Professional Documents
Culture Documents
DEPARTMENT OF
MECHANICAL ENGINEERING
Syllabus
Sub Code : ME452 CIA Marks : 25
Preparation of two models on lathe involving Plain turning, Taper turning, Step turning, Thread
cutting, Facing, Knurling, Drilling, Boring, Internal Thread cutting and eccentric turning.
Scheme of Examination:
1. Operate Machine tool equipment commonly found in industry like Lathe Machine Shaper
Machine, Milling Machine and grinding machine.
2. Manufacture parts from various materials in accordance with specifications from
blueprints, electronic drawings and shop sketches
3. Apply safety principles in a work environment to minimize hazards and prevent losses
to productivity
4. Demonstrate employability skills needed to obtain and retain employment in machine
tool and related fields
1) Select appropriate testing methods and identify equipment required for the testing Apply
knowledge of Machine tool operations in Industry
2) Ability to infer sequence of operations to carried out on different machine tools
3) Apply safety principles in work environment to minimize losses
4) Problem solving skills are enhanced.
Safety Precautions
1. Attention to be paid for clamping the job, tool, tool holders or supporting items.
2. Care should be taken for avoiding accidental contact with revolving cutters.
4. Do not handle chips with bare hands, use brush or hand gloves.
5. Pay attention while selecting tools or blades for the proposed use to avoid accidents.
9. Follow safety precautions while approach with cutter to avoid tool damage.
11. Use goggles for sparks, spatters, avoid the watch clearly with bare eyes.
Table of Contents
Description of
Sl.No Date Page No Marks Sign of Faculty
Experiments
Introduction of general
purpose machines- Lathe ,
1. Drilling machine, Shaping 6 - 33
machine, Milling machine
and Grinding machine
7. Surface Grinding 46 - 47
Machining is the process of converting the given work piece into the required shape and size with
help of a machine tools such as Lathe, Drilling machine, Milling machine, Shapers Grinders etc..
LATHE
Lathe is the machine tool which is used to perform several operations on the work piece. Lathe is
useful in making several parts which is further assembled to make new machine.
Hence lathe is known as mother of machines.
Type of Lathe:
Lathes of various designs and constructions have been developed to suit the various
conditions of metal machining. The types of lathes are.
1. Speed Lathe
2. Engine Lathe
(a) Belt drive
(b) Individual motor drive
(c) Gear head Lathe
3. Bench Lathe
4. Tool room Lathe
5. Capstan and turret Lathe
6. Special purpose
(a) Wheel Lathe
(b) Gap bed Lathe
(c) T-Lathe
(d) Duplicating Lathe
7. Automotive Lathe
The Engine Lathe:
The engine lathe is the most important member and it is so called as Engine Lathe because
in early days it were driven by steam engines. It has all basic components i.e., head stock, tail
stock. The head stock contains additional mechanism for driving the lathe spindle at multiple
speeds. The engine lathe can feed the cutting tool both in cross and longitudinal direction with the
help of carriage, feed rod and lead screw. Engine lathes are classified according to the various
designs of the head stock and methods of transmitting power to the machine. Different types of
lathes are classified according to the power.
These lathes are used for production work. In this the tailstock is replaced by a hexagonal
turret, on the face of which multiple tools may be fitted and feed into the work in proper sequence.
The advantage is that several different types of operations can be done on a work piece without re-
setting of work or tools, and a number of identical parts can be produced in the minimum time.
Specifications of Lathe:
Power input
The principle parts of the lathe are lathe bed, head stock, tail stock, carriage, Tool post,
Apron etc
Bed:
The lathe bed forms the base of the mechanism. The head stock, and the tail stock are
located at either end of bed and the carriage rests over the lathe bed and slides on it. On the top of
the bed there are two sets of slides or guide ways, outer ways and inner ways. The outer ways
provide bearing and sliding surfaces are accurately machined to make them parallel to the lathe
axis absolutely horizontal and sufficiently plain. In guide ways of the lathe bed may be flat and
inverted --v having an included angle of 90 . The bed material should have high compressive
strength, should be wear resistant and absorb vibrations. Cast iron alloyed with Nickel and
Chromium.
Head Stock:
The head stock is secured permanently on the inner ways at the left hand end of the lathe
bed and it provides mechanical means of rotating the work at multiple speeds. It has a hollow
spindle and mechanism for driving and altering the spindle speed. The spindle of the head stock is
made of carbon or Nickel chrome steel. There are two common types of spindle noses the threaded
design which carries the chuck, driving plate and face plate and the flanged nose which enable
them to be directly attached. For obtaining different speeds of lathe there are three methods:
(1) By belt drive on cone pulley fitted on the headstock spindle with are without a back
gear arrangement
(2) By all gear drive using sliding gears of clutches.
