Manufacturing Processes

MN 201 Laboratory Manual

MECHANICAL DISCIPLINE
PDPM INDIAN INSTITUTE OF INFORMATION TECHNOLOGY,
DESIGN AND MANUFACTURING JABALPUR

1
 PREFACE

Practical work is always the foundation for the theory. It gives the opportunity for observation; for
coming to one’s own understanding; for getting experience and for drawing conclusions in one’s own
way. It thus enriches the knowledge. It also gives us the motivation for further experimentation and
exploration to new frontiers of areas of research, engineering, technology, innovative ideas etc. In this
respect, the laboratory part of the Materials and Manufacturing Processes provides some basic
understanding and the experience in the manufacturing methods and practices followed by industry.

The primary objective of this course is to learn how a product is manufactured and to gain technical
knowledge and skills involved in the processes. Much of the knowledge in the course is conceptual and
a general mathematics exposure will be sufficient. This knowledge will be useful in whatever discipline
a student belongs to. The course is practical orientated and exposes the student to acquire basic skills
in handling of tools, machines and machine tools used in different manufacturing processes through the
hands-on experience. The practical knowledge is supplemented by the Lectures to provide the
knowledge and genesis of various manufacturing processes.

Theoretical background given in this manual is general in nature. Jobs given are typical in nature and
are likely to be changed every semester.

The students are requested to make best use of the practical training of the regular exercises, and try to
implement them during their academic projects.

Workshop Team

2
 GENERAL INFORMATION

The practical classes will be conducted in the Workshop, and they are intended to provide hands-on
experience in handling of basic hand tools, machine tools & processes so as to make simple utility jobs.

Here are some of the SAFETY related points.

Since the students may not be fully conversant with the operating mechanisms of the machinery of the
workshop, direct handling of the machines should always be avoided. They should do it, with
supervision and guidance of the concerned Workshop staff and faculty only.

Any ornamental rings & chains which may endanger the personal safety of the student are not
allowed in the workshop.
Wherever necessary, wear safety GOGGLES & APPARELS.
FIRST AID BOX is available in the workshop.
SHARP EDGES OF TOOLS or freshly cut chips can injure your hands.
Isolate yourself from any moving part of the machinery.

Chamber consultation hour:

Please record the Name and time of the consultation Hours of Instructor. They will be announced on
the workshop Notice Board separately during first week of commencement of classes.

Name: Time Day

Notices:

All notices concerning the course will be displayed on the Notice Board at the Workshop.

Mid-term grading: Mid-semester grading will be announced in mid-September and is subjected to the
Instructor In charge discretion.

Report Writing:

The student is required to make a report giving details of the job he/she has done according to the format
in the manual.

In addition, please refer to “Learn more” section of each of the practice job page to gain additional
knowledge about the process/equipment.

1. Nature of work: The work to be done in practical classes comprises of study of hand tools, machine
tools, measuring instruments, process utilities required for different manufacturing processes and
make practice on utility jobs in different shops.
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2. Schedule of work: Students of each practical section will be divided into 10 groups. Each group
will follow the order as per the practical work schedule. Learning objectives and practice/utility
job to be made, if any, for each shop are given in the following pages. Students must read the
relevant chapter in the manual, read relevant material from textbook and reference books, and
enhance their learning in practical class. Detailed work schedule will be distributed to the
students along with the course handout.
3. To Learn More: For each shop, a set of posters is given in the form of learning objectives. The
answers to these must be found during or before the practical class and suitable notes be made.
These notes will help you in understanding the topics discussed in the lecture classes, and will
help in answering questions in the Quiz. Some additional notes are included in the manual
which could be of use to enhance the knowledge in the manufacturing processes.
4. Make-up: If a student misses a practical class due to genuine reason he/she must take prior
permission from the instructor to complete the missed exercise on a Saturday session.
5. Discipline: Students should not leave the workshop before the time allotted. Last 15 minutes
of every session are meant for machine maintenance & returning of tools & instruments.
6. Request for a new job: If the student spoils a practice/utility job, they should approach the shop
floor instructor for fresh material. No extra time beyond the allotted will be provided in such a
case.
7. Attendance: Always mark the attendance for each practical class before proceeding for the
practical class session.

