Me 330 Lab Manual

SPSU, UDAIPUR Lab Manual
Department of Mechanical Engineering Machine Shop
School of Engineering
Udaipur
Laboratory Manual
ON
Machine Shop
DEPARTMENT OF MECHANICAL
ENGINEERING
1
LIST OF EXPERIMENTS
INDEX
S. No. Object Page Hours

No.
1. Introduction to machine tools and machining processes. 3 2
2. Selection of cutting tools, cutting speeds and feed. 14 2
To perform step turning, chamfering and facing operations

3. 23 2
on a centre lathe machine.
To perform taper turning, knurling and drilling operation
4. 25 2
using a center lathe machine
To make the threads of the given dimension on lathe

5. 27 2
machine
To perform shaping operation for finishing two sides of a job
6. 29 2
and drilling one hole and grinds the corners of a job.
To make the gear teeth on milling machine as per the given
7. 31 2
dimension
8. To perform alignment test on the lathe machine. 33 2
Write a manual part program to machine on CNC lathe

9. 34 2
machine for the components as shown in DWG.
To make the component of given drawing on CNC turning
10. 38 2
machine
2
EXPERIMENT NO. 01
Machine Tools
1. OBJECTIVE:
Introduction to machine tools and machining processes.
2. INTRODUCTION:
(a) Purpose of Machining

Most of the engineering components such as gears, bearings, clutches, tools, screws
and nuts etc. need dimensional and form accuracy and good surface finish for serving
their purposes. Performing like casting, forging etc. generally cannot provide the
desired accuracy and finish. For that such preformed parts, called blanks, need semi-
finishing and finishing and it is done by machining and grinding. Grinding is also
basically a machining process.
(b) Principle of Machining

The basic principle of machining is typically illustrated in Figure 1. A metal rod of
irregular shape, size and surface is converted into a finished rod of desired dimension
and surface by machining by proper relative motions of the tool-work pair.
Figure 1
(c) Definition of Machining:
Machining is an essential process of finishing by which jobs are produced to the
desired dimensions and surface finish by gradually removing the excess material from
the preformed blank in the form of chips with the help of cutting tool(s) moved past the
work surface(s).
3
The body which removes the excess material through a direct mechanical contact is
called the cutting tool and the machine which provides the necessary relative motions
between the work and the tool is commonly known as the machine tool.
3. MACHINING REQUIREMENTS:
The essential basic requirements for machining work are schematically illustrated in
Figure 2. The blank and the cutting tool are properly mounted (in fixtures) and moved
in a powerful device called machine tool enabling gradual removal of layer of material
from the work surface resulting in its desired dimensions and surface finish.
Additionally some environment called cutting fluid is generally used to ease machining
by cooling and lubrication.
Figure 2. Requirements for machining
4. BASIC FUNCTIONAL PRINCIPLES OF MACHINE TOOL OPERATIONS:
For material removal by machining, the work and the tool need relative movements and
those motions and required power are derived from the power source(s) and
transmitted through the kinematic system(s) comprised of a number and type of
mechanisms.
(1) Concept of Generatrix and Directrix:
(a) Generation of flat surface: The principle is shown in Figure 3, where on a flat plain a
straight line called Generatrix (G) is traversed in a perpendicular direction called
Directrix (D) resulting a flat surface.
4
(b) Generation of cylindrical surfaces: The principles of production of various cylindrical

surfaces (of revolution) are shown in Figure 4, where,
⎯ A long straight cylindrical surface is obtained by a circle (G) being traversed in the
direction (D) parallel to the axis as shown in Figure 4(a)
⎯ A cylindrical surface of short length is obtained by traversing a straight line (G) along
a circular path (D) as indicated in Figure 4(b)
⎯ Form cylindrical surfaces by rotating a curved line (G) in a circular path (D) as
indicated in Figures 4(c) and 4(d).
Figure 3. Generation of flat surfaces by Generatrix and Directrix
Figure 4. Generation of cylindrical surfaces (of revolution)
2. Tool – work motions:
The lines representing the Generatrix and Directrix are usually produced by the locus
of a point moving in two different directions and are actually obtained by the motions of
the tool-tip (point) relative to the work surface. Hence, for machining flat or curved
surfaces the machine tools need relative tool work motions, which are categorized in
following two groups:
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(a) Formative motions namely:
⎯ Cutting motion (CM)
⎯ Feed motion (FM)
(b) Auxiliary motions such as:
⎯ Indexing motion
⎯ Additional feed motion
⎯ Relieving motion
The Generatrix and Directrix, tool and the work and their motions generally remain
interconnected and in different way for different machining work. Such interconnections
are typically shown in Figure 5 for straight turning and Figure 6 for shaping.
Figure 5. Principle of turning (cylindrical surface)
The connections in case of straight longitudinal turning shown in Figure 5(a) are:
Generatrix (G) – Cutting motion (CM) – Work (W)
Directrix (D) – Feed motion (FM) – Tool (T)
In case of making flat surface in a shaping machine as shown in Figure 6 the

