SRM VALLIAMMAI ENGINEERING COLLEGE

(An Autonomous Institution)

SRM Nagar, Kattankulathur-603 203.

DEPARTMENT OF MECHANICAL ENGINEERING

1909305-Manufacturing Technology Laboratory

(III SEMESTER – MECHANICAL)

LABORATORY MANUAL
(REGULATION – 2019)
ACADEMIC YEAR 2021-22
 SAFETY PRECAUTION

 Always wear uniform, shoes and gloves for safety

 Never operate any machines until you have been instructed properly

 Always wear goggles to protect your eyes from flying chips.

 Never hold the job when the machine runs.

 Never give heavy cut on longer job

 Never change the gear and belt when the machine is running

 Always use the correct size spanner and tool for fitting and removing of tool

 Never try to clear the chips when the machine is running

 To prevent accident, clean the spilled oil and grease immediately

 Always clear the area around the machine and machine tool surface

 Leather shoes or boots with steel toes are recommended.

 No open toed shoes or sandals are allowed in the shop.

 Do not wear loose clothing. Cotton clothes are best to wear.

 Remove all jewelry and tie back longhair.

 Do not operate any machine equipment unless you have been instructed on its proper
use and the safety risks involved with the machining operation.

 Do not leave any machinery or power tools running and unattended.

 Clean up metal shavings, oil, etc. from machine tools after use; pick up after yourself
and return tools to their proper storage area.
 Wear closed toe shoes and appropriate clothing.

 Don‟t run, push or surprise other students. No horse play will be tolerated

 Don't eat, drink, or smoke, in the laboratory

 Always listen carefully to the teacher and follow instructions.

 Donot run in the workshop, you could „bump “into another pupil and cause an accident.

 Know where the emergency stop buttons are positioned in the workshop. If you see
an accident at the other side of the workshop you can use the emergency stop button
to turn off all electrical power to machines.

 Always wear an apron as it will protect your clothes and hold loses clothing such asties
in place..

 When attempting practical work all stools should be put away.

 Bags should not be brought into a workshop as people can trip over them.

 When learning how to use a machine, listen very carefully to all the instructions given
by the teacher. Ask questions, especially if you do not fully understand.

 Do not use a machine if you have not been shown how to operate it safely by the teacher.

 Always be patient, never rush in the workshop.

 Always use a guard when working on a machine.

 Keep hands away from moving/rotating machinery.

 Use hand tools carefully, keeping both hands behind the cutting edge.

 Report any damage to machines/equipment as this could cause an accident.

 SYLLABUS
1909305-MANUFACTURING TECHNOLOGY LABORATORY L T PC
0042

OBJECTIVES:

The main learning objective of this course is to prepare the students for:
 Selecting appropriate tools, equipments and machines to complete a given job.
 Performing various welding process using GMAW.
 Performing various machining process such as rolling, drawing, turning, shaping,drilling,
milling.
 Fabricating gears using gear making machines.
 Analyzing the defects in the cast and machined components.
LIST OFEXPERIMENTS:
1. Taper Turning – Compound rest swivelling method, Tailstock offset method.
2. External and Internal Thread cutting
3. Eccentric Turning
4. Square Head Shaping
5. Hexagonal Head Shaping
6. Fabrication of simple structural shapes using Gas Metal Arc Welding
7. Joining of plates and pipes using Gas Metal Arc Welding/ Submerged arc welding
8. Preparation of green sand moulds
9. Manufacturing of simple sheet metal components using shearing and bending operations.
10. Contour milling using vertical milling machine
11. Spur gear cutting in milling machine
12. Helical Gear Cutting in milling machine
13. Gear generation in hobbing machine
14. Gear generation in gear shaping machine
15. Plain Surface grinding
16. Cylindrical grinding
17. Tool angle grinding with tool and Cutter Grinder
18. Measurement of cutting forces in Milling / Turning Process
19. CNC Part Programming

TOTAL: 60 PERIODS
COURSE OUTCOMES:

Upon coupling of this course, the students will be able to:

 Demonstrate the safety precautions exercised in the mechanical workshop.
 Make the workpiece as per given shape and size using Lathe.
 Join two metals using arc welding.
 Use sheet metal fabrication tools and make simple tray and funnel.
 Use different moulding tools, patterns and prepare sand moulds

LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS

Sl.No. LIST OF THE EQUIPMENTS No.

1 Centre Lathes 7 Nos.
2 Horizontal Milling Machine 2 Nos
3 Vertical Milling Machine 1 No
4 Shaper 1 No.
5 Arc welding transformer with cables and holders 2 Nos
6 Oxygen and acetylene gas cylinders and blow pipe 1 No
7 Moulding table, Moulding equipment 2 Nos
8 Sheet metal forming tools and equipment 2 Nos.
9 Turret and Capstan Lathes 1 No each
10 Surface Grinding Machine 1 No
11 Cylindrical Grinding Machine 1 No
12 Radial Drilling Machine 1 No.
13 Lathe Tool Dynamometer 1 No
14 Milling Tool Dynamometer 1 No
15 Gear Hobbing Machine 1 No
16 Tool Makers Microscope 1 No
17 CNC Lathe 1 No
18 CNC Milling machine 1 No
 PO PSO

CO 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4

1 1 3 2 1 1 1
2 2 2 2 3 2 1 1
3 2 1 1 1 2 2
4 3 3 1 2 1 2 2

5 3 2 1 2 1 2
 CONTENT

EX. PAGE STAFF

DATE EXERCISE
NO. NO. SIGN.
 LIST OF EXPERIMENTS
1. Study of various machine tools in manufacturing technology laboratory.
a. Study of Centre Lathe
b. Study of Milling Machine
c. Study of Shaper
d. Study of Welding
e. Study of foundry
f. Study of Sheet metal operations
g. Study of metal spinning
h. Study of gear hobbing machine
i. Study of gear shaping machine
j. Study of grinding machine
k. Study of tool dynamometer
l. Study of centreless grinding
m. Study of CNC machines and FANUC coding.

2. Perform Taper Turning Operation in the given work piece Using Compound rest swivelling method
and Estimate the total machining time.
3. Carry out External Thread cutting and Internal Thread Cutting in the given work pieces and
calculate the total machining time.
4. Perform Eccentric Turning in the given work pieces and calculate the total machining time.
5. Perform square shape block on the given round work piece by using a shaper as per the given
dimensions.
6. Perform square shape block on the given round work piece by using a milling machine as per the
given dimensions.
7. Joining of given plates and pipes using Gas Metal Arc Welding.
8. Fabrication of simple structural shapes(Assembly of pipes) using Gas Metal Arc Welding
9. Manufacturing of Funnel in the sheet metal using shearing and bending operations.
10. Manufacturing of sheet metal components using metal spinning.
11. Perform contour milling operation on the given work piece using vertical milling machine.
12. Carry out Spur gear cutting on the given work piece using milling machine.
13. Carry out Helical gear cutting on the given work piece using milling machine
14. Perform the gear generation operation in the given cast iron blank as per the given dimension using
gear hobbing machine.
15. Perform the gear generation operation in the given cast iron blank as per the given dimension using
 gear shaping machine
16. Perform grinding operation on the given work piece using surface grinding machine.
17. Perform grinding operation on the given work piece using cylindrical Grinding machine
18. Measurement of cutting forces using lathe tool dynamometer
19. Measurement of cutting forces using Milling tool dynamometer
20. Grinding a single point cutting tool on the given material using tool and Cutter Grinder.
21. Perform grinding operation on the given work piece using Centreless Grinding machine.
22. NC part programming for facing, Turning and chamfering(turning).
23. NC part programming for circular Pocketing(milling).
CONTANT BEYOND SYLLABUS
1. Perform internal square shape block on the given round work piece by using a slotting machine as
per the given dimensions.
Ex. No:
Date:

Study of various machine tools in manufacturing technology laboratory

a) STUDY OF LATHE
Aim
To study about the lathe.

INTRODUCTION
In previous chapters, we have seen that with the help of forging and casting processes, we
can manufacture machine parts of different shapes and sizes. However, parts so manufactured have
poor geometry and size control (i.e., tolerance on dimensions) and their surface finish is not very
good. Hence, in most cases, castings and forgings undergo machining before these parts can be
assembled with other parts to form a complete machine like cycle or motor car etc.

In machining, we use a machine tool like lathe or shaper and a cutting tool made of a much harder
material than the material of the part to be machined. Material removed from the part is achieved by
the relative movement between the cutting tool and the part. The cutting tool is given a sharp cutting
edge and it is forced to penetrate inside the work piece surface to a small depth. The relative motion
between the tool and work piece results in a thin strip of material being sheared off from the work
piece reducing the thickness of the work piece. This process has to be repeated several times before
the entire surface of the work piece can be covered and reduced in depth. The thin strip of the material
sheared from the work piece is called „chip‟. It must be understood that chips are produced by
shearing action and not by cutting. Substantial amount of power is required for machining. The
function of the machine tool is to provide this power and the required motion of work piece relative to
the tool.

In some cases of machining, motion is given to the work piece and tool remains stationary. In some
other cases, the work piece is stationary and the machine tool provides motion to the cutting tool.
In yet other cases, motion is given both to tool as well as the workpiece.

Cutting tools are made of material which can be hardened by suitable heat treatment. During
machining, lot of heat is generated and the temperature of the cutting edge of the tool may reach
650– 700°C. The tool must maintain its hardness even at such elevated temperatures. This property

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of retaining its hardness at elevated temperatures is called „red hardness‟. Cutting tools develop the
property of red-hardness due to addition of tungsten and molybdenum to high carbon steel. These
days, cutting tools are made of high speed steel, or tungsten carbide. Tools made of ceramic
materials (like Al2O3, SiC), and polycrystalline diamonds are also used for specialapplications.
Cutting speed:
Readers must understand the concept of “cutting speed”. Cutting speed means the linear speed at
which cutting takes place. If the tool is stationary, the speed at which the work material approaches
the cutting edge of tool is the cutting speed. It is measured in meters perminute.

The optimum cutting speed depends upon the tool material, the material to be cut and whether a
cutting fluid is being used or not. The purpose of using cutting fluid is to remove heat from the cutting
area and to lubricate the tool face so that the friction between chip and tool surface reduces. Use of
cutting fluid makes cutting process more efficient. Similarly, cutting at recommended cutting speed
results in improved tool life and performance. Recommended cutting speed for machining cast iron
and mild steel with high speed tools is 35 meters per minute. However, if tungsten carbide tools are
used, cutting speeds of 65–70 meters per minute may be used. For non-ferrous material, much higher
cutting speeds are permissible.

CENTRE LATHE

A centre lathe is also called an engine lathe or simply a lathe. It is one of the commonest and oldest
machine tools. It is also one of the most versatile and widely used machines. Its main function is
production of cylindrical profiles.A centre lathe is shown in Fig. 1.1.

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3
The main parts of a centre lathe are:
1. Machine bed:

It is usually made of cast iron. It holds or supports all other parts of the lathe. The top of the machine
bed is flat and is machined to form guide ways on which the carriage slides along the length of the
lathe.

2. Headstock:

It is fixed at the extreme left hand of the bed and contains shafts and gears immersed in lubricating oil.
The driving shaft inside is driven by an electric motor. The driven shaft, which is in the form of a
hollow spindle can be driven at various rpm by changing gears, projects out of the headstock, A chuck
(either three jaw or four jaw), is screwed on this spindle. The work piece can be held in the jaws of the
chuck. When the spindle rotates, the chuck as well as the work piece held also rotate about the
longitudinal axis of the spindle.

3. Tailstock:

A tailstock(Fig:1.2) is provided at the right hand end of the bed. It can slide along the guide ways
provided on the bed and may be brought nearer to the headstock, if so desired. It can then be clamped
or fixed on the bed in that position. The tailstock has a spindle in the upper part of the tailstock, the
axis of which coincides with the axis of the headstock spindle, both being at the same height above the
bed. This spindle can be moved forwards or backwards by rotating a hand wheel. The front portion of
tailstock spindle carries a „dead „or „live‟ centre. When a long work piece is held in the chuck at the
headstock end, it is supported at the tailstock end by moving forward the tailstock spindle. Of course,
there has to be a small conical hole in the centre of the work piece, in which the tailstock centre may
be inserted to provide support. If the centre (being carried in its own bearings) rotates along with the
work piece, it is called a live centre. However, if the tailstock centre remains stationary and work piece
alone rotates, the centre is called „dead centre‟ and the conical tip of centre has to be lubricated with
grease to reduce the friction between the tailstock centre and the workpiece.

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4. Carriage:

A carriage is shown in Fig. 1.3. The carriage can slide along the length of the machine bed from
the tailstock end to the head stock end. This movement is controlled by manually operating the
hand traversing wheel. Itcan also be imparted this traversing motion at different speeds

automatically by engaging into the feed rod or feedshaft.

The carriage carries a cross slide, which can independently move in a crosswise direction at
right angles to the bed. The cross slide can also be moved either manually through a smaller hand
wheel or through an automatic device. Mounted upon the cross slide is another small slide, called the
com-pound rest (or tool post slide) which can be rotated in a horizontal plane. Its normal position at
0°rotation is parallel to bed. Its angle of rotation can be read off on a protractor. This compound rest
is used during taper turning to set the tool for angular cuts. The compound rest can be moved only
manually. The cutting tool is clamped in the tool post which is mounted on top of the compound rest.

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The gears, clutches and other mechanism required for giving movement to the carriage and cross
slide etc. is hidden from view by means of an apron (thin steel plate) screwed upon the front face of
the carriage. Half hidden in the front are two long shafts, (the screwed one is called the lead screw
shaft/rod and the plain one is called feed shaft/rod) extending from the headstock to the tailstock
end. These two shafts can be engaged one at a time to give longitudinal movement to the carriage.
Lead screw is only used during the screw cutting operation. Feed shaft is used in other operations
liketurning.

Size of a lathe is specified by the distance between headstock chuck to tailstock centre. This is the
length of the longest job which can be accommodated or machined on the lathe. In addition the swing
of the lathe (i.e., the vertical distance between chuck centre and the lathe bed) is specified as this is the
radius of the largest work piece which can be turned on the machine.

CUTTING TOOLS USED ON THE LATHE

In a centre lathe, the work piece is held and fastened in a chuck. If a component is manufactured out of
a round bar, the bar passes through the hollow spindle of the headstock, and the required length of bar
is pulled out and then clamped in the jaws of the chuck, free end of the bar projecting towards the tail
stock end. Mostly the movement of tool is from right to left. This is known as right hand working.
Sometimes, it becomes necessary to do some work while moving tools from left to right, i.e., left hand
working. The tools for right hand lathe operations are quite different than tools for left hand working.
In fact they are mirror images of each other.
Many different kind of operations are carried out on lathes such as;

1. Turning
2. Facing Lathe Taperturning
3. Profile turning or formturning
4. Boring
5. Threading
6. Knurling.
The tools used for these operations all different. Some of the right hand tools are shown in Fig. 1.4.

6
HOLDING THE WORK PIECE IN THE CHUCK AND CENTERING
All jobs have to be securely clamped in the chuck and centered before any of the above listed

Operation scan be performed on a lathe. 3-jaws chuck is a self-centering device and is used for
clamping round bar sets. A four jaws chuck is for clamping irregularly shaped jobs. In 4-jaws chuck
each jaw moves in radially independent of other jaws. Centering means that the centre line of the work
piece should nearly coincide with centre line of machine spindle. It is not enough to hold the job
centrally in the chuck, the portion of work piece projecting out of chuck should also be centrally
placed. Collet chuck, face plate sets are some other holding devices for the work piece.

Turning:

In this operation, the work piece is rotated at a suitable r.p.m., so that metal cutting may take place at
the recommended cutting speed. If „d ‟ is the diameter of work piece and N the r.p.m., the cutting
speed can be calculated as πdN. A cutting tool is clamped in the tool post taking care that the tip of the
tool is at the same height as the centre of job. In the turning operation, the job rotates and the cutting
tool is inserted in the surface of work piece by moving the cross slide, starting at the right hand end of
the work piece. The depth of cut of 1–1.5 mm may be taken and then the tool is steadily moved from
right to left by sliding the carriage on the machine bed. The operation of turning is shown in Fig. 1.5.

7
 Feed is given to the tool. Feed is measured in mm/rev of work piece. Since work piece
r.p.m. is N, Feed per minute will be N × feed/revolution (mm).

