Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

SHREE SARASWATI EDUCATION SANSTHANS GROUP OF INSTITUTIONS

Faculty of Engineering
Department of Mechanical Engineering
SUB: Production Technology (181903)
Experiment List Sr.No. 1 Title

STUDY OF SINGLE POINT AND MULTI POINT CUTTING TOOL GEOMETRY

2 3

STUDY OF VARIOUS CUTTING TOOL MATERIALS CHIP THICKNESS ANALYSIS TO OBSERVE THE EFFECT OF CUTTING PARAMETERS ON TYPES OF CHIP PRODUCED

5 6 7 8 9

STUDY OF PLAN LAYOUT OF CAPSTAN AND TURRET LATHE STUDY OF UNCONVENTIONAL MACHINING PROCESS NC AND CNC MACHINES MANUFACTURING OF GEAR JIGS AND FIXTURES

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO. 1 SINGLE POINT AND MULTI POINT CUTTING TOOL GEOMETRY

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

SINGLE POINT AND MULTI POINT CUTTING TOOL GEOMETRY

AIM: To study of tool geometry of single point and multi point cutting tool. THEORY: INTRODUCTION: It is an instrumental media which helps to remove material from the work piece, and to give desired shape and size with the help of single point contact tool or multi point cutting tool. The relative motion is established between work and the cutting tool to undergo cutting process. CUTTING TOOL CLASSIFICATION: According to different methods According to method of manufacturingForged tool, Tipped tool brazed to the carbon steel shank, Tipped tool fastened mechanically to the carbon steel shank. According to the method of holding the tool- Solid tool, Tool bit inserted in the tool holder. According to the method of using the tool- Turning, Chamfering, Thread cutting, Facing, Grooving, Forming, Boring, Internal thread cutting, parting off. According to the method of applying the feed- Right hand, Left hand, Round nose.

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

SINGLE POINT CUTTING TOOL GEOMETRY

MULTI POINT CUTTING TOOL GEOMETRY

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

MULTI POINT CUTTING TOOLS REVIEW QUESTIONS: 1. Define a cutting tool. 2. How the tools are classified? 3. Name at least 10 single point cutting tools and 10-multi point cutting tools. 4. Explain with sketch the difference between tool holders used for a) Brazed carbide b) Clamp on type c) Solid high-speed steel insert bit. 5. Differentiate between tool signature, tool geometry and tool nomenclature with sketch. 6. Write a short note on tool angles and effect of tool angles on cutting process. 7. Explain briefly the design factors affecting tool life.

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Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO.2 CUTTING TOOL MATERIALS

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

CUTTING TOOL MATERIALS

AIM: To study of various Cutting Tool Materials. THEORY: INTRODUCTION: Selection of cutting Tool material is among the most important factor for machining ooperation. Cutting Tool is subjected to a) High Temperature b) Contact Stress c) Sliding along the Tool Chip Interface and along machined surface Consequently it possesses following characteristics 1. Hardness 2. Toughness 3. Wear Resistance 4. Chemical Stability CLASSSIFICATION OF CUTTING TOOL MATERIALS: 1. Carbon and medium alloy steel 2. High speed steel 3. Cast cobalt alloys 4. Carbides (Cemented or Sintered Carbides) 5. Coated Tools 6. Cubic Boron Nitride 7. Ceramics 8. Diamond

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 REVIEW QUESTIONS: 1. State the factors responsible for the development of newer Tool materials. 2. Enlist commonly used cutting Tool materials stating their types, compositions, Red Hot Hardness Temperature, Permissible Cutting Speeds and Applications. 3. Discuss the basic requirements of materials for Cutting Tools. 4. State the desirable properties of Cutting Tool materials and differentiate between Cemented Carbide Tool and Cemented Oxide Tool with respect to the above Properties. 5. List out the important characteristics of Ceramic Tool materials and stating its advantages. 6. Enumerate some precaution while working with Diamond.