connections are:
G – CM – T
D – FM – W
6
which indicates that in shaping flat surfaces the Generatrix is provided by the cutting
motion imparted to the cutting tool and the Directrix is provided by the feed motion of
the work.
Flat surfaces are also produced by planning machines, mainly for large jobs, where the
cutting motion is imparted to the work and feed motion to the tool and the connections
will be:
G – CM – Work
D – FM – Tool
Figure 6. Principle of producing flat surface in shaping machine
5. CONFIGURATION OF BASIC MACHINE TOOLS AND THEIR USE:
1. Centre lathes
Configuration:
Figure 7 shows the general configuration of center lathe. Its major parts are:
I) Head stock: it holds the blank and through that power and rotation are transmitted
to the job at different speeds
II) Tailstock: supports longer blanks and often accommodates tools like drills,
reamers etc for hole making.
III) Carriage: accommodates the tool holder which in turn holds the moving tools
IV) Bed: headstock is fixed and tailstock is clamped on it. Tailstock has a provision
to slide and facilitate operations at different locations, carriage travels on the bed
V) Columns: on which the bed is fixed
VI) Work-tool holding devices
7
Uses of center lathes
 Centre lathes are quite versatile being used for various operations:
 Turning: internal, external (straight, stepped, taper)
 Facing, centering, drilling, recessing and parting
 Thread cutting; external and internal
 Knurling
Some of those common operations are shown in Figure 8. Several other operations
can also be done in center lathes using suitable attachments.
Figure 7. Centre Lathe Machine
Figure 8. Common machining operations done on centre lathe
8
2. Shaping machine
Figure 9 shows the general configuration of shaping machine. Its major parts are:
I) Ram: it holds and imparts cutting motion to the tool through reciprocation
II) Bed: it holds and imparts feed motions to the job (blank)
III) Housing with base: the basic structure and also accommodate the drive
mechanisms
IV) Power drive with speed and feed change mechanisms.
Uses:
Shaping machines are generally used for producing flat surfaces, grooving, splitting
etc. Because of poor productivity and process capability these machine tools are not
widely used now-a-days for production.
Figure 9. Shaping Machine
3. Planing Machine
The general configuration is schematically shown in Figure 10. This machine tool also
does the same operations like shaping machine but the major differences are:
a. In planing the job reciprocates for cutting motion and the tool moves slowly for the
feed motions unlike in shaping machine.
b. Planing machines are usually very large in size and used for large jobs and heavy
duty work.
9
Figure 10. Planing Machine

4. Drilling machine
Figure 11 shows general configuration of drilling machine, column drill in particular.

The salient parts are:
I. Column with base: it is the basic structure to hold the other parts
II. Drilling head: this box type structure accommodates the power drive and the speed
and feed gear boxes.
III. Spindle: holds the drill and transmits rotation and axial translation to the tool for
providing cutting motion and feed motion – both to the drill.
Drilling machines are available in varying size and configuration such as pillar drill,
column drill, radial drill, micro-drill etc. but in working principle all are more or less the
same.
Uses:
a. Mainly for drilling (originating or enlarging cylindrical holes)

b. Occasionally for boring, counter boring, counter sinking etc.
c. Also for cutting internal threads in parts like nuts using suitable attachment.
10
Figure 11. Drilling Machine
5. Milling machine
The general configuration of knee type conventional milling machine with horizontal
arbor is shown in Figure 12. Its major parts are:
I) Milling arbor: to hold and rotate the cutter
II) Ram: to support the arbor
III) Machine table: on which job and job holding devices are mounted to provide the
feed motions to the job.
IV) Power drive with Speed and gear boxes: to provide power and motions to the tool-
work
V) Bed: which moves vertically upward and downward and accommodates the various
drive mechanisms
VI) Column with base: main structural body to support other parts.
Uses
 Milling machines are also quite versatile and can do several operations like:
 Making flat surfaces
 Grooving, slitting and parting
 Helical grooving
 Forming 2-D and 3-D contoured surfaces
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Figure 12. Milling Machine
Figure 13. Common milling operations
6. SPECIFICATION OF MACHINE TOOLS:
A machine tool may have a large number of various features and characteristics. But
only some specific salient features are used for specifying a machine tool. All the
manufacturers, traders and users must know how machine tools are specified. The
methods of specification of some basic machine tools are as follows:
Centre Lathe
• Maximum diameter and length of the jobs that can be accommodated
• Power of the main drive (motor)
• Range of spindle speeds
• Range of feeds
• Space occupied by the machine.
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Shaping Machine
• Length, breadth and depth of the bed
• Maximum axial travel of the bed and vertical travel of the bed / tool
• Maximum length of the stroke (of the ram / tool)
• Range of number of strokes per minute
• Range of table feed
• Power of the main drive
• Space occupied by the machine
Drilling Machine (column type)