(3) By variable speed motor.
Tail Stock:
The tail stock is located on the inner ways at the right hand side of the bed. It is used to
support the other end of the work when it is being machined between centers. It holds a tool for
performing operation such as drilling reaming. tapping etc. The tail stock is moved toward are
away from the operator. To accommodate different lengths of work , the body of the tail stock can
be adjusted along the ways by sliding it to the derived position where it can be clamped by bolts
& plates Other features are incorporated for accurate length setting and felt wipes pads on the base
and spindle
Carriage:
The carriage of lathe have several parts that serve to support , move and control the cutting
tool . Saddle, cross slide, compound rest, tool post and apron are the main parts, that the carriage
consists.
Saddle:
The saddle in an H- shaped casting that fits over the bed and slides along the guide ways.
It carries the cross slide and too post.
Cross Slide:
It comprises a casting machined on the underside for attachment to the saddle and carries
locations on the upper face for the tool post or compound rest Automatic movement of cross-slide
can be obtained.
Compound rest:
The compound rest or compound slide is mounted on the top of the cross slide and has
a circular base graduates in degrees. It is used for obtaining angular ends and short tapers as well
as convenient positioning of the tool to the work
Tool Post: -
This is located on the top of the compound rest hold the tool and to enable it to be adjusted
in a convenient work position. The type and mounting of the tool post depends upon the class of
work for which it is to be used.
Apron:
The apron is fastened to the saddle and hangs over the front of the bed. It consists gears,
clutches and levers for aperciling the carriage by hand and power feeds. Usually a chasing dial is
fitted either to the side are tap of the apron and consists of a graduated dial.
The Lathe accessories are used either for holding and supporting the work are the holding
the tool. They are centres catch plates and carries, chucks, collects, face plates, mandrels and rests.
Centres: -
The most common methods of holding the work in a lathe is between the two centres
live centre and dead centre. These two take up the thrust due to metal cutting and the entire load
of the work piece on small bearing surface Different type of centres are used for holding different
type of works.
The ordinary type centre is the type used for most general work. In the tipped centre. The
point consists of a hard alloy tip brazed into and ordinary steel shank. The ball centre is used to
minimize we are and strain on the ordinary centre while tape turning by set over method. The holy
centre is little less than holy of the centre ground away while facilitates facing of the bar ends
without removal of the centres. The rotating are friction less center is always used in tail stock for
supporting heavy work revolving at high speed.
Carries and catch plates are used to drive a work piece when it is held between two centers
carries are driving dugs are attached to the end of the work piece by a set screw and catch plates
are either screwed are bottled to the nose of the head stock spindle . The projecting pin of a single
pin catch plate drives the and are tail by a carries attached to the work piece two pins of a double
pin catch plate engage with the double are double slotted carries and provide uniform drive . The
tail type is used in conjunction with a face plate are slotted catch plate.
Chucks:
It is most important devices for holding and rotating a piece of work in a lathe work piece
of short length and large diameter are of irregular shape which cannot be conveniently mounted
between centres are held rigidly in a chuck . A chuck is atf ached to the lathe spindle by means of
bolts with the back plate screwed on to the top spindle nose. Different types of chucks are
Collect chuck
Drill chuck
Combination chuck
Magnetic
It has three jaws of all are made to slide simultaneously by an equal amount within the slots
provided on the body by rotating any one of the three fun ions which meshes with the teeth cut on
the underside of the scroll disc. The scroll disc having the spiral groove cut on the top face meshes
with the teeth on the jaws when the disc is made to rotate by any one of pinions all the jaw all
moved backward or forward by equal amount. It is suitable for holding round or hexagonal work
force and the job is centered automatically & quickly. But it has less gripping capacity and
centering accuracy is soon lost due to wear.
Magnetic Chuck:
It is used for holding a very thin work piece made of magnetic material which cannot be
held in an ordinary chuck. It is also used where any distortion of the work piece due to pressure of
the jaws is undesirable. The holding power of chuck is obtained by the magnetic flux relating either
from the electromagnetic flux or from the permanent magnets introduced with in the chucks. In
ON position flux passes through the work piece and grips it. And in OFF position it is short
circuited and the flux passage mall by stopped, it causes the work piece free.
Face Plates:
A face plate consists of a circular disc bored out and threaded to fit the nose of the lathe
spindle. This has the radial, plain and T-slots for holding work by bolts and clamps. Face plates
are used for holding work pieces while cannot be conveniently held between the centres or by
chucks.
