DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF MORATUWA

ME 2023: MANUFACTURING ENGINEERING I

HANDBOOK OF LAB SESSIONS

Year 2021 Course BSc Eng Hons

Batch 19 Session Semester 3
Module Code ME 2023 Module Title Manufacturing Engineering I

Module Lab session

Dr JR Gamage Mr MDA Wickramasinghe
Coordinator Coordinator
Mr MDA Wickramasinghe
Mrs. N.H. Dias (Metrology
Mr GC Vimantha
Lab)
Mr MDSD Chandrasiri
Resource Laboratory Mr. K.P.S.P. Dayananda
Mr NM Fernando
Personnel Facilitators (Production Lab)
Mr PM De Saram
Mr G.P. Fernando (Work-
Mr M Ehalagasthenna
shop)

Laboratory Assignments

ME2023_P1 Familiarisation with basic measuring instruments Metrology Laboratory

ME2023_P2 Assessment of surface texture Metrology Laboratory

Production Engineering La-

ME2023_P3 Familiarisation with heat treatment
boratory
Analysis of cutting parameters using Lathe Tool
Production Engineering La-
ME2023_P4
Dynamometer boratory

ME2023_P5 Familiarisation with milling operations Machine Shop

Familiarisation with shaping, drilling and grinding

ME2023_P6 Machine Shop
operations

Name

Index No. Group No.

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Department of Mechanical Engineering, University of Moratuwa
Copyright Notice

Copyright © 2020 by the Department of Mechanical Engineering, University of Moratuwa, Katubedda,

Sri Lanka.

All rights reserved. No part of this book may be reproduced or quoted in any form or by any means, elec-
tronic or mechanical, including photocopying, recording or by any information storage or retrieval sys-
tem, without permission in writing from the Department of Mechanical Engineering, University of Mora-
tuwa.

Table of Contents
Introduction ......................................................................................................................................... 5

1.1 General Overview .................................................................................................................. 5

1.2 List of Practicals..................................................................................................................... 5

1.3 Submission of Work............................................................................................................... 5

1.4 Assessment ............................................................................................................................. 5

1.5 Safety at Work ....................................................................................................................... 6

Familiarisation with basic measuring instruments - Introduction ....................................................... 7

2.1 Background ............................................................................................................................ 7

2.2 Learning objectives of the lab session ................................................................................... 8

2.3 Learning outcomes of the lab session .................................................................................... 8

2.4 Work to be performed ............................................................................................................ 8

2.5 Instruments ............................................................................................................................. 9

Assessment of surface texture– Introduction .................................................................................... 10

3.1 Background .......................................................................................................................... 10

3.2 Learning objectives of the lab session ................................................................................. 11

3.3 Learning outcomes of the lab session .................................................................................. 11

3.4 Work to be performed .......................................................................................................... 11

3.5 Surface Roughness Chart ..................................................................................................... 12

Familiarization with heat treatment - Introduction ........................................................................... 13

4.1 Background .......................................................................................................................... 13

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4.2 Learning objectives of the lab session ................................................................................. 14

4.3 Learning outcomes of the lab session .................................................................................. 14

4.4 Work to be performed .......................................................................................................... 14

4.5 Heat treatment furnace ......................................................................................................... 15

Analysis of cutting parameters using Lathe Tool Dynamometer - Introduction............................... 16

5.1 Background .......................................................................................................................... 16

5.2 Learning objectives of the lab session ................................................................................. 17

5.3 Learning outcomes of the lab session .................................................................................. 17

5.4 Work to be performed .......................................................................................................... 17

5.5 Instructions to prepare the report ......................................................................................... 17

Annexe I: Guideline for the coursework report ........................................................................................ 19

Annexe II: Coursework marking scheme ................................................................................................. 21

Annexe III: Worksheet-P01 ...................................................................................................................... 22

Annexe IV: Worksheet – P02 ................................................................................................................... 24

Annexe V: Worksheet – P03 .................................................................................................................... 26

Annexe VI: Worksheet – P04 ................................................................................................................... 28

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Department of Mechanical Engineering, University of Moratuwa

Introduction
1.1 General Overview
Manufacturing engineering is a discipline of engineering dealing with different manufacturing technolo-
gies. Knowledge of the underlying principles is important for understanding the proper use of technology.
In that context, this practical series is designed to introduce basic operations relevant to production at Me-
trology & Production Engineering Laboratories as well as at the Machine Shop.