Obviously, it may not be possible to achieve the desired reduction of diameter in one pass of the tool,
the tool will have to be brought back to the right side, again advanced by 1–1.5 mm by moving the
cross slide and then traversed again from right to left side. This process will have to be repeated
several times until the desired diameter is reached. In the process of turning, a cylindrical shape is
generated as a result of the combined movement of the work piece and the tool.

Facing:
In this operation, the work piece is rotated as before, but the tool is moved across by cross
slide. The carriage remains fixed in one position. The result is production of a flat circular section at
one end of the cylinder. All lengths can be measured taking this surface as datum during further
machining operations.

TAPER TURNING

Taper turning means production of a conical surface by gradual reduction in diameter as we proceed
along the length of the cylinder. A conical surface will be produced, if the cutting tool moves along a
line which is inclined to the longitudinal axis of the work piece instead of moving parallel to it. A
taper is defined by the half angle (α) of the cone as shown in Fig. 1.6.

Following methods are used for taper turning on lathe:

1. By swiveling the compoundrest.
2. By offsettingtailstock.
3. By using a taper turningattachment.

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 4. By using a formtool.

Taper turning by swiveling compound rest

In this method the compound rest is swiveled i.e., rotated in a horizontal plane by half cone angle

(α).The work piece is rotated as usual, but instead of using the carriage to traverse the tool, the tool is
moved forward by the compound rest slide hand wheel. Since the compound rest has been swiveled
to an inclined position with respect to the longitudinal axis of lathe, the tool moves at an angle to the
longitudinal axis of lathe generating a conical surfaceaccurately.
By setting over the tailstock centre:

In this method, the tailstock centre is shifted in a direction at right angles to the longitudinal axis of
the machine. The tailstock base guide ways have some clearance and it can be shifted laterally by a
limited amount on the machine bed. The calculation of the taper angle can be under-stood from Fig.
1.7.

If length of job is Land set over of tailstock is „f‟ then half taper angle =−sin1f/ L. It will be
appreciated that in this case tool will traverse parallel to machine centre line but the work piece has
taken an inclined position with respect to the longitudinal centre line machine. This method can
only be used, if taper angle is small. Since the set over cannot be accurately measured, this method
is not accurate, but in this case, work pieces with long length can be tackled, which is not possible
with compound restmethod.
By using taper turning attachment

This method allows accurate production of a wide range of tapers. A taper turning attachment is used
on the backside of the cross slide. In this case the cross slide moves a certain distance for a given

9
amount of longitudinal traverse by the carriage. That is the tool gets a simultaneous movement in
two perpendicular axes. The angle of taper cut will depend upon the ratio of movement of tool in the
two axes.

Taper turning by form tool

In this case, tapers of only very short length are cut. The front profile of the form tool is such that
when the tool is pushed against the work piece, the taper is produced. This method is illustrated in
Fig. 1.8.

PROFILE OR FORM TURNING

The basic principle of this lathe operation has become clear from the example of taper turning with
the help of a form tool. Various other forms like a specified radius, semicircular shape etc. can be
generated in a similar manner with a suitably shaped form tool and taking a plunge cut (i.e., only
cross slide will be used while carriage will remain locked in position).Form tools should have a short
profile, otherwise the work piece and the tool tend to vibrate andchatter.
Parting off:

This operation is performed with a parting tool. This also requires a plunge cut. Gradually the
diameter of work piece at the tool contact surface will reduce and will become smaller and smaller as
the tool is fed in. Ultimately as the tip of tool will reach the centre line of job, the job will be parted in
two pieces, the left hand piece will remain clamped in the chuck, while the right hand piece of
requisite length will separateout.

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Boring:

Boring means enlarging an existing hole. For initial drilling of a hole on the lathe machine, tailstock
centre is removed and in the tailstock spindle a drill is inserted. The tailstock is brought closer to the
work piece, which is held in the chuck and rotated. Now using the hand wheel of the tailstock, the
drill is advanced. The advancing drill comes in contact with end face of the work piece and drills a
hole through it. After the hole has been drilled to required depth, the drill is withdrawn. This hole can
then be enlarged in diameter by using a boring tool. The operation of boring is shown in Fig. 1.9. It is
a delicate operation. The diameter of the boring tool or boring bar fitted with a tool bit has to be
smaller than the hole in the work piece. The boring operation is really an internal turning operation
but not being able to see the actual cutting, makes the operation tricky anddelicate.

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Threading:

Threading is an operation of cutting threads or helical grooves on the external cylindrical surface of
the job. In this process, the carriage is connected to the lead screw. The pitch of threads to be cut
equals (r.p.m.ofleadscrew/r.p.m.ofworkpiece)× Pitch of lead screw. Thus there should be an
arrangement to change the ratio of r.p.m. of work piece and the r.p.m. of lead screw. This is done by a
system of gears, which give the required ratio. Threads have a standard profile. The cutting tool
profile should match with this profile. Now the threads can be cut in the usual manner by traversing
the tool by engaging the clutch between carriage and lead screw. Such screw cutting lathes are
provided, with reversible motors. The r.p.m. of spindle is kept very low for threadcutting.

Knurling:

For providing better grip, some work pieces are provided with a shallow diamond shaped pattern on
its circumference. Knurling rollers, which have a similar pattern cut on their surfaces, is hardened.
When a work piece surface is required to be knurled, the work piece is held in a chuck and rotated and
the knurling roller is clamped in the tool post and by moving the cross slide, the roller is pressed into
the surface of the work piece. As the roller and work piece surface rotate together, the pattern is etched
into the surface of the workpiece.

Conclusion:

There are many accessories and fittings, which, if provided greatly improve the performance and
range of work which can be carried out on a lathe.

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 b). STUDY OF MILLING MACHINE
Aim
To study about the Milling machine.
INTRODUCTION
Milling is a machining process which is performed with a rotary cutter with several cutting
edges arranged on the periphery of the cutter. It is a multiple point cutting tool which is used in
conjunction with a milling machine. This process is used to generate flat surfaces or curved profile
and many other intricate shapes with great accuracy and having very good surface finish. Milling
machines are one of the essential machines in any modern machineshop.

BASIC MILLING PROCESS

Generally, there are two types of milling processes. These are called (a) Up milling or
conventional milling process, and (b) Down milling or climb milling process. Both these processes
are illustrated in Fig.4.1.

In up milling, the direction of rotation of milling cutter and the direction of work piece feed
are opposite to each other; whereas in down milling, they move in the same direction at the point of
contact of the cutter and the work piece. In up milling, the thickness of chip at the start is nil and is
maximum when the cutting teeth leave the surface of the work piece. In down milling, it is vice-
versa. In up milling, the cutting teeth try to up root and lift the work piece from the machine table, in
down milling, reverse happens. Technically, down milling is a superior process, but up milling is
commonly used. Down milling is not used unless the milling machine is fitted with a backlash
eliminator.

From Fig. 4.1, basic milling operation can also be understood. The milling cutter is circular
and a large number of cutting edges (or teeth) are arranged along its circumference. The cutter is
rotated at a speed of N r.p.m. If the cutter diameter is D, then cutting speed at the tip of teeth can be
calculated as π DN meters/minute and it should conform to the recommended values. The depth of
cut is clearly shown in the figure and the thickness of the work piece will reduce by this amount in one
pass. Usually, the width of the milling cutter is more than the width of the work piece; hence one pass
is all that isrequired.

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 Feed of the work piece is measured in terms of mm/minute. Actually, the correct measure of
feed is movement of work piece per revolution of cutter per teeth. If a milling cutter has z number of
teeth and if the table feed is „f‟ mm/minute, feed per rev per teeth will be f / NZ mm. It should
therefore be clear that metal removal rate in milling operation is much higher than in shaping or
planning operations.

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 However, as in shaping or planning operation, the stroke length is always a little more than the
length of the job, in milling operation also, the minimum table traverse required is L+ D, where L is
the length of job and D is the milling cutter diameter. D /2 are the minimum overlap required on either
side of job, so that the cutter becomes clear of thejob.

Unlike turning, the milling process involves intermittent cutting and the chip cross-
section is not uniform. The high impact loads at entry as well as fluctuating cutting force make
milling process subject to vibration and chatter. This aspect has great influence on design of
milling cutters.
TYPES OF MILLING PROCESSES

The milling process is broadly classified into peripheral milling and face milling. In peripheral
milling, the cutting edges are primarily on the circumference or periphery of the milling cutter (in Fig.
4.4, cutters shown are peripheral cutters) and the milled surface is generally parallel to cutter axis. In
face milling, although the cutting edges are provided on the face as well as the periphery of the cutter,
the surface generated is parallel to the face of the cutter and is perpendicular to the cutter axis. Refer to
Fig. 4.2; in which both these process have been illustrated.

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 The peripheral milling cutters are supported on a long arbor. The deflection of arbor restricts
the dimensional and form accuracy of this process. In face milling, the overhang of the cutter is
limited resulting in better dimensional control and flatness. Peripheral milling cutters are normally
used with a horizontal milling machine whereas the face cutters are used in conjunction with a vertical
milling machine. Milling cutters are made of solid high speed steel, or have high speed steel inserts.
The cutters are also made, with tungsten carbide blades (either brazed or with throw awayinserts).

1. PERIPHERAL MILLING

Peripheral milling is adopted for the following machining operations:

1. Slab milling to produce flatsurfaces.
2. Slot milling to produce precisionslots.
3. Side and face milling to machine adjacent horizontal and vertical surfacessimultaneously.
4. Form milling to produce prismatic shape of anyform,
e.g., involute form in gearcutting.
5. Straddle milling to machine two parallel verticalfaces.

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6. Gang milling to machine a number of surfaces simultaneously with a set of cutters.The
various peripheral milling operations are illustrated in Fig.4.3

A number of milling cutters of peripheral milling type are shown in Fig. 4.4. The hole and the
keyway provided in the centre of all peripheral cutters are for mounting them on the arbor of a
horizontal milling machine.

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2. FACE MILLING

Face milling is widely used for milling operations involving high metal removal rate. The
operation of face milling with a face milling cutter having coated tungsten carbide inserts is shown in
Fig. 4.

Face milling is a combination of up cut and down cut milling operation. The points
discussed earlier about up and down milling operations in peripheral milling, apply equally well tothe
face-milling operation (refer to Fig.4.6)

2. Down and up cut in facemilling

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In face milling, the position of the cutter with respect to the work piece is of considerable significance.
Three possibilities are there. Either the cutter may be symmetrically placed on the work piece or it
may be asymmetrically placed, offset slightly towards the entry side or it may be asymmetric, offset
slightly towards the exit side. All three positions are shown in Fig.4.7.

16Asymmetric milling with larger chip thickness at entry and smaller chip thickness at exit (Fig.4.7
(b)) is ideal and should be adopted.

3. ENDMILLING

End mills perform a combination of peripheral as well as face milling operations simultaneously. It
has got cutting edges on the bottom face as well as on its periphery. End mills are extremely useful
and are used for machining edges, shoulders, grooves, slots and keyway pockets. They are also widely
used for die-sinking and generation of sculpted surfaces. Today, end mills are available in many tool
materials:
1. Cobalt high speed steel (superH.S.S.)
2. CoatedH.S.S.
3. Solidcarbide
4. Micro grain solidcarbide

19
5. Index able inserts of cemented carbide or coated carbide. A solid carbide end mill and its
applications in shoulder and pocket machining are shown in Fig.4.8. End mills have a taper shank
which fits into a taper sleeve provided in the spindle of a vertical millingmachine.

MILLING MACHINES

All the milling cutters described above are used in conjunction with milling machines, which
provide rotary movement to the cutters, and feed to the work piece and arrangement for clamping,
automatic feed etc. Milling machines come in three basic models:

1. Horizontal millingmachines,
2. Vertical milling machines,and
3. Universal milling machines (This is also of horizontal type with a few specialfeatures).

Other configurations of the milling machine have been developed for special applications, but
above three are most common.

(1).HORIZONTAL MILLING MACHINE

The most common type of milling machine is the horizontal knee type; so called, because of the
over-hanging „„knee‟‟ which can slide up and down the front of the machine and which carries the
cross slide and the table. A diagram of the horizontal milling machine is given in Fig. 4.9.

Horizontal milling machines may be either plain or universal type. The main difference between the
two is that the table of the universal type is mounted on a turn table and may be swiveled in a
horizontal plane. This feature permits the cutting of helix. In addition, the standard accessories
20
provided on the universal machine include a „dividing head‟ for indexing. There are some other
minor refinements, which make the universal horizontal machine very useful for tool roomwork.

The plain version of the horizontal machine is much more robust and more suitable for production
work. In the diagram, the arbor on which peripheral cutters are mounted is not shown. It is fitted in
the spindle nose „C‟ and extends a little beyond arbor supportingbracket„B‟.

Even end mills, face milling cutters and drills etc. can be used with this machine. In such a situation,
arbor is removed and the taper shank of these cutters is fitted into the hollow spindle „C ‟.With such
an arrangement the vertical faces of the work piece may be milled without any difficulty. The table of
the horizontal milling machine can be given either hand feed or auto feed. It is also capable of being
traversed at high speed.

(2).Vertical milling machine:

The application and technique of this machine differ from that of a horizontal milling machine. It
does not have an arbor and instead has a vertical spindle into which the taper shank of end mills and
facing milling cutters and drills etc. can be fitted. The arrangement and movement of table are similar
to the table of a horizontal millingmachine.

This machine used for making, flat surfaces, grooves, slots, pockets and guide ways etc. in
21
work pieces using end mills and facing mills etc.

(3).Universal milling machine:

Its features have already been described under the heading of horizontal milling machine.
Conclusion:
There are many accessories and fittings, which, if provided greatly improve the performance and
range of work which can be carried out on a milling machine.

22
 c). STUDY OF SHAPEING MACHINE
Aim
To study about the shaping machine.
INTRODUCTION
Both shapers and planers are machine tools which produce a flat surface. They are capable of
machining a horizontal, vertical or inclined flat surface. They employ single-point cutting tools which
are essentially similar to single-point cutting tools used on lathe. In both these machine tools, the
cutting tool is subjected to interrupted cuts, the tools cuts in forward direction and is idle in the return
direction.

NOTE: 1.cutting tool is in moving condition whereas work piece is

stationary 2.small length work piece only workable in shapers
These are the main difference between planer and shaper
SHAPING MACHINES OR SHAPER
Principle of Working

Principal parts of shaper are shown in fig.2.1

23
 Shaper consists of a hollow machine bed made of cast iron which rests on the ground. Inside
the hollow portion the machine drive mechanism is housed. This mechanism is called slotted lever
quick return mechanism and it drives a horizontal ram which reciprocates in the guide ways provided
on the top surface of the machine frame. In the front face of the ram, a tool post is fitted. This is a very
special kind of tool post. It carries a slide which can be operated by a hand wheel and the entire tool
post can be lowered or raised. Besides, the tool slide can be swiveled in a vertical plane and its
inclination to the vertical (amount of swiveling) can be read off on a scale marked in degrees. The tool
is inclined, when an inclined surface has to be machined. In the front portion of the base, a table is
fitted. The table can be raised or lowered to vary its height. It can also be moved horizontally to left or
right. A vice to hold the work piece is provided on the table top. The tool does useful work i.e., cutting
only in the forward stroke of the ram. It does not cut i.e.; it is idle during the return stroke of ram. In
order that while returning, the tool may not rub and spoil the strip of the metal machined in the
forward stroke, a special device called the “clapper box” is provided in the tool post. It lifts the tip of
the tool during the returnstroke.

DRIVE

Since useful work is done only during the forward stroke of ram, the mechanism driving the
ram is so designed that the return stroke is completed in much less time than the forward stroke. The
slotted lever quick return mechanism is illustrated in Figs. 2.2(a) and 2.2(b).

24
 The crank AB (of adjustable length R) rotates with a uniform angular speed. The crank pin B
is in the shape of a die block which is free to slide inside the slot in the slotted lever OBC. This slotted
lever ispivotedatOandtheotherendCisconnectedtotherambyashortlinkarmasshowninFig.
(a). When the crank AB rotates clockwise from position AB1to AB2, the ram moves
forward from left to right and when it rotates from position AB2to AB1the ram returns back to
its original position. Clearly the time taken to complete forward stroke is proportional to angle
α(refer to Fig. 2.2 (b))and the return stroke is completed in less time which is proportional to
angleβ.

