Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 1

Step turning

Aim: To perform step turning operation on a given sample

Experimental Requirements:
1. Machine tool: Lathe machine
2. Cutting tool: Single-point cutting tool made up of H.S.S. material
3. Tool holding device: Tool post
4. Workpiece material: Mild steel [Ø32mmx100mm]
5. Workpiece holding device: Three-jaw chuck
6. Vernier callipers

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the workpiece dimensions using vernier callipers before
machining and tabulate the readings.
2. Fix the workpiece in the three-jaw chuck and tighten the screws.
3. Fix the single-point cutting tool in the tool post.
4. Choose suitable R.P.M. on the lathe machine. Switch on the motor of
the lathe machine to supply rotary motion to the workpiece.
5. Provide desired depth of cut to the cutting tool, then perform the turning
operation on the workpiece by providing the manual feed motion to the
workpiece parallel to the lathe axis.
6. Perform the turning operation to obtain desired maximum outer diameter
on the workpiece.
 Metal Cutting And Machine Tools Lab (22ME2281)

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the workpiece (D):
R.P.M of the workpiece (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

 Metal Cutting And Machine Tools Lab (22ME2281)

7. Perform initial cuts with a higher depth of cuts and the last few cuts with
a smaller depth of cuts to obtain desired dimensions and surface finish
for the workpiece.
8. After performing a turning operation throughout the length of the job,
depending on the number of steps, perform step turning operation from
the tail stock end up to the desired length of the workpiece.
9. Continue the step-turning process until a cylindrical workpiece is shaped
into the job of the given dimensions.
10. Remove the workpiece from the three-jaw chuck. Measure the
dimensions of the workpiece using vernier callipers and tabulate the
readings.

Precautions:
1. Fix the workpiece rigidly in the three-jaw chuck.
2. Check the alignment of the workpiece with the lathe axis.
3. Check the measurement of the depth of the cut carefully.

Result:
The desired dimension of the workpiece is obtained by performing a step-
turning operation on the cylindrical workpiece.

Viva questions:
1. What are the parts of the lathe machine?
2. What are generatrix and directrix for longitudinal turning operation?
3. Is it possible to have the generatrix as a straight line and the directrix as
a circle to obtain a cylindrical object? If yes, then justify your answer.
4. What are the work-holding devices used on lathe machines?
5. What are the specifications of the lathe machine?
6. Is it possible to obtain spherical jobs on lathe machines? Justify
7. What is the material removal rate?
 Metal Cutting And Machine Tools Lab (22ME2281)

Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

Before machining

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 2

Taper turning

Aim: To perform taper turning operation on a given sample

Experimental Requirements:
1. Machine tool: Lathe machine
2. Cutting tool: Single-point cutting tool made up of H.S.S. material
3. Tool holding device: Tool post
4. Workpiece material: Mild steel [Ø32mmx100mm]
5. Workpiece holding device: Three-jaw chuck
6. Vernier callipers

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the workpiece dimensions using vernier callipers before
machining and tabulate the readings.
2. Fix the workpiece in the three-jaw chuck and tighten the screws.
3. Fix the single-point cutting tool in the tool post.
4. Choose suitable R.P.M. on the lathe machine. Switch on the motor of
the lathe machine to supply rotary motion to the workpiece.
5. Rotate the compound rest to the desired angle to perform the taper cut
on the cylindrical job.
6. Provide desired depth of cut to the cutting tool, then perform the turning
operation on the workpiece by providing the manual feed motion to the
workpiece inclined to the lathe axis.
 Metal Cutting And Machine Tools Lab (22ME2281)

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the workpiece (D):
R.P.M of the workpiece (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

 Metal Cutting And Machine Tools Lab (22ME2281)

7. Perform initial cuts higher depth of cuts and the last few cuts with a
smaller depth of cuts to obtain desired dimensions for the workpiece.
8. Continue the taper-turning process until a cylindrical workpiece is
shaped into the job of the given dimensions.
9. Remove the workpiece from the three-jaw chuck. Measure the
dimensions of the workpiece using vernier callipers and tabulate the
readings.

