N/Cos
2. No of Teeth (N) = 18 Out side Dia = m x (N+2)/cos
3. Helix angle () = 150 Full Depth = m x 2.25
4. Pressure Angle = 14.50 Helix lead = Pie x Pd/ tan
5. Involutes, Full depth M/C lead = m/c lead pitch x
Index constant (5x40)
Calculation-
Pd =51.25mm Helix lead = 600 mm
OD = 57mm m/c lead = 200mm
Full Depth = 6.2mm Gearing = 3:1
Cutter no = 3 = 60/20
Bore Dia = 20mm Indexing = 40/18 = 2+4/18
Face with = 22mm

46