CUTTING TOOLS USED IN SHAPING

The cutting tools for shapers are generally made of H.S.S., either solid or with brazed tips. Due
to interrupted cuts, tungsten carbide tools are not preferred for shaping work. These tools are made
sturdy with fairly generous size for shank and tip. Various types of tools useful for shaping are shown
in Fig. 2.3

OPERATIONS PERFORMED ON SHAPERS

On a shaping machine, relatively small jobs can be machined. The size of a shaper is denoted
by the maximum length of stroke of its ram and work pieces longer than the maximum stroke cannot
be machined. The first step in machining a job is to mount the job on the shaper-table and clamp it
tightly in the vice or on the table by means of T -bolts etc. The second step is to adjust the stroke of

25
ram according to the length of work piece. The ram stroke is kept about 60–70 mm longer than job.
The stroke can be reduced or increased by altering the length of the crank AB (refer to Fig. 2.2). Now
by changing the position of the location where short link arm is connected to the ram, the stroke is
made to overlap the job, so that the stroke starts 30–35 mm before the job and covers the whole length
of work piece and ends 30–35 mm beyond it. A tool is now selected and clamped in the tool post. The
depth of cut is given by rotating the hand wheel and lowering the tool slide. Depth of cut is not given
by raising the table height. Table height is adjusted only at the time of fixing the job according to the
height of job. Feed is given by shifting the table laterally. The feed to the table can be given either
manually or automatically. The feed is given during the return stroke of ram. Operations performed on
a shaper can be easily understood from Fig. 2.4.

26
 Contour cutting is a very skillful job as it calls for simultaneous operation of horizontal
table feed as well as vertical hand feed of the cutting tool. It can be performed only by a very skilled
operator.

Conclusion:

There are many accessories and fittings, which, if provided greatly improve the performance
and range of work which can be carried out on a shaping machine.

27
 d). STUDY OF WELDING

Welding is a fabricationprocess that joins materials, usually metals or thermoplastics, by

causing coalescence. This is often done by melting the work pieces and adding a filler material to
form a pool of molten material (the weld puddle) that cools to become a strong joint, with pressure
sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with
soldering and brazing, which involve melting a lower-melting-point material between the work pieces
to form a bond between them, without melting the work pieces.

Many different energy sources can be used for welding, including a gas flame, an electric arc,
a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding can be
done in many different environments, including open air, underwater and in space. Regardless of
location, however, welding remains dangerous, and precautions must be taken to avoid burns,
electricshock, eye damage, poisonous fumes, and overexposure to ultravioletlight.

TYPES OF WELDING

Arc Welding

Arc welding is a process utilizing the concentrated heat of an electric arc to join metal by
fusion of the parent metal and the addition of metal to joint usually provided by a consumable
electrode. Either direct or alternating current may be used for the arc, depending upon the material to
be welded and the electrodeused.

Gas Welding

It is a metal joining process in which the ends of pieces to be joined are heated at their
interface by producing coalescence with one or more gas flames (such as oxygen and acetylene), with
or without the use of a fillermetal.

Welding Safety

Welding hazards pose an unusual combination of safety and health risks. By its nature,

28
welding produces fumes and noise, gives off radiation, involves electricity or gases, and has the
potential for burns, shock, fire, and explosions.

Types of arc welding

Different types of arc welding are.

1. Carbon arcwelding

2. Metal arc welding

3. Metal inert gaswelding

4. Submerged arcwelding

5. Plasma arc weldingetc.

Electric Arc Welding,

Electric arc welding is the most widely used of the various arc welding processes. Welding is
performed with the heat of an electric arc that is maintained between the end of a coated metal
electrode and the work piece (See Figure 1). The heat produced by the arc melts the base metal, the
electrode core rod, and the coating. As the molten metal droplets are transferred across the arc and
into the molten weld puddle, they are shielded from the atmosphere by the gases produced from the
decomposition of the flux coating. The molten slag floats to the top of the weld puddle where it
protects the weld metal from the atmosphere during solidification. Other functions of the coating are
to provide arc stability and control bead shape. More information on coating functions will be
covered in subsequent lessons.

Welding Power Sources: Shielded metal arc welding may utilize either alternating current (AC) or
direct current (DC), but in either case, the power source selected must be of the constant current
type.
29
This type of power source will deliver relatively constant amperage or welding current regardless of
arc length variations by the operator the amperage determines the amount of heat at the arc and since
it will remain relatively constant, the weld beads produced will be uniform in size andshape.
Whether to use an AC, DC, or AC/DC power source depends on the type of welding to be done and
the electrodes used. The following factors should be considered: 1. Electrode Selection - Using a DC
power source allows the use of a greater range of electrode types. While most of the electrodes are
designed to be used on AC or DC, some will work properly only onDC.

Oxy-Acetylene gas Welding

Oxyacetylene welding, commonly referred to as gas welding, is a process which relies on

combustion of oxygen and acetylene. When mixed together in correct proportions within a hand-held
torch or blowpipe, a relatively hot flame is produced with a temperature of about 3,200˚C. The
chemical action of the oxyacetylene flame can be adjusted by changing the ratio of the volume of
oxygen to acetylene.
Three distinct flame settings are used, neutral, oxidising and carburizing. Welding is generally carried
out using the neutral flame setting which has equal quantities of oxygen and acetylene. The oxidising
30
flame is obtained by increasing just the oxygen flow rate while the carburising flame is achieved by
increasing acetylene flow in relation to oxygen flow. Because steel melts at a temperature above
1,500˚C, the mixture of oxygen and acetylene is used as it is the only gas combination with enough
heat to weld steel. However, other gases such as propane, hydrogen and coal gas can be used for
joining lower melting point non-ferrous metals, and for brazing and silver soldering.

Equipment

Oxyacetylene equipment is portable and easy to use. It comprises oxygen and acetylene gases
stored under pressure in steel cylinders. The cylinders are fitted with regulators and flexible hoses
which lead to the blowpipe. Specially designed safety devices such as flame traps are fitted between
the hoses and the cylinder regulators. The flame trap prevents flames generated by a 'flashback' from
reaching the cylinders; principal causes of flashbacks are the failure to purge the hoses and
overheating of the blowpipenozzle.

When welding, the operator must wear protective clothing and tinted coloured goggles. As the
flame is less intense than an arc and very little UV is emitted, general-purpose tinted goggles provide
sufficient protection

Types of Flames:

Neutral Flame

As the supply of oxygen to the blowpipe is further increased; the flame contracts and the
white cone become clearly defined, assuming a definite rounded shape. At this stage approximately
equal quantities of acetylene and oxygen are being used and the combustion is complete, all the
carbon supplied by the acetylene is being consumed and the maximum heat given out. The flame is
now neutral, and this type of flame is the one most extensively used by the welder, who should
make himself thoroughly familiar with its appearance and characteristics.

31
 Fig.Gas Welding Equipment

Carburising Flame

This is a flame in which an excess of acetylene is burning, i.e. combustion is incomplete and
unconsumed carbon is present. When lighting the blowpipe the acetylene is turned on first and
ignited, giving a very smoky yellow flame of abnormal size, showing two cones of flame in addition
to an outer envelope; this is an exaggerated form of the carburising flame, but gives out comparatively
little heat and is of little use for welding.

Oxidising Flame

A further increase in the oxygen supply will produce an oxidising flame in which there is
more oxygen than is required for complete combustion. The inner cone will become shorter and
sharper, the flame will turn a deeper purple colour and emit a characteristic slight "hiss", while the
molten metal will be less fluid and tranquil during welding and excessive sparking will occur. An
32
 oxidising flame is only used for special applications, and should never be used for welding

GAS METAL ARC WELDING

Gas metal arc welding (GMAW) is a welding process where the heat is generated by an electric arc
incorporating a continuous-feed consumable electrode that is shielded by an externally supplied gas. A
simple schematic diagram of the GMAW process is shown in Figure .It shows the terminology used
with the GMAW process.

Fig.Gas metal arc welding

Besides the welding gun, the actual equipment required for the GMAW process includes an electric
power supply, the electrode wire-feed unit, and a source of shielding gas. The gun guides the electrode
wire, current wire, and shielding gas tube. As described in the next section, self-regulation of the arc
length is maintained by a constant voltage power supply with a constant wire-feed speed unit.
Alternatively, a constant-current voltage supply can be used with arc voltage controlling the wire-feed
speed.

33
 e). STUDY OF FOUNDRY
Aim
To study and observe various stages of casting through demonstration of Sand Casting Process.

Background
Casting is one of oldest and one of the most popular processes of converting materials into
final useful shapes. Casting process is primarily used for shaping metallic materials; although it
can be adopted for shaping other materials such as ceramic, polymeric and glassy materials. In
casting, a solid is melted, treated to proper temperature and then poured into a cavity called mold,
which contains it in proper shape during solidification. Simple or complex shapes can be made
from any metal that can be melted. The resulting product can have virtually any configuration the
designer desires.
Casting product range in size from a fraction of centimeter and fraction of kilogram to over
10 meters and many tons. Moreover casting has marked advantages in production of complex
shapes, of parts having hollow sections or internal cavities, of parts that contain irregular curved
surfaces and of parts made from metals which are difficult tomachine.
Several casting processes have been developed to suit economic production of cast products
with desired mechanical properties, dimensional accuracy, surface finish etc. The various
processes differ primarily in mold material (whether sand, metal or other material) and pouring
method (gravity, pressure or vacuum). All the processes share the requirement that the material
solidify in a manner that would avoid potential defects such as shrinkage voids, gas porosity and
trapped inclusions.
Any casting process involves three basic steps, i.e. mold making, melting and pouring of
metals into the mold cavity, and removal and finishing of casting after complete solidification.

SAND CASTING PROCESSES

Sand is one of the cheaper, fairly refractory materials and hence commonly used for making
mold cavities. Sand basically, contains grains of silica (SiO2) and some impurities. For mold
making purposes sand is mixed with a binder material such as clay, molasses, oil, resin etc.

34
Green Sand Molding
In green sand molding process, clay (a silicate material) along with water (to activate clay) is
used as binder. The mold making essentially consists of preparing a cavity having the same shape
as the part to be cast. There are many ways to obtain such a cavity or mold, and in this
demonstration you will learn to make it using a wooden „pattern‟, metal „flasks‟ and„green-sand‟
as moldmaterial.

A pattern is a reusable form having approximately the same shape and size as the part to be
cast. A pattern can be made out of wood, metal or plastic; wood being the most common material.
Green sand refers to an intimate mixture of sand (usually river sand), bentonite clay (3-7 percent

by weight of sand, to provide bonding or adhesion between sand grains), and water (3-6 percent
by weight of sand, necessary to activate the bonding action of the clay). Mixing the above
ingredients in a sand muller best provides the intimate mixing action. In practice, a major part of
this sand mixture consists of „return sand‟, i.e. the reusable portion of the sand left after the
solidified metal casting has been removed from the mold. Molding flasks are rectangular frames
with open ends, which serve as containers in which the mold is prepared. Normally a pair of flasks
isused;theupperflaskisreferredto as„Cope‟andtheloweroneas„drag‟.Ariddleisarelatively coarse
sieve. Riddling the green sand helps in breaking the lump and aerates thesand.

Sometimes the casting itself must have a hole or cavity in or on it. In that case the liquid
metal must be prevented from filling certain portions of the mold. A „core‟ is used to block-off
portions of the mold from being filled by the liquid metal. A core is normally made using sand
with a suitable binder like molasses. Core is prepared by filling the core-box with core sand to get
the desired shape and the baking this sand core in an oven at suitabletemperature.

During mold making a suitable „gating system‟ and a riser‟ is also provided. The gating
system is the network of channels used to deliver the molten metal from outside the mold into the
mold cavity. The various components of the gating system are pouring cup, sprue, runners and
gates. Riser or feeder head is a small cavity attached to the casting cavity and the liquid metal of
the riser serves to compensate the shrinkage in the casting during solidification.Fig.1.below shows
the various parts of a typical sand mold. Several hand tools, such as rammer, trowel, sprue pin,
35
 draw spike, slick, vent wire, gate cutter, strike off bar etc. are used as aids in making a mold.

Fig:1 : Cross Section of a typical two-part sand mold, indicating various mold comoponents
and terminology

Melting and Pouring of Metals

The next important step in the making of casting is the melting of metal. A melting process must
be capable of providing molten metal not only at the proper temperature but also in the desired quantity,
with an acceptable quality, and within a reasonable cost.
In order to transfer the metal from the furnace into the molds, some type of pouring device, or
ladle, must be used. The primary considerations are to maintain the metal at the proper temperature for
pouring and to ensure that only quality metal will get into themolds.
The operations involved in melting of metal in oil fired furnace/induction furnace and pouring of
liquid metal into the mold cavity will be shown during thedemonstration.

Removal and Finishing of Castings

36
 After complete solidification, the castings are removed from the mold. Most castings require
some cleaning and finishing operations, such as removal of cores, removal of gates and risers, removal of
fins and flash, cleaning of surfaces, etc

37
 f). STUDY OF SHEET METAL OPERATIONS

1. INTRODUCTION
Sheet metal work has its own significance in the engineering work. Many products, which fulfill the
household needs, decoration work and various engineering articles, are produced from sheet metals.
Common examples of sheet metal work are hoopers, canisters, guards, covers, pipes, hoods, funnels, bends,
boxes etc. Such articles are found less expensive, lighter in weight and in some cases sheet metal products
replace the use of castings orforgings.

2. METALS USED IN SHEET METALWORK:

A metal plate of thickness less than 4 mm is considered as sheet. The size of the sheet is specified by
its length, width and thickness in mm. In British system, the thickness of sheet is specified by a number
called Standard Wire Gauge (SWG).
The following metals are generally used in sheet metal work:

i. Black IronSheet

It is the cheapest among ail. It has a bluish-black appearance and is uncoated sheet. Being uncoated,
it corrodes rapidly. It is prepared by rolling to the desired thickness, then annealed by pleasing in a furnace
and then set aside to cool gradually. The use of this metal is limited to articles that are to be painted or
enameled such as stovepipes, tanks, pans etc.

ii. GalvanizedIron

It is soft steel coated with molten zinc. This coating resist rust, improves appearances, improves
solderability, and improves water resistance. It is popularly known as G.I. sheets. Articles such as pans,
buckets, furnaces, cabinet etc. are made from Glsheets.

iii. StainlessSteel

It is an alloy of steel with nickel, chromium and traces of other metals. It has good corrosive

38
resistance. The cost of stainless steel is very high but tougher than Gl sheets. It is used in kitchenware, food
handling equipment, chemical plants etc.

iv. Copper

It is a reddish colored metal and is extremely malleable and ductile. Copper sheets have good
corrosion resistance as well as good appearances but costs are high as compared to Gl and stainless steel.
Because of high thermal conductivity, it is used for the radiator of automobiles, domestic heating
appliances etc.

v. Aluminium

Aluminium cannot be used in its pure form, but is used in alloy form. Common additions are copper,
silicon, manganese and iron. It has many qualities like high ratio of strength to weight, corrosion resistant
qualities, and ease in fabrication and whitish in color. It is used in manufacturing

of a number of products such as refrigerator trays, household appliances, lighting fixtures, window work,
construction of airplanes and in many electrical and transportation industries.

vi. Tin Plates

It is an iron sheet coated with the tin to protect it against rust. This metal has a very bright silvery
appearance and is used principally in making food containers, cans and pans.

vii. Lead

It is a very soft, malleable, low melting point and possesses high resistance to acid corrosion. It is
having low mechanical strength so it is used to provide lining to the highly corrosive acid tanks. It is also
used in radiation shielding.

3. HANDTOOLS:

39
 For measuring, marking cutting and forming, various types of hand tools are used in sheet metal
work. A list of them is given below:
I. Measuringtools
II. Markingtools
III. Cuttingtools
IV. Formingtools
V. Joiningtools

I. MEASURINGTOOLS

The following types of tools are commonly used in sheet metal shops to measure the dimensions of work
pieces:
1. Steelrule
2. Vernier caliper
3. Micrometer
4. Sheet Metalgauge

II. MARKING TOOLS:

1. Scriber:It is used to scribe or mark line on a metal surface for a variety of purposes. It is a
metalworker'spencil
2. Trammel: These are used for drawing large circles and arcs that are beyond the limit of dividers. It has
two straight, removable legs tapered to a needle point mounted on separate holders which slide on steel (or
wooden) bar and held in position by thumbscrews.
3. Punches: It is used in sheet metal work for marking on sheet, locating centers. There are twotypes of
punches. a) Dot punch and b) Prick punch.