1.2 List of Practicals

Duration
Topic Lab / Workshop
(hours)
P01 Familiarisation with basic measuring instruments 3 Metrology
P02 Assessment of surface texture 3 Metrology
P03 Familiarisation with heat treatment 3 Production Engineering
Analysis of cutting parameters using Lathe Tool Dyna-
P04 3 Production Engineering
mometer
P05 Familiarisation with milling operations 3 Machine Shop
Familiarisation with shaping, drilling and grinding oper-
P06 3 Machine Shop
ations

1.3 Submission of Work

The following work to be submitted at the end of each practical session.
• Fully completed worksheets in P01, P02 & P03
• Completed work-piece in P05, & P06
The following work to be submitted two weeks after the date of conduct of practical.
• Report on P04

1.4 Assessment
Practical work will contribute 12% to the final grade of the module.
Practical work will be assessed based on;
• Submissions, and
• The questionnaire given at the end of each practical session.
A student will be eligible to obtain the marks for the practicals if and only if he/she has completed the
practical session according to the guidelines given by the instructors. 100% attendance for all practical
sessions is compulsory to complete the module. A student may be excused for his/her absence only for a
justifiable and valid reason. However, only one make-up session will be arranged to accommodate the
eligible absentees.

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Department of Mechanical Engineering, University of Moratuwa
1.5 Safety at Work
In a workshop or laboratory, there are several machines and other equipment which have different types
of moving parts and other dangerous projections which may cause hazardous accidents, fatal injuries if
proper measures are not taken for safeguarding against them. It is thus very essential for its user to know
the basic safety measures and be aware of the dangers which may exist in a workshop. Workshop users
should understand and practice safe working procedures, to avoid accidents, not only for themselves but
also for others.

Common causes of accidents are poor housekeeping, lack of skill or knowledge, loose clothing, careless-
ness, use of improper or defective tools, bad lighting and ventilation, insufficient working space, violation
of safety rules, non-observance of safety precautions, etc. Students are required to wear proper dress and
shoes when working in a workshop. He or she should adhere to the safety rules imposed by the workshop
personnel and act responsibly. Wear safety goggles, face shields, dust masks, safety gloves, etc. where
necessary. Clean the workbenches and machines at the end of the practical. The scrap should also be kept
in scrap boxes at all times.

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Department of Mechanical Engineering, University of Moratuwa ME2023 – P1

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF MORATUWA

Year 2021 Course BSc Eng Hons

Batch 19 Session Semester 3
Module code ME2023 Module title Manufacturing Engineering I
Laboratory
MET Laboratory Metrology Laboratory
code
Coursework ME2023- Title of Lab
Familiarisation with basic measuring instruments
No. P1 class

Instructor Mr MDSD Chandrasiri Facilitators Mrs. N.H. Dias

Familiarisation with basic measuring instruments - Introduction

Engineering production incorporates the requirement of precision measurement. This necessitates the de-
sign and use of different devices to fulfil individual requirements. This laboratory session is designed to
familiarise with the basic measuring instruments used frequently in the manufacturing world.

2.1 Background
‘Engineering Metrology’ is defined as the measurement of dimensions: length, thickness, diameter, taper,
angle, flatness, profiles, and others. Numerous measuring instruments and devices are used in engineering
metrology of which has its own, sensitivity, precision and application.

Sensitivity and precision are two terms that are commonly used to describe the type and quality of an in-
strument. Sensitivity, also called Resolution, is the smallest difference in dimensions that the instrument
can detect or distinguish. A wooden yardstick, for example, has far less sensitivity than a finely graduated
steel ruler. Precision, sometimes incorrectly called as accuracy, is the degree to which the instrument
gives a repeated measurement of the same standard. A wooden or aluminium ruler, for example, will ex-
pand or contract, depending on the environment, thus giving different measurements. Accuracy of an in-
strument is defined as the degree of agreement of the measured dimension with its true magnitude. It is
highly depended upon the aforementioned sensitivity and precision

Traditionally, measurements have been made after the part has been produced; this is known as post-
process inspection. Here, the term “inspection” means checking the dimensions of what has been pro-
duced or is being produced and determining whether it complies with the specified dimensional accuracy.
The trend now is to make measurements while the part is being produced on the machine; this is known
as in-process or real-time inspection. Inspection of parts or products can be done in two ways.
1. By variables, with the use of calibrated instruments to determine the actual dimensions of the
product for comparison with the size desired. These are adjustable devices and can measure di-
mensions with greater accuracy.