Precautions:
1. Fix the workpiece rigidly in the three-jaw chuck.
2. Check the alignment of the workpiece with the lathe axis.
3. Check the measurement of the depth of the cut carefully.

Result:
The desired dimension of the workpiece is obtained by performing taper-
turning operation on the cylindrical workpiece.

Viva questions:
1. What are the different methods used to perform taper turning operation
on lathe machine?
2. What is generatrix and directrix for taper turning operation?
3. Among the different taper turning operations, which method can be used
to produce long taper cuts accurately?
4. How does the taper-turning attachment method differ from the
swivelling compound rest method?
5. What is the working principle of the taper-turning attachment method?
6. Is it possible to obtain taper cuts using a copying attachment? Justify
 Metal Cutting And Machine Tools Lab (22ME2281)

Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

Before machining

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 3

Knurling

Aim: To perform step Knurling operation on a given sample

Experimental Requirements:
1. Machine tool: Lathe machine
2. Cutting tools: Single-point cutting tool made up of H.S.S. material &
Knurling tool made up of hardened steel.
3. Tool holding device: Tool post
4. Workpiece material: Mild steel [Ø30mmx120mm]
5. Workpiece holding device: Three-jaw chuck
6. Vernier callipers

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the workpiece dimensions using vernier callipers before
machining and tabulate the readings.
2. Fix the workpiece in the three-jaw chuck and tighten the screws.
3. Fix the single-point cutting tool in the tool post.
4. Choose suitable R.P.M. on the lathe machine. Switch on the motor of
the lathe machine to supply rotary motion to the workpiece.
5. Provide desired depth of cut to the cutting tool, then perform the turning
operation on the workpiece by providing the manual feed motion to the
workpiece parallel to the lathe axis.
6. Perform the turning operation to obtain desired maximum outer diameter
on the workpiece.
 Metal Cutting And Machine Tools Lab (22ME2281)

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the workpiece (D):
R.P.M of the workpiece (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

 Metal Cutting And Machine Tools Lab (22ME2281)

7. Perform initial cuts higher depth of cuts and the last few cuts with a
smaller depth of cuts to obtain desired dimensions for the workpiece.
8. After performing the turning operation throughout the length of a job,
replace the single-point cutting tool with a knurling tool, and perform
the knurling operation from the tail stock end up to the desired length of
the workpiece.
9. Remove the workpiece from the three-jaw chuck. Measure the
dimensions of the workpiece using vernier callipers and tabulate the
readings.

Precautions:
1. Fix the workpiece rigidly in the three-jaw chuck.
2. Check the alignment of the workpiece with the lathe axis.
3. Check the measurement of the depth of the cut carefully.

Result:
The desired dimension of the workpiece is obtained by performing the
knurling operation on the cylindrical workpiece.

Viva questions:
1. What is the purpose of the knurling operation?
2. Is knurling operation a metal-cutting process? Justify?
3. Why do the dimensions of the workpiece after the knurling operation
increase?
4. Can we perform the knurling operation with the aluminium knurling tool
on the M.S. rod? Justify.
5. Are the feed rates for knurling and turning operations are identical or
different? Justify.
 Metal Cutting And Machine Tools Lab (22ME2281)

Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

Before machining

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 4

External thread cutting

Aim: To perform a thread-cutting operation on a given sample

Experimental Requirements:
1. Machine tool: Lathe machine
2. Cutting tools: Single-point cutting tools made up of H.S.S. material
3. Tool holding device: Tool post
4. Workpiece material: Mild steel [Ø30mmx120mm]
5. Workpiece holding device: Three-jaw chuck
6. Vernier callipers
7. Thread gauge

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the workpiece dimensions using vernier callipers before
machining and tabulate the readings.
2. Fix the workpiece in the three-jaw chuck and tighten the screws.
3. Fix the thread-cutting tool in the tool post.
4. Choose suitable R.P.M. on the lathe machine. Switch on the motor of
the lathe machine to supply rotary motion to the workpiece.
5. Provide desired depth of cut to the cutting tool, then perform the turning
operation on the workpiece by providing the manual feed motion to the
workpiece parallel to the lathe axis.
 Metal Cutting And Machine Tools Lab (22ME2281)

6. Perform the turning operation to obtain desired maximum outer diameter

on the workpiece.