Reference Books:
Hermann Jutz, Eduard Scharkus, Westerman Metal Tables, New Age International (P)Limited,
New Delhi,2003
Gerling, All about Machine Tools, Skip Series No 2, New Age International (P)Limited, New Delhi
Workshop Technology Vol. I & II, Hazra Choudhary

4
LIST OF EXPERIMENTS

Phase 1:

1) Practice on various Measuring Instruments.

2) To performed joining of two thick MS plates by ‘V’ Groove Butt Joint using arc welding
(MMAW).
3) To learn and practice turning, parting operation on lathe machine.
4) To learn operations of Vertical Milling M/C and perform a practice job like T slot cutting.
5) To learn various fitting operations like Drilling, Taping, Radius, Square Cut in MS metal
working.
6) Process demonstration of Ultrasonic Plastic & Metal Welding

Phase 2:

1) To perform Grooving, Threading and knurling operations on lathe machine.

2) To performed joining of two thin MS plates by Lap Joint using Oxy acetylene gas welding.
3) To perform Step and Taper turning operation on lathe machine and process demonstration of
Tool Wear Measurement.
4) To learn operations of Horizontal Milling M/C and prepare a Spur Gear.
5) To learn various Sheet Metal operations of G.I. Sheet and prepare a funnel cone by using G.I.
Sheet.
6) Process demonstration of Shaper Machine.

5
 Phase I

1. PRACTICE ON VARIOUS MEASURING INSTRUMENTS

Vernier Caliper

Bevel Protractor

Gear Teeth Vernier Height

Measurement gauge

6
 1. PRACTICE ON VARIOUS MEASURING INSTRUMENTS

Instrument No: 1
Title: To understand construction of Vernier Caliper and calculate its least count.
Objectives: After studying this experiment you should be able to: Understand the constructional
parts of Vernier Caliper, how to calculate least count of vernier caliper, how to take measurement
with the help of vernier caliper.
Theory: Vernier Caliper

Following are the constructional parts of vernier caliper:

1. Fixed scale and movable scale: The Vernier Caliper consists of two scales: one is
fixed and the other is movable.
2. Fixed and movable jaw: The fixed scale is called as main scale which is calibrated on L-
shaped frame and carries a fixed jaw. The movable scale, called vernier scale slides over
the main scale and carries a movable jaw. The movable jaw as well as the fixed jaw carries
measuring tip. When the two jaws are closed the zero of Vernier scale coincides with the
zero of main scale. For precise setting of the movable jaw an adjusting screw is provided.
3. Lock nut: An arrangement is provided to lock the sliding scale on the fixed main scale.
4. Graduated beam: Main scale markings are there on graduated beam.
5. Blade or Depth probe: Measures depth.
Least count: The smallest value that can be measured by the instrument is known as its least count.
Observation Table:
No. of divisions on
SrNo. Range Smallest division value of main scale Vernier Least count
1
2
3
4
5

7
Measurements with Vernier caliper: (all dimensions are in mm)
Main scale No of vernier scale Total
Sr. reading division Vernier scale division X Least count Reading
No A in coincidence B A+B
1
2
3
4
5

Instrument No: 2
Title: To understand construction of outside micrometer and calculate its least count

Observation Table:
Outside Micrometer
No. of divisions on
SN Range Pitch of spindle screw thimble Least count
1
2
3

Range: Least count: Make:

No of circular division Circular division X
Sr.No Main scale reading in Least Total Reading
A coincidence count B A + B mm
1
2
3

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Instrument No: 3
Title: Direct and indirect measuring instruments like Screw pitch gauge, radius gauge and Feeler
gauge.

Theory:
(A) Radius Gauges:
Radius gauges are
employed for checking
external and internal radii
on a curved surface.
Radius gauges consists of
set of blades.
Corresponding radius is
permanently marked on
each blade. The set of
blades with internal radius
on one side and external
radius on the other so that
it may be suitable for
checking fillets as well as
radius. The passage of light between the gauge and the work allows the radius to be checked
properly.
(B) Feeler Gauge:
Feeler gauge is used to
measure the clearance
between the two mating
parts. For example, it can
be used in gauging of the
clearance between the
piston and cylinder and
also for adjusting the
spark plug between the
distributor points of an
automobile. The feeler
gauge set consists of
narrow strips of sheet
steel of different
thickness assembled together in holder. A set of feeler gauge consists of series of blades of
thickness varying from 0.03mm to 1mm. The width of blade is 12 mm at heal and tapered for outer
part of their length so that the width of tip is 6mm.