III CUTTINGTOOLS:

To cut the sheet metal as per the pattern drawn and to make holes for rivets etc., the following types
of tools are used.
40
 A snip is a hand shear used to cut thin sheets of gauge size number 20 or above. It works like
ordinary scissors. There are several types and sizes of snips available to cut along straight lines or curved
lines. These snips are used for cutting thin sheets. The heavier types are known as bench shear and
blockshear.

IV. FORMING TOOLS:

Shaping of the sheet metal such as folding, bending, curling, etc., are done by using the following
types of forming tools.

1. Stakes:
Stakes are the sheet metal anvils used for bending, seaming and forming by using ahammer or mallet.
2. HAMMERS:
The sheet metal is shaped by hammering or striking with mallet, after keeping the work on suitable
form of stake. The hammers used for sheet metal work are (a) Setting hammer, for setting down the edge
while making double seam, (b) Raising hammer for forming curved or hollow shape from flat piece, and (c)
Riveting hammer for riveting purpose. Mallets are soft hammers used to give soft blows which will not
damage the sheet at the same time will shape them. The commonly used types of hammers and mallets are
shown in Figure.

IV JOININGTOOLS:
The tools exclusively used for making and finishing joints are:
a) Hand grooves b) Rivet set c) Solderingirons

41
 g). STUDY OF METAL SPINNING

Metal spinning is a plasticity forming process that forms a metal sheet or tube by forcing the metal
onto a rotating mandrel using a roller or a paddle tool. It is widely used for producing round hollow metal
parts and products, e.g. tableware, kitchenware, ornaments, lighting fixtures, parabola antennas, boilers,
tanks, gas canisters, nozzles, engine parts, and tire wheels. This forming process is also known as a highly-
skilled manufacturing craft by artisans that requires decades of experience. Even nose cones for H-IIA
spacerockets launched by JAXA in Japan are produced by such manual metal spinning.

FIG.Metal spinning

Metal spinning has several merits over other metal forming processes as follows.

 It can create more complicated shapes than sheet metal stamping or deep drawing.
 As it needs only one mandrel, it is easier to set up for forming.
 Forming force is rather small and the forming apparatus can be compact.
 Material can be saved in comparison with cutting processes.
 It can provide precision products and good surface finishing.

42
Metal Forming
• This step involves the laying down of the material onto the mandrel.
• It is accomplished with short inside to outside moves.

• Material gets easier to form as the part is closer to completion.

Trimming
Parts having been spun are trimmed at the end to blunt sharp edges and also to bring the
component to the desired length.

Finishing
Finishing is done at very high RPMs (1200+) so that a minimum of force need be applied and very
smooth strokes can be used. • The flat side of Duckbill spinning tool is used for straight surfaces
and rounded side for curves and radii.

43
 h). STUDY OF GEAR HOBBING MACHINE

 Gear Hobbing is a process that generates the gear profile by engagement of the tool and the work
piece
In this process, the gear blank is rolled with a rotating cutter called hob
 The Hob is a multi-point cutting tool having a number of straight flutes all around its periphery
parallel to its axis
These flutes are so shaped by giving proper angles to themso that these work as cutting edges
 In gear Hobbing operation, the hob is rotated at a suitable rpm and simultaneously fed to the gear
blank
 Also the gear blank is kept revolving. Rpm of both gear blank and gear hob are so synchronized
that for each revolution of gear hob, the gear blank rotates by a distance equal to one pitch distance
of the gear to be cut
Motion of both gear blank and hob are maintained continuously and steady
A gear hob (tool) and the process of gear Hobbing are illustrated in Figure below

Schematic of gear Hobbing process

44
 Three important parameters are to be controlled in the process of gear Hobbing
indexing movement
feed rate
angle between the axis of gear blank and gear Hobbing tool

A schematic diagram of the setup of a gear Hobbing machine is illustrated in Figure below

 The axis of hob is set at an inclination equal to the helix angle of the hob, with the vertical axis of
the blank
 If a helical gear is to be cut, the hob axis is set at an inclination equal to the sum of the helix angle
of the hob and the helix angle of the helical gear
Proper gear arrangement is used to maintain rpm ratio of gear blank and hob
 The operation of gear Hobbing involves feeding the revolving hob till it reaches to the required
depth of the gear tooth.
Simultaneously it is fed in a direction parallel to the axis of rotation.
 The process of gear Hobbing is classified into different types according to the directions of feeding
the hob for gear cutting.

45
 i). STUDY OF GEAR SHAPER MACHINE

 This process uses a pinion shaped cutter carrying clearance on the tooth face and sides and a hole at
its centre for mounting it on a stub arbor or spindle of the machine
The cutter is mounted by keeping its axis in vertical position
It is made to reciprocate up and down along the vertical axis up to a pre decided amplitude
Both the cutter and the gear blank are set to rotate at a very low RPM about their axis
 The relative rpm of both (cutter and blank) can be fixed to any of the available value with the help
of a gear train.
 This way all the cutting teeth of cutter come is action one-by-one giving sufficient time for their
cooling and incorporating a longer tool life
The principle of gear cutting by this process as explained above is depicted in the Figure below

The main parameters to be controlled in the process are described below

Cutting Speed:
Shaper cutter can move vertically upward and downward during the operation.
 The downward movement of the cutter is the cutting stroke and its speed (linear) with which
it comes down is the cutting speed.
Length of cutting stroke can be adjusted to any value out of available values on the machine

Indexing motion:

46
  Indexing motion is equivalent to feed motion in the gear shaping operation. Slow rotations
of the gear cutter and work piece provide the circular feed to the operation.
These two rpms are adjusted with the help of a gear train
Depth Of Cut:
The required depth is maintained gradually by cutting the teeth into two or three pass
In each successive pass, the depth of cut is increased as compared to its previous path
 This gradual increase in depth of cut takes place by increasing the value of linear feed in
return stroke

A Schematic representation of gear shaper is shown above with various parts

 The main advantage of gear shaper is that the process can be used to make a variety of gears and the
cycle time for producing one work piece is very less compared to many other processes. Close
tolerances can be maintained
 The main disadvantage is that there is no cutting in the return stroke. The process cannot be used to
manufacture worm and worm wheel, which is a special type of gear
:

47
 j). STUDY OF GRINDING MACHINE

 Grinding is the process of removing metal by the application of abrasives which are bonded
to form a rotating wheel.
 When the moving abrasive particles contact the workpiece, they act as tiny cutting tools,
each particle cutting a tiny chip from the work piece.
 Itisacommonerrortobelievethatgrindingabrasivewheelsremovematerialbyarubbing action;
Actually, the process is as much a cutting action as drilling, milling, and lathe turning.
A schematic of grinding operation is shown below

Mechanism of Grinding

Types of Grinding Machines:

The various types of grinding machines are described as follows
Utility grinding machine
Cylindrical grinding machine
Surface grinding machine.
Angle Grinder
Tool Grinding machine

48
 Construction of Grinding Machine and wheel
 The construction of grinding machine and grinding wheel are described in figure as
follows

Reciprocating surface grinding machine

Perfect located grinding wheel

Applications
The Grinding operations are mainly used for the applications are described as follows
I)Surfacefinishingii)slitting&partingiii)Descaling,deburringIV)Stockremovalfinishing of flat as
well as cylindrical surface
:

49
 k). Study of Tool Dynamometer

 In orthogonal cutting resultant force applied to the chip by the tool lies in a plane normal to
the tool cutting edge
This force is usually found experimentally by measurement of two of its components
Cutting force - FC
Thrust Force - FT
 The Principal cutting force is the resultant of these two forces and the figure below explains
the same

Cutting forces in chip formation

 In most metal cutting force dynamometers, tool force is determined by measuring the
deflection or strain in the elements supporting the cutting tool

The dynamometer must give deflections that are large enough to be measured accurately.
Hence the design of a dynamometer largely depends on the strain or deflection measuring
device employed
A simple two component type cutting force dynamometer is shown below
Here it can be observed that the cutting tool is supported on the tool post like a cantilever

50
  The vertical and horizontal deflections of the cantilever under the action of the resultant tool
force are taken as a measure of the two force components FCand FT

Simple two component tool dynamometer for lathe

 Many effective dynamometers have been developed using a range of deflection / strain
measuring methods including strain gauges, piezoelectric load cells etc for increased
resolution and stiffness
 The two force components FCand FTthus measured using the dynamometer can be used to
calculate various important variables in the process of continuous chip formation
 The forces thus calculated determines the stress / load on the tool during machining and
hence is a very important data for designing the tool shank
 They also give us a bare minimum value of load that the workpiece has to withstand which is
imposed upon it during machining. So during the design of the product itself, considerations
are to be given such that the workpiece will not fail during machining, owing to the cutting
force imposed on it during machining process
 Thus the cutting force measurement gives us a deep insight into the tool life, product design,
tool design etc., and hence is a very important for any manufacturing firm doing mass
production

51
 l). STUDY OF CRNTERLESS GRINDING

 Centerless grinding is the process of continuously grinding cylindrical surfaces, in which the
work piece is not supported by centersor chucks but by a resting blade
The work piece is ground between two wheels
 The larger grinding wheel does the grinding while the smaller regulating wheel does not
contribute to the material removal process
The schematic of the Centerless grinding process is shown below

Centerless grinding setup

The regulating wheel is tilted at an angle i, which in turn regulates the velocity of axial
movement of the cylindrical work piece

Centerless grinding wheels &work piece position

The relative position of the wheels and the workpiece, along with the inclination of the
regulating wheel is shown above

141
There are three velocities involved in the above setup. They are
Velocity of the Grinding wheel, Vg

Velocity of the regulating wheel, Vr

Velocity of Feed / axial movement of the work piece against the wheels, Vf
The relationship of the three velocities is shown by the following self-explanatory velocity triangle

Velocity Triangle
Centerless grinding can be internal or external, traverse feed or plunge grinding
But anyway, external is the most common type of Centerless grinding
Centerless grinding is most suited for mass production and a Centerless grinding machine is shown
below

Centerless Grinding Machine

The main disadvantage of Centerless grinding process is that, it requires specialized
machinery which can perform no other task

146
 m).STUDY OF CNC MACHINES AND FANUC CODING

Modern precision manufacturing demands extreme dimensional accuracy and surfacefinish

Such performance is very difficult to achieve manually, if not impossible, even with expert
operators
In cases where it is possible, it takes much higher time due to the need for frequent dimensional
measurement to prevent overcutting
Developmentofcomputernumericallycontrolled(CNC)machineshasalsomadepossiblethe
automationofthemachiningprocesseswithflexibilitytohandleproductionofsmalltomedium batch
of parts
A typical CNC machining centre is shown below

CNC Turning Centre

Here programs are written in the form of special codes specifically coded for CNC machine
 Each code performs a specific task assigned, with the integration of the microprocessor of
the on board computer, which in turn regulates the voltage supplied to the various actuators
of the machining centre such as
Servo Motor of the main spindle / chuck
Stepper motor of the tool carriage
Stepper motor of the tool changer pallet
Coolant on / off pumps and so on
 It is mandatory to have a sound knowledge of the coding, in order to write a part program
which in turn is executed by the machine once the program is loaded on to its RAM
 The structure of the coding system is shown below, which shows the typical coding used for
various functions of a lathe

147
 CNC program structure
Given below is the systemof coding used for writing CNC part programs

GROUPS OF PROGRAM WORDS:

The sequence of the words in an NC – block is designated as follows:

S.No Address Definition

1 N Block number

2 G G-functions

3 X,Y,Z Coordinates

4 I,J,K Interpolation Parameter

5 F Feed

6 S Speed

7 T Tool position

8 M Additional functions


SEQUENCE OF PROGRAM WORDS:

148
Block number N:

The block number is the first word in a block and designates it.

 It can only be conferred once. The block number has no influence on the execution of the
individual blocks since they were entered into the control.

G – FUNCTION:

Together with the words for the coordinates, this word essentially determines the geometric
part of the NC program. It consists of the address letter G and a two-digit code.

COORDINATES X,Y,Z:

The coordinates X, Y, Z define the target points that are needed for travel.

INTERPOLATION PARAMETERS I, J, K:

 The interpolation parameters I, J, K are e.g. used to define the centre of a circle for circular
movements. They are usually entered incrementally.

FEEDF:

 ThespeedatwhichthetoolistobemovedisprogrammedwiththefunctionF;theinfeed speed is
usually entered in mm/min. For turning, the unit mm/min pertaining to spindle rotation can
also be used.

SPINDLE SPEED S:

 This function is for entering the spindle speed. It can be directly programmed in rotations
per minute.

TOOL POSITION T:
 TheaddressTtogetherwithanumericalcodedesignatesaspecifictool.Thedefinitionof this
address differs according to the control and can have the following functions:

Saving the tool dimensions in the tool offset table.

Loading the tool from the tool magazine.

149
ADDITIONAL FUNCTIONS M:

 The additional functions, also known as auxiliary functions, primarily contain technical
data that is not programmed in the words with address letters F, S, T.

These functions are entered with the address letter M and a two-digit code.

150
G–CODES&M–CODESFORFANUCMILLING:

G–Code Function M–Code Function

G00 Rapid transverse M00 Program stop
G01 Linear interpolation M01 Optional stop
Circular interpolation
G02 (clockwise) M02 End of program
Circular interpolation/(anti
G03 clockwise) M03 Spindle rotation(cw)
G04 Dwell M04 Spindle rotation(ccw)
G20 In put in inch M05 Spindle stop
G21 Input in mm M06 Auto tool change
G28 Go to reference M07 Mist coolant on
G40 Cutter compensation cancel M08 Flood coolant on
G41 Compensation left M09 Coolant off
G42 Compensationright M10 Work clamp
G50 Coordinate system setting M11 Work unclamp
G73 Fast peck drilling M20/21 ATC arm in/out
G84 Tapping cycle M22/23 ATC arm down/up
G85 Boring cycle M24/25 ATC arm clamping
G90 Absolute Command M32/33 ATC cw/ccw
G91 Incremental command M38 Door open
G92 Set datum M39 Door close
G94 Feed per minute M62/63 Aux1/2on
G95 Feed per revolution M70 X mirror ON
G98 Return to initial position M71 X mirror OFF
G99 Return to R point M80 Y mirror ON
M81 Y mirror OFF
M99 End of sub program M98 Sub program call

150
OTHERFUNCTION:

Function
Code
N Sequence number
X,Y,Z, Coordinate axis motion
A,B,C command
R Arc radius, thread lead
I,J,K Coordinate values of arc centre
F Feed rate thread lead
S Spindle speed
Tool number, Tool offset
T
number
B Index table
H Designation of off set number
P,X Dwell time

CANNED CYCLE:

 A canned cycle or fixed cycle may be defined as a set of instructions in built or stored in the
system memory to perform a sequence of operations.

 It is a combination of machine movements that perform machining operations like drilling,

milling, boring and tapping.

 This cycles implifies the program by using a single block with a G-code to specify the
machining operations usually specified in several blocks. It is also called as fixed cycle.

Result:
Thus the important features, programming structures, codes used in manual part
programming were studied.

151
 TAPER TURNING

JOB DRAWING

All dimensions are in mm

Materials Supplied: Mild Steel Rod Ø25x 102mm

Tool Material: High Speed Steel (H.S.S)
Model Calculation:

Where:
D = Major diameter of the work
piece d = Minor diameter of the work
piece L = Length of the workpiece

152
Ex. No.:
Date:
Perform Taper Turning Operation in the given work piece Using Compound rest
swivelling method and Estimate the total machining time.
Aim:
To machine the given cylindrical rod as per the diagram, by using the lathe machine.
Tools required:
a. Chuck Key
b. Tool post spanner
c. Turningtool
d. Chamferingtool
e. Vernier caliper
f. Steelrule
Procedure:

1. The work piece is held in the lathechuck

2. The tool is set at latheaxis

3. The work piece is rotated about latheaxis

4. The facing and plain turning operations are carried out to the requireddimensions

5. The step is machined at the end of the workpiece

6. The carriage is clamped on the bed at requiredplace.

7. The compound rest base is swiveled to the required taper angle and it istightened

8. By moving the cross slide the angular feed is given the requireddimensions.

9. The taper cylindrical surface is machined

10. Then both ends of the job are chamfered by chamfering tool.
153
Result:

The given work piece machined as per the diagram by using the lathe machine.

Viva questions

1. State the various methods for taper turning operation.

1) Form tool method.
2) Tailstock set over method.
3) Compound rest method.
4) Taper turning attachment method.

2. State the important requites of capstan and turret lathe.

1) Bed 2) Head stock. 3) Turret head
4) Saddle and Cross slide.