• Maximum drill size (diameter) that can be used
• Size and taper of the hole in the spindle
• Range of spindle speeds
• Range of feeds
• Range of the axial travel of the spindle / bed
• Floor space occupied by the machine
Milling Machine (knee type and with arbor)

• Type; ordinary or swiveling bed type
• Size of the work table
• Range of travels of the table in X-Y-Z directions
• Arbor size (diameter)
• Range of spindle speed
• Range of table feeds in X-Y-Z directions
• Floor space occupied.
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EXPERIMENT NO. 02
Cutting Tools
1. OBJECTIVE:
Selection of cutting tools, cutting speeds and feed.
2. INTRODUCTION:
Machining is one of the processes of manufacturing in which the specified shape to the
work piece is imparted by removing surplus material. Conventionally this surplus
material from the work piece is removed in the form of chips by interacting the work
piece with an appropriate tool. This mechanical generation of chips can be carried out
by single point or multi point tools or by abrasive operations.
The single-point tool is the simplest cutting device available. It has a cutting edge on
the end or along the edge of a rod. Common single-point tools include knives, chisels,
and wood planes.
The multiple-point tool has a series of single-point tools arranged on a cutting device.
Most often, these single-points are arranged in a pattern. For example, a circular saw
has teeth evenly spaced around the circumference of the blade.
Machining Processes
Single point tool operations Multi-point tool operations Abrasive operations
Turning Milling Grinding

Boring Drilling Lapping
Shaping Tapping Honing
Planing Reaming Super Finishing
Hobbing
Broaching
Sawing
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3. SELECTION OF CUTTING CONDITIONS:
For each machining operation, a proper set of cutting conditions must be selected
during the process planning. Decision must be made about all three elements of cutting
conditions:
1. Depth of cut• 2. FeedŽ 3. Cutting speed
Selection of cutting conditions is made with respect to the type of machining operation.
Cutting conditions should be decided in the order depth of cut - feed - cutting speed.
1. Selecting depth of cut:
Depth of cut is predetermined by work piece geometry and final part shape. In roughing
operations, depth of cut is made as large as possible (max depths are in the range of
6~10 mm) with respect to available machine tool, cutting tool strength, and other
factors. Often, a series of roughing passes is required. Roughing operations must
leave a thin layer of material (~0.5 mm on a side) required for the subsequent finishing
operation. In the finishing cut, depth is set to achieve the final dimensions with a single
pass removing the excessive material left after roughing.
Figure 1
Figure 2
15
2. Selecting feed:
In roughing operations, feed is made as large as possible to maximize metal removal

rate. Upper limits on feed are imposed by cutting forces and setup rigidity. Feeds in
roughing can be as big as 0.5mm to1mm.
If the operation is finishing, feed should be small to ensure good surface finish. Surface
Finish can be used to estimate the feed that will produced a desired surface finish.
Typical feeds in finishing are in the range of 0.05~0.15 mm to 1mm.
3. Selection of cutting speed:
As with most engineering problems, in machining we want to minimize costs, while

increasing productivity. Efficiency is the key term - it suggests that good quality parts
are produced at reasonable cost and at high production rate. Unfortunately, it is almost
impossible to combine these contradictable requirements - cutting at high speed
increases productivity but reduces tool life; therefore increases the production cost as
more cutting tools will be necessary to finish the job. Hence, the optimal cutting speed
has to be calculated for two objectives:
a) Cutting speed for maximum production rate, Vmax
b) Cutting speed for minimum unit cost, Vmin
Both objectives seek to achieve a balance between material removal rate and tool life.
Maximizing production rate: For maximum production rate, the speed that minimizes
machining time per unit part is determined. Minimizing cutting time is equivalent to
maximizing productivity. It can be shown, that the cutting time for one part T c is
minimized at a certain value of cutting speed denoted as Vmax.
Minimizing cost per unit: For minimum cost per unit, the cutting speed that minimizes
production cost per part is determined. Again, the total cost of producing one part is
minimized at a value of cutting speed denoted as Vmin. In all cases, Vmax is always
greater than Vmin. Since it is difficult to precisely calculate either value, a general
recommendation is to operate within these two values, an interval known as the high-
efficiency range.
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Figure 3
4. TOOL LIFE:
Tool life generally indicates the amount of satisfactory performance or service rendered
by a fresh tool or a cutting point till it is declared failed. Tool life is defined as:
“The actual machining time (period) by which a fresh cutting tool (or point) satisfactorily
works after which it needs replacement or reconditioning.”
The modern tools hardly fail prematurely or abruptly by mechanical breakage or rapid
plastic deformation. Those fail mostly by wearing process which systematically grows
slowly with machining time. In that case, tool life means the span of actual machining
time by which a fresh tool can work before attaining the specified limit of tool wear.
Mostly tool life is decided by the machining time till flank wear, VB reaches 0.3 mm or
crater wear, KT reaches 0.15 mm.
17
Figure 4. Growth of flank wear and assessment of tool life
Taylor’s tool life equation