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the workpiece (D):
R.P.M of the workpiece (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

 Metal Cutting And Machine Tools Lab (22ME2281)

7. Perform initial cuts higher depth of cuts and the last few cuts with a
smaller depth of cuts to obtain desired dimensions for the workpiece.
8. After performing the turning operation throughout the length of the job,
replace the single point cutting tool with a thread cutting tool, and
perform thread cutting operation from the tail stock end up to the desired
length of the workpiece.
9. Remove the workpiece from the three-jaw chuck. Inspect the workpiece
by using thread gauges.

Precautions:
1. Fix the workpiece rigidly in the three-jaw chuck.
2. Check the alignment of the workpiece with the lathe axis.
3. Check the measurement of the depth of the cut carefully.

Result:
The desired dimension of the workpiece is obtained by performing
thread-cutting operation on the cylindrical workpiece.

Viva questions:
1. What are the different types of screw threads? Which type of threads are
obtained in your experiment?
2. Why are both cutting and feed motion provided in the generation of
directrix for thread cutting operation? Justify?
3. How is the thread-cutting tool different from the turning tool?
4. What is a half-nut screw mechanism? What is its purpose?
5. Are the feed rates for thread cutting and turning operations the same or
different? Justify?
 Metal Cutting And Machine Tools Lab (22ME2281)

Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

Before machining

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 5

Internal thread cutting

Aim: To perform Internal thread-cutting operation on a given sample

Experimental Requirements:
1. Machine tool: Tap set
2. Cutting tools: Centre punch, drill bit, boring tool, single point cutting
tool.
3. Tool holding device: Tap wrench
4. Workpiece material: Mild steel Flat plate [50mmx70mm]
5. Workpiece holding device: Table vice
6. Vernier callipers
7. Thread gauges

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the workpiece dimensions using vernier callipers before
machining and tabulate the readings.
2. Fix the workpiece in the three-jaw chuck and tighten the screws.
3. Fix the centre punch drill tool in the tailstock.
4. Provide the manual feed to the centre punch tool until the desired depth
of indentation is obtained on the workpiece.
5. Choose suitable R.P.M. on the lathe machine. Switch on the motor of
the lathe machine to supply rotary motion to the workpiece.
 Metal Cutting And Machine Tools Lab (22ME2281)

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the workpiece (D):
R.P.M of the workpiece (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

 Metal Cutting And Machine Tools Lab (22ME2281)

6. Replace the centre punch with the drilling tool and perform the drilling
operation to obtain the desired length of a hole by providing manual feed
to the cutting tool.
7. Replace the drilling tool with a boring tool in the tail stock spindle.
8. Perform a boring operation up to the desired length of the workpiece by
providing manual feed to the cutting tool.
9. After performing a boring operation, replace the boring tool with a
thread-cutting tool, and perform the thread-cutting operation up to the
desired length of the workpiece.
10. Remove the workpiece from the three-jaw chuck. Measure the
dimensions of the workpiece using vernier callipers and tabulate the
readings.

Precautions:
1. Fix the workpiece rigidly in the three-jaw chuck.
2. Check the alignment of the workpiece with the lathe axis.
3. Check the measurement of the depth of the cut carefully.

Result:
The desired dimension of the workpiece is obtained by performing thread
cutting operation on the cylindrical workpiece.