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(C) Screw Pitch Gauge:

Screw pitch gauge is

used to check the pitch
of screw thread. They
quickly determine the
pitch of thread by
matching the teeth on
the strips with the teeth
on the work.

Instrument No: 4
Title: Vernier Bevel Protractor

Bevel Protractor:

It is also called universal bevel

protractor. It is one of the simplest
instruments for angular measurement.
It is a direct type of angular measuring
instrument. The range of this
instrument is 0 to 360 degrees i.e. it can
measure angles upto 3600 which any
other angular metrological instrument
cannot measure. It has two arms (Fixed
blade and Adjustable Blade), which can
be set along the faces and a circular
scale to indicate the angle between
them. Workpiece is set in between these
two arms (two blades, fixed blade and
adjustable blade), and the difference of
two scale (main scale and vernier scale)
readings gives accurate measurement.

Sr. No. Notation of Angle Vernier Bevel Protractor Remarks

1 A
2 B
3 C

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Instrument No: 5
Title: Gear Teeth Measurement

Objectives:
Students will be able to
1. Understand working and use of Gear tooth
Vernier caliper,
2. Understand the importance of gear
measurement,

Apparatus:
(a) Spur Gear (b) Gear tooth Vernier Caliper
Theory:
The main parameters determining the profile of
a spur gears are pressure angle, circular pitch,
tooth thickness, crest circle diameter and root
circle diameter. Here we describe the method for
measuring of tooth thickness by means of a gear
tooth vernier caliper. The measuring principle is
based upon the determination of the exact depth
from the crest of the tooth at which the chordal
thickness should be measured. The correct depth
must ensure that the chordal tooth thickness is
measured at the pitch circle. For spur gears, it
can be shown that:

Where m = module, dp = pitch circle diameter, z = no. of teeth

Observation Table:
Number of teeth on gear, z = __________ and outside gear dia do = _____________

Sr. No Width (w) Height (h) Sr. No Width (w) Height (h)
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8

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Instrument No: 6
Title: Vernier Height gauge, Digital Height gauge and Vernier Depth gauge.

Apparatus:
Vernier height gauge (L.C. 0.02 mm and Range 0–300mm), Digital Vernier height gauge, Vernier depth
gauge (L.C. 0.02 mm and Range 0–300mm) and Specimen
Vernier Height gauge:
Vernier height gauge is similar to vernier caliper but in
this instrument the graduated bar is held in a vertical
position and it is used in conjunction with a surface
plate. A Vernier height gauge consists of.
(i) a finely ground and lapped base. The base is
massive and robust in construction to ensure rigidity
and stability. (ii) A vertical graduated beam or column
supported on a massive base. (iii) Attached to the beam
is a sliding vernier head carrying the vernier scale and
a clamping screw? (iv) an auxiliary head which is also
attached to the beam above the sliding vernier head. It
has a fine adjusting and clamping screw. (v) a
measuring jaw or scriber attached to the front of the
sliding vernier. The important features of vernier
height gauge:

stainless steel.

the base.
The measuring jaw should have a clear projection from
the edge of the beam at least equal to the projection of
the base from the beam.
The upper and lower gauging surfaces of the measuring
jaw shall be flat and parallel to the base
The scriber should also be of the same nominal depth
as the measuring jaw so that it may be reversed

Observation Table:
For Vernier Height Gauge
Sr. Main scale reading (A) mm No. of vernier Vernier scale readings Total reading
No. scale division div X L.C. A+B
(B)

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Instrument No: 7
Title: Study of steel rule

Objectives:

Students will be able to

1. Understand working and use of Steel Rule.
2. Understand the importance of Steel Rule.

Apparatus:

Steel Rule

Theory:
The steel rule is a basic measuring tool. When used correctly, a good steel rule is a surprisingly
accurate measuring device.
Some people confuse rules and scales. A scale is a measuring device used by
architects and engineers that assists them in making drawings to a scale other than full size. A rule
is used to measure actual sizes. (But don’t ask about shrink rules, which are used to make casting
patterns and include an allowance for shrinkage of the casting during cooling.)