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2. By attributes, with the use of gauges to determine if the product is good or bad, resulting in a yes
or no, go or not-go decision. In most cases, these have no adjustable member for measuring vary-
ing dimensions of lengths and angles.

The parts manufactured on a large-scale manufacturing basis must be produced according to rigid engi-
neering specifications to facilitate easy assembly. The measuring instruments, tools and gauges are used
to measure, check and set the dimensions specified. They are used to detect an inaccuracy in machining to
eliminate defects and rejections. In addition to measurements, they are used to set, adjust tools, to align
machines and layout the surfaces to be machined.

In modern manufacturing technology, many parts are processed using a high degree of accuracy, and thus
require measuring instrumentation with several features and characteristics. Major advances have been
made in electronic measuring instruments to support such manufacturing operations. Digital callipers/
micrometres, laser scanners and coordinate measuring machines are some of the popular devices which
are available for inspection in most modern manufacturing facilities.

2.2 Learning objectives of the lab session

• To develop an awareness of some basic measuring instruments.
• To familiarize with the correct usage of the instruments.
• To understand the need of selecting the correct measuring instrument for a given job.
• To develop an awareness of the interaction between Engineering Metrology and Manufacturing.

2.3 Learning outcomes of the lab session

On successful completion of this lab session, the student should be able to:
• Identify the key aspects or features of some basic measuring instruments.
• Identify key dimensions and features of a manufactured item.
• Select appropriate measuring instruments and techniques for a given application.
• Use the instruments to measure and compare dimensions.

2.4 Work to be performed

STEP 1 – Overview
• Introduction to the practical work and general safety precautions inside the laboratory.

STEP 2 – Familiarisation
• Examine each of the instruments given to you and study the method of construction, kind of
measurements possible, limits, resolution (the least count), etc. (Read Pg. 6 & 7)
• Use each instrument to measure key dimensions of given test specimens.
• Compare the results obtained from each instrument.
• Discuss errors of measurement and how to avoid them.

STEP 3 – Practice
• Identify the key dimensions (i.e., linear, angular…etc.) of the given components.
• Draw a neat free-hand sketch of the components and give appropriate notations (i.e., A, B,
C…etc.) to its key dimensions. (Fill WORKSHEET)

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• Measure the identified key dimensions using the given apparatus and use different instruments to
measure the same dimensions.
• Show the results in tabular form (Refer Appendix). (Fill WORKSHEET)
• Compare and discuss the results obtained from each instrument.

2.5 Instruments
The list of items given below comprises several commonly encountered measuring instruments in me-
chanical engineering work, especially in the area of manufacturing engineering. Apply check marks on
the instruments which you have come across during the practical.

Steel Ruler Venire Protractor Go, No-Go Gauges

Venire Caliper Sine Bar Bore Gauge
Dial Vernier Caliper Try Square Feeler Gauge
Digital Vernier Cali-
Combination Set Square Wire Gauge
per
Micrometer Spirit Level Screw Pitch Gauge
Digimatic Micrometer Surface Plate Radius/ Fillet Gauge
Inside Micrometer Angle Plate Pin Set
Depth Gauge Slip Gauges Inside Caliper
Height Gauge Dial Gauges Outside Caliper
Thickness Gauge V-Blocks Mikrokator
Dial Caliper Gauge Dial Indicator Stand Profile Projector

Any other (specify in the space given below)

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Department of Mechanical Engineering, University of Moratuwa ME2023-P2

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF MORATUWA

Year 2021 Course BSc Eng Hons

Batch 19 Session Semester 3
Module code ME2023 Module title Manufacturing Engineering I
Laboratory
MET Laboratory Metrology Laboratory
code
Coursework ME2023- Title of Lab
Assessment of surface texture
No. P2 class

Instructor Mr GC Vimantha Facilitators Mrs. N.H. Dias

Assessment of surface texture– Introduction

Every part’s surface is made up of a texture which varies due to manufacturing techniques and the part
structure itself. To understand a component’s surface and to control the manufacturing process to the de-
gree required in today’s modern world, it is necessary to quantify the surface in both two and three di-
mensions. This laboratory session is designed to familiarise basic surface texture parameters and standard
methods used to assess them.