3. What type of mechanism is used for indexing the turret head for the next
operation? Geneva or Indexing mechanism.

4. Name any four work holding devices.

.1) Collets 2) Chucks 3) Fixtures 4) Power chucks

5. Name any four tool holding devices

1) Multiple cutter holder.
2) Offset cutter holder.
3) Sliding cutter holder.
4) Knee tool holder.

6. What is the use of Mandrels?

Mandrels are used for holding hollow work pieces.

154
7 Define steady and follower rest.
Steady rest:-
It is fixed on bed ways of the lathe by .clamping the bolts.
Follower rest: -
The saddle is mounted on the saddle and moves together with the tool.

8. What are the different operations performed on a lathe?

1) Centering 3) Rough turning 5) Shoulder turning 7)Chamfering
2) Straight turning 4) Finish turning 6) Facing 8) Knurling etc.

9. Define filing operation.

Filing is the process of removing bars, sharp corners and feed marks on a work piece by
removing Very small amount of metal.

10. Define the process "grooving".

Grooving is the process of reducing the diameter of the work piece over a very narrow
surface.

155
 EXTERNAL THREAD CUTTING
JOB DRAWING

Materials Supplied: Mild Steel Rod Ø25x 102mm

Tool Material: High Speed Steel (H.S.S)

INTERNAL THREAD CUTTING

JOB DRAWING

Gearing ratio= Driver teeth/Driven teeth= TPI to

be cut / TPI on lead screw(inch) Gear ratio= Driver
teeth/Driven teeth=5Pn/127(metric)
Depth of cut = 0.6403Xpitch
Pitch=1/No of TPI

All dimensions are in mm

1 27
2
7

156
Ex. No.:
Date:

Carry out External Thread cutting and Internal Thread Cutting in the given work
pieces and calculate the total machining time.
Aim:

To machine the given cylindrical rod as per the diagram, by using the lathe machine.
Tools required:
a. Chuck Key
b. Tool post spanner
c. Turning tool
d. Chamfering tool
e. Vernier caliper
f. Steelrule
Procedure:

1. The work piece is held in the lathe spindle and it is rotated about lathe axis

2. By adopting usual procedure the facing and plain turning operations are carried
out to the required dimensions.

3. Next the taper turning operation is carried out to the required dimensions
by compound rest method

4. Then both ends of the job are chamfered by chamfering tool.

5. Remove the chamfering tool and insert the parting tool. Then calculate parting
diameter and remove the material as per dimension.

6. The gear ratio is calculated and the suitable size gears are fitted in the change gear train

7. The “V” tool is clamped in the tool post and it is set perpendicular to lathe axis

8. The tool is moved away from job end. After giving suitable depth of cut the half
157
 nut is engaged.

9. The required depth of cut is given and the cycle is repeated to obtain therequired
depth.

Result:

The given work piece machined as per the diagram by using the lathe machine.

Viva questions

1. Classify the relative motion between work piece and cutting tool.
(i) Rotation of work against the tool. Example:Turning,
(ii) Rotation of tool against work piece. Example: Drilling, Milling,
(iii) Linear movement of the work piece against the tool. Example: Planer,

2. What are all the different types of cutting tool?

(i) Single point cutting tool, (ii) Multiply point cutting tool.

3. Classify the various angles in cutting tool?

1) Back rake angle 2) Side rake angle 3) End relief angle 4) Side relief angle 5) Side cutting
angle 6) End cutting angle.

4. What is tool signature?

The various angles of tools are mentioned in a numerical number in particular order. That order
is known as tool signature.

5. When will the negative rake angles be used?

a. To machine high strength alloys. b. The machine tools are more rigid. c. The feed rates are
high. To give heavy and interrupted cuts.

6. Classify the types of metal cutting process?

The metal cutting processes are mainly classified into two types.

158
a. Orthogonal cutting process (two dimensional cutting),
b. Oblique cutting process (Three dimensional cutting).

7. Define orthogonal and oblique cutting?

Orthogonal cutting:-The cutting edge of tool is perpendicular to the work piece axis.
Oblique cutting:-
The cutting edge is inclined at an acute angle with normal to the cutting velocity vector is called
oblique cutting process.

8. What is shear plane?

The material of work piece is stressed beyond its yield point under the compressive force. This
Causes the material to deform plastically and shear off. The plastic flow takes place in a
localized region is called shear plane.

9. What is cutting force?

The sheared material begins to flow along the cutting tool face in the form of small pieces. The
compressive force applied to form the chip is called cutting force.

10. What is chip and mention its different types?

The sheared material begins to flow along the cutting tool face in the form of small pieces is
called chip. The chips are mainly classified into two types.
a. Continuous chip. Discontinuous chip. c. Continuous chip with built up edge.

159
 ECCENTRIC TURNING

JOB DRAWNG

All dimensions are in mm

Materials Supplied: Mild Steel Rod Ø25x 102mm

Tool Material: High Speed Steel (H.S.S)

160
Ex. No.:
Date:

Perform Eccentric Turning in the given work pieces and calculate the total
machining time.
Aim:
To machine the given cylindrical rod as per the diagram, by using the lathe machine.

Tools required:

a. Chuck Key
b. Tool post spanner
c. Turningtool
d. Chamferingtool
e. Vernier caliper
f. Drill bit ø10mm
g. Steelrule

Procedure:

1. The work piece is held in the lathe spindle and it is rotated about lathe axis

2. The tool is held in the tool post and it is set to lathe axis

3. The facing and turning operations are carried out to the required dimensions

4. Then the axis of the work piece is shifted to the required eccentricity

5. The longitudinal feed is given to the required length and job is eccentrically turned.

6. Two or more cuts with suitable depth of cut are given to obtain required diameter

161
 7. Then both ends of the job are chamfered by chamfering tool.

Result:
The given work piece machined as per the diagram by using the lathe machine.

Viva Questions

1. What are the factors affecting the machinability?

a. Chemical composition of work piece material,

b. Microstructure of work piece material
c. Mechanical properties like ductility, toughness etc.

2. What are all the tool variables affecting the machinability?

a. Tool geometry and tool material.

b. Nature of engagement of tool with the work.
c. Rigidity of tool.

3. What are the machine variables affecting the machinability?

a. Rigidity of machine. Power and accuracy of the machine tool.

4. How the machinability can be evaluated?

a. Rate of removal per tool grind,

b. Magnitude of cutting forces and power consumption. Surface finish.
c. Dimensional stability of finished work.
d. Heat generated during cutting.
5. Mention the advantage of high machinability?

a. Good surface finish can be produced,

b. High cutting speed can be used,
162
6. Classify the tool wear?

The tool wear is generally classified as follows, (i) Flank wear or crater wear (ii) Face wear (iii)
Nose wear

7. How tool life is defined?

Tool life is defined as time elapsed between two consecutive tool sharpening. During, this period
tool serves effectively and efficiently.

8. What are the factors affecting tool life?

i. Cutting speed ii. Feed and depth of cut iii. Tool geometry iv. Tool material v. Cutting fluid vi.
Work material vii. Rigidity of work, tool and machine.

9. Mention the various parts single point cutting tool?

1) Shank 2) Face 3) Flank 4) Base 5) Nose 6) Cutting edge.

10. What are purposes of chip breakers?

The chip breakers are used to break the chips into small piece for removal, safety and to
prevent to machine and work.

163
 SQUARE HEAD SHAPING

Ex. No.:

JOB DRAWNG

All dimensions are in mm

Materials Supplied: Mild steel: ø40mmX25mm

Tool Material: High Speed Steel (H.S.S)

164
Ex. No:
Date:

Perform square shape block on the given round work piece by using a shaper as per
the given dimensions
Aim
To machine the given circular block in the shaping machine.
Tools required:
a. Chuck Key
b. Tool post spanner
c. Turning tool
d. Chamfering tool
e. Vernier caliper
f. Drill bit ø10mm
g. Steelrule
Procedure:
1. The given raw material block is measured. The machining allowances are noted.
Then the job is coated with white chalk for marking purpose.

2. The job is position in the marking table. The vernier height gauge is set to the
correct dimensions as per the part drawing dimensions

3. After, the height in mm is corrected in the vernier height gauge; the vernier scriberis
marked in the face sides of the block.

4. To identify the dimensions of the job, the marking lines are punched

5. The work piece is placed in the shaping machine work holding device incorrect
position. Tool is held in the head in suitable position.

6. The stroke length and initial cutting position are corrected by adjusting the ram
and table manually

7. The tool is held in the tool post in vertical position

8. Now, the machine is switched ON. The tool moves over the work, the materials is
removed from the work by the tool cutting force.
165
 9. By giving cross-feed movement to the table, the total length of work is machined, after
completion of one cut, the depth of cut is adjusted in the tool head. Then the next cut is
taken

10. By repeating the above same procedure, the other faces are machined to the required
dimensions

11. After completion of six faces, the work is removed from the vice, cleaned and
inspection is carried out. The job No / Roll No are punched in the face side of the
work.
Result

The given work piece is machined as per the dimension in the shaping
machine.

166
Viva questions:

1. What is shaper?

The shaper is a reciprocating type of machine tool intended to produce flat surface. These
Surfaces may be horizontal, vertical or inclined.
2. Classify the shaper according to the reciprocating of ram.

i. Crank type, ii. Hydraulic type, iii. Geared type.

3. Classify the shaper according to the travel and position of the ram

a. Horizontal type, b. Vertical type, c. Traveling head type.

4. Classify the shaper according to the design of table

a. Standard type, b. Universal type.

5. Classify the shaper according to the type of cutting stroke

a. Push type, b. Draw type

6. List the different types of parts involved in the shaper

a. Base, b. Column, c. Cross rail, d. Saddle, e. Table, f. Ram, h. Tool head.

7. List the parts in tool head.

a. Swivel base, b. Vertical slide, c. Apron, d. Tool post

8. List the parts in apron.

a. Clapper box,

b. Clapper block

c. Tool post

9. What are the different types of mechanism used in shaper?

a. Crank and slotted Mechanism

b. Whit worth mechanism

c. Hydraulic shaper cmechanism

167
 HEXAGONAL HEAD SHAPING

JOB DRAWNG

All dimensions are in mm

Materials Supplied: Mild steel: ø40mmX 20mm

Tool Material: High Speed Steel (H.S.S)

168
Ex. No:
Date:

Perform square shape block on the given round work piece by using a
milling machine as per the given dimensions.

Aim:

To machine a hexagon in the given work piece to the dimensions as shown in the figure using
Milling Machine

Tools Required:
a. Milling Machine,
b. Scriber, Divider,
c. Steel Rule,
d. Chalkpiece,
e. Bevel Protractor.
Procedure:
1. The given work piece is measured for its initial dimensions.

2. With the help of scriber, mark the hexagon dimensions in the workpiece.

3. Fix the work piece in the vice of the Milling machine.

4. After fixing the work piece and the shaping tool, allow the ram to reciprocate.

5. Start the shaping process by giving the required depth by lowering the tool.

6. Slowly increase the depth of cut and repeat the procedure to make the hexagon shape.

7. The work piece is now checked for final dimensions.

Result:

Thus, a hexagon is machined in the given work piece to the dimensions as

shown in the figure using Milling Machine.
169
Viva questions:

1. What is the type of milling machines?

1. Column and knee type milling machine, 2. Manufacturing of fixed table type.

3. Planer type, 4. Special type.

2. What are the special attachments made in the universal milling machine?

1. Dividing head 2. Vertical milling attachments, 3. Rotary attachment

4. Twist drill 5. Reamer

3. What is vertical milling machine?

In vertical milling machine the spindle is mounted vertical or perpendicular to the table.

4. What are the parts used in the column and knee type milling machine?

1. Base 2. Column 3. Knee 4.Table 5.Over hanging arm 6.Front brace7.Arbour

5. Write any four advantages of milting gears?

The advantages of milling gears are:
1. All types of gears i.e. spur, helical, worm, bevel are possible and easy to cut.

2. Both roughening and finishing operations can be easily done and fine surface finish can
be obtained.
3. It is useful for any tooth form

4. Initial cost is low

6. Where is the form of relieved convex involute gear used?

Involute gear cutter is used in forming of gear in milling machine.

7. Give any three differences between gear bobbing and gear

milling? Gear Hobbing:
a) Hob operates on several teeth at a time.

b) It is not necessary to disengage cutter and work before

indexing. Gear Milling:
a) Milling machine can cut only one tooth at a time.

b) It requires cutter and work to get disengaged before indexing can occur.

170
8. What is meant by up-milling (conventional milling),

The feed direction of the cutting tool is opposite to its rotation

9. What is meant by down-milling (climb milling),

The cutting tool is fed with the direction of rotation.

10. Types of milling cutters

1. End mill

2. Roughing end mill

171
 JOINING OF PLATE WITH PIPE

JOB DRAWNG

ALL DIMEMSIONS ARE IN mm

172
Ex. No:
Date :
Joining of given plates and pipes using Gas Metal Arc Welding.
Aim:

Joining of plate with pipe on the given Plate and pipe using arc welding.

Apparatus required:

Work pieces, Welding electrodes, MIG Welding machine, Tongs, Wire brush, chipping
hammer, Gloves and Goggles.

Procedure:

1. The given work pieces are cleaned with the wire brush to remove the rust, scale and other
impurities.

2. Edges are prepared suitably to the given dimension and positioned one over another for the
Plate and pipe joint.

3. Depending upon the thickness of the parent metal, the amperage and correct voltage is
selected.

4. With goggles covering the eyes and gloves on hands, an arc is struck on the work piece
and tacksare made at the extreme ends.

5. Welding process is progressed along the seam at a constant speed and keeping
uniform distance between the electrode and the workpiece.

6. Using chipping hammer the flux in the form of slag is chipped off and then cleaned.

7. After welding, the work pieces should be handles only using the tongs.

Result:

Thus the required Plate and pipe joining is obtained as per the given dimensions.

173
VIVA QUESTIONS AND ANSWERS

1. Which welding process uses non-consumable electrodes?

TIG welding

2. What is gas welding?

Mixture of gases is used to produce high temperature flame.

3. What is filler material?

It is the material added to the weld pool to assist in filling the gap.

4. What is flux?
Flux avoids oxidation in welding flame by giving a cover.

5. What are the advantages of using LPG over acetylene for

cutting? LPG fuel produces rich flame for cutting process.

6. Which equipment is used to supply power for welding?

Welding transformer

7. What is over head welding?

Welding done at the top of welding booth is called overhead welding.

8. What are the applications of welding?

Fabrication of steel windows and rods.

9. What is flux change in welding?

Flux change is done to switch from one type of welding to other.

10. What are the advantages of using electric arc welding? EAW can
be done without the use of oxygen cylinder.

174
 ASEMPLY OF PIPES

JOB DRAWNG

175
Ex. No:
Date:
Fabrication of simple structural shapes (Assembly of pipes) using Gas Metal
Arc Welding
Aim:

To make a pipe assembly on the given work pieces using arc welding.

Apparatus required:

Work pieces, Welding electrodes, MIG Welding machine, Tongs, Wire brush, chipping
hammer, Gloves and Goggles.

Procedure:

1. The given work pieces are cleaned with the wire brush to remove the rust, scale and
otherimpurities.

2. Edges are prepared suitably to the given dimension and positioned at right angles for the tee
joint.

3. Depending upon the thickness of the parent metal, the amperage and correct voltage
isselected.

4. With goggles covering the eyes and gloves on hands, an arc is struck on the work piece
and tacks are made at the extreme ends.

5. Welding process is progressed along the seam at a constant speed and keeping
uniform distance between the electrode and the workpiece.

6. Using chipping hammer the flux in the form of slag is chipped off and then cleaned.

7. After welding, the work pieces should be handles only using the tongs.

Result:

Thus the required pipe assembly is obtained as per the given dimensions using arc welding.

176
VIVA QUESTIONS AND ANSWERS

1. What is arc welding?

Electric arc is produced between carbon electrode and work piece to produce heat.

2. What is electrode?
Filler rods used in arc welding are called electrodes.

3. Name the materials used for coating on electrodes.

Copper, Carbon and Graphite.

4. What are the types of resistance welding?

Spot welding, Projection welding and Butt welding.

5. What are the welding defects?

Undercut, Cracking and Incomplete penetration.

6. What is coating done on electrode surface? Coating is done to avoid melting of electrode

7. What is butt joint?

Work pieces are welded to either sides.

8. What is lap joint?

Work pieces are welded one over other.

