MANUFACTURING TECHNOLOGY LABORATORY

Sri Ramakrishna Institute of Technology, Coimbatore-10 (Approved by AICTE, Affiliated to Anna University) Accredited by NAAC with ‘A’ Grade (Accredited by NBA)

DEPARTMENT OF MECHANICAL ENGINEERING Academic year 2016 – 2017

MANUFACTURING TECHNOLOGY LABORATORY – I (ME6311) LABORATORY REPORT

October - 2016


Department of Certified

that

this

MECHANICAL ENGINEERING is

the

bonafide

record

of

work

done

_

by

in the MANUFACTURING TECHNOLOGY LABORATORY – I (ME6311)

laboratory of this institution, as prescribed by the Anna University of Technology, Chennai. For the Third Semester B.E, during the Academic year 2016-2017.

Staff in-Charge [R. Thirunavukkarsu] Register No.

Submitted for the Third Semester B.E., Examination of the ANNA UNIVERSITY, CHENNAI conducted on _______________________

Internal Examiner

External Examiner

TABLE OF CONTENT S. No

Date

Experiment

Page No

Marks

Signature

1 2 3 4 5 6 7 8 9 10

Internal Mark


ME 6311- MANUFACTURING TECHNOLOGY LABORATORY - I MANUAL

STUDY OF LATHE MACHINE

Name: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Register Number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Year/ Semester: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL

STUDY OF LATHE MACHINE

Name:_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Register Number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Report Submitted on: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Important Instructions:

Safety precautions 1. Do not wear watch, ring and etc., in your hand while machining 2. Wear shoe and lab coat 3. Attention to be paid for clamping the job, tool, tool holders or supporting items. 4. Care should be taken for avoiding accidental contact with revolving cutters. 5. Do not handle chips with bare hands, use brush or hand gloves. 6. Pay attention while selecting tools or blades for the proposed use to avoid accidents. 7. Do not remove chip while machine is running. 8. Care should be taken while selecting rapid feed. 9. Follow safety precautions while approach with cutter to avoid tool damage. 10. Use coolants for heat dissipation. 11. Avoid sharp edge tools. 12. Select proper speed or feed or depth of cut.

STUDY OF LATHE MACHINE INTRODUCTION TO LATHE MACHINE

Bed Bed is mounted on the legs of the lathe which are bolted to the floor. It forms the base of the machine. It is made of cast iron and its top surface is machined accurately and precisely. Headstock of the lathe is located at the extreme left of the bed and the tailstock at the right extreme. Carriage is positioned in between the headstock and tailstock and slides on the bed guideways. Headstock Headstock is mounted permanently on the inner guideways at the left hand side of the leg bed. The headstock houses a hollow spindle and the mechanism for driving the spindle at multiple speeds. The headstock will have any of the following arrangements for driving and altering the spindle speeds (i) Stepped cone pulley drive (ii) Back gear drive

(iii) All gear drive Spindle The spindle rotates on two large bearings housed on the headstock casting. A hole extends through the spindle so that a long bar stock may be passed through the hole. The front end of the spindle is threaded on which chucks, faceplate, driving plate and catch plate are screwed. The front end of the hole is tapered to receive live center which supports the work. On the other side of the spindle, a gear known as a spindle gear is fitted. Tailstock Tailstock is located on the inner guideways at the right side of the bed opposite to the headstock. The body of the tailstock is bored and houses the tailstock spindle or ram. The spindle moves front and back inside the hole. The spindle has a taper hole to receive the dead center or shanks of tools like drill or reamer. If the tailstock handwheel is rotated in the clockwise direction, the spindle advances. The spindle will be withdrawn inside the hole, if the handwheel is rotated in anti-clockwise direction. To remove the dead center or any other tool from the spindle, the handwheel is rotated in anticlockwise direction further. The movement of the spindle inside the hole may be locked by operating the spindle clamp located on top of the tailstock.In order to hold workpieces of different lengths. The uses of tailstock 1. It supports the other end of the long workpiece when it is machined between centers. 2. It is useful in holding tools like drills, reamers and taps when performing drilling, reaming and tapping. 3. The dead center is offset by a small distance from the axis of the lathe to turn tapers by set over method. 4. It is useful in setting the cutting tool at correct height aligning the cutting edge with lathe axis. Carriage Carriage is located between the headstock and tailstock on the lathe bed guideways. It can be moved along the bed either towards or away from the headstock. It has several parts to support, move and control the cutting tool. The parts of the carriage are: a) saddle b) apron

