IIMT COLLEGE OF POLYTECHNIC

GREATER NOIDA

Production Technology

LAB MANUAL

Department of Mechanical Engineering

 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA

EXPERIMENT NO: 1

OBJECTIVE: To Perform Gear cutting on milling machine (Spur Gear).

TOOLS/INSTRUMENTS REQUIRED: Indexing head attachment, Milling cutter,

Spanner, Mandrel, Dog Carrier
MATERIALS REQUIRED: Mild steel or plastics blank
THEORY: Milling is the machining process of using rotary cutters to remove
material from a work piece advancing (or feeding) in a direction at an angle with the
axis of the tool. It covers a wide variety of different operations and machines, on
scales from small individual parts to large, heavy-duty gang milling operations. It is
one of the most commonly used processes in industry and machine shops today for
machining parts to precise sizes and shapes.

Main Components of milling machine:

Base, column, knee, saddle, table

Type of milling machine:

Plain milling machine, vertical milling machine, universal milling machine,

Simplex milling machine, triplex milling machine

Type of Milling Cutter:

Plain milling cutter, slide milling cutter, arbor cutters, shank cutters, face cutters.

Indexing: Indexing is the process of evenly dividing the circumference of a circular

work piece into equally spaced divisions, such as in cutting gear teeth, cutting
splines, milling grooves in reamers and taps, and spacing holes on a circle.
Types of Indexing: There are different indexing methods in popularity. These are
(a) Direct indexing
(b) Simple indexing
(c) Compound indexing
(d) Differential indexing
For simple indexing,

N is the number of divisions to be made on the circumference of workpiece.

PROCEDURE:

Fig. Geometry of Milling Cutter

1. The raw blank is selected with reference to the number of teeth to be cut.
2. Indexing number is calculated to the position of the blank.
3. Gear blank is mounted on mandrel in milling machine.
4. Centering of the blank is done by upward and cross feed.
5. The depth of the cut is calculated for the given module.

RESULT: Thus the gear cutting is performed in a milling machine.

PRECAUTIONS:

1. Clamp the work and tool properly.

2. Use chip Guards to protect from flying chips.
3. Never reach near or over the rotating cutter.
4. Feed should be gradual and optimum.
5. Proper coolant supply to the tool should be made.
 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA
EXPERIMENT NO.2
OBJECTIVE: To Perform External Thread cutting on lathe machine
APPARATUS: Power hacksaw, Center Lathe, Pedestal Tool Grinder, HSS
Tool bit and Straight or Right Hand Tool Holder, Center Drill, Live Center, Stock and
Die.
MATERIALS REQUIRED: Mild Steel Cylindrical bar (----×----×----).
THEORY: It is economical to cut single threads on a single piece of both external
and internal threads. While cutting screws a lead-screw is provided on centre lathes
and capstan lathes. The lead screw is geared with work spindle through a gear box or
a change gear train; the carriage, when engaged to lead screw through half nut, gets
the required lead motion w.r.t the spindle rotation. A form tool is used made of HSS,
brazed tungsten carbide. The full depth of the feed of thread is machined in a number
of successive passes by giving a small incremental in feed in every pass. During the
process as the tool cuts on both the flanks resulting in crowding of chips on the face of
the tool, the in feed per pass is to be necessarily small.
During threading speed ratio between lead screw and the stud is controlled by gear
connections having suitable number of teeth either by simple or compound gear train.
The screw (thread) cutting ratio can be calculated as:
screw cutting ratio= no. of teeth on driver/no. of teeth on the driven
= lead screw turns/spindle turn
= TPI on lead screw/TPI on work-piece
PROCEDURE:
1. Cut hexagonal material to length, with allowance for facing.
2. Face one end in the Centre Lathe to 90 mm length overall.
3. Centre Drill one end for the live center.
4. Hold the hexagonal bar in the 3 jaw chuck by around 5-8 mm with the
other end held by the live center.
5. Turn the 12 mm diameter for the thread x 80 mm long – measure With
the micrometer, size to finish at 12 mm minus 0.05 – 0.10.
6. Adjust the tool and clean up the corner for the head of the bolt.
7. Chamfer the 12 diameter end at 45 degrees x 2 mm.
8. Hold the 12 diameter in the chuck and chamfer the head at 45degrees.
9. Hold by the 12 diameter and start the thread using the Stock and Die
With the tailstock ensuring that the axis is square to the die – use cutting
compound.
10. When sufficient has been cut to ensure the trueness of the thread, Take it
out of the lathe and finish the tread depth to 60 mm in the metal working
vice.

RESULT: Bolt by lathe machine has been prepared.