9. What is T-joint?
Work pieces are welded at perpendicular to each other.

10. What is corner joint?

Work pieces are welded at the corners.
177
Ex. No:
Date:
Preparation of green sand moulds

Aim

1. To prepare a pattern for given object for lost form casting.

2. To prepare a molasses sand mold from the prepared pattern.
3. To melt and pour iron metal into the mold.

Equipment and Materials

Pattern, core box, molding flasks, molding tools, sand muller, riddle, sand, molasses, bentonite,
core baking oven, thermocole, melting furnace, fluxes, pouring ladle, pyrometer, hacksaw, file.

Procedure
Core making
(i) Prepare the core sand
(ii) Assemble (clamp) the core-box after applying some parting sand
(iii) Fill the core box cavity with core sand and ram it
(iv) Make vent holes or insert reinforcing wire as desired
(v) Tap the mold box on all sides to loosen the core from the box, unclamp the core box
and carefully transfer the core on to a baking plate or stand.

Mold Making

(i) Place the drag part of the pattern with parting surface down on ground or
molding board at the center of the drag(flask).
(ii) Riddle molding sand to a depth of about 2 cm in the drag and pack this
sand carefully around the pattern with fingers.
(iii) Heap more molding sand in the drag and ram with rammer carefully.
(iv) Strike off the excess sand using strike bar.
(v) Make vent holes to within 1 cm of the pattern surface in the drag.

178
 (vi) Turn this complete drag and place the cope portion (flask) over it.
(vii) Place the cope half of the pattern over the drag pattern matching the guide pins and
apply parting sand over the parting surface. Also place the sprue pin and riser pin in proper
positions.
(viii) Complete the cope half by repeating steps (ii) to(v).
(ix) Remove the sprue and riser pins and make a pouring basin. Separate the cope and
drag halves, and place them with their parting faces up.
(x) Moisten sand at the copes of the pattern and remove pattern halves carefully
using draw spikes.
(xi) Cut gate and runner in the drag. Repair and clean the cavities in the two mold
halves.
(xii) Place the core in position, assembled the two mold halves assemble and clamp
them together.

179
Melting and Pouring

(i) Melt the metal in the furnace. Use appropriate fluxes at proper stages and measure metal
temperature from time to time.
(ii) Pour the molten metal into the pouring ladle at a higher temperature (say 100oC higher)
than the pouring temperature. As soon as the desired pouring temperature is reached, pour the liquid
metal into the mold in a steady stream with ladle close to the pouring basin of the mold. Do not allow
any dross or slag to goin.
(iii) Allow sufficient time for the metal to solidify in the mold. Break the mold carefully
and remove the casting.
(iv) Cut-off the riser and gating system from the casting and clean it for any sand etc.
(v) Inspect the casting visually and record any surface and dimensional defects observed.

180
 FUNNEL MAKING

JOB DRAWNG

181
Ex. No :

Date:
Manufacturing of Funnel in the sheet metal using shearing and bending operations.

Aim: To make a funnel of the given sheet with specified dimensions.

Tools required:
1.Sheetmetal 2. Anvil 3. Try square 4. Steelrule

5. Divider 6. Snip 7. Scriber

8. Mallet 9. File 10. Hand shearingmachine

11. Protractoretc.
Materials required:
Tin or mild steel of suitable size.

Procedure:
1. Development of cone for the given dimensions is drawn on the provided sheet metal using
protractor and scriber. (Sector of radius equal to the slant length of the cone and arc length
equal to the circumference of the cone)

2. Assume, joining allowance of 10 to 15mm on either side of the development.

3. The sheet metal is exactly cut as per the markings made on it using a straight shear / snip. The
burrs are removed using a file.

4. Then the edges are bent for a length of joining allowance. This is done with the help of a
mallet and an appropriate stake /anvil.

5. The sheet metal is then formed to the conical shape using a cylindrical stake / anvil and a
mallet as shown in fig.

6. Now the bent edges are made to overlap each other and are struck with a mallet to get the
requiredjoint.
182
Result:

Thus the cone of given dimension is fabricated with the given sheet metal.

VIVA QUESTIONS AND ANSWERS

1. What is sheet metal work?

Sheet metal work is used for making, Cutting and bending of sheet metals to desired shape.
2. Which are the materials used for sheet metals?
a. Galvanized iron (ii) Stainless steel (iii) Copper (iv)Aluminium
3. Name the sheet metal hand tools.
a. Steel rule (ii) Vernier calliper (iii) Micrometer (iv) Scriber (v) Divider (vi) hammer(viii)
mallet(ix) Shears
4. What is G.I.?
G.I. stands for galvanized iron
5. What is shearing?
Shearing means sheet metal cutting

6. What is the name of vice used in fitting shop?

Bench vice
7. Name the different files?
(i)Flat file (ii) Square file (iii) Round file (iv) Triangular file (v) Half round file
8. What are the metals that can be used for sheet metal work?
Aluminium, Brass, Copper and steel.
9. What are the cutting tools?
Straight snip and Curved snip
10. What is Curved snip?
Curved blades are used for making circular cuts.

183
METAL SPINNING

184
Ex. No:

Date :
Manufacturing of sheet metal components using metal spinning.
Aim:
To produce the component in sheet metal as per the required shape and dimensions.

Apparatus Required:

Metal Spinning lathe, Sheet metal blank, Mandrel, follower, Spinning tool.

Procedure:
1. The blank is clamped between spinning mandrel and a follower on the tailstockspindle.
2. The mandrel, blank, and follower are then set in rotation at controlledspeeds.
3. Spinning tools or spinning rollers are forced against the rotating blank either by hand
or byauxiliary power orboth.
4. Employing a series of axial and radial (swivel) strokes, the blank is spun onto the
mandrelcausing the metal to flow to the shape of the desiredpart.

Result:
Thus the component of the required shape is made by metal spinning process.

185
Calculation:
Feed in mm/rev = Feed per tooth (ft) X Number of cutter teeth(n)

Feed per min (table feed) = F = feed per rev x cutter speed in RPM(V) = ftX n X V

186
Ex.No:
Date:
Perform contour milling operation on the given work piece using
vertical milling machine.

Aim: To perform the contour milling on given work piece using vertical milling machine
Apparatus Required:
Vertical Milling machine
HSS – M8 end mill cutter
Materials Required:
Aluminium work piece– 100mmX100mmX10mm
Procedure:
Hold the work piece in the Arbor which holds it perfectly for machining
Switch the spindle on and required RPM of rotation is set for the milling cutter
The average cutting speed can be taken from the table listed as follows
Material of Brass Cast Bronze Mild High Hard Aluminium
Carbon Alloy
W/p Iron Steel
steel Steel
Cutting 45-60 21-30 24-45 21-30 15-18 9-18 150-300
speed
m/min

Depth of cutcanbe 3mm to 8mm for roughing operation and 0.5mm to1.5 mmfor finishing
operation
After setting the depth of cut,machining is carried out on the workpiece with the specified cutting
parameters
The required contour profile is produced on the work piece

Result:Hence the required contour profile is produced on the workpiece using vertical milling
machine

187
Viva Question

1. What is Crank and slotted Mechanism?

The rotary motion of the bull gear is transmitted in to reciprocating motion of the ram through
the rocker arm.

2. What are the different types of adjustment made in the Crank and slotted Mechanism?
a. Adjusting the length of stroke.
b. Adjusting the position of the stroke.

3. What is the use of shaper dog in hydraulic shaper mechanism?

It is used to change the position of the flow to facilitate the reciprocating motion.

4. What are the advantages of hydraulic shaper mechanism?

a. The cutting and return speed are partially constant through out the stroke.
b. Infinite number of cutting may be obtained from zero to maximumvalue and control
easier.

5. What are the work holding devices used in shaper.

1. Clamping the vise
2. Clamping on the table
3. Clamped to the angular plate.

6. What are the devices used to hold the work in to the table?
a. T bolt and clamps
b. Stop pins
c. Strip and stop pins

7. What are the different operations performed by using shaper?

1. Horizontal surface
2. Vertical surface
3. Angular surface

188
 4. Cutting slot and key ways
5. Irregular surface

8. What is planer?
The planer like a shaper is a machine tool primarily intended to produce plane and flat
surfaces by a single point cutting tools. it is used to machining a large work piece which
cannot accommodate by shaper table.

9. What is the difference between shaper and planer?

The fundamental difference between shaper and planer is that in a planer the work
which is supported on the table reciprocate and the cross wise and perpendicular
movement of the tool but shaper the tool reciprocate cross wise and vertical movement
of the table.

10. What are the types of planer?

Double housing planer
Open side planer
Pit planer
Edge or plate planer

189
 Calculation:
Blank Diameter ( D)= (Z+2) * MODULE

Module of the cutter (m) =_______mm


Number of Teeth (Z) =_______mm


Indexing Calculation:

Indexing = 40 / Z

190
Ex.No:
Date:
Carry out Spur gear cutting on the given work piece using milling machine
Aim:To produce a spurgear out ofthe given work piece using milling machine

Apparatus Required:
Horizontal Milling machine
M10 – End Mill Cutter (HSS )
Gear tooth Vernier

Materials Required:
Cast Iron Work piece – 55mmdiameter, 20mmthickness
Procedure:

The gear blank is held between the dividing head and tailstock using a mandrel.
The cutter is mounted on the arbor and the cutter is centred accurately with the gear blank
 Set the speed and feed for machining. For givingdepth of cut, the tableisraisedtillthe
periphery of the gear blank just touches the cutter
 The Micrometre dial of vertical feed screw is set to zero at this position. Then the table is
raised further to give the required depth of cut

The machine is started and feed is given to the table to cut the first groove of the blank.
After the cut, the table is brought back to the starting position. Then the gear blank is
indexed for the next tooth space
This is continued till all the teeth are cut
Dimensions of the gear teeth profile are checked using the gear tooth Vernier

Result:Thus a spur gear is made from the given work piece using milling machine

191
Viva Question
1. State the principle involved in gear shaping?
The principle involved in gear shaping is that an involute gear will roll with any other involute gear of
the same base pitch

2. What are the various methods of shaping the gear blank?

There are two methods involved in shaping the gear blank. They are:
1) Shaping with single point tool formed to the tooth space of the gear.
2) Generating with pinion type cutter.

3) What do you understand by gear generating?

Gear generating process is based on the fact that any two motives gear of the some module will mesh
exactly. In this process one of the gears act as cutter. Due to relative rolling motion of the cutter and
blank, gear teeth are generated.

4) Distinguish between the forming and generating methods?

Single point Tool (Forming): Here the tool is a single point tool. The job should be indexed for every
tooth; The tool is fixed.
Pinion type cutter (Generating): Here the tool is also a gear made of hard steels, (Used as cutter). The
job is not indexed for every tooth. The cutter as well as the blank rotates simultaneously meshing
with each other.

5) What are the factors affecting geometrical accuracy of the circular component . in shape?
Geometrical accuracy of the circular component depends upon: a) The trueness of the work piece
rotation, b) Parallelism of the tool movement with the work spindle axis, c) The effect of the tool
wear.

6) Write the advantages of gear shaping (Generating)?

The advantages of Gear shaping are: a) with a particular module of DP cutter, gears having the same
module of DP but different number of teeth can be cut accurately, b) Quicker and economical, c)
Only one cutter is used for cutting all spur gears of same pitch, d) Both internal and external gears
can be cut.

192
7) What is the main disadvantage of gear shaping?
The main disadvantage of gear shaping is that Worm and worm wheels cannot be generated on a gear
shaper.

8) When do you prefer shaping process for generating a gear?

Gear shaping is preferred for operations like cutting gear segments, cutting, spur gear, herring-bone
gears, splines and sprockets etc., of gear shaping over other diameter.

9) What are the advantages of gear shaping over the other methods?
The advantages are:
a) The finished gear has a generated profile
b) It is suitable for cutting internal gears
c) Only one cutter is used for cutting all spur gears of the same pitch.
10.What are the specific types of gears that could be formed specifically by gear shaping process?
Shaping process can operate on classes of gearing outside the capacity of other methods. Example
are: a) Internal gears with or without back shroud, b) Cluster gears.

193
 Calculation:

Blank Diameter ( D)= (Z+2) * MODULE

Module of the cutter (m) =_______mm


Number of Teeth (Z) =_______mm


Indexing Calculation:

Indexing = 40 / Z

194
Ex.No:
Date:

Carry out helical gear cutting on the given work piece using milling machine
Aim: To cut a helical gear out of the given blank in milling machine

Apparatus Required:
Horizontal Milling machine
M10 – End Milling cutter

Materials Required:Cast Iron Blank – 65mm diameter and 20mm thickness

Procedure:
The M10 milling cutter is set on the mandrel
The table isswivelled to an inclination ofα ( Helix Angle ) with the axis of work piece
 The required gear ratio is set between the work table and the mandrel holding the work
piece so that movement of the work table rotates the work piece through the proper helix
angle progressively
 The spindle is switched on and the required depth of cut is set before the tool cuts the work
piece.
Single teeth cavity is cut through the work piece.
After Indexing the next tooth is cut in similar fashion and so on
The gear tooth dimensions are checked using a gear tooth vernier

Result: Thus a helical gear is cut out of the given blank using horizontal milling machine

195
Viva Question

1. Distinguish between gear shaping and gear planning?

Gear shaping:
a) The job is indexed and tool reciprocates
b) Gear can be generated by using form tool as well as pinion cutter.
Gear planning:
a) Job is indexed and reciprocated but the tool is fixed.
b) Gear can be produced by means of form tool and Rack cutters.

2. What is the basic condition to use 'Bobbing' in geers?

Hobbing can be done only if the gear blank to be generated are of the same modules

3. Write the formula for calculating index change gears in gear bobbing?
For Index change gear:
Driving Teeth - Indexing constant x Number of teeth of hob Driven Teeth Number of teeth to be cut.

4. Name the different types of bobbing?

Different types of bobbing arc classified under the direction of feed of hob are:
a) Axial hobbing b) Radial hobbing c) Tangential nobbing.

5. Explain axial hobbing process?

a) Gear blank is brought towards the hob for required depth. Table slide is then clamped.

6. What are the advantages of gear hobbing?

The advantages of gear hobbing are:
a) The method is versatile and can generate spur, helical, worm and worm wheels.
b) It is rapid, economical and highly productive.

7. Give any three differences between gear hobbing and gear milling?
Gear Hobbing:
a) Hob operates on several teeth at a time.
b) It is not necessary to disengage cutter and work before indexing.
196
c) Gear hobbing is faster process than gear milling.
Gear Milling:
a) Milling machine can cut only one tooth at a time.
b) It requires cutter and work to get disengaged before indexing can occur.
c) It is slower process compared to gear hobbing process.

8. What is Sawing?
Sawing is one of basic machining process, it removes a very small amount of material which
consumes less power and at same time cuts large sections

9. Classify Sawing machines.

i) Hack saw manual Power i) Band Saw a) Vertical b) Horizontal c) Circular saw

10. Define Kerf?

The tooth set makes the saw cut termed as kerf.

197
 Calculation:
Blank Diameter ( D)= (Z+2) * MODULE

Module of the cutter (m) =_______mm


Number of Teeth (Z) =_______mm


198
Ex.No:
Date:
Perform the gear generation operation in the given cast iron blank as per the
given dimension using gear hobbing machine.

Aim: To machine a Spur Gear using a gear Hobbing machine

Materials Required: Cast Iron Blank

Tools Required:

Gear Hobbing machine

Hob
Gear Tooth Vernier
Spanners

Procedure:
The given work piece is held firmly on the spindle of the gear Hobbing machine
 The Hob is set at an angle equal to its helix angle, with the axis of the blank for cutting spur
gear
 Gear ratio is set at a desired value to achieve the required speed of the hob and the work
piece
 The machine is switched on. The work piece and the hob are allowed to rotate, at the desired
speed
The hob or the work piece is given full depth of cut equal to the tooth depth
The cutter is given feed for full width of the work piece
After machining all the teeth the machine is switched off
The dimensions of the teeth are checked using a gear tooth Vernier

Result: Thus the given blank ( workpiece ) is converted into a gear of required dimensions by
gear generation operation in a gear Hobbingmachine
199
Viva Question

1. What is honing?
Honing is a machining process similar to grinding, used to finish a fine before surface.

2. How does honing differ from grinding?

Grinding machines run at high speeds and pressure, which results in high temperatures. But, Honing
requires slow speed and low-Pressure, which keeps surface temperature relatively low.