c) cross-slide d) compound rest Cross slide Cross-slide is situated on the saddle and slides on the dovetail guideways at right angles to the bed guideways. It carries compound rest, compound slide and tool post. Cross slide handwheel is rotated to move it at right angles to the lathe axis. It can also be power driven. The cross slide hand wheel is graduated on its rim to enable to give known amount of feed as accurate as 0.05mm. Compound rest Compound rest is a part which connects cross slide and compound slide. It is mounted on the cross-slide by tongue and groove joint. It has a circular base on which angular graduations are marked. The compound rest can be swiveled to the required angle while turning tapers. A top slide known as compound slide is attached to the compound rest by dove tail joint. The tool post is situated on the compound slide. Tool post This is located on top of the compound slide. It is used to hold the tools rigidly. Tools are selected according to the type of operation and mounted on the tool post and adjusted to a convenient working position. There are different types of tool posts and they are: 1. Single screw tool post 2. Four bolt tool post 3. Four way tool post 4. Open side tool post Types of Lathe Operations Various operations are performed in a lathe other than plain turning. They are 1. Facing 2. Turning a. Straight turning b. Step turning 3. Chamfering 4. Grooving 5. Forming 6. Knurling 7. Undercutting

8. Eccentric turning 9. Taper turning 10. Thread cutting 11. Drilling 12. Reaming 13. Boring 14. Tapping Facing Facing is the operation of machining the ends of a piece of work to produce flat Surface Square with the axis. The operation involves feeding the tool perpendicular to the axis of rotation of the work. Facing operation is illustrated in Fig

Turning Turning in a lathe is to remove excess material from the work piece to produce a cylindrical surface of required shape and size. Straight turning The work is turned straight when it is made to rotate about the lathe axis and the Tool is fed parallel to the lathe axis. The straight turning produces a cylindrical surface by removing excess metal from the work pieces.

Step turning Step turning is the process of turning different surfaces having different diameters. The work is held between centers and the tool is moved parallel to the axis of the lathe. It is also called shoulder turning. Chamfering Chamfering is the operation of beveling the extreme end of the work piece. The form tool used for taper turning may be used for this purpose. Chamfering is an essential operation after thread cutting so that the nut may pass freely on the threaded work piece

Knurling Knurling is the process of embossing a diamond shaped pattern on the surface of the work piece. The knurling tool holder has one or two hardened steel rollers with edges of required pattern. The tool holder is pressed against the rotating work. The rollers emboss the required pattern. The tool holder is fed automatically to the required length. Knurls are available in coarse, medium and fine pitches. The patterns may be straight, inclined or diamond shaped.

Eccentric turning If a cylindrical work piece has two separate axes of rotating, one being out of center to the other, the work piece is termed as eccentric and turning of different surfaces of the work piece is known as eccentric turning. Eccentric turning is shown in Fig. The distance between the axes is known as offset. Eccentric turning may also be done on some special machines. If the offset distance is more, the work is held by means of special centers. If the offset between the centers is small, two sets of centers are marked on the faces of the work. The work is held and rotated between each set of centers to machine the eccentric surfaces.

Taper turning Taper A taper may be defined as a uniform increase or decrease in diameter of a piece of work measured along its length.

(i) Compound rest method The compound rest of the lathe is attached to a circular base graduated in degrees, which may be swiveled and clamped at any desired angle. The angle of taper is calculated using the formula.

Where = Half taper angle D = Major diameter of the work piece in mm d = Minor diameter of the work piece in mm L = Length of the taper in mm. The compound rest is swiveled to the angle calculated as above and clamped. Feed is given to the compound slide to generate the required taper.