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Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO. 3 CHIP THICKNESS ANALYSIS

CHIP THICKNESS ANALYSIS

AIM: To study effect of cutting parameters on chip thickness APPARATUS/INSTRUMENTS: Lathe with a three-jaw chuck, Vernier Caliper, 20; 20 mm long M.S. rod. PROCEDURE: Set up the lathe and machine the MS rod for different set of cutting parameters. The cutting parameters are speed, feed and depth of cut. In the first set up vary the depth of cut, keeping the speed and feed constant. In the second set up vary the speed, keeping the feed and depth of cut constant. In the third setup, vary the feed, keeping the speed and depth of cut constant. Collect the chips and measure the thickness at four different points along the length. OBSERVATIONS:

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 1. Material: MS, 20 and 20 mm long 2. Parameters: Speed

TABLE A: Speed = 250rpm; Feed = 0.12mm/rev

Depth of cut (mm) T1 0.5 1.0 1.5 T2

Chip Thickness (mm)

T3

T4

Average

TABLE B: Feed = 0.12mm/rev; Depth of cut = 0.5 mm

Speed (rpm) T1 0.06 0.12 0.24 T2

Chip Thickness (mm) T3 T4 Average

TABLE C: Speed = 350 rpm; Depth of cut = 1 mm

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 Feed (mm/rev) T1 0.06 0.12 0.24 T2 Chip Thickness (mm) T3 T4 Average

GRAPHS:

TABLE A: Depth of cut Vs Chip Thickness TABLE B: Speed Vs Chip Thickness TABLE C: Feed Vs Chip Thickness

CONCLUSION:

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Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO. 4 MECHANICS OF METAL CUTTING AND CHIP FORMATION

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

MECHANICS OF METAL CUTTING AND CHIP FORMATION

AIM: TO STUDY OF MECHANICS OF METAL CUTTING AND CHIP FORMATION.

THEORY: INTRODUCTION: Every convectional machining process involves the formation of chips. Chip formation is a complex phenomenon where a force is applied to work piece to remove the material from the work piece. The metal is sheared along the shear plane, which makes an angle with the direction of tool travel because of shearing action. CHIP FORMATION: The shape and size of the chips obtained depends on the types of the material to be cut and other cutting conditions. It also indicates the type and quality of pieces. The following three basic types of the chips are produced in any convectional machining process.

I. Segmental or Discontinuous chip. II. Continuous chip. III. Continuous chip with built-up edge.

I.

Segmental Chip: This type of chips consist of separate, plastically deformed segments which loosely

where to each other or ..which are produced by actual frature of the metal ahead of the cutting edge. The fracture of the metal take place when the magnitude of the compression forces reaches the fracture limits of the metal. Facture affecting the segmental chip: 1.) Brittle material (C.I., Brass, Casting etc) 2.) Low speed and high depth of cut. while cutting ductile material. 3.) Small rake angles too ductile material, segmental chips.

II.

Continuous Chip: This type of chips produced when material ahead of the too continuously deforms without fracture and flows off the rake face in the form of nibbeu. The following factors are responsible for the continuous chip 1. Ductile material Steel Copper Aluminum etc.

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 2. High cutting speed. 3. Large rake angle. 4. Sharp cutting edge. 5. Efficient cutting fluid. 6. Low friction between tool face & chips. III. Continuous chip with Built Up Edge: This type of chip is similar to continuous chip except that a built up edge is formed on the nose of the tool. The built of edge is formed

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO.5 PLAN LAYOUT OF CAPSTAN AND TURRET LATHE

PLAN LAYOUT OF CAPSTAN AND TURRET LATHE

AIM:

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 To study of Plan layout of Capstan and Turret lathe. THEORY: INTRODUCTION: The Capstan (C) & Turret (T) lathes are developed for the purpose of producing mass identical parts with more production rates and at the same time very less rejection rates.

A - HeadStock C - Capstan Slide B - Capstan D - Adjustment For Capstan Stops E - BED CAPSTAN LATHE PARTS

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 TURRET LATHE MAIN PARTS: Bed, All geared headstock, Saddle, Multi station tool post. Here, tailstock is replaced by hexagonal turret sliding on the machine bed. Six faces of turret holds six different operation tools, either with auto indexing or manual indexing. By indexing the operator brings tool in the axis of lathe, keeping in view the sequence of operations. The job is clamped either in chucks or collets and all feed movements are regulated with the help of adjustable stops, for specific operations. WORKING PRINCIPLE OF SEMI AUTOMATS AND FULL AUTOMATS:

CONSTRUCTION DETAILSEVALUATION PROCESS OF WORKING: 1. For properly setting up a turret, skill is necessary in the selection, mounting, and adjustment of the tools. 2. In small lot production, it is important that this work can be done quickly, so as not to consume too much of the total production time, which consists of set up, work piece handling, machine handling and cutting time. 3. Set up time is reduced by having the tool in up to date condition and readily available. 4. For short run jobs, a permanent set up of the usual bar tools on the turret is a means of reducing time. 5. The tools selected are standard and when permanently mounted, they may be quickly adjusted for various jobs. 6. The loading and unloading time, which is the time consumed in mounting or removing the work, depends largely on the work holding devices used. 7. For bar work, this time is reduced to a minimum by using bar stock collets. 8. The time it takes, to pre position the tools ready for cutting is part of the cycle time. 9. This is reduced by having the tool in proper sequence for convenient use and by taking 10. Multiple or combined cuts whenever possible. 11. The balance of the machine handling time is made up of the time necessary to change the speeds and feeds. 12. Cutting time is controlled with proper cutting tools, feeds and speeds.

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 13. Combined cuts refer to the simultaneous use of both slide and turret tools. 14. In bar work, combined cuts are especially desirable, as an additional support is given, to the work piece, thereby, reducing spring and chatter. 15. In chucking work, internal operations such as drilling or boring may frequently be combined with turning or facing cuts from the square turret. 16. Time is also saved, by taking multiple cuts, that is, having two or more tools mounted on one tool station. 17. For outside turning, a single cutter turner or box tool has been developed As bar stock is supported only at the collets, additional support must be provided for heavy cuts to be taken. 18. This is done by means of two rollers that contact the turned diameter of the stock to counter the thrust of the cutting tool. MAJOR OPERATIONS TO BE CARRIED OUT USING AUTOMATES: Turning, Drilling, Boring, Threading, Reaming, Necking, Chamfering and cutting off or parting off. Other specialized operations are possible with specialized tools. REVIEW QUESTIONS: 1. What are the main parts of capstan and turret lathes? Where they differ? 2. Explain step-by-step procedure of part you already made using Capstan & Turret lathe in your workshop. 3. Write down different types of turret lathes and their applications. 4. Compare engine lathe with automats. 5. Compare and differentiate between capstan and turret lathe. 6. Explain with sketch the function of bar feeding mechanism.

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Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO. 6 UNCONVENTIONAL MACHINING PROCESS

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

UNCONVENTIONAL MACHINING PROCESS

AIM: To study of Unconventional Methods of Machining. THEORY: INTRODUCTION: Last few decades have witnessed a rapid growth in the development of harder and difficult to machine metals and alloys. It has been realized that such materials are difficult to machine by conventional methods, and therefore their machining is not only costly but also results into poor surface finish and shorter tool life. To overcome these difficulties a number of newer machining methods have been developed. These methods are not convectional in the sense that material removal does not occur due to plastic deformation and with the formation of the chips. These methods have found successful applications in several important industries for machining of components having complicated shapes made of hard materials like tungsten carbides, super alloys, ceramics, refractory materials etc. Today unconventional machining techniques play an important role in manufacturing industries. CLASSIFICATION: Newer machining methods can be classified on the basis of the type of energy they employ for purpose of metal removal. Broadly, speaking they can be classified as below: 1. Mechanical metal removal processes. 2. Electro-chemical metal removals processes. 3. Thermal Metal Removal processes

Mechanical methods are characterized by the fact that material removal is due to the application of mechanical energy in the form of high frequency vibrations or kinetic energy of an abrasive jet. Practical machining methods that employ mechanical energy are:

I. II. III.

Ultra Sonic Machining (USM) Abrasive Jet machining (AJM), and Water Jet machining (WJM)

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

ULTRA SONIC MACHINING

Electro chemical methods are based on electrochemical dissolution of materials by an electrolyte under the influence of an externally applied electric potential. The practical methods that utilize this principle are: (a) Electro Chemical machining (ECM) (b) Electro Chemical grinding (ECG)

ELECTRO CHEMICAL MACHINING In thermal method, the material is removed due to controlled, localized heating of the work piece. This results into material removal by melting and evaporation. The source of heat generation in such cases can be widely different. Practical machining method based on this principal are (a) Electro Discharge Machining (EDM) (b) Plasma Are Machining (PAM)

(c) Electron beam machining (EBM) and (d) Laser Beam Machining (LBM)