Angle Plates:
This is C.I plate having two faces machined to make me absolutely at right angles to each
other. Holes & slots are provided on both faces so that it may be clamped on face plate and can
hold the work piece on the other face by bolts and clamps. Angle plates are used in conjunction
which a face plate when the holding surface of the work piece should be kept horizontal, as for
example, in machining a flange of pipe elbow.. When the eccentric jobs are bolted on the face plate
a balance weight or counter weight must be added.
Mandrels:
A mandrel is a device for holding and rotating a hollow piece of work that has been
previously drilled or bored. The work receives with me mandrel should be true with accurate centre
holes for machining outer surface torsion. The ends of a mandrel are slightly smaller in diameter
and attached to provide effective gripping surface of one lathe dog set screw. The mandrel is
rotated by the lathe dog and the catch plate and it drives the work by friction. Different types of
mandrels are: plain mandrel, step mandrel, collar mandrel, gang mandrel, expansion mandrel.
Plain Mandrel:
It is used when a large number of identical pieces having standard size holes are required
to be mounted on it. The body of the mandrel is slightly tapered, the difference in diameter is 1 to
2 mm per 100 mm length. The length varies from 55 to 43 0mm. The taper is provided for proper
gripping of the work piece. It is suitable for only one size of bore.
Step Mandrel:
The step mandrel having steps of different diameter employed to drive different work
pieces having different sizes of holes without replacing the mandrel each time. It is suitable for
turning collars, washers and odd jobs.
Lone Mandrel:
It consists of a solid cone attached to the one end of the body and a sliding cone which can
be adjusted by turning a hut at the threaded end. It is suitable for holding work pieces having
different hole diameters by placing the work on two cones and lightning the nut. Avbid forcing the
cone tightly upon the work to prevent spoil as its outer edge.
Expansion Mandrel:
This has a fixed collar at one end and a movable collar at the threaded end which may be
adjusted to its position by a nut. The mandrel is used to hold a set of holler work pieces between
two collars by tightening the nut. The friction between the sides of the work and the collar is
sufficient to drive the work without slipping in the mandrel.
Gang Mandrel:
One type of a mandrel is that consists of a tapered pin which is driven into a sleeve that is
parallel outside and tapered inside. The sleeve has three longitudinal slots, two are hear by cut
through and the third splits it completely. This construction enables an expansion mandrel to grip
various work pieces with different hole diameters with in a limit that cannot otherwise be held in
all ordinary mandrel. The sleeve first placed within the work with pin removed. The tapered pin is
then pressed from the end into the sleeve and the sleeve expands. Gripping the work securely and
accurately can hold work pieces of diameter 0.5 to 2mm.
Rests:
A rest is a mechanical device which supports a long slender work piece, which is turned
between centres at some intermediate point to prevent bending of the work piece due to its own
weight and vibrations set up due to the cutting force that acts on it. A rest should always be used
when the length is 10 to 12 times the diameter of work piece rests when properly set provide
greatest accuracy in machinery and permit heaver depth of cut on the work pieces the two types of
rests used in an engine lathe are the steady or centre rest and the follower rest.
Steady Rest:
It consists of a C.I base, which may be made to slide on the lathe bed ways and clamped at
any desired ways and clamped where a support is necessary. The upper portion is hinged at one
end which facilitates setting and removal of work piece without disturbing the rest. The three jaws
are moved then acts as bearing and holds the work piece rigidly. The main junction is to support a
long slender work. Also used to support the free end of a long work piece for drilling, boring, etc.,
Follower Rest:
It consists C like casting having two adjustable jaws which support the work piece the
rest is bolted to the back end of the carriage. It moves with the carriage movement. The follower
rest prevents the job from away when cut is made and is used in turning operation or where the
entire length of the work piece is required to bed turned without distributing the setting.
Centering:
When the work is required to be turned between centres or between chuck and a centre,
conical shaped boles must be provided at the ends of the work piece: c provide bearing surface for
lathe centers. Centering is the operation of producing conical holes in work pieces. To prepare a
cylindrical work piece for centering, it is first necessary to locate the centre hole by marking off
this is done by rubbing the end with a chuck and the centre may be located by anyone of the
following instruments.
After the centre has been located, a centre punch and a hammer are used to make a deep
indentation to produce the hole to hold and to revolve the work on lathe centres. Centre holes are
produced by using a drill and drill and counter sink tool. This is held on a drill chuck and may be
mounted on the head stock or on the tail stock spindle to provide a conical hole on the ends of the
work piece. The included angle as the hole should be exactly 60 to fit with the 60 point angles of
the lathe centres. The straight hole projected beyond the conical hole serves as a small reserving
for lubricating oil & receives the tip of the dead centre from rubbing with the work piece.