3.1 Background
‘Surface Texture’ of a given surface can be expressed as the degree of irregularities from its nominal sur-
face. Any manufactured surface has irregularities due partly to the nature of the material but to a greater
extent to the finishing operation used. The description of surface texture as a geometrical property is
complex. However, certain guidelines have been established for identifying surface texture in terms of
well-defined and measurable quantities. Surface-texture parameters can be grouped into these basic cate-
gories are as follows.

Parameter Description
Closely spaced, irregular deviations with relatively small pitches, expressed in terms
Roughness
of its height, its width and its distance along which it is measured
Recurrent deviation from a flat surface, expressed in terms of space between adja-
Waviness cent crests of the waves (waviness width) and height between the crests and valleys
of the waves (waviness height)
Lay The direction of the predominant surface pattern, usually visible to the naked eye
Random irregularities, such as scratches, cracks, tears, dents and other local damage
Flaws caused by surface contact with another part, tool or container; imperfections due to
the presence of slag, checks, blowholes, inclusions and scale.

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‘Machine Finish Designation’ provides a series of limiting values between the extremes of machine fin-
ish. Such designation set up several standard measurable roughness values for universal acceptance as
reference points in controlling the surface quality of precision parts. A comprehensive program of surface
finish designation, to do its job properly, must clearly state which surfaces are critical and what are not.
Surface finish control directly affects industrial personnel all along the line. The engineer must know how
to specify the surface finish most satisfactorily for a specific application. The inspector must know how
to judge the surface roughness of a part, how to compare it accurately with given standards, and how to
determine whether the part confirms to the drawing requirements. The machinist must know the range of
finishes he can produce on a machine, and how to produce them at will to lie within the roughness limits
specified on a drawing. The control of all these factors falls within the objectives of a practical system of
machine finish designation.

3.2 Learning objectives of the lab session

• To appreciate the surface quality of a manufactured item and its importance.
• To develop an awareness of some surface texture parameters.
• To familiarize with surface standards.
• To familiarize with the correct usage of the Surtronic Tester.

3.3 Learning outcomes of the lab session

• On successful completion of this lab session, the student should be able to:
• Appreciate the theory of surface texture measurement.
• Measure the surface texture of a manufactured item.
• Select appropriate methods to control surface texture.

3.4 Work to be performed

STEP 1 – Overview
• Introduction to the practical work and general safety precautions of instrumentation.
STEP 2 – Familiarisation
• ACTIVITY 1 – Estimation of surface texture using the Surface Standard Book
The test specimens are first compared to surface texture standards. The surface standards are in the form
of small replicas of machined surfaces moulded in plastic. Each surface replica has the method of ma-
chining and the Centre Line Average (C.L.A) index embossed into it. By stroking the tip of the index fin-
ger across the test specimen and across the surface standards an assessment of the C.L.A index can be
made. The method of production and the estimated C.L.A index are noted.
• ACTIVITY 2 – Measurement of the surface texture using the Surtronic Tester
To determine an accurate value for the surface texture the Surtronic Tester is used. The tester consists of
a drive unit, which carries the pickup, and an electronic computation device to produce surface measure-
ments directly as the test is taking place. The stylus head is positioned on to the test piece and the drive
unite is actuated. After the unit has stabilized itself, the range of the surface index is determined by posi-

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tioning stop at extremes of the meter needle movement. The index range is then read off the meter unit at
the positions of the stops and the figures recorded.
STEP 3 – Practice
• Identify and state the respective finishing operations of the given test pieces. (Fill Worksheet)
• Measure and estimate the surface texture (roughness and lay) using the Surtronic Tester and Sur-
face Standard Book. (Fill Worksheet)

3.5 Surface Roughness Chart

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Department of Mechanical Engineering, University of Moratuwa ME2023-P3

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF MORATUWA

Year 2021 Course BSc Eng Hons

Batch 19 Session Semester 3
Module code ME2023 Module title Manufacturing Engineering I
Laboratory
PDE Laboratory Production Engineering Laboratory
code
Coursework ME2023- Title of Lab
Familiarisation with heat treatment
No. P3 class

Instructor Mr NM Fernando Facilitators Mr. K.P.S.P. Dayananda

Familiarization with heat treatment - Introduction

The properties and behaviour of metals and alloys during manufacturing and their performance during
service life depend on various factors such as the composition, structure, and processing history and on
the heat treatment to which they have been subjected to. Important basic properties such as hardness, re-
sistance to wear and scratching are greatly influenced by heat treatment processes.
This laboratory session is designed to familiarise various heat treatment processes commonly employed
in engineering practice. Methods and techniques of heating, normalising, annealing hardening, and tem-
pering are discussed in detail. Characteristics of the equipment used are also discussed.