Least count of steel rule = 0.5 mm

Steel rule can be used to measure length in Inches and Metric units.

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Instrument No: 8
Title: Study of Wire Gauge

Objectives:
Students will be able to
1. Understand working and use of Wire Gauge.
2. Understand the importance of Wire Gauge.

Apparatus:
(a) Wire Gauge (b) Sheet and thin wire
Theory:
Wire gauges are reference tools used by artists, jewellery makers and craftspeople. They are used
for selecting the appropriate diameter wire for a specific purpose. A wire gauge is a quick and easy
way of identifying the thickness of a wire for artwork and construction.

Using a wire gauge can help you identify the size of an unknown wire you may have. This may be
beneficial if you need to finish a project by matching a wire type to one that you have used in the
past. The wire gauge also allows you to take the guesswork out of converting measurements.
Gauges often come with metric and imperial inscriptions - these can be found either on the same
side or the reverse of the gauge.

Procedure

A wire gauge, either British or American, can be used to measure either wire or metal sheets. To
do this follow the step

To measure the wire, slide it into a slot on the gauge which looks to be the same width. Keep
moving the wire around the gauge until the wire fits into the slot with a tight fit. The number next
to the slot will state what size it is, for example 16 gauge.

 There are 36 Gauges in practical wire gauges.

 When we increase the gauge their size will decrease.

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 2. ELECTRIC ARC WELDING

ARC WELDING MACHINE

15
 2. ELECTRIC ARC WELDING

Aim: To learn arc welding processes, welding equipment, and practice by making BUTT joints.
Tools required: Hand gloves, protective screen, helmet, scaling hammer, scratch brush. Work
holding fixture.
Machine Required: MMAW-Manual Metal Arc Welding.
Material Required: M S flat-75x50x5mm [2 pieces], MS welding electrodes No.8 [3.15 mm]
Sequence of Operations:

1. Prepare edges of the two work pieces as shown in the following Figure
2. Set the machines for the desired current to suit to the dia. of electrode.
3. Hold & tack weld the pieces in the fixture provided to maintain desired root gap.
4. Perform the arc welding for entire length with the help of AC welding machine.
5. Remove scales using scaling (chipping) hammer.
6. Clean the weld using wire brush.

Learn more
Welding and cutting torches and functional differences.
Different types of welding joints, welds and welding positions.
Differences between arc welding and gas welding.
What are the differences in the welding rod material, and the parent metal?
How the arc is produced? Can you control the temperature of the arc?
Electrode base metal and coating.
Welding machine specification.
Edge preparation for arc welding.

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3. METAL TURNING ON LATHE

LATHE MACHINE

17
 3. METAL TURNING ON LATHE
Aim: To learn and practice different operations performed on Lathe.
Tools required: Turning, parting, knurling and drilling tools.
Machine Required: Lathe with necessary accessories.
Material Required: MS rod Ø25x70mm

Lathe Operation:

 Centering: centering is the operation of producing conical holes in work pieces at

the ends to provide bearing surface for lathe centers.
 Turning: Turning is the process to remove excess material from the work piece
basically to produce cylindrical or cone shaped objects, to the required shape and
size. The most common center or engine lathe is used for preparing of various turning
parts by different turning process. Straight turning produces a cylindrical surface by
feeding the single point cutting tool against the rotating work parallel to the work.
 Taper turning: means to produce a conical surface by gradual reduction in diameter
from a cylindrical work piece.
 Facing: Facing is the operation of machining the ends of a work piece to produce
flat surface square with the axis. This is also used to cut the work to the required
length. The tool is fed perpendicular to the axis of rotation of the work piece.
 Knurling: Knurling is the process of embossing a diamond shaped pattern on the
surface of the work piece. It provides grip to the work piece.
 Eccentric turning: If the cylindrical work piece has two separate axis of rotation,
one being out of the centre to the other, the work piece is eccentric and turning of
different surfaces of the work piece is known as eccentric turning.

18
 Sequence of operations for the Turning Job

Sr. No. Operation Drawing

Read the drawing and understand symbols

& conventions.
1. Identify the sequence of operations.
Note: All dimensions are in mm,
Chamfer of 1x 45º
Figure 1: Lathe Job

Hold the work piece in the 3-jaw chuck.