Cutting tool nomenclature means systematic naming of the various parts and angles of a
cutting tool. The principle underlying cutting tool angles are the same whether the tool is single or
multi point tool or a grinding wheel. The different points of the single point cutting tool are:
Shank: Shank is that portion of the tool bit which is hot ground to form cutting edges and is
rectangular in cross section.
Face: Face is the surface against which the chip slides upward.
Heel: Heel is the lowest portion of the side cutting and end cutting edge.
Rake: Rake is the slope of the tape away from the cutting edge. There are two types back rake
angle and side rake.
Side clearance: Side clearance is that the plane the forms the flank or side of a tool has been
ground back at an angle sloping down from the side cutting edge.
End cutting edge angle: Indicates that the plane which forms the end of a tool has been ground
back at an angle sloping from the hose to the side of the shank.
Lip or Cutting angle: It is the included angle when the tool has been grand wedge at shaped.
Lathe Operations:
Operations which are performed in a lathe either by holding the work piece
2. Reaming 7, Tapping
5. Taper boring
1. Grinding
2. Milling
SHAPER
The shaper is a reciprocating type of machine tool used to produce flat surface. The surface
may be horizontal, vertical or inclined. Modern shaper can generate contoured surfaces also. The
metal working shaper was developed in the year 1836 by James Nesmyth an English man.
It is possible to form vertical and angular surfaces also. With proper tools and
accessories even irregular surfaces can be formed.
Working Principle.
The job is rigidly fixed on the machine table. The single point cutting tool held properly in the tool
post is mounted on a reciprocating ram. The reciprocating motion of the ram is obtained by a quick
return motion mechanism. As the ram reciprocates, the tool cuts the material during its forward
stroke. During return, there is no cutting action and this stroke is called the idle stroke. The forward
and return strokes constitute one operating cycle of the shaper.
Types of Shaper.
Push type
Draw type
Shaping Machine
Base
Column
Cross rail
Table
Ram
Tool head
Base:
It is made of cast iron to absorb vibration and it takes the entire load coming on the machine.
Column:
It is made of cast iron. It has a hollow box construction. Quick return mechanism for ram is placed
inside the column. There is two guide ways at the top in which the ram reciprocates horizontally.
There are two guide ways at the front vertical face of column in which cross rail can moves
vertically.
Cross rail:
The cross rail has got two horizontal guide ways in the face. Horizontal cross feed screw is fitted
in the crossed side. For vertical movement of the slide elevating screw is provided.
Table:
It is rectangular hollow cast iron block the table slide on horizontal guide ways of cross rail. The
surface has T-slots for clamping work. The table can be moved horizontally by rotating cross feed
screw. The front face of the table is supported by the adjustable table support
Ram:
Ram carries the tool head at its flank end. Ram reciprocates on the guide ways. It is connected to
the quick return mechanism; stroke of ram can be adjusted by hand wheel at the top.
Tool head:
Vertical and angular feed can be given to the tool head, the slide can be moved vertically by
rotating down feed screw. There is swivel base for the tool head graduated in degrees the tool can
be swivelled to any required angle. Apron can be titled to the right or left and clamped in that
position. A tool block is hinged inside the box and is rigidly placed inside the clapper box. During
the return stroke the tool block lifts out of clapper box. This prevents the rubbing of the tool on the
job.
MILLING MACHINE
A milling machine is a machine tool that removes the metal as the work is feed against a
rotating multipoint cutter. The cutter rotates at a high speed and because of the multiple cutting
edges it removes metal at a very fast rate. The machine can also hold one or more number of cutters
at a time. This is superior to other machines as regards accuracy and better surface finish.
The Milling Machine may be classified in several forms covering a wide range of work
and capacities. There are some milling machines classified according to size and operation to be
performed.
They are:
(1) Column and knee type
(a) Hand milling machine
(b) Plain milling machine
(c) Universal milling machine
(d) Omniversal milling machine
(e) Vertical milling machine
(2) Manufacturing or fixed bed type
(a) Simplex Milling Machine
(b) Duplex milling machine
(c) Triplex milling machine
(3) Planar type
(4) Special type
(a) Rotary table milling machine
(b) Draw milling machine
(c) Planetary milling machine
(d) Pantograph, profiling and traces controlling machine
In this type, table is mounted on the knee-casting which in turn is maintained on the knee-
casting on the vertical slides of the main column. The knee is vertically adjustable on the column
so that the table can be moved up and down to accommodate work of various heights. The column
and knee type milling machine are classified according to the various methods of supplying power
to the table, different movements of table is supplied by hand control and is useful in machining,
slots and grooves and keyways etc., In a plain milling machine the table may be fed in a
longitudinal, cross or vertical direction. They are much rigid and sturdy. In case of Omniversal
milling machine the table can be fitted in a vertical plane by providing a swivel arrangement at the
knee. Also the entire knee assembly is mounted in such a way that it may be fed in a longitudinal
direction horizontally. The table enables to machine taper spiral grooves in reamers, bevel gears
etc., More ever this knee column type milling machine is mostly used shop work machine. In
vertical Milling Machine the position of the spindle is vertical or perpendicular to the work table.