(ii) Tailstock set over method Turning taper by the set over method is done by shifting the axis of rotation of the work piece at an angle to the lathe axis and feeding the tool parallel to the lathe axis. The construction of tailstock is designed to have two parts namely the base and the body. The base is fitted on the bed guide ways and the body having the dead center can be moved at cross to shift the lathe axis. The amount of set over –(s), can be calculated as follows

Where s - Amount of set over D – Larger diameter d – Smaller diameter L - Length of the work l – Length of the taper

The dead center is suitably shifted from its original position to the calculated distance. The work is held between centers and longitudinal feed is given by the carriage to generate the taper the advantage of this method is that the taper can be turned to the entire length of the work. Taper threads can also be cut by this method. The amount of set over being limited, this method is suitable for turning small tapers (approx. up to 8°). Internal tapers cannot be done by this method.

Thread cutting Thread cutting is one of the most important operations performed in a lathe. The Process of thread cutting is to produce a helical groove on a cylindrical surface by feeding the tool longitudinally. 1. The job is revolved between centers or by a chuck. The longitudinal feed should be Equal to the pitch of the thread to be cut per revolution of the work piece. The advantage of this method is that long tapers can be machined. As power feed can be employed, the work is completed at a shorter time. The disadvantage of this method is that internal tapers cannot be machined. 2. The carriage should be moved longitudinally obtaining feed through the lead screw of the lathe. 3. A definite ratio between the longitudinal feed and rotation of the headstock spindle should be found out. Suitable gears with required

number of teeth should be mounted on the spindle and the lead screw. 4. A proper thread cutting tool is selected according to the shape of the thread. It is mounted on the tool post with its cutting edge at the lathe axis and perpendicular to the axis of the work. 5. The position of the tumbler gears are adjusted according to the type of the thread (right hand or left hand). 6. Suitable spindle speed is selected and it is obtained through back gears. 7. Half nut lever is engaged at the right point as indicated by the thread chasing dial. 8. Depth of cut is set suitably to allow the tool to make a light cut on the work. 9. When the cut is made for the required length, the half nut lever is disengaged. The carriage is brought back to its original position and the above procedure is repeated until the required depth of the thread is achieved. 10. After the process of thread cutting is over, the thread is checked by suitable Gauges.

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL

STUDY OF SHAPER MACHINE




STUDY OF SHAPER MACHINE INTRODUCTION TO SHAPER MACHINE

Base It is rigid and heavy cast iron body to resist vibration and takes up high compressive load. It supports all other parts of the machine, which are mounted over it. The base may be rigidly bolted to the floor of the shop or on the bench according to the size of the machine. Column The column is a box shaped casting mounted upon the base. It houses the ram-driving mechanism. Two accurately machined guide ways are provided on the top of the column on which the ram reciprocates. Cross rail Cross rail of shaper has two parallel guide ways on its top in the vertical plane that is perpendicular to the rai1 axis. It is mounted on the front vertical guide ways of the column. It consists mechanism for raising and lowering the table to accommodate different sizes of jobs by rotating an elevating screw which causes the cross rail to slide up and down on the vertical face of the column. Saddle The saddle is located on the cross rail and holds the table on its top. Crosswise movement of the saddle by rotation the cross feed screw by hand or power causes the table to move sideways.

Table The table is a box like casting having T -slots both on the top and sides for clamping the work. It is bolted to the saddle and receives crosswise and vertical movements from the saddle and cross rail. Ram It is the reciprocating part of the shaper, which reciprocates on the guideways provided above the column. Ram is connected to the reciprocating mechanism contained within the column. Tool head The tool head of a shaper performs the following functions(1) It holds the tool rigidly, (2) It provides vertical and angular feed movement of the tool, and (3) It allows the tool to have an automatic relief during its return stroke. The various parts of tool head of shaper are apron clamping bolt, clapper box, tool post, down feed, screw micrometer dial, down feed screw, vertical slide, apron washer, apron swivel pin, and swivel base. By rotating the down feed screw handle, the vertical slide carrying the tool gives down feed or angular feed movement while machining vertical or angular surface. The amount of feed or depth of cut may be adjusted by a micrometer dial on the top of the down feed screw. Apron consisting of clapper box, clapper block and tool post is clamped upon the vertical slide by a screw. Operations performed in a shaping machine Different types of operations are performed in a shaping machine. They are broadly classified as 1. Regular operations 2. Special operations Machining horizontal surfaces A shaper is mostly used to machine a flat, true surface on a work piece. Horizontal surfaces are machined by moving the work mounted on the machine table at a cross direction with respect to the ram movement. The clapper box can be set vertical or slightly inclined towards the uncut surface. This arrangement enables the tool to lift automatically during the return stroke. The tool will not drag on the machined surface

Machining vertical surfaces A vertical cut is made while machining the end of a work piece, squaring up a block or machining as holder. The feed is given to the tool by rotating the downfeed screw of the vertical slide. The table is not moved vertically for this purpose. The apron is swiveled away from the vertical surface being machined as shown in the diagram.