2.
Turn & Face to  22x50. Chamfer is 1x450

Cut the groove for 6 mm length 2.5 mm

3.
deep , 7 mm length 5 mm deep

Perform the Knurling for 15 mm length with

Diamond knurl supporting the job from tail
4.
stock end with a revolving center In
minimum rpm.

19
 Engage the gear for M2 thread and mount
the ‘V’ shape tool on tool post with
5
minimum speed and feed should be automatic.

Precaution:

 Operator should always be sure that all guards are in place before running the
lathe machine.
 Always clamp the work and tool properly with the correct size of work and tool
holding the device.
 Wear an apron or a properly fitted shop coat. Goggles should also be used to
avoid chip particles contact with human body.
 One should remove necktie, wrist watch and jewelry while working on the
machine.
 One should check the work frequently when the workpiece is being machined.
 Stop the machine and remove chips with pliers. One should not touch remove the
chips by hand because they will be hot.

Learn More:
Principal parts of the Lathe machine.
Sequencing of the operations, so that the machining time is minimized.
Explore faster ways of machining so as to increase the productivity.
Types of threads used on different components of Lathe.
Types of taper turning methods adopted on Lathe.
Relationship between speed, feed and depth of cut for different metals.
Machining operations performed on Lathe.
Work holding devices used on Lathe.
 4. VERTICAL MILLING MACHINE

VERTICAL MILLING MACHINE

 4. VERTICAL MILLING MACHINE
Aim: To learn operations on Vertical Milling M/C and to make a practice job.

Tools required: End mill cutter, T-slot cutter, spanner, scale, vernier caliper, mallet, tri square, vice
and Brush

Machine Required: Vertical Milling M/C

Material Required: M.S. block 55mm x 55mm x 40mm

Theory:

 A milling machine is a machine tool that removes metal as the work is fed against a rotating
multipoint cutter.
 A vertical milling machine can be described as a milling machine in which the position of
the spindle is perpendicular to work table. This machine is adapted for machining grooves,
slots and flat surfaces.
 Cutting speed is the peripheral linear speed resulting from the rotation
𝜋𝐷𝑁
V=1000 m/min

Where V= cutting speed in m/min, D = diameter of cutter in mm, N = cutter speed in RPM.

 Feed is defined as the rate at which work piece advances.

 Depth of cut is the thickness of the material removed in one pass of the work under the
cutter.
Sequence of operations:


Study the drawing and select the machine speed according to tool and job material.

Set the machine for desired length and depth of cut position.

Clamp the job in the vice and tool with collets in spindle.

Clamp End mill cutting tool with collets in spindle

After cutting the key way clamp next tool T-slot cuter and make a slot as per the dimensions.
Note: all dimensions are in mm

Precautions:

 Keep hands and body away from the revolving cutter.

 Do not measure the work while the cutter is cutting or revolving near the work piece.
 Work piece must be rigidly held on the work table.
 Do not remove the chips while machine is running.
Learn More:

1. Selection of cutter
2. Selection of cutting speed according to tool and materials
3. relation of cutting speed and number of rotation according tool and materials
4. Machines used for producing the flat surfaces.
5. How to increase the productivity of the machine?
6. Number of Speeds available?
5. DRILLING AND FITTING

DRILLING MACHINE & BENCH VICE

 5. DRILLING AND FITTING

Aim: - To learn various fitting operations in metal working.

Tools required : - Flat file bastard, second cut triangular file second cut, center punch, vernier
caliper, tri-square, universal marking gauge, hammer and surface plate, hacksaw frame and
hacksaw blade.
Material required: - M S Flat 50 x 50 x10 mm one piece.
Theory:-
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed against
the work-piece and rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the work-piece, cutting off chips from the hole as it is drilled.
Procedure : -

Study the drawings of the utility job to be made.

Before marking on the material, clean the surface with emery paper.
Apply chalk on one side of the raw material to facilitate the marking.
Use marking gauge for marking the dimensions on the raw material according to Figure2.
Punch the boundary line using center punch.
Use Hacksaw for the cutting operation.
Finish work piece using a second cut file and give the undercut.

Precaution : -

2. The work should not be held by hand in any case.

3. Proper work holding device should be used to hold. If the work is not held properly, the
work tends to rotate along with the drill causing damage to the operator, the machine tool
and the cutting tool.
4. Proper safety plates should be installed around rotating parts like belt drive and gears.
5. The shank of the drill should conform with the spindle hole.

