MECHANICAL ENGG. DEPT., DR. S. & S. S. GHANDHY COLLEGE OF ENGG. & TECH.

, SURAT

HOURS
4341904 ME-II EXP.NO. 05 10 TYPE Performance
:

TITLE: Shaping and drilling Job

STUDENT ACTIVITY:

1. Make one job using shaping and drilling machine.

2. Observe and write used cutting parameters.
3. Make operations sequences and fill observation table.

Part-I Shaping machine operations

1. Machining Horizontal Surfaces

It is the most common shaper machine operations. In this, the work is fed in a
horizontal direction under the reciprocating tool and the surface produced is
horizontal and flat.

The work is either held in a vice or clamped directly on the machine table,
depending upon its size. The tool is held in a proper tool holder. It is set at a proper
inclination and at the correct height above the work, as described later in this
article. The depth of cut adjusted and the machine get starts.

Cross feed to the table is given initially by hand until the cut starts. After that
power feed can be employed. After the cut is finished, the machine is stopped and
the work inspected. If more material is to be removed, the procedure is repeated
until the desired surface is obtained.

A special precaution is required in setting the tool for horizontal cutting. The tool
should be held vertically in such a way that its cutting edge points in a direction
MECHANICAL ENGG. DEPT., DR. S. & S. S. GHANDHY COLLEGE OF ENGG. & TECH., SURAT

slightly away from the work, as moves, due to the cutting pressure, it will move
away from the work instead of digging into it.

Another precaution to be taken in tool set is that its cutting edge should not be
projected much below the tool holder. The vertical slide of the tool head should not
be made to overhang too far below the ram. If otherwise, the tool will be weakened
and subjected to under strain. Also, a lot of chatter will result.

2. Machining Vertical Surfaces

A vertical cut is made while machining the end of a workpiece, squaring up a block
or cutting a shoulder. The work is attached in the vice or directly on the table and
the surface to be machined is carefully aligned with the axis of the ram.

A side cutting tool is set on the tool post and the position and length of stroke are
adjusted. The vertical slide is set accurately at zero position.

This is necessary to enable the tool to move upwards and away from the work
during the return stroke. This prevents the side of the tool from dragging on the
planed vertical surface during the return stroke. The down–feed is given by rotating
the down feed screw by hand. The feed is about 0.25mm given at the end of each
return stroke. Both roughing and finishing cuts are done to complete the job.

4. Machining Angular Surface

The workpiece is placed on the table, and the tool head vertical slide is rotated to
the required angle, either to the left or right, from its vertical position.

The apron is then further swivelled away from the work so that the tool will clear
the work during the return stroke.

The down feed is given by rotating the down feed screw. The angular surface can
also be machined in a universal shaper or by using a universal vice without
swivelling the tool head.

4. Machining Irregular Surfaces

A shaper can also produce a contoured surface, i.e. a convex or concave surface or
a combination of any of the above surfaces. To manufacture a small contoured
surface a forming tool is used.

If the curve is large, power cross feed in conjunction with manual down feed is so
adjusted that the wool will trace the required contour. If the contour (workpiece
shape) has too many ups and downs both the feeds are operated by hand.

For machining irregular surfaces a round nose tool is used. For a shallow cut the
apron may be set vertical but if the curve is quite sharp, the apron in swivelled
MECHANICAL ENGG. DEPT., DR. S. & S. S. GHANDHY COLLEGE OF ENGG. & TECH., SURAT

towards the right or left away from the surface to be cut. The figure shows the
machining of a concave surface using a round nose tool.

5. Cutting Slots and Keyways

With suitable tools, a shaper can very conveniently machine slots or grooves on
work or cut external keyways on shafts and internal keyways on pulleys or gears.
For cutting slots or keyways on shafts and internal keyways on pulleys or gears. For
cutting keyways or slots a square nose tool similar to a parting tool is used.

External keyways are made on a shaft by first drilling a hole at the blind end of the
keyway. The diameter of the hole should be 0.5 to 0.8mm oversize than the width of
the keyway and the depth should be about 1.5mm larger than the depth of the
keyway.

This is important to leave clearance on the tool at the end of the stroke. The length
and position of stroke are carefully adjusted so that the stroke will terminate
exactly at the clearance hole. The speed is reduced while cutting keyways.

Internal keyways are cut by holding the tool on a special tool holder so that the tool
post will not hit against the work at the end of the stroke. The clapper block is
locked in the clapper box to prevent the tool from lifting during the return stroke.
Lubrication is necessary on the work to prevent the cutting edge of the tool form
wear due to

6. Machining Splines or Cutting Gears

This types of shaper machine operations done by using an index centre, illustrated
in a gear or equally spaced splined may be cut. The work is placed between two
centres, and a spline is cut similar to the cutting of a keyway. After the first spline
is cut, the work is rotated through a predetermined amount by using the index
plate and index pin.

The periphery of a gear blank is divided, and equally spaced grooves are cut using
an index plate having proper hole circles. While cutting gear a forming tool is used.