Viva questions:
1. How internal thread cutting is different from external thread cutting?
2. What are the sequence of operations to be performed to obtain thread
cutting on the lathe machine?
3. How is a thread cutting different from the tapping operation?
4. How through hole is different from a blind hole?
5. What is the difference between boring and drilling operations?
6. Which operation is used to improve the surface finish of drilled hole?
 Metal Cutting And Machine Tools Lab (22ME2281)

Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

Before machining

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 6

Conversion Of Circular Rod Into Square Rod

Aim: To convert a circular rod into a square rod

Experimental Requirements:
1. Machine tool: Vertical milling machine
2. Cutting tool: End mill cutter [Ø25mm] made up of H.S.S. material
3. Tool holding device: Collet
4. Workpiece material: Aluminium [Ø30mmx120mm]
5. Workpiece holding device: Universal indexing head attachment
6. Vernier callipers

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the workpiece dimensions using vernier callipers before
machining and tabulate the readings.
2. Fix the workpiece in the universal indexing attachment placed on the
machine table.
3. Fix the End milling cutting tool in the tool holder (collet). Switch on the
motor of the milling machine to supply rotary motion to the cutting tool.
4. Now move the worktable in the Z-axis direction until the workpiece
touches the cutting tool. Then move the table in Y-direction just ahead
of the workpiece.
5. Provide desired depth of cut to the workpiece, then perform the milling
operation on the workpiece by providing the manual feed motion to the
workpiece along the Y-direction.
 Metal Cutting And Machine Tools Lab (22ME2281)

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the cutting tool (D):
R.P.M of the cutting tool (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

 Metal Cutting And Machine Tools Lab (22ME2281)

6. Perform initial cuts higher depth of cuts and the last few cuts with a small
depth of cuts to obtain desired dimensions for the workpiece.
7. After machining one side of the workpiece, index it at an angle of 90 0
using a universal indexing attachment. Then steps 4 & 5 are repeated
until desired dimensions can be obtained on the workpiece.
8. Continue this process until a circular workpiece is shaped into a square
rod of the given dimensions.
9. Remove the workpiece from the universal indexing head. Measure the
dimensions of the workpiece using vernier callipers and tabulate the
readings.

Precautions:
1. Fix the workpiece rigidly in the worktable.
2. Check the alignment of the tool with the machine axis.
3. Check the measurement of the depth of the cut carefully.

Result:
Desired dimensions of the square rod is obtained from the given Circular
rod.

Viva questions:
1. What are the parts of the milling machine?
2. What is the purpose of universal indexing head attachment in this
experiment?
3. What is the mechanism involved in universal indexing head
attachment?
4. How many rotations of the crank pin of the universal indexing head
are required to produce a hexagonal shape on the workpiece?
5. What are the different ways to mount the workpiece and the tool on a
vertical milling machine?
6. What are the specifications of the milling machine?
7. What is the purpose of providing smooth cuts in the last few
machining cuts?
 Metal Cutting And Machine Tools Lab (22ME2281)

Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

Before machining

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 7

Drilling operations

Aim: To perform drilling, tapping on the given workpiece according to

the given dimensions

Experimental Requirements:
1. Machine tool: Vertical milling machine
2. Cutting tool: Drill bit [Ø25mm] made up of H.S.S. material and
Tapping tool [Ø25mm] made up of H.S.S. material
Centre puch made up of H.S.S material
3. Tool holding device: Collet
4. Workpiece material: Aluminium [Ø30mmx120mm]
5. Workpiece holding device: Bench vice
6. Vernier callipers
7. Scribe
8. Try sqare
9. Hammer

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Using a scribe and trysquare, mark the dimensions on the workpiece to
identify the location on the workpiece to drill the hole.
2. After identifying the location on the workpiece, indent the location with
the centre punch manually using a hammer.
3. Fix the workpiece in the bench vice, which is placed on the machine
table.
 Metal Cutting And Machine Tools Lab (22ME2281)

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the cutting tool (D):
R.P.M of the cutting tool (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading
Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

4. Fix the drill bit in the tool holder (collet). Switch on the motor of the
milling machine to supply rotary motion to the cutting tool.
5. Align the indenter location on the workpiece with the drill bit axis. Then
move the worktable in the Z-axis direction until the workpiece touches
the cutting tool.
6. Provide manual feed to the cutting tool to drill the hole. Supply suitable
coolant while performing drilling operation.
7. After drilling the hole, replace the drill bit in the tool holder with a
tapping tool.
 Metal Cutting And Machine Tools Lab (22ME2281)

8. Tapping operation is performed on the cutting tool by providing the

manual feed.
9. Remove the workpiece from the bench vice.