Tool life of any tool for any work material is governed mainly by the level of the
machining parameters i.e., cutting velocity, (VC), feed, (so) and depth of cut (t). Cutting
velocity affects maximum and depth of cut minimum. The usual pattern of growth of
cutting tool wear (mainly VB), principle of assessing tool life and its dependence on
cutting velocity are schematically shown in Figure 5
.
Figure 5. Cutting velocity - Tool life relationship
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When F. W. Taylor plotted the same figure taking both V and T in log-scale, a more
distinct linear relationship appeared as schematically shown in Figure 6. With the
slope, n and intercept, c, Taylor derived the simple equation as:
VTn = C
where, n is called, Taylor’s tool life exponent. The values of both ‘n’ and ‘c’ depend
mainly upon the tool-work materials and the cutting environment (cutting fluid
application). The value of C depends also on the limiting value of VB undertaken (i.e.,
0.3 mm, 0.4 mm, 0.6 mm etc.)
Figure 6. Cutting velocity vs. Tool life on a log - log scale
5. DETERMINING CUTTING SPEED AND CALCULATING RPM:
Cutting Speeds
Lathe: the rate at which a point on the work circumference travels past the cutting tool -
expressed in feet per minute
Drill Press: the rate at which a point on the tool circumference travels into the work is
expressed in feet per minute
Milling Machine: the speed in surface feet per minute at which the metal may be
machined efficiently
Once the CS or Cutting Speed is determined, the RPM or revolutions per minute the
machine needs to turn can be calculated as follows:
RPM = CS x 4/ D
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RPM = Revolutions per Minute

CS = Cutting Speed
D = Diameter of: Work on a Lathe, or Drill on a Drill Press or Milling Cutter on a Mill
Table 1. Lathe cutting speed Using High-Speed Steel Tool bit
Turning and Boring

Rough Cut Finish Cut Threading
Material ft/min m/min ft/min m/min ft/min m/min
Mach steel 90 27 100 30 35 11
Tool steel 70 21 90 27 30 9
Cast iron 60 18 80 24 25 8
Bronze 90 27 100 30 25 8
Aluminum 200 61 300 93 60 18
Feed
Feed - the distance travelled along the axis during each revolution of the spindle.
On a lathe the tool travels past the turning work.
On a drill press the turning tool travels past the work.
On a milling machine, a calculation must be done due to a varying number of teeth on
the cutter and a chart must be referred to check for “Feed per Tooth”
No. of Teeth = Number of teeth or flutes on a cutting tool
FPT = Feed per Tooth according to chart
RPM = Calculated Revolutions per Minute
Feed = No. of teeth x FPT x RPM
Table 2. Lathe Feed rates: High-speed steel cutting tool feed rate per revolution of
spindle
Rough Cuts Finish Cuts
Material in. mm in. mm
Mach steel .010–.020 0.25–0.5 .003–.010 0.07–0.25
Tool steel .010–.020 0.25–0.5 .003–.010 0.07–0.25
Cast iron .015–.025 0.4–0.65 .005–.012 0.13–0.3
Bronze . 015–.025 0.4–0.65 .003–.010 0.07–0.25
Aluminum .015–.030 0.4–0.75 .005–.010 0.13–0.25
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6. ESSENTIAL PROPERTIES FOR CUTTING TOOL MATERIALS:
The cutting tool material of the day and future essentially require the following
properties to resist or retard the phenomena leading to random or early tool failure:
i) High mechanical strength; compressive, tensile, and TRA
ii) Fracture toughness – high or at least adequate
iii) High hardness for abrasion resistance
iv) High hot hardness to resist plastic deformation and reduce wear rate at elevated
temperature
v) Chemical stability or inertness against work material, atmospheric gases and cutting
fluids
vi) Resistance to adhesion and diffusion
vii) Thermal conductivity – low at the surface to resist incoming of heat and high at the
core to quickly dissipate the heat entered
viii) High heat resistance and stiffness
ix) Manufacturability, availability and low cost.
7. TOOL MATERIALS:
(1) High speed steel (HSS): can withstand cutting temperatures up to 1100F. Have
improved hardness and wear resistance, used to manufacture drills, reamers, single
point tool bits, milling cutters, etc. HSS cutting tools can be purchased with additional
coatings such as TiN which add additional protection against wear.
(2) Cobalt: one step above HSS, cutting speeds are generally 25% higher.
(3) Carbides: Most widely used cutting tool today. Cutting speeds are three to five
times faster than HSS. Basic composition is tungsten carbide with a cobalt binder.
Today a wide variety of chemical compositions are available to meet different
applications. In addition to tool composition, coatings are added to tool materials to
increase resistance to wear
(4) Ceramics: Contain pure aluminum oxide and can cut at two to three times faster
than carbides. Ceramic tools have poor thermal and shock resistance and are not
21
recommended for interrupted cuts. Caution should be taken when selecting these
tools for cutting aluminum, titanium, or other materials that may react with aluminum
oxide.
(5) Cubic Boron Nitride (CBN): This tool material maintains its hardness and resistance
to wear at elevated temperatures and has a low chemical reactivity to the chip/tool
interface. Typically used to machine hard aerospace materials. Cutting speeds and
metal removal rates are up to five times faster than carbide.
(6) Industrial Diamonds: diamonds are used to produce smooth surface finishes such
as mirrored surfaces. Can also be used in “hard turning” operations to eliminate finish
grinding processes. Diamond machining is performed at high speeds and generally fine
feeds. Is used to machine a variety of metals.
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EXPERIMENT NO. 03
LATHE JOB
1. OBJECTIVE:
To perform turning, chamfering and facing operations on a centre lathe machine.
2. MATERIAL REQUIRED:
Mild Steel (Carbon 0.15 % to 0.3%) rod, Φ 32* 95 mm
3. TOOL REQUIRED:
H.S.S. rough tool, Outside caliper, Engineering steel scale, Chuck key etc.
4. JOB FIGURE:
Turning Step Turning
Chamfering
Φ 30 Φ 25 Φ 20 Facing
50 20 20
All dimensions are in mm.
5. WORKING STEPS:
1) Check the material for its size.