These are comparatively large, heavy and rigid from column and knee type and differs in
table construction. The table is maintained directly on the ways of fixed bed. The table movement
is restricted to reciprocating at right angles to the spindle axis with no provision for cross or vertical
adjustment. The name Simplex, Duplex and Triplex type indicates that the machine is provided
with single, double and triple spindle heads respectively. In a duplex machine, the spindle heads
are arranged one on each side of the table. In triplex type the third spindle is maintained on a cross
rail.
Planer Type:
The planer miller as it is called is a massive machine built up for heavy duty work, having
spindle heads adjustable in vertical, in transverse directions. It resembles a planar and like a planar,
it has a cross rail capable of being raised or lowered carrying the cutters, their heads, and the
saddles, all supported by rigid uprights. There may be a number of independent spindles carrying
cutters on the rail as well as two heads on the uprights. This arrangement as independently driving
multiple cutter spindles enables number of work surfaces to be machined simultaneously there by
obtaining great reduction in production time.
Special Type:
Milling machines of non-conventional design have been developed to suit special purposes.
The features they have in common are the spindle for rotating the cutter and provision for moving
the tool or the work in different directions. In special type milling machines there are rotary table
machine. Drum milling machine, planetary milling machine, pantograph, profiling and tracer
controlling milling machine.
PRINCIPAL PARTS:
Base:
The base of the machine is a grey iron casting accurately machined on its top and bottom
surface and serves as a foundation member for all the other parts which rest upon it. It carries the
column at its one end.
Column:
It is maintained vertically upon the frame. Many mechanisms for the spindle and table feed
are maintained on it. Front face has the guide ways for supporting the knee.
Knee:
It slides up and down on the vertical ways of the column face. The adjustment is effected
by screw mechanism. The knee houses the feed mechanism of the table and different controls to
operate it.
On the top of the knee is placed saddle, which slides on guide ways set exactly at 900 to
the column face. A cross feed screw near the top of the knee engages a nut on the bottom of the
saddle to move it horizontally, by a hand power for cross feed.
Table:
The table rests on ways of the saddle and travels longitudinally.
Overhanging arm:
Maintained on the top of the column extends beyond the column face and serves as a
bearing support for the other end of the arbor.
Arbor:
An arbor may be considered as an extension of the machine spindle on which milling
cutters are securely mounted and rotated, the arbors are made with taper shanks for proper
alignment with the machine spindles having taper holes at their nose.
Front brace:
The front brace is an extra support that is fitted between the knee and the over arm to ensure
further rigidity to the arbor and knee.
It is necessary that the work should be properly and securely held on the milling machine
table for effective machining operations.
Different types of work holding devices are
o T-bolts and clamps
o Angle plates
o V-bolts
o Vises : plain vise
Swivel vise
Universal vise
o Special fixtures
There are several methods of supporting and rotating milling cutters with the machine
spindle depending on the different designs of the cutters. The following are the different devices
for holding and rotating cutters
(1) Arbors
(2) Collets
(3) Adapters
(4) Spring Collets
(5) Bolted cutters
(6) Screwed on cutters
Milling Cutters:
The milling cutters are revolving tools having one or several cutting edges
of identical form equally spaced on the circumference of the cutter. The cutting elements are called
teeth, which intermittently engages the work piece and remove material by
relative movement of the work piece and cutter. Milling cutters are classified as
(1) According to the constructional features of the cutter
(a) Solid cutter
(b) Tipped Solid cutter
(c) Inserted teeth cutter
(2) According to the relief characteristics of cutter teeth
(a) Profiler relieved cutter (b) Form relieved cutter
(3) According to the methods of mounting the centre
(a) Arbor type cutter
(b) Shank type cutter
(c) Facing type cutter.
(4) According to the direction of rotation of cutter
(a) Right hand rotational cutter
(b) Left hand rotational cutter
1. Plain milling
2. Face milling
3. Side milling
4. Straddle milling
5. Angular milling
6. Gang milling
7. Form milling
8. Profile milling
9. End milling
10. Saw milling
11. Milling keyways, grooves and slots
12. Gear cutting
13. Helical milling
Types of cutters and typical milling operations ( a) Slotting with a straight-tooth side-milling
cutter. ( b) Slotting with a concave slitting saw. ( c) Plain milling. (d) Angle milling. (e) and ( f)
Form milling. ( g) Straddle milling ( h) Profile milling with an end mill.