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

ELECTRO DISCHARGE MACHINING

LASER BEAM MACHINING REVIEW QUESTIONS: 1. Differentiate between convectional and unconventional machining. State the advantages of unconventional machining. 2. Give the classification of unconventional machining method. Why they are developed. 3. Describe the below mention process in detail with neat sketch. (a) Ultra Sonic Machining (b) Electric Discharge Machining (c) Abrasive Jet Machining (d) Electro Chemical Grinding and Electro Chemical Machining (e) Laser Beam Machining

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Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO.7 MANUFACTURING OF GEAR

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

MANUFACTURING OF GEAR
AIM: To study manufacturing of a gear on milling machine. THEORY: INTRODUCTION: Gears are commonly used to transmit power or rotary motion from one shaft to another. They have the advantage over friction and belt drives that they are positive in action. To meet the stringent service conditions the gear should be fatigue free, free from noise and chatter, should ensure high load carrying capacity at constant velocity ratio. Gear cutting is a very complex process. CLASSIFICATION OF GEAR MANUFACTURING METHODS: 1. Casting 2. Stamping 3. Extrusion 4. Forging 5. Roll forming 6. Powder metallurgy 7. Machining methods: Copying / Forming: By disc type milling cutter on milling machine By end mill on milling machine By single point cutting tool on shaper By broach on broaching machine

Generating / Rolling: By rack in gear cutter

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 By pinion in gear cutter By hob in gear cutter

Forming method: In this method single point or multi point cutting tool can be used. The shape of the tool tip corresponds to the shape of tooth space of the gear to be manufactured. According to gear theory different gears with different number of teeth but same module differ to some extent in tooth profile. So produce exact profile of tooth on the gear blank, one cutter for each number of teeth is required. So it is costly practice. To reduce this cost separate set of cutters are used to range of teeth. Generating method: In this method when two cylinders are rolled one acts as cutter and the other acts as blank and the gear teeth are generated on the blank. Single cutter can have different number of teeth provided the module is same. Gear finishing methods: Gear shaving Gear burnishing Gear grinding Gear honing Gear lapping

REVIEW QUESTIONS: 1. Explain the forming and generating methods of gear manufacturing. 2. Explain the gear finishing methods.

3. Explain the method that you used for the manufacturing of gear

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Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

PRACTICAL NO. 8 JIGS AND FIXTURES

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903

JIGS AND FIXTURES

AIM: To study different jigs and fixtures available in workshop. THEORY: INTRODUCTION: Work piece control is biggest issue for a process planner. Because loss of work piece control will result in work pieces having out of dimension condition. Once the drawing for a part is completed it is sent to process planning department where method and sequence of manufacture are finalized. This department also floats the requirements for different tooling needed for the completion of job. Jigs and fixtures are tooling needed for the satisfactory work piece control, in simple terms work holding devices. Fixtures are used to hold and locate the work piece. Fixtures are heavier in construction. Turning, milling, shaping, planning, grinding, broaching etc. operation require fixtures to hold and job. Jigs are used to guide and control the tool; hold and locate the work piece. Jigs are required in drilling, reaming, tapping etc. operations. Locator locates the job in jig and fixture body. Locating device are listed below: 1. Jack pin, jack screw 2. Cylindrical locator 3. Conical locator 4. Diamond locator 5. Vee locator Clamps in jigs and fixtures are used to provide holding force to the work piece.

Clamps are of different types: 1. Strap clamp 2. Screw clamp

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 3. Hinged clamp 4. Wedge clamp. 5. C- clamp 6. Toggle clamp 7. Cam operated clamp Bushes in jig dose the function of guiding the tool. 1. Fixed bush 2. Liner bush 3. Renewable bush 4. Slip bush. 5. Screw bush

6. Special bush
Different types of jigs are: 1. Template jig 2. Plate jig 3. Channel jig 4. Leaf jig 5. Universal jig 6. Index jig 7. Turn over jig etc. Fixtures are mainly classified on base of method of manufacture. 1. Milling fixture 2. Turning fixture 3. Grinding fixture

Faculty of Engineering, SSESGI- Rajpur Kadi, Production Technology-181903 4. Boring fixture 5. Broaching fixture 6. Welding fixture

7. Assembly fixture
OBSERVATION: Analyze each and every jig and fixture in our workshop in context of function location and clamping facility. REVIEW QUESTIONS: 1. Explain the principle of 3-2-1 locations. 2. Differentiate between jigs and fixtures. 3. List out different types of clamps. 4. List out different types of bushes. 5. Explain various types of jigs. 6. What considerations are taken while designing a clamp?

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