2) Hold the job in three-jaw chuck with the required overhanging turn it.
3) Set the right hand facing tool in the tool post rigidly to the correct height.
4) Set the machine to the required R.P.M. for facing.
5) Face one end (right hand of the job).
6) Reset the R.H. turning tool in the tool post rigidly.
7) Turn the job to Φ 30 mm, to the 90 mm length.
8) Step turn to Φ 25 and Φ 20 by hand feed.
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9) Face the both ends up to 90 mm.

10) Chamfer one end of 3 X 3 mm.
11) Deburr the job.
6. SAFETY PRECAUTION:
1. Keep distance from rotating parts of machine.

2. Always wear tight clothes and shoes while working on machine.
3. Never try to touch job by hand during & after machining.
4. Wear plain goggles to safe your eyes from hot chips.
5. Take all the measurements when spindle is at rest.
6. Switch off machine immediately if it causes any unsound noise (chattering etc.).
7. Don’t lean too much over machine.
8. Always trip MCB after finishing your work.
9. Leave the cutting tool away from chuck after completion of your job.
10. Clean your machine properly by brush after machining.
7. RESULT:
Job completed successfully.
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EXPERIMENT NO. 04
LATHE JOB
1. OBJECTIVE:
To perform taper turning, knurling and drilling operation using a center lathe machine
Mild Steel (Carbon 0.15 % to 0.3%) rod, Φ 32* 95 mm
3. TOOL REQUIRED:
H.S.S. rough tool, Outside caliper, Engineering steel scale, Chuck key etc.
4. JOB FIGURE:
10 Knurling Taper Turning Drilling
30 8 20
40 50
5. WORKING STEPS:
1) Check the material for its size.

2) Hold the job in three-jaw chuck with the required overhanging turn it.
3) Set the right hand facing tool in the tool post rigidly to the correct height.
4) Set the machine to the required R.P.M. for facing.
5) Face one end (right hand of the job).
6) Reset the R.H. turning tool in the tool post rigidly.
7) Turn the job to Φ 30 mm, to the 90 mm length.
8) Face the both ends up to 90 mm.
9) Calculate the angle of taper turning using following formula
25
 D1  D2 
  tan 1  
 2L 
where D1= Major diameter of job at one end of taper
D2= Minor diameter of job at other end of taper
L= Length of taper
10) Taper turning operation from 40 mm to 90 mm
11) Finally make a drill of 10 mm deep of 8 mm diameter from right end.
12) Perform the knurling operation up to 10 mm on 30 mm side
13) Deburr the job.
1. Keep distance from rotating parts of machine.