DRILLING MACHINE
The drilling machine or drill press is one of the most common and useful machine employed in
industry for producing forming and finishing holes in a work piece.
A spindle which turns the tool (called drill) which can be advanced in the work piece either
automatically or by hand.
Working principle:
The rotating edge of the drill exerts a large force on the work piece and the hole is generated. The
removal of metal in a drilling operation is by shearing and extrusion.
1. Base: The base is a heavy casting that supports the machine structure; it provides rigid mounting
for the column and stability for the machine. The base is usually provided with holes and slots
which help to Bolt the base to a table or bench and allow the work-holding device or the work
piece to be fastened to the base.
2. Column: The column is a vertical post that Column holds the worktable and the head containing
the driving mechanism. The column may be of round or box section.
3. Table: The table, either rectangular or round. Drill machine/press in shape supports the work
piece and is carried by the vertical column. The surface of the table is 90-degree to the column and
it can be raised, lowered and swiveled around it. The table can be clamp/hold the required the work
piece. Slots are provided in most tables to allow the jigs, fixtures or large work pieces to be securely
fixed directly to the table.
4. Drilling Head: The drilling head, mounted close to the top of the column, houses the driving
arrangement and variable speed pulleys. These units transmit rotary motion at different speeds to
the drill spindle. The hand feed lever is used to control the vertical movement of the spindle sleeve
and the cutting tool.
The system is called the sensitive drilling machine/press as the operator is able to sense the
progress of drill with hand-faced.
Specification of drilling machine
Body clearance is the portion of the body surface with reduced diameter which provides diametral
clearance.
Face is the portion of the flute adjacent to the lip on which chip flows as it is cut from the work
piece.
Flank is the conical surface of a drill point which extends behind the lip to the following flute.
Flutes are helical grooves cut on the cylindrical surface of the drill and provide the lip.
Heel is the edge formed by the intersection of flute surface and the body clearance.
Land is the cylindrically ground narrow strip on the leading edges of drill flutes. It keeps the drill
aligned. It is also known as margin.
Point is the cone shaped sharpened end of the drill that produces lips, faces, flanks and chisel edge
of the drill.
Lips also known as cutting edges are the edges formed by the intersection of flanks and faces.
They are two in number with identical length and angle.
Web is the thickness of the drill between the flutes which extends from point towards the shank.
The point end of the web forms the chisel edge.
Shank is the cylindrical portion of the drill which is used to hold and drive the drill. It extends
from the neck and it may be either straight or tapered.
Tang is flattened end of the taper shanks which fits into socket or drill holder. It ensures positive
drive of the drill from the drill spindle.
GRINDING MACHINE
Grinding is a metal cutting operation performed by means of a abrasive wheel that acts as
cutting tool. This is used to finish work pieces which are showing a high surface quality, accuracy
of shape and dimension. In grinding operation a little metal 0.25 to 0.5 mm with an accuracy of
order 0.00025 mm can be obtained columns and status were shaped and finished with a globular
stone which abraded the surface.
Types of Grinding:
Grinding is done on surfaces of almost all conceivable shapes and mat dials of all kinds. Grinding
may be classified broadly into two groups.
1. Rough or non-precision grinding
2. Precision grinding
Rough Grinding:
The common forms of rough grinding are snagging and offhand working where the work is held
in the operators hand. The work is pressed hold against the wheel or vice-versa. The accuracy and
surface finish is obtained are of secondary importance.
Precision Grinding:
This is concerned with producing good surface finish and high degree of accuracy. The wheel or
work both are guided in precise paths.
Grinding in accordance with the type of surface to the ground is classified as.
External cylindrical grinding
Internal cylindrical grinding
Surface grinding
Form grinding
According to the quality of surface finish grinding machines are classified as.
1. Rough Grinders
(a) Floor stand and bench grinders
(b) Portable and flexible shaft grinders
(c) Swing frame grinders
(d) Abrasive belt grinders
(2) According to the direction of helix of the cutter teeth
(a) Parallel or straight teeth cutter
Rough Grinders:
A floor-stand grinder as a horizontal spindle with wheels usually at both ends and is
maintained on a base or pedestal. A motor at floor level drives the wheel spindle through a belt. A
flexible shaft grinder has the grinding wheel on the end of a long flexible shaft driven.by a motor
on a relatively station from widely separated areas. The swing frame type grinder has a horizontal
frame about 2 to 3 m long suspended at its centre of gravity so as to move freely within the area
of operation. This machine is moved around with a job crane suspended from columns or by mobile
units.
As a true floating conditions exists during the grinding process, less metal to be
removed.