FIG. 1 Types of Reamer

 FIG. 2 Types of Files

FIG. 3 FINISHED WORKPIECE

FIG. 4 TWIST DRILL

 6. ULTRASONIC PLASTIC WELDING

ULTRASONIC PLASTIC WELDING MACHINE

 6. ULTRASONIC PLASTIC WELDING

Aim: To learn and perform ultrasonic plastic welding on Acrylic sheet

Materials & tools required: Acrylic sheet of 100×100 mm, blades and steel rule.
Introduction: Ultrasonic plastic welding is the joining or reforming of thermoplastics through the
use of heat generated from high-frequency mechanical motion. The following Figure 1 illustrate the
basic principle of ultrasonic welding.

Figure 1. The ultrasonic welding process

❶The two Acrylic sheets to be joined are placed together, one on top of the other, on a supportive
surface called a fixture/anvil.
❷A aluminum component called a horn is brought into contact with the upper plastic part.
❸A controlled pressure (Compressed air) is applied to the horn, clamping the two plastic parts
together against the fixture.
❹The horn supply high frequency mechanical vibrations 20,000 (20 kHz) or 30,000 (30 kHz) times
per second, at distances measured in thousandths of an inch (microns), for a predetermined amount
of time called weld time.
❺The clamping force is maintained for a predetermined amount of time to allow the parts to fuse
as the melted plastic cools and solidifies. This is known as hold time.
❻Once the melted plastic has solidified, the clamping force is removed and the horn is retracted.
The two plastic parts are now joined as if molded together and are removed from the fixture as one
part.
System components and Functions: Figure 2 shows the ultrasonic plastic welding system
components and Figure 3 shows the function of each basic system component and how the
vibrational energy is created and increased.

• The generator changes standard electrical power (120 – 240 volts, 50/60 Hz) into electrical
energy at the frequency at which the system is designed to operate.
• The high frequency electrical energy produced by the generator is sent through a cable to
the transducer, which changes the electrical energy into vertical, low amplitude mechanical
motion, or vibrations
• These vibrations are then transmitted to a booster, which is used to increase or decrease the
amplitude of the vibrations.
• The vibrations are then transmitted to a horn of the proper size and shape to best deliver the
vibrational energy to the workpiece.
 Figure 2. Ultrasonic plastic welding system components

Figure 3. Basic System Components and Their Functions

Learn more
 Working principle of the ultrasonic welding
 Difference between arc welding and ultrasonic welding
 Different types of horns available
 Welding machine specifications
 Advantages, disadvantages and applications of ultrasonic plastic welding.
 Phase II

1. Grooving, Threading and Knurling operations on Lathe

Machine

Lathe Machine
 1. Grooving, Threading and Knurling operations on Lathe Machine
Aim: To perform Grooving, Threading and knurling operations on lathe machine.

Tools required: Knurling, grooving, and threading tools.

Machine Required: Lathe with necessary accessories.

Material Required: MS rod 37x76mm

Lathe Operation:

 Centering: centering is the operation of producing conical holes in work pieces at the ends to
provide bearing surface for lathe centers.
 Turning: Turning is the process to remove excess material from the work piece basically to produce
cylindrical or cone shaped objects, to the required shape and size. The most common center or engine
lathe is used for preparing of various turning parts by different turning process. Straight turning
produces a cylindrical surface by feeding the single point cutting tool against the rotating work
parallel to the work.
 Taper turning: means to produce a conical surface by gradual reduction in diameter from a
cylindrical work piece.
 Facing: Facing is the operation of machining the ends of a work piece to produce flat Surface Square
with the axis. This is also used to cut the work to the required length. The tool is fed perpendicular
to the axis of rotation of the work piece.
 Knurling: Knurling is the process of embossing a diamond shaped pattern on the surface of the
work piece. It provides grip to the work piece.

 Eccentric turning: If the cylindrical work piece has two separate axis of rotation, one being out of
the centre to the other, the work piece is eccentric and turning of different surfaces of the work piece
is known as eccentric turning

 Grooving: Grooving is the act of making grooves of reduced diameter in the work piece.
  Threading: Threading is the act of cutting of the required form of threads on the internal or external
cylindrical surfaces.