3. What are the materials normally be worked by the Honing process?

Steels of all varieties, Cast iron, aluminum, magnesium, brass, bronze, glass, ceramics, hard rubbers,
graphite etc., are few examples honing.

4. Give the product applications of lapping?

Lapping is done as precision tools, gauges, valves and on othersimilar places, where resistance to wear
of moving parts, better sealing characteristics and longer life of cutting edges are preminent factors.

5. What is meant by polishing?

Polishing is the surface finishing operation performed by a polishing wheel, for the purpose of
removing appreciable metal to take out scratches, hole marks, pits and other defects from rough
surfaces.

6. How is the polishing wheel made?

Polishing wheel is made of leather, papers, canvas, wool, the-abrasive grains are set up with the glue
or thermosetting, buffing resins on the face of the wheel.

7. What is meant by Buffing?

Buffing is used to give a much higher, lustrous, reflective finish, that cannot be obtained by polishing.
The buffing process consists of applying a very fine abrasive with a rotating wheel.

8. What are the abrasives and binders used in binding?

Iron oxide, chromium oxide, emery, wax mixed with grease, paraffin's and kerosene are the abrasives
and binders used in buffing.

200
9. Write any four advantages of milting gears?
The advantages of milling gears are:
1. All types of gears i.e. spur, helical, worm, bevel are possible and easy to cut.
2. Both roughening and finishing operations can be easily done and fine surface finish can be
obtained.
3. It is useful for any tooth form
4. Initial cost is low

10. Where is the form of relieved convex involute gear used?

Involute gear cutter is used in forming of gear in milling machin

201
 Calculation:

Blank Diameter ( D)= (Z+2) * MODULE

Module of the cutter (m) =_______mm


Number of Teeth (Z) =_______mm


115
Ex. No:
Date:
Perform the gear generation operation in the given cast iron blank as per the
given dimension using gear shaping machine

Aim: To machine the given gear blank into a spur gear in gear shaper machine

Apparatus Required:

Gear Shaper Machine

Shaper cutter

Material required:

Cast iron blank

Procedure:

The given gear blank is mounted on the work piece spindle

 The shaper cutter having the necessary cutting teeth in the shape if tooth spacing of the
required work piece is mounted on the cutter spindle

 Necessary gear ratio is set between the work piece spindle and the cutter spindle for the
purpose of indexing

 Machine is switched on and shaping process of the tooth spacing of the gear profile is done
with the shaper cutter, in two to four passes per teeth. This feed motion is given during the
return stroke

 With the indexing done through a gear train, the cutter gradually rotates and the work piece
rotates in accordance with the cutter, as if they are two gears in mesh

 With one complete revolution of the work piece on its spindle the gear shaping process will
be complete

The dimensions of the gear teeth are checked using a gear tooth vernier

Result: Thus the required spur gear is cut from the given blank by gear shaping process
.

116
Viva Question

1) What do you understand by gear generating?

Gear generating process is based on the fact that any two motives gear of the some module will
mesh exactly. In this process one of the gears act as cutter. Due to relative rolling motion of the
cutter and blank, gear teeth are generated.

2) Distinguish between the forming and generating methods?

Single point Tool (Forming): Here the tool is a single point tool. The job should be indexed for
every tooth; The tool is fixed.
Pinion type cutter (Generating): Here the tool is also a gear made of hard steels, (Used as cutter).
The job is not indexed for every tooth. The cutter as well as the blank rotates simultaneously
meshing with each other.

3) What are the factors affecting geometrical accuracy of the circular component . in
shape? Geometrical accuracy of the circular component depends upon: a) The trueness of the work
piece rotation, b) Parallelism of the tool movement with the work spindle axis, c) The effect of the
tool wear.

4) Write the advantages of gear shaping (Generating)?

The advantages of Gear shaping are: a) with a particular module of DP cutter, gears having the
same module of DP but different number of teeth can be cut accurately, b) Quicker and
economical, c) Only one cutter is used for cutting all spur gears of same pitch, d) Both internal and
external gears can be cut.

5) What is the main disadvantage of gear shaping?

The main disadvantage of gear shaping is that Worm and worm wheels cannot be generated on a
gear shaper.

6) When do you prefer shaping process for generating a gear?

Gear shaping is preferred for operations like cutting gear segments, cutting, spur gear, herring-
bone gears, splines and sprockets etc., of gear shaping over other diameter.

7) What are the advantages of gear shaping over the other methods?
117
The advantages are:
d) The finished gear has a generated profile
e) It is suitable for cutting internal gears
f) Only one cutter is used for cutting all spur gears of the same pitch.

8What are the specific types of gears that could be formed specifically by gear shaping process?
Shaping process can operate on classes of gearing outside the capacity of other methods. Example
are: a) Internal gears with or without back shroud, b) Cluster gears.
9State the principle involved in gear shaping?
The principle involved in gear shaping is that an involute gear will roll with any other involute
gear of the same base pitch

10.What are the various methods of shaping the gear blank?

There are two methods involved in shaping the gear blank. They are:
Shaping with single point tool formed to the tooth space of the gear.
Generating with pinion type cutter

118
PLAIN SURFACE GRINDING

125
Ex. No:
Date:
Perform grinding operation on the given work piece using surface grinding
machine.

Aim: To perform plain surface grinding on the given work piece to the required dimensions
Apparatus required:
Grinding machine
Grinding Wheel
VernierCalliper
MaterialRequired:
MS / CI plate 12mm X 50mmX 75mm
Procedure:
First the work piece is placed on the magnetic chuck
 The positioning of the work piece is aligned at right angles to the grinding wheel and
exactly parallel to the sides of the magnetic chuck by using slip gauges if necessary
 The magnetic chuck is switched on and the powerful electromagnet holds the job firmly in
position

 Now the spindle is turned on and the grinding wheel is just touched the work piece surface
to mark its zero / reference position

 Now the required feed, either totally or in steps, is given to the grinding wheel and the
wheel is traversed all over the work piece
Same procedure is repeated until the required dimensions are achieved
Care should be taken for maintaining the surface finish
Finally the dimensions are checked using either a Verniercalliper or a screw gauge

Result: Thus plain surface grinding is performed on the given work piece up to the required
dimensions

126
Viva Question

l.What is meant by Grinding?

Grinding is a metal removal process or operation performed by means of rotating abrasive wheel that
acts as a cutting tool against the work piece.

2.Why is grinding called finishing process?

Grinding is called finishing process, because the grinding process removes metal usually in the order
of 0.25 to 0.50 mm. Which produces very high quality surface finish.

3.What is the approximate thickness of metal removed in grinding operation ?

The approximate thickness of metal removed in grinding operation is 0.01 to 0.03 mm.

4.What are the main types of grinding?

The two main types of grinding are:
a) Rough or Non-precision grinding
b) Precision grinding.

5.What are the different types of rough grinders?

a) Floor stand and bench type grinders b) Portable and flexible shaft grinders c) Swing frame grinders
d) Abrasive belt grinders.

6.What are the types of precision grinders?

a) Cylindrical grinders b) Internal grinders c) Surface grinders d) Tool and cutter grinders e)
Special grinding machines

7.What is surface grinding?

Surface grinding is the process of producing and finishing flat surfaces by means of a grinding
machine using a revolving abrasive wheel.

8.What are the types of surface grindings?

The different types of surface grindings ate:
1. Reciprocating table surface grindings a. Horizontal type b. Vertical type.
127
2. Rotating table.
a. Horizontal spindle b. Vertical spindle.

9. What types of work can be ground by a surface grinder?

Surface grinder can be used for flat surface, irregular surface, curved surface, tapered surface, convex
surface and concave surface.

10. What are the types of internal grinders?

The different types of internal grinders
are: 1. Chucking grinders
a) Plain
b) Universal
2. Planetary grinders 3. Centreless grinders

128
 CYLINDRICAL

GRINDING

Cylindrical grinding Process Schematic:

129
Ex.No:

Date:
Perform grinding operation on the given work piece using cylindrical
Grinding machine

Aim: To grind the cylindrical surface of the given work piece by cylindrical grinding
Apparatus Required:
Grinding machine
Cylindrical grinding wheel setup
Steel Rule
VernierCalliper
Materials Required:
Cast iron work piece
Procedure:
 First the given work piece is preliminarily finished to the pre-required dimensions on a lathe
before beginning the grinding process
Now the work piece is fitted in the chuck of the cylindrical grinding machine
The grinding wheel is just touched with the workpiece and is taken as the zero reference
Coolant circulation is switched on and the grinding wheel is engaged with the work piece
 Both the work piece and the grinding wheel roll on contact with each other like two gears in
mesh
 Now slowly the wheel is moved over the entire length of the work piece to get the grinded
finish
 After one feed is over, the grinding wheel is moved further towards the axis of the work
piece and the process is repeated until the required dimensions are achieved
Finally the dimensions are checked using a Verniercalliper

Result:Thus cylindrical grinding is performed on the given work piece to the given dimensions
130
 Viva Question

1. What is the use of internal grinders?

Internal grinders are used to finish straight, tapered, or formed holes to correct size, shape and
finishing.

2. What are the different types of external

grinders? External grinders are divided into a)
Plain cylindrical grinders
b) Universal grinders
c) Special grinders such as the centre less grinders.

3. What are the uses of external grinders?

External grinders are used for grinding cylindrical surfaces and to produce external cams eccentrics
and special form on the outside diameter of the work.

4. List out the surfaces ground by the plain cylindrical grinder?

External cylinders, tapers, fillets, undercuts and shoulders are
some a) The head stock spindle may be used alive or dead.
b) The headstock can be swiveled at an angle in horizontal plane.
c) The wheel head and slide can be swiveled and traversed at any angle.

5. Explain briefly; the meaning of centre less grinding?

Grinding the diameter of the work piece without mounting on centres is known as centre less
grinding.

6. What are the operations done in centre less grinders?

The various operations are:
a) Through feed grinding b) In feed grinding c) End feed grinding

7. What are the main disadvantages in centre less grinding?

The main disadvantages are:
a) The hollow work cannot be grinded
131
b) The work having multiple diameters is not easily handled.

8. How does the centre less grinding operate ?

The centre less grinding operates with two wheels as the cutting or grinding wheel, to remove
excess stock and a regulating wheel is used to control the speed of rotation of work and rate of
feed.

9. Why is the centre less grinders called specialized machine for Cylindrical parts?
Centre less grinders are called specialized machine for cylindrical parts because it was developed
form the rapid production of cylindrical, external taper, or external profile work.

10. What are the advantages of centre less grinding? The advantages of centre less grinding are:
a) The work piece is suppressed through the operations.
b) No tendency for chatter or deflection of work
c) Easy control of the size of the work
d) No need of chucking or mounting.

132
 LATHE CUTTING FORCE MEASUREMENT

Forces involved in turningprocess

Atypical dynamometer sensing unit setup around carbide tipped cutting tool

Principal Forces Measurement Tabulation:

S.No Depthofcut(mm) Speed(RPM) FCKgF FTKgF

1 0.2mm

2 0.5mm

3 0.8mm

133
Ex.No:

Date:
Measurement of cutting forces using lathe tool dynamometer

Aim: To measure the principal forces in orthogonal machining by lathe tool dynamometer
Apparatus Requires:
Centre lathe
Cutting tool with carbide tip insert
Lathe tool Dynamometer
(i)Sensing Unit (ii) Force Indicator Unit (iii) Connecting wires
Material Required:
 MS / CI work piece for which the principal cutting forces of machining are to be
measured
Procedure:
 The tool on which the dynamometer is to be mounted is first fixed on the tool post of
the lathe

 Next the dynamometer is inserted via the cutting edge and is pushed and made square
with the tool post, resting suspended on the tool itself through the slot on the
dynamometer

 Now the dynamometer setup is tightened so that any further movement / deflection
of the tool body will activate the strain gauges and will give output
 Now the sensing unit of the dynamometer is connected to the force indicator unit
with the help of the connecting wires
 First the lathe is switched on and the carbide tip of the tool is just made to touch the
work piece surface very gently and the force indicator setup is calibrated to read zero

 Now the machining is carried out and the corresponding values of the principal
forces cutting force (FC)and Thrust force (FT)are noted down
 The same experiment is repeated for various depth of cuts and cutting speeds and
the values of the corresponding principal forces are tabulated

Result: Thus the principal forces FC and FT turning in lathe are measured using a
dynamometer and the results are tabulated
134
Viva Question
1. When will the negative rake angles be used?
a. To machine high strength alloys. b. The machine tools are more rigid. c. The feed rates
are high. d. To give heavy and interrupted cuts.

2. Classify the types of metal cutting process?

The metal cutting processes are mainly classified into two types.
a. Orthogonal cutting process (two dimensional cutting), b. Oblique cutting process (Three
dimensional cutting).

3. Define orthogonal and oblique cutting?

Orthogonal cutting :- The cutting edge of tool is perpendicular to the work piece axis.
Oblique cutting :- The cutting edge is inclined at an acute angle with normal to the cutting
velocity vector is called oblique cutting process.

4. What is shear plane?

The material of work piece is stressed beyond its yield point under the compressive force. This
causes the material to deform plastically and shear off. The plastic flow takes place in a localized
region is called shear plane.

5. What is cutting force?

The sheared material begins to flow along the cutting tool face in the form of small pieces. The
compressive force applied to form the chip is called cutting force.

6. When will the continuous chip deformed?

The following factor favours the formation of continuous chip.
(i) Ductile material (ii) Smaller depth of cut (iii) High cutting speed (iv) Large rake angle (v)
Sharp cutting edge (vi) Proper cutting fluid, (vii) Low friction between tool face and chips.

7. What are the favourable factors for discontinuous chip formation?

a. Machining of brittle material b. Small rake angle c. Higher depth of cut d. Low cutting
speeds e.

135
Excess cutting fluid. f. Cutting ductile material with low speed and small rake angle of the
tool.

8.What are the favorable factors for continuous chip with built up
edge? a. Low cutting speed.
b. Small rake angle. Coarse feed.
d .Strong adhesion between chip and
tool face.
e. Insufficient cutting fluid.

9.What is chip reduction co-efficient?

The reciprocal of chip thickness ratio is called chip reduction co-efficient.

10. What are purposes of chip breakers?

The chip breakers are used to break the chips into small pieces for removal, safety and to prevent
to machine and work.

136
 MILLING TOOL MEASUREMENT

Milling force measurement – strain gauge octagonal ring setup

Cutting force measurement Tabulation:
Speed
S.No Depthofcut(mm) (RPM) FXKgF FYKgF FZKgF

1 0.2mm

2 0.5mm

3 0.8mm

137
Ex. No:
Date:
Measurement of cutting forces using Milling tool dynamometer

Aim: To measure the cutting forces in milling process using a side milling cutter
Apparatus Required:
i) Horizontal milling machine ii) Side Milling cutter iii) Milling dynamometer
Material Required:
MS or CI work piece of required dimensions
Procedure:
 The principal difference between the lathe tool dynamometer and the milling
dynamometer is that, in a lathe the tool is stationary whereas in the milling machine
the tool is rotating cutter

 Hence here the dynamometer sensing unit cannot be fixed to the tool but could be
fixed to the work piece that is stationary

 Work piece is kept on a plat form which is mounted over four octagonal rings as
shown in figure

 The octagonal ring is mounted with a strain gauge for measuring transverse force
and one for measuring radial force.

 In total the setup has four octagonal rings place in strategic positions as shown in the
figure. Hence in total there are four strain gauges measuring transverse force and
four for measuring radial force
 As the milling process proceeds, forces in all the three directions are measures by
summing up the data from all the strain gauges and taking average

The results are displayed in the force indicator unit of the dynamometer
The experiment is repeated for various feeds, cutting speeds and depth of cuts
The cutting forces in all three directions are tabulated

Result: Thus the cutting forces involved in milling operation have been measured using a
dynamometer

138
 Single point cutting tool Nomenclature

Single point cutting tool angles

Grinding Angles To be followed:

Back Rake Side Rake End cutting Side cutting End Clearance Side Clearance
angle Angle edge angle edge angle angle Angle

8° 10° 15° 15° 5° 5°

139
Ex. No:
Date:
Grinding a single point cutting tool on the given material using tool
and Cutter Grinder.

Aim: To perform grinding operation on the given HSS tool bit to make it into a single
point cutting tool
Apparatus Required:
Universal two axis vice
Tool grinding machine, with alumina wheel
Tool maker’s microscope
Material Required:
HSS tool bit
Procedure:
The given tool mounted on the vice and the jaws of the vice are tightened
 The horizontal axis nut is loosened and the required angle is set on the vice with
respect to the end cutting edge angle and the end cutting edge is ground first

 Similarly the side cutting edge inclination is set on the vice and the side cutting edge
is ground
 Now the vertical axis nut of the vice is loosened and the back rake angle is set on the
vice, the back rake angle is ground
 Now the vice is loosened and the tool is removed from the vice and is fixed in a
different position, with the cutting edge pointing upwards, perpendicular to the
previous position

Now similarly end clearance, side clearance and side rake angle are ground
Thus a single point cutting tool is made out of the given HSS blank

Result: Thus single point cutting tool has be ground out of the given HSS blank using tool
grinder and universal 2 axis vic

140
CENTERLESS

141
Ex.No:

Date:
Perform grinding operation on the given work piece using Centreless
Grinding machine.