The process is continuous and adopted for production work
The size of the work is easily controlled.
Disadvantages:
These are primarily intended for grinding plain cylindrical parts also for grinding
controlled cylinders, tapers, faces & Shoulders, fillets and even cams and crankshafts. In this type
work piece is held between dead centers and by rotating by a dog and driver on the face plate.
In this
(1) The work must revolve
(2) The wheel must revolve
(3) The work must pass the wheel
(4) The wheel must pass the work,
(5) The main feature in this type is that the operation may be stopped automatically.
A plain grinding machine is essentially a lathe on which a grinding wheel has been substituted
for the single point tool: It consists of following parts.
Base:
The base is the main casting that rests on the floor and supports the parts mounted on it.
On the top of the base are precision horizontal ways set at right angles for the table to slide on.
Table:
These are lower and upper type. The lower table slides on ways on the bedand provides
traverse of the work past the grinding wheel. The upper block (table) has T-s!ots for securing the
head stock and tail stock or float stock and can be positioned along the table to suit the length of
the work.
Head stock:
The head stock supports the work piece by means of a dead centre and drives it by means
of a dog, as it may hold and drive in a work piece.
Tail Stock:
This may adjusted and clamped in various positions to accommodate different lengths of
work piece.
Wheel head:
It carries a grinding wheel and its driving motor is mounted on a slide at the top and rear
of the base. It may be removed perpendicular to the table ways.
Cross feed:
The grinding wheel is fed to the work by hand or power as cross feed control. In this type
of the operation may be stopped automatically when the work piece has been finished to the size.
In one method it uses an automatic calipee type ganging attachment to measure the work piece and
stop the operation at the proper time.
Surface Grinder:
Surface grinding machines are employed to finish plane or flat surfaces. Also capable of
grinding irregular, curved, tapered, convene and concave surfaces. The two classes are: One has
reciprocating tables for work tables for continuous rapid grinding. In an horizontal type of grinding
machine, grinding is normally done on the periphery of the wheel the area of contact is small and
the speed is uniform over the grinding surface. Small grain wheels can be used and the finest
finishes obtained the different types are.
Tool and cutter grinders used mainly to sharpen and recondition multiple tooth cutters like
reamers, milling cutters, drills, laps, knobs and other type of tools used in the snap with various
attachments. They can also do light surface, cylindrical and internal grinding to finish such items
as figs, fixtures, die and gauge details and shaper single point tools. They are two types
(1) Universal tool and cutter grinders: They are particularly intended for sharpening of
miscellaneous cutters.
(2) Single-purpose grinders: These are used for grinding tools such as drills, tool- bits etc.,
in large production plates where large amounts of grinding tools such as drills, work is
necessary to keep production. Tools can be ground uniformly and with accurate cutting
angles.
The work holding devices and attachments cover a wide range and include the following.
lathe
Calculations:
Signature of faculty
Ex.No.1
FACING AND PLAIN TURNING OPERATIONS
Date:
AIM:
To perform Facing and Plain Turning Operation using Lathe machine on a given material made
of Mild steel.
MATERIAL REQUIRED:
Lathe machine, cutting tool, outside Caliper, Steel Rule, Vernier Caliper and Vernier height
gauge
PROCEDURE :
AIM:
To perform Facing, Plain Turning, Step turning and Taper Turning Operation using Lathe
machine on a given material made of Mild steel.
MATERIAL REQUIRED:
Lathe machine, cutting tool, outside Caliper, Steel Rule, spanner, Vernier Caliper and
Vernier height gauge
CALCULATION:
The taper angle is calculated using the following formula:
Dd
Taper angle () = tan1
2l
Where
D = large diameter of taper in mm
d = small diameter of taper in mm
l = length of tapered part in mm
= angle of taper
PROCEDURE :
2. The cutting tool is set in a tool post such that the point of the Cutting
tool coincides with the lathe axis.
3. The machine is switched on to revolve the work piece at the selected speed.
4. By giving Cross feed and longitudinal feed to the cutting tool (grooving tool) to
obtained Steps at specified dimension.
6. By giving angular feed to the cutting tool through the compound slide the taper
turning operation is done.
8. The work piece is removed from the chuck and all the dimensions are measured
and checked.
AIM:
To perform Facing, Plain Turning, Step turning, Taper turning, V-Thread cutting and Knurling
Operation using Lathe machine on a given material made of Mild steel.
MATERIAL REQUIRED:
Lathe machine, cutting tool, outside Caliper, Steel Rule, V- tool, Knurling tool, Vernier
Caliper and Vernier height gauge
CALCULATION:
The number of teeth on change gears is calculated using the following formula:
Driver teeth/ Driven teeth = Pitch of the work / pitch of the lead screw
PROCEDURE :
2. The cutting tool is set in a tool post such that the point of the Cutting
tool coincides with the lathe axis.