4.1 Background
The heat treatment is defined as an operation or a combination of operations, involving the heating and
cooling of a metal or an alloy in the solid-state to obtain certain desirable conditions and properties. Heat
treatment aims to achieve one or more of the following objectives.
• To change the microstructure and increase the hardness of the metals
• To relieve the stresses set up in the material after hot or cold working and soften the metal
• To improve machinability
• To modify the structure of the material to improve its electrical and magnetic properties
• To increase the qualities of metal to provide better resistance to heat, corrosion and wear.

Heat treatment will alter properties of the material and the results can be beneficial or harmful. Thus the
designer who selects the material and the engineer who specifies its processing must be aware of the pos-
sible changes in properties during heating and cooling. Heat treatment must be understood and correlated
with the other manufacturing processes if effective results are to be obtained.
Normalising, Annealing, Spheroidising, Hardening, Tempering, Carburising, Nitriding, Cyaniding, In-
duction hardening, Flame hardening, etc. are some of the various heat treatment processes commonly
employed in engineering practice. The furnace is the most important equipment used in the heat treatment

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of metals at elevated temperatures. There are various types of furnaces available, but the selection of the
furnace depends upon the factors, such as size and shape of the product, the volume of production and
type of heat treatment. All furnaces should be capable of meeting the following requirements.
The form of heating should be such that it can raise the temperature of the loaded furnace to the required
temperature in a reasonably short time.
• The temperature control should be flexible and accurate.
• The heating chamber should gain or reject heat uniformly at all surfaces
• The controlled atmosphere should be maintained to prevent the oxidation of steel surfaces, the
formation of scale, decarburisation, etc.
• It should occupy less space as far as possible.

4.2 Learning objectives of the lab session

• To develop an awareness of heat treatment processes and their characteristics.
• To understand physical and metallurgical changes in heat treatment.
• To familiarise different features and modes of operation of heat treatment furnaces.
• To understand the correct practice of heat treatment.

4.3 Learning outcomes of the lab session

On successful completion of this lab session, the student should be able to:
• Identify key characteristics of different heat treatment processes.
• Recognise process parameters in heat treatment.
• Identify key features of heat treatment furnaces.
• Select an appropriate heat treatment method to obtain required properties for a given metal.

4.4 Work to be performed

STEP 1 – Overview
▪ Introductory discussion on heat treatment processes and process parameters (heating, normalising
annealing, quenching, tempering, etc.).
▪ Discussion on types of heat treatment furnaces and their functionalities.

STEP 2 – Familiarisation
▪ Observe and analyse different parts of the furnace and its arrangement.
▪ Discuss types of heat treatment that can be performed on the furnace.
▪ Examine methods of measuring and controlling furnace temperature.

STEP 3 – Demonstration
▪ Discuss metallurgical properties of the material to be heat treated.

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▪ Study steps involved in operating the furnace and related activities.

▪ Examine process parameters and methods of controlling them.
▪ Observe and analyse physical & metallurgical changes in the material after heat treatment.

STEP 4 – Practice
▪ Test hardness of the specimens using the Hardness Tester at the Laboratory (i.e., Rockwell
scale).
▪ Compare and contrast measured hardness values against their method of treatment. (Fill WORK-
SHEET)

4.5 Heat treatment furnace

A furnace or kiln is a thermally insulated chamber or oven in which a controlled temperature regime is
produced. A kiln is required to come to a controlled temperature, often very high, and so the design of the
ovens normally focuses on insulation, and the ability to add fuel over a course of time.
The electric kiln is considered to be the new kiln technology of the 20th century. Instead of burning fuel,
these operate by radiant heat generated from an electrical current passing through coiled wires. Modern
electric kilns are equipped with electronic shutoff devices, called kiln sitters, to monitor the firing pro-
cess.
Regardless of what type of kiln is used, its user needs to be able to accurately determine the temperature
inside the kiln. For this, we use the pyrometer and pyrometric cones. A pyrometer is an instrument used
to measure heat at high temperatures. It consists of a calibrated dial connected to wires which protrude
into the kiln. When heated, the welded junction of these wires produces a small electrical current which
registers as a temperature reading on an indicator dial.