2. Always wear tight clothes and shoes while working on machine.
3. Never try to touch job by hand during & after machining.
4. Wear plain goggles to safe your eyes from hot chips.
5. Take all the measurements when spindle is at rest.
6. Switch off machine immediately if it causes any unsound noise (chattering etc.).
7. Don’t lean too much over machine.
8. Always trip MCB after finishing your work.
9. Leave the cutting tool away from chuck after completion of your job.
10. Clean your machine properly by brush after machining.
7. RESULT:
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EXPERIMENT NO. 05
LATHE JOB
1. OBJECTIVE:
To make the external thread of the given dimension on lathe machine.
2. APPARATUS:
All geared lathe machine, threading tool, scale, outside caliper, cylindrical job.
3. DRAWING:
All dimensions are in mm
4. CALCULATIONS:
1. The outer diameter of the thread will be 12mm and pitch will be 1.75mm.
2. From the chart we get the minor diameter which is 10.11mm.
3. Depth of thread = 0.6143x1.75=1.075mm.
5. PROCEDURE:
1. Turn the work-piece to a diameter of 12 mm.

2. Mount threading tool on tool post.
3. Fix the combination of the gears from the given chart.
4. Set the cross-slide reading to zero, with no gap between the tool and the work-
piece.
5. Take tool to the work-piece for zero setting.
27
6. Give a depth of cut; say 0.1mm (arbitrary)

7. Engage the automatic thread feed lever from start point of thread.
8. When the desired thread length is reached, back off the cross slide with hand wheel
and at the same time disengage the automatic feed lever.
9. Return the carriage to the thread start point.
10. Move the cross-slide by another 0.1mm, it should now read as 0.2mm.
11. Repeat the steps 7 to 11, until the thread of required depth (1.075 mm) is achieved.
12. Clean the thread by a file or emery paper
13. Check the thread dimensions by using a thread gage.
6. RESULT:
Following the above calculation and procedure the threads of the given size is
produced.
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EXPERIMENT NO. 06
Shaping and Drilling Job
1. OBJECTIVE:
To perform shaping operation for finishing two sides of a job and drilling one hole and
grinds the corners of a job.
M.S flat square plate
3. TOOLS USED:
Shaper machine, drill machine, twist drill, surface plate, surface gauge, center punch,
and hammer.
48
48 10
4. WORKING STEPS:
 Place the job on shaper by clamping device

 Remove the material 2 mm from the job by shaping operation.
 Mark the shaping job on the point where holes are required.
29
 Drill a hole of 14 mm diameter at the centre of the plate by drill machine.

 Use tap set to do the tapping operations.
5. PRECAUTIONS:
 Be sure ram, tool head, tool work, table support, clamping screws, and vice are
properly secured in position and that the tool head and tool clear the work
before starting the shaper.
 Never remove chips while ram is in motion.
 Stand parallel to direction of stroke of machine when it is in motion and never
reach across the table between strokes of the ram.
 If work slips from clamp, never attempt to stop it with hands. Stop the machine
and make adjustments.
 File all burrs from drilled holes.
 Keep your head and back well away from any moving part of the drilling
machine.
6. RESULTS:
Job has been done successfully.
30
EXPERIMENT NO. 07
Milling Machine
1. OBJECTIVE:
To Make spur Gear teeth on Milling Machine as per the given dimension
2. THEORY:
To machine gear of the given module and number of teeth.

Ø50
Ø18
3. TOOLS AND EQUIPMENTS REQUIRED :
Milling machine, Vernier caliper, Mandrel.
4. PROCEDURE:
1. Calculate the gear tooth proportions.

Blank diameter = ( Z + 2 ) m
Tooth depth = 2.25 m
Tooth width = 1.5708 m
where,
Z = Number of teeth required m =
module
2. Indexing calculation
Index crank movement = 40 / Z
3. The dividing head and the tail stock are bolted on the machine table. Their axis
must be set parallel to the machine table.
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4. The gear blank is held between the dividing head and tailstock using a mandrel.
The mandrel is connected with the spindle of dividing head by a carrier and catch
plate.
5. The cutter is mounted on the arbor. The cutter is centered accurately with the gear
blank.
6. Set the speed and feed for machining.
7. For giving depth of cut, the table is raised till the periphery of the gear blank just
touches the cutter.
8. The micrometer dial of vertical feed screw is set to zero in this position.
9. Then the table is raised further to give the required depth of cut.
10. The machine is started and feed is given to the table to cut the first groove of the
blank.
11. After the cut, the table is brought back to the starting position.
12. Then the gear blank is indexed for the next tooth space.
13. This is continued till all the gear teeth are cut.
5. CALCULATION:
Z = No. of teeth = 23
m = module = 2 mm
Blank Diameter = (Z + 2) m
= (23 + 2) 2
= 50 mm
Tooth Depth = 2.25 m

= 2.25 * 2
= 4.5 mm
Indexing Calculation = 40 / Z
= 40 / 23
= 1 17/23
5. RESULT:
Thus the required gear is machined using the milling machine to the required number
of teeth.
32
EXPERIMENT NO. 08
Lathe Machine Alignment
1. OBJECTIVE:
To perform the alignment test on the lathe machine.
2. APPARATUS:
Dial gauge with stand.
3. Figure:
4. PROCEDURE:
1) Clamp the job in universal chuck.