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL STUDY OF MILLING MACHINE




STUDY OF MILLING MACHINE INTRODUCTION TO MILLING MACHINE

Milling is the machining process of using rotary cutters to remove material from a workpiece advancing (or feeding) in a direction at an angle with the axis of the tool. Milling is a cutting process that uses a milling cutter to remove material from the surface of a workpiece. The milling cutter is a rotary cutting tool, often with multiple cutting points. Two major classes of milling process: 1. In face milling, the cutting action occurs primarily at the end corners of the milling cutter. Face milling is used to cut flat surfaces (faces) into the workpiece, or to cut flat-bottomed cavities. 2. In peripheral milling, the cutting action occurs primarily along the circumference of the cutter.

Milling Machine Parts and their Function Base The base of the machine is Grey iron casting accurately machined on its top and bottom surface and serves as a foundation member for all the other parts which rest upon it. It carries the column at its one end. In some machines, the bage is hollowed and working as a reservoir for cutting fluid. Column The column is the main supporting frame mounted vertically on the bage. The column is box shaped. Heavily ribbed inside and houses all the driving mechanisms for the spindle and table feed. The front vertical face of the column is accurately machined and is provided with dovetail guide ways of supporting knee. The top of the column is finished to hold an over-arm that extends outward at the front of the machine. Knee The knee is the rigid gray iron casting that slides up and down on the vertical way of the column face. The adjustment of height is effected by elevating screw on the base that also supports the knee. The knee houses the feed mechanism of the table, and in different controls to operate it. The top face of the knee forms slid way for the saddle to provide cross travel of the table. Saddle The saddle is placed on the top of the knee, which slides on guide ways set exactly at 90 to column face. A cross feed screw near the top of the knee engages a nut of the bottom of the saddle to move it horizontally, by hand or power, to apply cross feed. The top of the saddle is accurately machined to provide guide ways for the table. Table The table rest on ways on the saddle and travels longitudinally. The top of the table is accurately finished and T-slots are provided for clamping the work and

other fixtures on it. A lead screw under the table engages a nut on the saddle to move the table horizontally by hand or power. The longitudinal travel of the table may be limited by fixing trip dogs on the side of the table. In universal machines, the table may also be swiveled horizontally. For this purpose the table is mounted on a circular bage which in its turn is mounted on the saddle. The circular bage is graduated in the degree. Over Hanging Arm Over hanging arm is mounted on the top of column extends beyond the column face and serve as a bearing support may be provided nearest to the cutter. More than one bearing support may be provided for the arbor. Front Brace The front brace is an extra support that is fitted between the knee and over arm to ensure further rigidity to the arbor and the knee. The front brace is slotted to allow for adjustment of the height of the knee relative to over arm. Spindle The spindle of the machine is locates in the upper part of the column and receive power from the motor through belts, gears and clutches and transmit it to the arbor the front end of the spindle just projects from the column face and it is provided with a tapered hole into to which various cutting tools and arbors may be inserted. The accuracy in metal machining by the cutter depends on primarily accuracy, strength and rigidity of the spindle. Arbor An arbor is considered as an extension of the machine spindle on which cutters are securely mounted and rotated. The arbors are made with taper shanks for proper alignments with machine spindles having taper hole on their nose.