PRECAUTIONS:

1. The job should be tightly clamped in the chuck.

2. The tool should be properly fastened in the tool post.
3. Don’t attempt to cut the job (w/p) held between the centres using a parting tool.
4. When mounting the tool in the tool post. It must be ensured that the top of the tool
is horizontal and is inline with the axis of rotation of the job.
5. Don’t keep tool and other implements on the lathe bed, keep guide ways clean.
 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA
EXPERIMENT NO.3
OBJECTIVE: To Perform rectangular slot (Key-way) cutting on shaper machine.
APPARATUS: Horizontal Shaper machine, Steel rule, Hammer, Shaper tool, Try
Square
MATERIALS REQUIRED: Mild steel plate (----×----×----).
THEORY: The shaper is a reciprocating type of machine tool intended primarily to
produce flat surfaces. These surfaces may be horizontal, vertical, or inclined. The
principal parts of a standard shaper are: Base, Column, Cross rail, Saddle, Table,
Ram, Tool head etc.

Fig. Schematic Diagram of Shaper Machine Tool Fig: Quick return Mechanism

PROCEDURE:
1. The job was checked to the given dimensions.
2. The square was scribed in the outer circle of diameter of 50mm and Punching was
done.
3. The job was attached in the vice of a shaper
4. The job was checked for perpendicular dimension.
5. Then the square from round was obtained in the shaper
6. The work piece was removed and burns are removed with accuracy was
check
RESULT: Thus the square from round was performed on the given dimension
in a shaper machine with the required dimensions.

PRECAUTIONS:
1. Do not over hang the tool.
2. Fix the tool and work piece firmly.
3. Speed of tool should be optimum.
4. Use proper approach and over travel distances.
5. Keep out of line of the stroke of shaper.
6. Set the clapper box such that tool lifts clear off the machined surface on
return stroke.
 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA

EXPERIMENT NO.4
OBJECTIVE: To perform drilling operation on drilling machine for a given work-
piece for the required dimension and study of twist drill.
APPARATUS: Drilling machine
MATERIALS REQUIRED: Square Mild steel plate (----×----×----).
THEORY: When drilling a hole using a hand or power drill, it can be tricky to drill the
hole at a right angle to the work. Drills often have a level incorporated into the drill
housing, but usually this requires good vision to read. There are, however, several
techniques that persons with low vision or no vision use which can make drilling quite
accurate. These techniques include:
Drill guides in a range of diameters are available from hardware stores or building
supply centers. Placing the guide on the surface of the work to be drilled and inserting
the bit through the guide makes it possible to drill a hole straight into the work. If you
have access to a drill press, you can make a set of drill guides yourself by drilling holes
of different diameters into small blocks of wood. These work just like the drill guides
described above. If you don't have access to a drill press, you might ask a sighted friend
to make drill guides using a portable drill with a built-in level.
Drilling Time: Drilling time can be calculated by

L is the sum of hole depth approach and over travel distances

f is the feed (mm/rev)
N is the rotational speed (rpm)
Tip: Over time, the guide hole in the wooden guide may become slightly enlarged,
which may make it a bit more difficult to position the drill at exactly a 90 degree angle.

Remove a square or rectangle of wood from a board, creating a right angle; then
place the bit into the corner to help align the bit.

Place a large-headed nail with the head down on the surface of the board, and align the
bit with the nail by touch.

Use an empty spool of thread or sewing machine bobbin (pictured below). Mark the spot
by making a "start hole" with an awl, nail, or ice pick. Place the drill bit through the
spool or bobbin and align the point of the bit with the start hole you've created. With the
drill in the "off" position, place the flat end of the spool or bobbin firmly against the
surface and hold it in place with pliers. Please note: Do not use your hands to hold the
spool in place. With the drill and spool in this position, start the drill – and your hole
will be straight/perpendicular with the surface.

TWIST DRILL: Twist drills are rotary cutting tools normally having two cutting
edges and two flutes which are grooves formed in the body to provide cutting lips, to
permit the removal of chips and to allow coolant or cutting fluid to reach the cutting
action. They are identified by the shank style, straight or taper, then by length, screw
machine, jobber or taper length, by the material they are made from and finally by the
helix or spiral of the flutes.

RESULT: Drilling operation has been performed.

PRECAUTIONS:
1. Work being drilled must be held in a drill press vice or clamped to a table.
2. Use a centre punch to score the material before drilling.
3. Run the drill at the correct speed.
4. Pull back the drill out of deep holes frequently to clear the chips and cool the drill.
5. Never attempt to loosen the drill chuck unless the power is off.
 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA
EXPERIMENT NO.5

AIM: To make a locked grooved joint as the given dimension.