2) Place the dial gauge stand on the compound slide and turn on magnetic lock
3) Adjust the stylus of the dial gauge so that it touches the surface of the job
with pressure.
4) Rotate the chuck by hand.
5) If there is change in the reading of the dial gauge adjust the job to compensate the
deflection
6) Rotate the chuck by hand
7) See if there is any deflections do the same as in step number 5
8) Repeat the procedure till there is no deflection in the reading of the dial gauge
during complete revolution.
5. RESULT:
Using the above procedure the alignment of the chuck is done.
33
EXPERIMENT NO. 09
CNC
1. OBJECTIVE:
Write a manual part program to machine on CNC lathe machine for the components as
shown in DWG.
2. REQUIREMENTS:
Mild Steel (Carbon 0.15 % to 0.3%) rod, ϕ32* 95 mm
3. THEORY
Numerical control (NC) refers to the automation of machine tools that are operated by
abstractly programmed commands encoded on a storage medium, as opposed to
manually controlled via hand-wheels or levers, or mechanically automated via cams
alone. The first NC machines were built in the 1940s and 1950s, based on existing
tools that were modified with motors that moved the controls to follow points fed into
the system on punched tape. These early servomechanisms were rapidly augmented
with analog and digital computers, creating the modern computer numerical control
(CNC) machine tools that have revolutionized the manufacturing process. In modern
CNC systems, end-to-end component design is highly automated using computer-
aided design (CAD) and computer-aided manufacturing (CAM) programs. The
programs produce a computer file that is interpreted to extract the commands needed
to operate a particular machine via a postprocessor, and then loaded into the CNC
machines for production. Since any particular component might require the use of a
number of different tools-drills, saws, etc., modern machines often combine multiple
tools into a single "cell". In other cases, a number of different machines are used with
an external controller and human or robotic operators that move the component from
machine to machine. In either case, the complex series of steps needed to produce
any part is highly automated and produces a part that closely matches the original CAD
design.
34
4. STRUCTURE OF A CNC PART PROGRAM:
N G X Y Z F S T M
N – Block Number
G – Preparatory code function
X Y Z – Co ordinate values
F – Feed
S – Spindle speed
T – Tool function
M – Miscellaneous code function
Preparatory function Miscellaneous Function

(G Code) (M CODE)
G00 – Rapid Position M03 – Spindle rotation (cw)
G01 – Linear interpolation M05 – Spindle stop
G02 – Circular interpolation (CW) M06 – Tool change
G03 - Circular interpolation (CCW) M08 – Coolant ON
G20 – Inch data input M09 – Coolant OFF
G21 – Metric data input M70 – X-axis mirror ON
G28 – Reference point return M71 – Y-axis mirror OFF
G40 – Tool nose radius compensation M81 – Y-axis mirror OFF

cancel
M98 – Sub program call
G50 – Maximum spindle speed setting
M99 – Sub program exit
G70 – Finishing cycle
G71 – Stock removal in turning
35
G72 – Stock removal in facing
G74 – Peck drilling in z – axis
G75 – Multiple grooving cycle
G76 – Multiple thread cutting cycle
G98 – Feed per minute
5. JOB FIGURE:
1. Prepare a job on CNC lathe Machine as per the given dwg.
2. Write a CNC program of the given dwg.
36
6. PROCEDURE:
1. Login in linux operating system.

2. Open Sherine CNC (metric) software
3. Click on editor tab and open a new file
4. Write a program as per the drawing.
5. Click on Save and load option in File Tab.
6. Load the program
7. Select auto mode
8. Now run the program
1) Keep distance from rotating parts of machine.