Precaution:

 Operator should always be sure that all guards are in place before running the lathe machine.
 Always clamp the work and tool properly with the correct size of work and tool holding the
device.
 Wear an apron or a properly fitted shop coat. Goggles should also be used to avoid chip
particles contact with human body.
 One should remove necktie, wrist watch and jewelry while working on the machine.
 One should check the work frequently when the work piece is being machined.
 Stop the machine and remove chips with pliers. One should not touch remove the chips by
hand because they will be hot.
 2. GAS WELDING

GAS WELDING MACHINE

 2. GAS WELDING
Aim: To study about sheet metal Gas Welding LAP
joint. Tools required: Scriber and C-clamp.
Equipment required: Gas welding equipment, fixture, brass rod of
1.7mm dia. Material required: MS sheet 2.5 mm thickness (60x60mm) 2
pieces.
Sequence of operations:
1. Study the drawings
2. Using a smooth file bring the pieces A and B to dimensions as shown in the figure and round
up the corners.
3. Use the scriber and mark the center along the 40mm width.
4. Weld both the pieces A and B by gas welding process.

Learn more:

 What do you understand by ‘gauge’ of the sheet metal? What are the different gauge
systems, the industry uses? 


 How sheet metals can be produced. 



 Applications of sheet metal. 



 Application of Gas Welding. 



 Different gases used in gas welding. 



 Pressure required for gas welding

3. STEP AND TAPER TURNING OPERATION ON
LATHE MACHINE

LATHE MACHINE
 3. STEP AND TAPER TURNING OPERATION ON LATHE MACHINE

Aim: To perform Step and Taper turning operation on lathe machine and process
demonstration of Tool Wear Measurement
Tools required: Turning, grooving, and parting tools.
Machine Required: Lathe with necessary accessories.
Material Required: MS rod Ø37x76mm

Sequence of operations for the Turning Job:

S.No. Operation Drawing

Read the drawing and understand symbols &
Conventions.
1.
Identify the sequence of operations. Note: All
dimensions are in mm.

Hold the work piece in the 3-jaw/four jaw

2. chuck, turn & face to  30x51mm.
Center drill the face.

Cut the groove for 5 mm length 6.25 mm

3.
deep. Drill Ø 14mm hole, 16mm deep.

For taper turning, swivel compound rest to

an angle ,
𝐷−𝑑
𝜃 = 𝑡𝑎𝑛−1 ( )
2𝐿
4.
where D= larger diameter of taper,
d=smaller diameter, L=length of taper,
perform turning operation for Ø25 mm
for 16 mm length.

Hold the work piece in the four jaw chuck

5. and shift the center of work piece according
drawing and machine it
Tool wear measurement:

Fig 1. Types of tool wear

Fig 2. SEM image of tool wear Fig 3. UM 5 USB Microscope

Learn more:

 Tool nomenclature
 Other tool wear measurement techniques
 Types of tool wears
 4. HORIZONTAL MILLING

Horizontal Milling Machine

 4. HORIZONTAL MILLING
Aim: To learn operations on horizontal milling machine and to make a practice job.

Tools required: Gear cutter, spanner, vernier caliper and tri square, machine vice and Brush

Machine Required: Horizontal milling m/c

Material Required: M.S. bar Ф 60mm x 20mm

Theory:

 A milling machine is a machine tool that removes metal as the work is fed against a
rotating multipoint cutter.
 A Horizontal milling machine can be described as a milling machine in which the
position of the spindle is parallel to work table.
 The gear cutters have formed cutting edges which reproduce the shape of the cutter teeth
on the gear blank.
 Cutting speed is the peripheral linear speed resulting from the rotation
𝜋𝐷𝑁
V=1000 m/min

Where V= cutting speed in m/min, D = diameter of cutter in mm, N = cutter speed in

RPM.

 Feed is defined as the rate at which work piece advances.

 Depth of cut is the thickness of the material removed in one pass of the work under the
cutter.
Sequence of operations:

1. Prepare work piece as shown in the following figure

2. Set the machine & indexing head for the desired gear teeth of the outer dia. of the work
piece
3. Hold & tack work pieces on the horizontal milling machine with (fixture) main drill
4. using center of the work piece for gear cutter
5. calculate the gear depth ( total depth of teeth) = addendum + dedendum
6. calculate the gear indexing for 10 teeth =40/number of teeth
Precautions:

 Keep hands and body away from the revolving cutter.