Precautions:
1. Fix the workpiece rigidly in the worktable.
2. Check the alignment of the tool with the machine axis.
3. Check the measurement of the depth of the cut carefully.

Result:
Desired dimensions of the threaded hole is obtained by performing
drilling operations on the workpiece.

Viva questions:
1. What is a drilling operation? How is it performed?
2. What are the parts of the drilling machine?
3. How is the feed motion obtained on the drilling machine?
4. What are the generatrix and directrix for the drilling operation?
5. What are the types of drilling machines?
6. How is a turret drilling machine different from a pillar-type drilling
machine?
Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 8

Gear tooth cutting

Aim: To perform gear tooth cutting using the milling machine

Experimental Requirements:
1. Machine tool: Horizontal milling machine
2. Cutting tool: Peripheral mill cutter [Ø25mm] made up of H.S.S.
material
3. Tool holding device: Arbor
4. Workpiece material: Aluminium [Ø30mmx120mm]
5. Workpiece holding device: Universal indexing head attachment
6. Vernier callipers and Gear tooth vernier callipers
 Metal Cutting And Machine Tools Lab (22ME2281)

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the gear blank dimensions using vernier callipers before
machining and tabulate the readings.
2. Assemble the gear blank on the mandrel and fix it in the chuck of the
universal indexing attachment placed on the machine table.
3. Select the suitable gear-cutting tool and fix it on the arbour of the
horizontal milling machine. Switch on the motor of the milling machine
to supply rotary motion to the cutting tool.
4. Now move the worktable in the Z-axis direction until the workpiece
touches the cutting tool. Then move the table in Y-direction just ahead
of the cutting tool.

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the cutting tool (D):
R.P.M of the cutting tool (N):
Cutting velocity (V.C.):
Simple indexing
Number of index turns = 40/(No. of teeth required)
Depth of tooth required = 2.25 x Module
Blank diameter = (No. of teeth required + 2) x Module
Tooth width = 1.5708 x Module
 Metal Cutting And Machine Tools Lab (22ME2281)

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Table for dimensions of the workpiece after machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

5. Provide desired depth of cut to the workpiece, then perform the milling
operation on the workpiece by providing the manual feed motion to the
workpiece along the Y-direction.
6. Perform initial cuts higher depth of cuts and the last few cuts with a small
depth of cuts to obtain desired dimensions for the workpiece.
7. After machining, perform the initial gear tooth to the desired dimension.
Index the workpiece per the calculation by rotating the index crank to
the desired hole location on the crank plate. Then steps 4 & 5 are
repeated until desired dimensions can be obtained on the workpiece.
8. Continue this process until a gear of the desired number of the tooth is
machined on the gear blank.
9. Remove the gear blank from the universal indexing head. Measure the
dimensions of the workpiece using gear tooth vernier callipers and
tabulate the readings.
 Metal Cutting And Machine Tools Lab (22ME2281)

Precautions:
1. Fix the workpiece rigidly in the worktable.
2. Check the alignment of the tool with the machine axis.
3. Check the measurement of the depth of the cut carefully.

Result:
The desired number of teeth are machined on the circular gear blank.

Viva questions:
1. What is the purpose of gears? Classification of gears?
2. What are the different manufacturing routes to produce spur gears?
3. What is indexing? What is the principle of simple indexing?
4. How is simple indexing different from compound and differential
indexing?
5. What is the mechanism used in the universal indexing head?
Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions
 Metal Cutting And Machine Tools Lab (22ME2281)

After machining
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 9

Surface milling

Aim: To perform surface milling on a metal workpiece using a milling

machine

Experimental Requirements:
1. Machine tool: Surface grinding machine
2. Cutting tool: Grinding wheel (Note down the specification)
3. Tool holding device: Spindle
4. Workpiece material: M.S. plate [Ø30mmx120mm]
5. Workpiece holding device: Magnetic chuck
6. Surface roughness tester
7. Vernier callipers