2) Never try to touch job by hand during & after machining.
3) Wear plain goggles to safe your eyes from hot chips.
4) Take all the measurements when spindle is at rest.
5) Switch off machine immediately if it causes any unsound noise (chattering etc.).
6) Always trip MCB after finishing your work.
7) Leave the cutting tool away from chuck after completion of your job.
8) Clean your machine properly by brush after machining.
9) wear suitable protective clothing
10) Check that the equipment is suitable for the electrical supply with which it is
going to be used, and the electrical supply is safe.
8. RESULT:
37
EXPERIMENT NO. 10
CNC Turning
1. OBJECTIVE:
To make the component of given drawing on CNC turning machine.
2. APPARATUS:
CNC turner, Cylindrical Job, Vernier caliper, scale
3. Drawing:
4. THEORY:
a) Basic Components of CNC Machine:-

Three basic components are used
i) the Program of instruction
ii) The machine control unit (MCU) based on computer technology iii) the processing
unit
38
The MCU in CNC consists of following subsystems
b) NC part programming
There are three types of part programming i) Manual part programming ii) Computer
assisted part programming iii) Computer assisted part programming using CAD/CAM
c) Manual Part Programming in word format:- The structures of the program in

word format has following sequence of commands
 Sequence number (N- word)
 Preparatory word (G-word); see Table for definition of G-words
 Coordinates (X, Y, Z words for linear axes, A, B, O words for rotational axes)
 Feed rate (F-word)
 Spindle speed (S-word)
 Tool selection (T-word)
 Miscellaneous command (M-word); see Table for definition of M-words
 End-of-block (EOB symbol)
39
Table showing the important word prefixes
G words and M-words require some elaboration. G-words are called preparatory
words. They consist of two numerical digits (following the "G" prefix in the word
address format) that prepare the MCU for the instructions and data contained in the
block. For example, G02 prepares the controller for clockwise circular interpolation, so
that the subsequent data in the block can be properly interpreted for this type of move.
In some cases, more than one G-word is needed to prepare the MCU for the move.
Most of the common G-words are presented in Table.
40
41
Important M words are given in table below:
Example of CNC programming:-
42
5. PROCEDURE:
1) Write down the program using syntax of the word format.

2) Clam the work piece in the chuck.
3) Define the origin of the tool
4) Execute the program.
5) Stop the spindle
6) Unclamp the job.
7) Measure all the dimensions.
6. RESULT:
To obtain the finished component the program attached is written. The finished job
obtained is as per the drawing.
43

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SPSU, UDAIPUR Lab Manual

Department of Mechanical Engineering Machine Shop

S. No. Object Page Hours

1. Introduction to machine tools and machining processes. 3 2

2. Selection of cutting tools, cutting speeds and feed. 14 2

To perform step turning, chamfering and facing operations

To make the threads of the given dimension on lathe

8. To perform alignment test on the lathe machine. 33 2

Write a manual part program to machine on CNC lathe

Introduction to machine tools and machining processes.

(a) Purpose of Machining

(b) Principle of Machining

Figure 2. Requirements for machining

4. BASIC FUNCTIONAL PRINCIPLES OF MACHINE TOOL OPERATIONS:

(1) Concept of Generatrix and Directrix:

(b) Generation of cylindrical surfaces: The principles of production of various cylindrical

Figure 3. Generation of flat surfaces by Generatrix and Directrix

Figure 4. Generation of cylindrical surfaces (of revolution)

2. Tool – work motions:

(a) Formative motions namely:

⎯ Cutting motion (CM)

⎯ Feed motion (FM)

(b) Auxiliary motions such as:

⎯ Additional feed motion

Figure 5. Principle of turning (cylindrical surface)

Generatrix (G) – Cutting motion (CM) – Work (W)

Directrix (D) – Feed motion (FM) – Tool (T)

In case of making flat surface in a shaping machine as shown in Figure 6 the

Figure 6. Principle of producing flat surface in shaping machine

5. CONFIGURATION OF BASIC MACHINE TOOLS AND THEIR USE:

Uses of center lathes

Figure 7. Centre Lathe Machine

Figure 8. Common machining operations done on centre lathe

Figure 9. Shaping Machine

Figure 10. Planing Machine

Figure 11 shows general configuration of drilling machine, column drill in particular.

a. Mainly for drilling (originating or enlarging cylindrical holes)

Figure 11. Drilling Machine

Figure 12. Milling Machine

Figure 13. Common milling operations

6. SPECIFICATION OF MACHINE TOOLS:

Drilling Machine (column type)

Milling Machine (knee type and with arbor)

Selection of cutting tools, cutting speeds and feed.

Single point tool operations Multi-point tool operations Abrasive operations

Turning Milling Grinding

3. SELECTION OF CUTTING CONDITIONS:

1. Selecting depth of cut:

In roughing operations, feed is made as large as possible to maximize metal removal

3. Selection of cutting speed:

As with most engineering problems, in machining we want to minimize costs, while

a) Cutting speed for maximum production rate, Vmax

b) Cutting speed for minimum unit cost, Vmin

Figure 4. Growth of flank wear and assessment of tool life

Taylor’s tool life equation

Figure 6. Cutting velocity vs. Tool life on a log - log scale

5. DETERMINING CUTTING SPEED AND CALCULATING RPM:

RPM = Revolutions per Minute

Table 1. Lathe cutting speed Using High-Speed Steel Tool bit