 Do not measure the work while the cutter is cutting or revolving near the work piece.
 Work piece must be rigidly held on the work table.
 Do not remove the chips while machine is running.

Learn more

1. Relation of module , pitch diameter, number of teeth

2. Relation of module , addendum and dedendum
3. Relation of module and diametric pitch
4. Relation of module and depth of teeth
5. How to make gear
6. Selection of cutter
 5. SHEET METAL OPERATIONS OF G.I.SHEET
Aim: - To learn various sheet metal operation & prepare a funnel cone.

Tools required: - Flat file (bastard), second cut, round file, center punch, vernier caliper, tri-
square, scriber, hammer & sheet metal scissors.

Material required: - 170 mm x 170 mm x 28 gauge sheet.

Theory: - A metal which is formed by an industrial process into thin, flat pieces is known as sheet
metal. It is the most fundamental form listed in metal working and can be cut and bent into variety
of shapes. Extremely thin sheets are regarded as foil or leaf and pieces thicker than 6mm are
regarded as plate. The thickness of sheet metal is measured in gauge number. Larger the gauge
number, thinner is the metal.

Procedure:-

1. Study the drawing, select the cutting tool, scissors & GI sheet.
2. Marking and cutting of sheet.
3. Marking with using development of cylinder surface and cone surface.
4. Cutting the sheet using with extra sheet for seem joint.
5. Then try to learn how to make the funnel.

Precautions:-

1. Always hold the sheet at proper angle.

2. Before bending ensure that sheet is parallel to the bender.
3. Always wear safety gloves.
4. Always ensure that all the burr are filed properly.
5. Avoid running your hands over sharp cut.
6. PROCESS DEMONSTRATION OF SHAPER
MACHINE

SHAPING MACHINE
 6. PROCESS DEMONSTRATION OF SHAPER MACHINE
AIM: Process Demonstration of Shaper Machine.

SPECIFICATION OF THE MACHINE:

Length of ram stroke: 457 mm
Length of ram: 914 mm
Max/min. distance from table to ram 406 x 89
Max. Vertical travel of tool slide 152 mm
Max. Swivel of tool head 60 degrees L & R
Power of the motor 2 H.P.

Working Principle:
The working principle of a shaper is illustrated in fig1.

FIG. 1

In case of shaper; the job is rigidly held in a suitable device like a vice or clamped directly on
the machine table. The tool is held in the tool post mounted on the ram of the machine. This
ram reciprocates to and fro and in doing so makes the tool to cut the material in the forward
stroke. No cutting of material takes place during the return stroke of the ram. Hence it is termed
as idle stroke. However in case of a draw cut shaper the cutting takes place in the return stroke
 and the forward stroke is an idle stroke. The job is given an index feed in a direction normal to
the line of action of the cutting tool.

PROCEDURE:

1. The two ends of the work piece are first smoothened by filing and apply chalk on its surface.
2. Place the work piece on the V-block and mark centre on the end face using surface gauge, scriber
and Vernier height gauge.
3. Mark square on the end face according to the required dimensions.
4. By using dot punch made permanent indentation marks on the work piece.
5. The tool is fixed to the tool post such that the tool movement should be exactly perpendicular
to the table.
6. The work piece is then set in the vice such that the tool is just above the work piece.
7. Adjust the length of the stroke.
8. Make sure that line of action of stroke should be parallel to the surface of the work piece.
9. Give depth of cut by moving the tool and feed is given to the work piece during return stroke of
the ram.
10. Continue the process, until the required dimensions are to be obtained. Repeat the process for
all the four sides.
PRECAUTIONS:
1. Marking should be done accurately.
2. The work piece should be set securely and rigidly in the vice.
3. Before starting a shaper make sure that the work piece, tool, and ram are securely fastened.
4. Check that the tool and tool holder will clear the work and also the column on the return stroke.
5. Always stand parallel to the cutting stroke and not in front of it.
6. Never attempt to remove chips or reach across the table while the ram is in motion.
7. Never attempt to adjust a machine while it is in rotation.
8. Suitable feeds and depth of cut should be maintained uniformly.
9. Apply cutting fluids to the tool and work piece properly.
10. Always feed will be given to the tool in the backward stroke only