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Department of Mechanical Engineering, University of Moratuwa ME2023-P4

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF MORATUWA

Year 2021 Course BSc Eng Hons

Batch 19 Session Semester 3
Module code ME2023 Module title Manufacturing Engineering I
Laboratory
PL Laboratory Production Engineering Laboratory
code
Coursework ME2023- Title of Lab Analysis of cutting parameters using Lathe Tool Dy-
No. P4 class namometer

Instructor Mr PM De Saram Facilitators Mr. K.P.S.P. Dayananda

Analysis of cutting parameters using Lathe Tool Dynamometer -

Introduction
The theory on mechanics of cutting allows researchers and engineers to determine the influence of vari-
ous parameters such as cutting parameters, tool parameters and other process parameters on cutting force
and energy/ power.
This laboratory session is designed to familiarise with the effect of feed rate and cutting fluid on cutting
force and cutting energy.

5.1 Background
Theory on mechanics of cutting or machining has been developed over the years by many scientists.
There are many books and articles available explaining the theories and concepts in detail. However, the
material given hereunder is just a summary for your reference.

PS = FC / AC where, FC = cutting force (V )

Specific cutting energy,
AC = cross-sectional area of uncut chip
(feed x depth of cut)

𝑡0
Cutting ratio, 𝑟𝐶 = ⁄𝑡 ; 𝑤ℎ𝑒𝑟𝑒 𝑡𝑐 = 𝑐ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑎𝑛𝑑 𝑡0 = 𝑢𝑛𝑐𝑢𝑡 𝑐ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
𝐶

𝑟𝑐 cos(𝛼𝑛 )
Shear angle, ∅ = tan−1 [ ] ; 𝑤ℎ𝑒𝑟𝑒 𝛼𝑛 = 𝑛𝑜𝑟𝑚𝑎𝑙 𝑟𝑎𝑘𝑒 𝑎𝑛𝑔𝑙𝑒
1− 𝑟𝑐 sin(𝛼𝑛 )

F C Cos − FnC Sin

S =  Sin where, FnC = normal cutting force
Shear stress, AC
𝐹𝑛𝑐
Mean friction angle, 𝛽 = 𝛼𝑛 + tan−1 [ ]
𝐹𝑐

From the theory of Ernst and Merchant, (for the minimum power consumption), 2∅ + 𝛽 − 𝛼 = 𝜋⁄2

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From the theory of Lee and Shaffer, ∅ + 𝛽 − 𝛼 = 𝜋⁄4

5.2 Learning objectives of the lab session

▪ To develop an understanding of the cutting mechanics.
▪ To appreciate the functionality of the Lathe Tool Dynamometer.
▪ To study the influence of cutting parameters on the cutting force and cutting energy.
▪ To understand the influence of cutting fluid on the cutting process.

5.3 Learning outcomes of the lab session

On successful completion of this lab session, the student should be able to:
▪ Explain the theory on mechanics of cutting.
▪ Operate the Lathe Tool Dynamometer.
▪ Explain the influence of feed rate on the cutting force and cutting energy.
▪ Describe the influence of cutting fluid on the cutting process.

5.4 Work to be performed

STEP 1 – Overview
▪ Introduction to the merchant’s model and appreciation of theory on mechanics of cutting.
▪ Discuss the effects of cutting parameters (cutting speed, feed rate, etc.) on cutting force and energy.

STEP 2 – Familiarisation
▪ Observe and analyse different parts of the dynamometer, its arrangement and operation.
▪ Discuss how the measurements are taken.

STEP 3 – Practice
▪ Balance the strain amplifier.
▪ Calibrate the cutting force dynamometer using known weights. Apply loads in horizontal and vertical
directions to check the presence of any cross-sensitivity.
▪ Plot calibration graphs of Strain reading vs. Loads by varying feed rate in a wide range. (Fill WORK-
SHEET)

5.5 Instructions to prepare the report

Prepare a report based on the following,
▪ Define the objectives and rationale of the tests performed.

▪ State the governing theories used.

▪ Describe the methodology followed in performing the tests.
▪ Present results in tabular and graphical forms.