Fundamental milling processes The various milling processes may be grouped under two headings: 1. Peripheral milling 2. Face milling 1. Peripheral milling The machining is performed by the cutting edges on the periphery of the milling cutter. It is classified under two headings 1. Up milling 2. Down milling I. Up milling In this method, the workpiece mounted on the table is fed against the direction of rotation of the milling cutter. The cutting force is minimum during the beginning of the cut and maximum at the end of cut. The thickness of chip is more at the end of the cut. As the cutting force is directed upwards, it tends to lift the workpiece from the fixtures. A difficulty is felt in pouring coolant on the cutting edge. Due to these reasons the quality of the surface obtained by this method is wavy. This processes being safer is commonly used and sometimes called conventional milling. II. Down milling The workpiece mounted on the table is moved in the same direction as that of the rotation of the milling cutter. The cutting force is maximum at the beginning and minimum at the end of cut. The chip thickness is more at the beginning of the cut. The workpiece is not disturbed because of the bite of the cutter on the work. The coolant directly reaches to the cutting point. So the quality of surface finish obtained is high. Because of the backlash error between the feed screw of the table and the nut, vibration is setup on the workpiece.

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL EXPERIMENT 1 – TAPER TURNING




EXPERIMENT - 1 TAPER TURNING OBJECTIVE At the end of this course student can able to machine a taper turning by using compound rest method in lathe. MATERIAL REQUIRED Cylindrical work piece of diameter …….. mm and length ……….. mm mild steel rod. TOOLS REQUIRED 2. Chuck Key 3. Cutting Tool 4. Try Square 5. Scriber 6. Vernier caliper 7. Tool Post Key 8. Spanner SEQUENCE OF OPERATION 1. Checking the dimensions 2. Setting the work pieces 3. Setting the tool 4. Taper turning QUESTIONS

WORKING STEPS 1. The given work piece is checked for its dimensions. 2. The work piece is held in the chuck; Chuck key is used to tighten the work piece firmly, ensuring the centering of the job. 3. The single point cutting tool is held in the tool post and tightens the nuts of tool using spanner. 4. Keep the cutting tool away from the work piece and switch on the lathe. 5. Facing and turning is done to get the required length and the diameter of the work piece. 6. Taper angle is calculated using the formula. 7. The compound rest base is swiveled and set at half taper angle which is already calculated. 8. Cutting tool is moved at an angle to the lathe axis from right to left in stages. Tool is moved by hand wheel of the compound rest.

DISCUSSION

CONCLUSION

REPORT EVALUATION S.NO

DESCRIPTION

WEIGHTAGE

1

Experimental Results

50

2

Dimension

10

3

Finishing

20

4

Viva-voce

20

Total

100

MARK AWARDED

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL EXPERIMENT 2 - EXTERNAL THREADS CUTTING




EXPERIMENT - 2 EXTERNAL THREADS CUTTING OBJECTIVE At the end of this course student can able to create an External Thread Cutting by using lathe. MATERIALS REQUIRED Cylindrical work piece of diameter …….. mm and length ……….. mm mild steel rod. TOOLS REQUIRED 1. Single point cutting tool 2. V-thread tool 3. Chuck key 4. Spanner MEASURING TOOL 1. Steel Rule 2. Vernier Caliper 3. outside caliper SEQUENCE OF OPERATIONS 1. Job setting 2. Tool setting 3. Facing 4. Plain turning 5. Marking 6. Thread cutting

QUESTIONS

PROCEDURE 1. The work piece is held in the three jaw chuck of the lathe. 2. The cutting tool is fixed on the tool post. 3. Facing, turning, and chamfering operation is completed to get the required diameters. 4. The grooving tool is fixed in the tool post and the carriage is moved to make the tool touch the work piece. 5. Feed is given slowly using the cross slide to complete grooving. 6. The depth of cut of thread is calculated. 7. The gears are changed to obtain the required speed for thread cutting using the back gear mechanism. 8. The half nut lever is engaged for automatic speed. 9. A small cross feed is given and thread is cut. The process is repeated till the required depth of threading is obtained. The depth of thread is measured using thread pitch gauge.