MATERIALS REQUIRED:GI sheet of size 140 X 100mm of 26 swg.

TOOLS REQUIRED:
Steel rule
Mallet
Scriber
Straight snips
Bench shear
Try square
Anvil
Hand Groover

LIST OF OPERATIONS :
Laying out and marking
Cutting
Joint Making
Finishing
PROCEDURE :
1. Copy the given drawing.
2. Collect the tools and sheet metal.
3. Draw the layout on the work material.
4. Cut the Sheet along the marked out line.
5. Check the edges of sheet for straightness and perpendicularity with the help of try
square.
6. Mark all the necessary lines to make the required model of size132 x 90mm.
7. Cut the sheet into two of size 66 x 90mm.
8. Mark the necessary line to form the hook on each, need for bending.
9. The hooks were fold together to form the joint by striking with mallet.
10. Locked the joint with the help of hand groover and finished the model.
11. Finish the model and check all the dimensions.

PRECAUTIONS:
1. ALWAYS wear heavy-duty gloves when handling sheet metal.
2. Wear a respirator or dust mask to prevent inhalation of sheet metal dust.
3. Never attempt to carry an oversized piece of sheet metal by yourself.
4. Wash your hands thoroughly with soap and water after working with sheet metal
(even if you wore gloves).
5. Wear safety glasses to protect your eyes from flying debris.
6. Ensure your power tools work properly before attempting to use them on sheet
metal.
 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA
EXPERIMENT NO.6

AIM: To perform exercise on slotting machine to obtain flat surfaces and key way.

MATERIALS REQUIRED: Cast Iron cube of size 50 mm

TOOLS REQUIRED
1. “V” nose tool
2. Square nose tool
3. Vernier Height Gauge
4. Centre punch
5. Ball peen hammer.
6. Try square.

LIST OF OPERATIONS
1. Machining Flat surfaces
2. Marking
3. Punching
4. Key way cutting

PROCEDURE:
1. Copy the drawing.
2. Fix the tool and work piece in position.
3. Adjust the stroke length properly.
4. Machining the top of the cube, followed by any two adjacent sides then check
perpendicularity of these sides.
5. Mark the dimensions of key way.
6. Perform key way cutting.
7. Check the dimensions.
RESULT: Machined the flat surfaces and key way on the work piece.

PRECAUTIONS:

1. Fix the tool and work piece firmly.

2. Speed of tool should be optimum.
3. Use proper approach and over travel distances.
4. Keep out of line of the stroke of shaper.
5. Set the clapper box such that tool lifts clear off the machined surface on return
stroke.
 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA
EXPERIMENT NO.7

AIM: To grind the given single point cutting tool as per given specifications.

TOOLS & EQUIPMENT:

1) Tool and cutter grinding machine
2) Profile projector
3) Mild steel square.

FIGURE:

PROCEDURE:
1. Swing the circular slide by operating the belt.
2. Set the table and the table slides at right angles to the grinding wheel spindle.
3. Mount the universal vice on the movable table and fix the job.
4. Set the required clearance angle on the vice.
5. Grind the face of the job at that particular side with cross-slide adjustment.
6. Similarly, set the vice to given end clearance and side clearance angles and grind
the surfaces.
Side cutting Edge angle End cutting Edge angle End clearance angle Angle to be cut

PRECAUTIONS:
1. Take care about the setting of the angle of the vice

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 IIMT COLLEGE OF POLYTECHNIC
GREATER NOIDA

EXPERIMENT NO.8
OBJECTIVE: To prepare square section from surface–grinding machine.
APPARATUS: Steel rule Try square, Vernier caliper
MATERIALS REQUIRED: Square Mild steel plate (----×----×----).
THEORY: Surface grinding machines are useful to produce and finish flat and
plane surface.
Types of grinding machines: Transverse grinding, Plunger grinding

PROCEDURE: (take square section)

1. The given work piece is taken and checked for its dimensions.
2. The job is placed on the grinding magnet at opened position.
3. Then each face is grinded to the required accuracy by constant speed.
4. The job is removed from the required accuracy. It is checked by using
vernier caliper and squarness is checked by using try square.
RESULT: Thus the square section is grinded to the required accuracy in grinding
machine.
PRECAUTIONS:
1. Balance the wheel properly while mounting.
2. Use the face of the grinding wheel that is meant for grinding.
3. Slowly move work piece across the face of wheel in a uniform manner.
4. Do not operate the grinding wheel beyond its bursting speed.
5. Make sure that the clamp has been placed far enough below the face to be
ground.
6. Also ensure that the screw end is located inside the angle plate to reduce the
overhang and not interfere with the grinding operations.

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