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▪ Discuss the following

• Explain possible reasons for variation in specific cutting energy.

• Recommend conditions that are best within the tested range.

• Explain the effect of cutting fluid to the mechanics of cutting and cutting energy.
▪ Coursework submission deadline: Please submit the coursework by 09:15 on the second Monday
before the lab session (i.e. after 2 weeks) to the production engineering laboratory.

5.6 Reference
▪ Serope Kalpakjian, Steven R. Schmid, “Fundamentals of Machining” in Manufacturing Engi-
neering and Technology.

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Department of Mechanical Engineering, University of Moratuwa Annex 1

Annexe I: Guideline for the coursework report

Frontpage format

ME2023: Manufacturing Engineering I

Semester: 3

Coursework title here

By

Index No. Name Marks

Date of submission dd/mm/yyyy

Due date of submission dd/mm/yyyy

Instructors’ names Signature

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka

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Department of Mechanical Engineering, University of Moratuwa Annex 1II

Summary
(100-200 words)

Table of Contents

1. Introduction
▪ Introduce the practical
▪ Theories behind
▪ Aim and objectives of the practical

2. Material and methods

▪ Explanations and equations (if any), supported with references
▪ Experimental setup and procedure
▪ Indicate any apparatuses involved

3. Observations
▪ The datasheet and other notable observations

4. Discussion and Conclusions

▪ May include recommendations

5. References
▪ Use IEEE referencing style

Appendices (if any)

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Department of Mechanical Engineering, University of Moratuwa Annex 1I

Annexe II: Coursework marking scheme

Description Marks
Frontpage (use the correct given format) (05 marks) 05
Overall formatting (10 marks) 10
Keeping the report in line with the given MS Word format, Tables being centre
aligned with captions at the top of the Tables, Figures being centre aligned with
captions centred below the Figures, including Figure numbers and titles, including
Table numbers and titles, equations being numbered and the overall neatness of the
coursework
Introduction (10 marks)
General (01) / Functional (02)/ Technical information (02) 05
Introduction to the practical 05
Aim and objectives (5 marks)
Aim 02
Objectives 03
Observations (10 marks)
Apparatus 05
Procedure (steps followed) 05
Completed Worksheet 15
Discussion (45 marks)
Discussion of points (given in the handbook) 30
Conclusions (10 marks) 10
References (05 marks) 05
Total 100
* Late submission: A 70% of the marks will be awarded for all late submissions within a
week. Submissions delayed over a week will NOT be marked.

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Department of Mechanical Engineering, University of Moratuwa Annex 1II

Annexe III: Worksheet-P01

Name

Index No Group Date

Note: Use additional sheets if the given space is not sufficient.

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Department of Mechanical Engineering, University of Moratuwa Annex 1II

L
K
J
I
H
G
F
E
D
C
B
A
Count
Least
Instrument/Gauge
Item

Instructor: Date:

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Department of Mechanical Engineering, University of Moratuwa Annex 1V

Annexe IV: Worksheet – P02

Name

Index No Group Date

Note: Use additional sheets if the given space is not sufficient.

I
H
G
F
E
D
C
B
A

Manufacturing / Finish-

Max

Min
Touch comparison
C.L.A index (μm)
ing Process
Specimen

C.L.A index
Surtronic

(μm)

Instructor: Date:

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Department of Mechanical Engineering, University of Moratuwa Annex IV
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Department of Mechanical Engineering, University of Moratuwa Annex V

Annexe V: Worksheet – P03

Student Name: Index No:

Note: Use additional sheets if the given space is not sufficient.

Non-heat
treated
sample
E
D
C
B
A

Method of heat treatment

Hardness Value
Specimen

Instructor: Date:

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Department of Mechanical Engineering, University of Moratuwa Annex IV
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Department of Mechanical Engineering, University of Moratuwa Annex VI

Annexe VI: Worksheet – P04

Student Name: Index No:

Note: Use additional sheets if the given space is not sufficient.

Strain
Load (Kg)
Vertically loaded Horizontally loaded

Effects for feed rate,

Work-piece diameter =
Cutting speed =
Rake angle =
Depth of cut =

Feed rate
mm/rev

Strain

Chip thick-
ness
mm

Instructor: Date:

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Department of Mechanical Engineering, University of Moratuwa Annex VI
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Department of Mechanical Engineering, University of Moratuwa Annex VIII

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