DISCUSSION

CONCLUSION


DESCRIPTION

WEIGHTAGE

1


50

2

Dimension

10

3

Finishing

20

4

Viva-voce

20

Total

100

MARK AWARDED

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL EXPERIMENT 3 - INTERNAL THREAD CUTTING




EXPERIMENT - 3 INTERNAL THREAD CUTTING

OBJECTIVE At the end of this course student can able to create an Internal Thread Cutting by using lathe. MATERIALS REQUIRED Cylindrical work piece of diameter …….. mm and length ……….. mm mild steel rod. TOOLS REQUIRED 1. Single point cutting tool 2. single point boring tool 3. internal thread cutting tool 4. chuck key 5. spanner MEASURING TOOLS 1. Steel rule 2. vernier caliper 3. outside caliper SEQUENCEI OF OPERATION 1. Job setting 2. Tool setting 3. Facing 4. Plain turning 5. Marking 6. Drilling 7. Boring 8. Thread cutting

QUESTIONS

PROCEDURE 1. Facing ,Turning and chamfering operation is completed to get the required diameters 2. The grooving tool is fixed in the tool post and the carriage is moved to make the tool touch the work piece. 3. Feed is given slowly using the cross slide to complete grooving 4. Then the drilling tool is fixed in the tailstock 5. The drilling tool is replaced by boring tool and made boring operation 6. The depth of cut of thread is calculated 7. Then internal thread cutting tool is fixed in the tool post. 8. The gears are changed to obtain the required speed for thread cutting using the back gear mechanism. 9. The half nut lever is engaged for automatic speed. 10. A small cross feed is given and thread is cut. The process is repeated till the required depth of threading is obtained. The depth of thread is measured using thread pitch gauge.

DISCUSSION

CONCLUSION


DESCRIPTION

WEIGHTAGE

1


50

2

Dimension

10

3

Finishing

20

4

Viva-voce

20

Total

100

MARK AWARDED

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL EXPERIMENT 4 - ECCENTRIC TURNING




EXPERIMENT – 4 ECCENTRIC TURNING OBJECTIVE At the end of this course student can able to machine an Eccentric Turning by using lathe. MATERIALS REQUIRED Cylindrical work piece of diameter …….. mm and length ……….. mm mild steel rod. TOOLS REQUIRED 1. Single point cutting tool 2. drill bit 3. reamer 4. Chuck key 5. Spanner MEASURING TOOL 1. Steel Rule 2. Vernier Caliper 3. outside caliper SEQUENCE OF OPERATIONS 1. Job setting 2. Tool setting 3. Packing 4. Eccentric turning 5. Marking ECCENTRIC TURNING THEORY This process describes the making of a simple eccentric with a diameter of 22mm and a throw of 5mm.It was machined from a piece of steel bar using just the 3 jaw chuck on the lathe. This process uses a packing piece in the 3 jaw chuck

QUESTIONS

PROCEDURE 1. Fix the job piece in the chuck so that axis of the job and axis of the chuck coincides with the help of chuck key and marking block. 2. Fix the single point cutting tool in the tool post using tool key. 3. Facing operation is done and plain turning is performed for the major diameter as per figure. 4. The cutting speed of the job is reduced by changing the pulley belts and by engaging back gear. 5. Chamfering is done as per the figure. 6. Remove the job from the chuck. 7. Marking is done by applying chalk on the second side face of the job using outside calipers and dot punch. 8. Shift the axis of the work piece as per the required eccentricity as per figure and mark the eccentric diameter as per figure. 9. Fix the job in the four jaw chuck and center the job such that the center of the eccentric diameter coincides with the lathe axis as per the required eccentricity mentioned in the figure. 10. By giving proper longitudinal feed and depth of cut the required eccentric diameter is obtained.

11. Facing is done to maintain the required length as per figure. Chamfering is made as per figure.

DISCUSSION

CONCLUSION


DESCRIPTION

WEIGHTAGE

1


50

2

Dimension

10

3

Finishing

20

4

Viva-voce

20

Total

100

MARK AWARDED

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL EXPERIMENT – 5 KNURLING




EXPERIMENT – 5 KNURLING OBJECTIVE At the end of this course student can able to create a knurling by using lathe. MATERIALS REQUIRED Cylindrical work piece of diameter …….. mm and length ……….. mm Mild steel rod. TOOLS REQUIRED 1. Single point cutting tool 2. knurling tool 3. Chuck key 4. Spanner MEASURING TOOL 1. Steel Rule 2. Vernier Caliper 3. outside caliper SEQUENCE OF OPERATIONS 1. Job setting 2. Tool setting 3. Facing 4. Plain turning 5. Marking 6. Knurling