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Measure the workpiece dimensions using vernier callipers before
machining and tabulate the readings.
2. Fix the workpiece on the magnetic chuck placed on the machine table.
3. Fix the grinding cutting tool on the spindle. Switch on the motor of the
milling machine to supply rotary motion to the cutting tool.
4. Now move the worktable in the Z-axis direction until the workpiece
touches the cutting tool. Then move the table in Y-direction just ahead
of the workpiece.
 Metal Cutting And Machine Tools Lab (22ME2281)

Model calculations:
Vernier coincidence (V.C):
Least count of vernier callipers (L.C):
(Provide detailed calculations of least count)

Main scale reading (M.S.R):

Vernier scale reading (V.S.R):
Total scale reading (T.S.R):
Diameter of the cutting tool (D):
R.P.M of the cutting tool (N):
Cutting velocity (V.C.):

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Table for dimensions of the workpiece before machining:

S.no. M.S.R(mm) V.C V.S.R(mm) T.S.R(mm)

1
2
3
Average reading

Note: Separate table to be drawn for each dimension of the workpiece

 Metal Cutting And Machine Tools Lab (22ME2281)

5. Provide desired radial depth of cut to the workpiece in the X-direction,

then perform the milling operation on the workpiece by providing the
feed motion to the workpiece along the Y-direction. Desired feed motion
can be obtained by the adjust the stops on the table.
6. Continue this process until the workpiece is shaped into the desired
dimensions.
7. Remove the workpiece from the magnetic chuck. Measure the
dimensions of the workpiece using vernier callipers and also surface
roughness using a roughness tester and tabulate the readings.

Precautions:
1. Fix the workpiece rigidly in the worktable.
2. Check the alignment of the tool with the machine axis.
3. Check the measurement of the depth of the cut carefully.

Result:
Desired dimensions of the workpiece is obtained after performing a
surface grinding operation.

Viva questions:
1. How grinding is different from conventional machining?
2. What is the nomenclature used for specifying the grinding wheel?
3. What are the types of materials used for grinding wheel?
4. What are the different surface roughness parameters?
5. What is the difference between surface roughness and surface finish?
6. What is surface integrity?
 Metal Cutting And Machine Tools Lab (22ME2281)

Experiment No: 10

Regrinding of single-point cutting tool

Aim: To perform regrinding of single point cutting tool to desired tool

geometry

Experimental Requirements:
1. Machine tool: Tool and cutting grinder
2. Cutting tool: Grinding wheel
3. Tool holding device: Spindle
4. Workpiece material: Mild steel
5. Workpiece holding device: 2-D vice

Machining Conditions:
Cutting velocity (V.C.):
Feed (So):
Depth of cut (t):
Cutting Environment: Dry / Wet
Type of cutting fluid:

Procedure:
1. Fix the workpiece on the 2-D vice placed on the machine table.
2. Fix the grinding wheel in the tool holder (collet). Switch on the motor
of the grinding machine to supply rotary motion to the cutting tool.
3. Set the desired angle on the 2-D vice to machine the rake surface of the
single-point cutting tool.
4. Provide desired depth of cut to the workpiece, then perform the surface
grinding operation on the workpiece by providing the feed motion to the
workpiece along the Y-direction.
5. Repeat the process for the other faces of the cutting tool also until the
workpiece is machined to desired tool geometry.
6. Remove the workpiece from the 2-D vice
 Metal Cutting And Machine Tools Lab (22ME2281)

Precautions:
1. Fix the workpiece rigidly in the worktable.
2. Check the alignment of the tool with the machine axis.
3. Check the measurement of the depth of the cut carefully.

Result:
Regrinding of the single-point cutting tool is performed.

Viva questions:
1. What is the tool signature in A.S.A., O.R.S. and N.R.S. systems?
2. Define rake angle and clearance angle in general.
3. What are the planes used in A.S.A., O.R.S. and N.R.S. systems?
4. What are the differences between O.R.S. and N.R.S. systems?
Detailed drawings of the workpiece before and after machining:

Include the drawings of all the orthographic views (after machining)

and isometric views (before and after machining) with dimensions

After machining