Part-ii Drilling machine operations

MECHANICAL ENGG. DEPT., DR. S. & S. S. GHANDHY COLLEGE OF ENGG. & TECH., SURAT

Drilling Operation:

When we need a circular hole in a workpiece of any size there, we can use drilling
operation, by a drilling operation you can form any size of holes in a workpiece.
Although you can use a lathe for drilling operation too, drill machine is an
appropriate machine to do holes in a workpiece.

The cutting tool we used for this type of operation is drill bit. A drill bit is a
multipoint rotary cutting tool which helps to remove material from a workpiece.

Core Drilling:

When sand castings are made, cores are used to displace the metal where holes are
desired. When cast the molten metal flows around the core. After the metal
solidifies the casting is removed from the mold and the core disintegrates leaving
the desired holes. the holes are usually quite rough and require heavy body drill to
clean up the sidewall of the whole.

Step Drilling:

More than one diameter can be ground on the drill body which saves an extra
operation.

Boring:

When you need to enlarge the diameter of the existing hole you need to perform the
boring operation, but the accuracy is not greater than reaming operation. The
boring tool is generally a single-point cutting tool.
MECHANICAL ENGG. DEPT., DR. S. & S. S. GHANDHY COLLEGE OF ENGG. & TECH., SURAT

Reaming:

It is an operation of finishing a drilled hole.

A finished hole has the specified diameter size, is perfectly round, the diameter is
the same size from end to end, and it has a smoothly finished surface.

A drill hole is seldom accurate enough in size or sufficiently smooth to be called a

precision hole.

When greater accuracy is required the whole must be drilled undersize by a certain
amount and finished by the reaming.

In short, When we need to enlarge the size of an existing hole with great accuracy in
a workpiece we have to performed reaming operation. In this type of operation, we
need a reamer to perform the operation. A reamer is a rotary cutting tool that
removes the material from the existing hole which has several parallel and helical
cutting edge throughout its cylindrical body.

Counter Boring:

It is the operation of boring a second hole, a larger diameter than the first but
concentric with it.When this operation is done on a drilling machine a tool known
as counterbore is used.

The small diameter on the end of the tool known as the pilot keeps the counterbore
concentric with the original hole.Pilots are interchangeable with others of different
sizes to fit the various size of holes.

Counter Sinking:

It is the operation of producing an angular surface at the end of a hole. A

countersink is used.

The countersink is made in many diameters size and several angles. The angle size
depends upon the reason for countersinking.

Flathead screws require a countersink with an 82 included angle, where is a Centre

hole must be 60. Various types of rivet heads have included angles of from 90 to
145 degree.

Spot Facing:

It is the operation of machining a flat, circular surface around a whole to provide a

seat for a Bolt head, nut or washer.
MECHANICAL ENGG. DEPT., DR. S. & S. S. GHANDHY COLLEGE OF ENGG. & TECH., SURAT

It is usually performed on casting. A Counterbore may be used for spot facing.The

Surface machined should be a square with the hole.

Tapping:

Holes that are to be tapped(threaded) are first are drilled to a specified size. In order
to tap holes on a standard drilling machine, a tapping attachment must be used.

This attachment is held in the spindle of the drill press by a tapered Arbor, who
drives the friction type mechanism.

The tap holding chuck accurately centers the tap on the round part of the shank
and floating jaws hold the tap on its square end in a firm, rigid grip, which prevents
the tap from pulling out of the chuck when reversing.

Trepanning:

It is a hole making operation where an annular groove is produced leaving a solid

cylindrical core in the center.

In Trepanning a cutter consisting of One or more cutting edges placed along the
circumference of a circle is used to produce the annular groove.

Trepanning is feasible if the hole has a diameter of more than 50 mm. Hole depth of
160 times the diameter can be obtained in Trepanning.

Job drawing

Material : MS round bar 40 mm dia. X 30 mm long – 1 no.

Machine : shaping machine and drilling machine

Job making steps:

 Take round bar and cut by power hacksaw machine

MECHANICAL ENGG. DEPT., DR. S. & S. S. GHANDHY COLLEGE OF ENGG. & TECH., SURAT

 Make drawing on the round face of the round bar by chalk stick
 Take small cuts by shaping machine
 Measure flat surface dimensions.
 Make all four side of the square as per drawing.
 Measure diagonal length of the square.
 If it is ok, then draw center on the round face of the round bar, now it is
square.
 make punch on center by manual center punch.
 Take square job piece for drilling hole 10 mm dia. By drilling machine.
 Make hole through out of the job.

OBSERVATION TABLE

SR. SHAPING MACHINE ACTUAL USED IN MAKING JOB

NO. JOB
PARAMETRS
1 Type of shaping
machine
2 Type of cutting tool
used
3 Machine
manufacturer name
4 Stroke length

ASSESMENT:

PA MARKS PA MARKS SIGN OF BATCH

ME-II DATE
(MAX) (OBTAINED) TEACHER

EXP. NO. 05 20