QUESTIONS

PROCEDURE 1. The job is held in three jaw automatic chuck and is tightened by using chuck key such that ¾ of the length is projected outside the chuck 2. The single point cutting tool is held on the tool post. 3. Facing is an operation on lathe which is used to bring the length of the cylinder to required dimension. Rough facing is done first and then smooth facing is done. 4. Now carriage is moved parallel to the job by giving a depth of cut by means of cross slide. Reducing the diameter to the required shape does the turning. 5. HSS single point cutting tool is replaced by the knurling tool and knurling operation is performed at the slowest speed of the spindle. 6. The knurling tool with required pattern is selected and it is held tightly in the tool post. 7. The knurling tool is pressed against the surface of the work piece and it produces pattern on the surface of the work piece.

DISCUSSION

CONCLUSION


DESCRIPTION

WEIGHTAGE

1


50

2

Dimension

10

3

Finishing

20

4

Viva-voce

20

Total

100

MARK AWARDED

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL EXPERIMENT - 6 SQUARE HEAD SHAPING



Safety precautions 1. Do not wear watch, ring and etc., in your hand while machining 2. Wear shoe and lab coat 3. Attention to be paid for clamping the job, tool, tool holders or supporting items. 4. Care should be taken for avoiding accidental contact with revolving cutters. 5. Do not handle chips with bare hands, use brush or hand gloves. 6. Pay attention while selecting tools or blades for the proposed use to avoid accidents.. 7. Do not remove chip while machine is running. 8. Care should be taken while selecting rapid feed. 9. Follow safety precautions while approach with cutter to avoid tool damage. 10. Use coolants for heat dissipation. 11. Avoid sharp edge tools. 12. Select proper speed or feed or depth of cut.

EXPERIMENT – 6 SQUARE HEAD SHAPING OBJECTIVE At the end of this course student can able to machine a Square head shaping by shaper. MATERIALS REQUIRED Work piece of height …….. mm ,breath ……. Mm and length ……….. mm mild steel rod. MEASURING TOOL 1. Vernier caliper, 2. steel rule. MACHINE Shaping machine. TOOLS REQUIRED 1. Shaping Machine 2. Scriber 3. Divider 4. Steel Rule 5. Chalk piece 6. Bevel Protractor. QUESTIONS

PROCEDURE

1. The given workpiece is measured for its initial dimensions. 2. With the help of scriber, mark the square dimensions in the workpiece. 3. Fix the workpiece in the vice of the shaping machine. 4. After fixing the workpiece and the shaping tool, allow the ram to reciprocate. 5. Start the shaping process by giving the required depth by lowering the tool. 6. Slowly increase the depth of cut and repeat the procedure to make the square shape. 7. The work piece is now checked for final dimensions. DISCUSSION

CONCLUSION


DESCRIPTION

WEIGHTAGE

1


50

2

Dimension

10

3

Finishing

20

4

Viva-voce

20

Total

100

MARK AWARDED

ME 6311- MANUFACTURING TECHNOLOGY LABORATORY – I MANUAL EXPERIMENT - 7 HEXAGONAL HEAD SHAPING




EXPERIMENT – 7 HEXAGONAL HEAD SHAPING

OBJECTIVE At the end of this course student can able to create a Hexagonal head shaping by using vertical milling machine.

MATERIALS REQUIRED Cylindrical work piece of diameter …….. mm and length ……….. mm mild steel rod.

MEASURING TOOL 1. Vernier caliper, 2. Steel rule.

MACHINE Vertical milling machine

TOOLS REQUIRED 1. Scriber 2. Divider 3. Steel Rule 4. Chalk piece 5. Bevel Protractor.

QUESTIONS

PROCEDURE 1. Turning and facing of the given work piece is done in a lathe. 2. By using Venire height gauge, the hexagonal profile is marked in the work piece. 3. The job is held in the machine vice. 4. The end mill cutter is mounted in the spindle. 5. The spindle is switched on and the material is removed on one face. 6. Similarly by changing the face, the other sides of the work piece is machined. 7. The job is removed from the machine vice and checked for dimensions

using vernier. DISCUSSION

CONCLUSION


DESCRIPTION

WEIGHTAGE

1


50

2

Dimension

10

3

Finishing

20

4

Viva-voce

20

Total

100

MARK AWARDED