Aim: To grind the cylindrical surface of the given work piece by centerless
grinding

Apparatus Required:

centerless Grinding machine

Cylindrical grinding wheel setup

Steel Rule

VernierCalliper

Materials Required:MS work piece

Procedure:

 First the given work piece is preliminarily finished to the pre-required dimensions on a lathe
before beginning the grinding process
Now the work piece is fitted in the centerless grinding machine
The grinding wheel is just touched with the workpiece and is taken as the zero reference

Coolant circulation is switched on and the grinding wheel is engaged with the work piece

 Both the work piece and the grinding wheel roll on contact with each other like two gears in
mesh
 Now slowly the wheel is moved over the entire length of the work piece to get the grinded
finish
 After one feed is over, the grinding wheel is moved further towards the axis of the work
piece and the process is repeated until the required dimensions are achieved

142
 Finally the dimensions are checked using a Verniercalliper

Result:Thuscenterless grinding is performed on the given work piece to the given dimensions
Viva Question

1. What are the types of wheel that are mounted on way grinders?
Cup, Ring or segmented wheels are the wheels that are mounted on vertical spindle of a way grinders.

2. What are the work holding and supporting devices used in grinders ?
Work holding and supporting devices include:
a) Steady rest for cylindrical grinders.
b) Chucks and fixtures for other grinders,
c) Magnetic chucks used particularly on surface grinders.

3. What are the two types of magnetic chucks?

a) Electromagnetic chuck b) Permanent magnetic chuck.

4What is the use of magnetic chuck in surface grinding?

The magnetic chuck helps in firmly holding the workplace without any distortion due to pressure of the
jaws, which is undesirable. Magnetic chuck is used for holding a very thin work piece, made of
magnetic material. Moreover more number of similar work piece can be conveniently located on the
surface for simultaneous grinding.

5. How are the non-ferrous metals held in magnetic chuck?

Non-ferrous metals may be held on a magnetic chuck by clamping them in suitable fixtures made of
iron or steel by exhausting air from a vaccum chuck.

6. What are the attachments used in grinding machines?

The different attachments are:
a) Equipments for contour grinding
b) Attachments to improve grinding results
c) Measuring and sizing device
143
7. What is meant by measuring and sizing devices?
The measuring and sizing devices range from simple measuring devices to continuous reading gauge,
which actually control the feeding of the machine.

8. What are the attachments used to improve grinding results?

The attachments include wheel reciprocating attachments for better finish, ultrasonic cleaning devices
and electrolytic attachments to aid in grinding extremely hard materials.

9. What is meant by dressing of grinding wheels?

Dressing of the grinding wheels refer to conditioning the face of the wheel for the operations to be
performed ,like opening the face for free cutting, smoothing the face for finishing and removing and
load from the free face.

10. What are the different types of fine finishing process?

Milling, super finishing, polishing, buffing, metal spraying,galvanising and electroplating are the fine
finishing process.

144
NC PART PROGRAM FOR FACING TURNING A ND CHAMFERING

145
 Ex.No:

Date:
NC part programming for facing, Turning and chamfering(turning).

AIM:

To write a program and simulate the tool path for the operation involved in the component as given
in the figure using FANUC turning software.

SOFTWAREUSED:

FANUC Turning simulator

PROGRAMCODE:

CODE
CODE EXPLANATION
DESCRIPTION
[BILLET X60Z150 Workpiece size of 60mmdiameter 150mmlength
G21G40 Input in mm, Cutter compensation cancel,
G98 Feed per minute
G28 U0W0 Gotoreference0,0
M06 T0101 Tool change and select toolT0101fromtoolkit

Spindle rotates at the speed of 1200 Rpm in

M03 S1200
clockwise direction

Constant cutting speed ON, Move tool to 60mm in X

G96G00 X60Z1
Axis and 1mm in Z axis from its home position
G90 X59Z-110F30 By turning operation remove 1mm for the length 110 mm

X58 By turning operation remove 1mm for the length 110 mm

X57 By turning operation remove 1mm for the length 110 mm

X56 By turning operation remove 1mm for the length 110 mm

X55 By turning operation remove 1mm for the length 110 mm

CODE
CODE EXPLANATION
DESCRIPTION

146
 X54 By turning operation remove 1mm for the length 110 mm
X53 By turning operation remove 1mm for the length 110 mm
X52 By turning operation remove 1mm for the length 110 mm
X51 By turning operation remove 1mm for the length 110 mm
X50 By turning operation remove 1mm for the length 110 mm
Move tool to 50 mm in X axis and 1 mm in Z axis from
G00 X50Z1 its position

G90 X49Z-75 By turningoperationremove1mmforthelength75mm

X48 By turning operation remove 1mm for the length 75mm
X47 By turning operation remove 1mm for the length 75mm
X46 By turning operation remove 1mm for the length 75mm
X45 By turning operation remove 1mm for the length 75mm
X44 By turning operation remove 1mm for the length 75mm
X43 By turning operation remove 1mm for the length 75mm
X42 By turning operation remove 1mm for the length 75mm
X41 By turning operation remove 1mm for the length 75mm
X40 By turning operation remove 1mm for the length 75mm
Move tool to 40 mm in X axis and 1mm in Z axis from its
G00 X40Z1
position
G90 X39Z-45 By turning operation remove 1mm for the length 45mm
X38 By turning operation remove 1mm for the length 45mm
X37 By turning operation remove 1mm for the length 45mm

X36 By turning operation remove 1mm for the length 45mm

X35 By turning operation remove 1mm for the length 45mm

X34 By turning operation remove 1mm for the length 45mm

X33 By turning operation remove 1mm for the length 45mm

CODE
CODE EXPLANATION
DESCRIPTION
X32 By turning operation remove 1mm for the length 45mm
147
 X31 By turning operation remove 1mm for the length 45mm
X30 By turning operation remove 1mm for the length 45mm
Move tool to 30mmin X axis and1mm in Z axis from its
G00 X30Z1
position
By turning operation, chamfering is done with the radius
G90 X30 Z-2 R2 F30
2mm for the length 2mm
G28 U0W0 Go to reference0,0
M05 Spindle stop
M30 End of program

RESULT:

Thus the program for given component drawing was written and checked using FANUC
turning simulator

148
Viva Question

1. What is a part program ?

Part program is a high level language program containing the instructions for-machining a part on sheets
with respect to various standard words / codes and symbols.

2. What is post processing?

Post processing is a computer program that takes a generalized part program output and adopts it to a
particular machine control unit/machine tool combination. It is the basic intelligence required to change
the program into computer language.

3. Name the language used in CNC programming.

The language used in CNC programming is APT(Automatically Programmed Tool).

4. Write the various types of tape readers.

The various types of tape readers are:
a) Electromagnetic tape reader. b) Magnetic tape reader.
c) Photo eletrical tape reader. d) Pneumatic tape reader.

5. Write the order of the instructions in a part program.

The order of the part program is
1). Preparatory function.
2). Feed function.
3). Tool function.
4). End of block

6. What is meant by manual part programming?

Manual part programming is a process of writing programs which consist of a set of instructions to carry
out the machining of the work.

7. Write the disadvantages of manual part programming.

The disadvantages of manual part programming are:
a) It is difficult to perform several co-ordinate calculation for complex shapes.
b) Setting of the tool can be done to an approximate dimension and the difference is adjust by
suitable external switches set.

149
8. What is preparatory function/?
It is word address format represented by the letter G ,followed by a numerical code for the operation of
the control unit to instruct the machine tool.

9. What is tool length offset?

When tools with different length are used, then the difference in their lengths with respect to a datum is
known as offset of each tool.

10. Give a brief note on Canned Cycle.

The canned cycle simplifies and shortens the programming in such way whenever any one of the above
operation is required.

150
158
Ex.No:

Date:
NC part programming for circular Pocketing(milling).

AIM:Towriteaprogramandsimulatethetoolpathfortheoperationinvolvedinthecomponent as given in
the figure using FANUC milling software.

SOFTWAREUSED:

FANUC Milling simulator

PROGRAMCODE:

CODE
CODE EXPLANATION
DESCRIPTION
[BILLE Workpiece size of150mmlength,150mmwidthand
X150Y150Z20
T 20mmthickness
[TOOL
T01L65T10 SelectingthetoolseriesT01,length65mm
DEF
G21
Inputinmm,Cuttercompensationcancel, Returntoinitial
G40
position
G98
M06 Autotoolchange
Spindlerotatesat thespeedof1500Rpminclockwise
M03 S1500
direction
G00 X0Y0Z0 Gotoreference0,0,0
G00 X0Y5 MovetoolinYaxisfor5mm
Linearinterpolation,movetoolinZaxisfor5mm(Depth
G01 Z-5F30
ofcut)
Linearinterpolation,movetoolinXaxisfor5mmwith5
G01 X5Y0
mminZaxisasdepthofcut
159
 MovetoolinXaxisfor50mmwith5mminZaxisas
G01 X50Y0
depthofcut

CODE
CODE EXPLANATION
DESCRIPTION

Linearinterpolation,movetoolinXaxisfor50mmandin
G01 X50Y10
Yaxisfor10mmwith5mminZaxisasdepthofcut

Linearinterpolation,movetoolinXaxisfor52.5mmand
G01 X52.5Y15
inYaxisfor15mmwith5mminZaxisasdepthofcut
Linearinterpolation,movetoolinXaxisfor97.5mmand
G01 X97.5Y15
inYaxisfor15mmwith5mminZaxisasdepthofcut
Linearinterpolation,movetoolinXaxisfor100mmand
G01 X100Y10
inYaxisfor10mmwith5mminZaxisasdepthofcut
Linearinterpolation,movetoolinXaxisfor100mmwith
G01 X100Y0
5mminZaxisasdepthofcut
Linearinterpolation,movetoolinXaxisfor145mmwith
G01 X145Y0
5mminZaxisasdepthofcut

Linearinterpolation,movetoolinXaxisfor150mmand
G01 X150Y5
inYaxisfor5mmwith5mminZaxisasdepthofcut

Linearinterpolation,movetoolinXaxisfor150mmand
G01 X150Y145
inYaxisfor145mmwith5mminZaxisasdepthofcut

G01 X145Y150 Linearinterpolation,movetoolinXaxisfor145mmand

inYaxisfor150mmwith5mminZaxisasdepthofcut

160
G01 X100Y150 Linearinterpolation,movetoolinXaxisfor100mmand
inYaxisfor150mmwith5mminZaxisasdepthofcut

G01 X97.5Y135 Linearinterpolation,movetoolinXaxisfor97.5mmand

inYaxisfor135mmwith5mminZaxisasdepthofcut

CODE
CODE EXPLANATION
DESCRIPTION

Linearinterpolation,movetoolinXaxisfor52.5mmand
G01 X52.5Y135
inYaxisfor135mmwith5mminZaxisasdepthofcut
Linearinterpolation,movetoolinXaxisfor50mmandin
G01 X50Y140
Yaxisfor140mmwith5mminZaxisasdepthofcut
Linearinterpolation,movetoolinXaxisfor50mmandin
G01 X50Y150
Yaxisfor150mmwith5mminZaxisasdepthofcut
Linearinterpolation,movetoolinXaxisfor5mmandin
G01 X5Y150
Yaxisfor150mmwith5mminZaxisasdepthofcut
Linearinterpolation,movetoolinYaxisfor145mmwith
G01 X0Y145
5mminZaxisasdepthofcut
Linearinterpolation,movetoolinYaxisfor5mmwith5
G01 X0Y5
mminZaxisasdepthofcut
G00 X0Y0Z0 Gotoreference0,0,0
R0P0Q1X75 MovetoolinXaxisfor75mmandinYaxisfor75mm,5
G170 Y75Z-5I0J0 mminZaxisasdepthofcut,interpolationcoordinatesI
K10 as0mm,Jas0mmandKas10mm(Radiusofthecircle)
P90S1500R15
Spindlespeedas1500Rpm,eachcycle with1mmdepthof cut
G171 F100B2500
J200

161
G00 X0Y0Z0 Gotoreference0,0,0
G28 U0W0 Gotohomeposition
M05 Spindlestop
M30 Endofprogram

RESULT: Thustheprogramforgivencomponentdrawingwaswrittenandcheckedusing
FANUC Milling simulator.

162
Viva Question
1. What is a part program ?
Part program is a high level language program containing the instructions for-machining a part
on sheets with respect to various standard words / codes and symbols.

2. What is post processing?

Post processing is a computer program that takes a generalized part program output and adopts
it to a particular machine control unit/machine tool combination. It is the basic intelligence
required to change the program into computer language.

3. Name the language used in CNC programming.

The language used in CNC programming is APT(Automatically Programmed Tool).

4. Write the various types of tape readers.

The various types of tape readers are:
a) Electromagnetic tape reader. b) Magnetic tape reader.
c) Photo eletrical tape reader. d) Pneumatic tape reader.

5. Write the order of the instructions in a part program. The order of the part program is
• Preparatory function.
•Feed function.
•Tool function.
•End of block

6What is meant by manual part programming?

Manual part programming is a process of writing programs which consist of a set of instructions
to carry out the machining of the work.

7Write the disadvantages of manual part programming.

The disadvantages of manual part programming are:
c) It is difficult to perform several co-ordinate calculation for complex shapes.
d) Setting of the tool can be done to an approximate dimension and the difference is adjust
by suitable external switches set.

163
8.What is preparatory function/?
It is word address format represented by the letter G ,followed by a numerical code for the
operation of the control unit to instruct the machine tool.

9.What is tool length offset?

When tools with different length are used, then the difference in their lengths with respect to a
datum is known as offset of each tool.

10.Give a brief note on Canned Cycle.

The canned cycle simplifies and shortens the programming in such way whenever any one of
the above operation is required.

164
SLOTTING

165
Ex.No:

Date:

Perform internal machining on the given round work piece by using a

slotting machine as per the given dimensions.

AIM:
To Make internal splines, space 900 apart on the given hollow cylindrical work piece by using
slotting machine.

REQUIRED MATERIAL: M.S. Hollow Cylindrical work piece of 65 mm diameter and 70 mm

REQUIRED TOOLS: H.S.S. Cutting tool, Adjustable wrench, Scriber

PROCEDURE:

 The tool is fixed to the tool post such that the movement should be exactly perpendicular to
the table.

 The work piece is then set in the vice such that the tool is just above the work piece. Adjust
the length of the stroke of the ram..Then bring the tool to the initial position

 Rotate the work table by an angle 900 and continue the process for the second slot.

 Repeat the process for the remaining slots

RESULT: The job is completed successfully and safely.

166
Viva Question
1. List the feed mechanism used in planer.
a. By friction disc
b. By electric drive.

2. List the feed involved in the planer.

1. Cross feed
2. Down feed

3. What are the factors considered to hold the work piece in planer?
1. Work should be rigidly fixed to the table so that it may not be shifted out of its position
while cutting activity progresses.
2. Proper clamping should be needed all around the work piece.

4. What are the devices used to clamp the work in planer?

1. By standard clamping
2. By special fixtures

5. List the standard clamping devices used in planer.

1. Heavy duty vice
2. T bolt and clamps
3. Angle plate
4. Stops

6. What is the use of planer jack?

It is used to support the overhanging parts.
7. List the planer operation.
1. Horizontal surface
2. Vertical surface
3. Planning curved surfaces
4. Planning slots and grooves.

167
8. What is slotter?
It is falls under the category of reciprocating types of machine tool similar to shaper.

9. What is the difference between shaper and slotter?

1. In shaper ram reciprocate about horizontal axis but slotter the ram reciprocate about
vertical axis.

10. What is the difference between vertical shaper and slotter?

In vertical shaper the holding the tool may also reciprocate at an angle to the horizontal
table in addition to the vertical stroke.

168