3. The machine is switched on to revolve the work piece at the selected speed.
4. By giving Cross feed and longitudinal feed to the cutting tool, the facing and turning
operations are done respectively.
7. The machine is switched off and the change gears of calculated teeth(as per
calculation) are connected.
9. The external thread cutting operation is done using external Vthread cutting tool
by engaging thread cutting mechanism.
11. The work piece is removed from the chuck and all the dimensions are measured
and checked.
Shaping
M/c
Calculations:
Signature of faculty
Ex.No.4
AIM:
MATERIAL REQUIRED:
Shaping machine, H.S.S tool bit, Vernier calipers, V tool, Vernier height gauge, Plain tool, Dial
indicator
PROCEDURE :
RESULT: Thus, a V-Shape is made in the given work piece to the dimensions using
Shaping machine.
Milling
M/c
Signature of faculty
Ex.No. 5
AIM:
To perform hexagonal head and the slot cutting on the given blank using Milling machine
MATERIAL REQUIRED:
CALCULATION:
Indexing calculation
Index crank movement = 40 / N N = Number of faces required
PROCEDURE :
1. Fit the helical cutter on the arbor and the specimen between the centers of the dividing head
and the tail center.
2. Carefully adjust the work piece so that the cutter just touches the top surface of the
specimen.
3. Calculate the necessary depth of cut and then mill the six faces of the hexagonal head in
succession.
4. Change the cutter and mill the rectangular slot.
RESULT: The Spur gear is machined using the milling machine to the required number of teeth.
Lathe is a machine, which removes the metal from a piece of work to the
required shape &size
1. Single screw
2. Open side
3. Four bolt
4. Four way
7. What is an apron?
The integral part of several gears, levers clutches mounted with the saddle for
moving the carriage along with lead screw while thread cutting
The lathe in which all the machining operations are performed automatically and
loading and unloading of work piece, coolant on or off is performed manually.
The tool of the lathe follows a template or master through a stylus or tracer.
12. State the various feed mechanisms used for obtaining automatic feed?
4. Apron mechanism
1. Chucks
2. Centers
3. Face plate
4. Angle plate
Centering, straight turning, rough turning, finish turning, shoulder turning, facing,
chamfering, knurling, etc...
16. State any two specifications of capstan lathe & turret lathe?
1. Mechanical drives
2. Air drives
3. Hydraulic drives
21. What are the components that can be turned on a copying lathe?
1. Cam shaft
2. Crank shaft
3. Journal bearings
The machine, which is having a reciprocating type of machine tool with a single
point cutting tool, used to produce flat surfaces called as Shapers
24. How the feed & depth of cut is given to the shaper?
Feed is given by rotating the down feed screws of tool head depth of cut is given by
rotating by raising or elevating the table
The planer is used for machining heavy & large casting Ex. lathe bed ways, machine
guide ways
1. Double housing
3. Pit planer
4. Edge planer
1. Bed
2. Table
3. Columns
Drilling is the process of producing hole on the work piece by using a rotating cutter
called drill
When a number of single spindles with essential speed & feed are mounted side by side
on one base and have common worktable is known as gang drilling machine.
34. List any four machining operations that can be performed on a drilling machine?
1. Drilling
2. Counter sinking
3. Tapping
4. Trepanning
35. What are the different ways to mount the drilling tool?
2. By using a sleeve
3. By using a socket
4. By means of chucks
Advantages:
1. Roughing, semi finishing & finishing cuts are completed in one pass of the
broach
2. Broaching can be used for either external or internal surface finish
Limitation:
1. High initial cost of the broach tool compare to other tools
2. Job work or batch work is not advisable due to the high tool cost.
39. What are the different operations that can be performed on a broaching machine?
1. Broaching splines
The boring machine is designed for machining large &heavy work piece in mass
production work of engine frame, cylinder, machine housing etc.
1. A jig boring machine is a precision boring machine used for boring accurate
holes at proper center to center distances.
2. The machining accuracy of holes produce by this machine tool lies with in a
range of 0.0025mm.
1. To remove small amount of metal from work pieces & finish then to close
tolerances.
4. It should be odourless.
The tool is subjected to three important factors such as force, temperature and sliding
action due to relative motion between tool and the work piece. So the tool is wear easily.
49. State any two comparisons between plain &universal milling machine?
1. Arbors
2. Adaptors
3. Collets
51. List the various type of milling attachment?
1. Vertical milling
2. Universal milling
4. Rotary
5. Slotting
6. Rack milling
Body of cutter, cutting edge, face, fillet, gash, lead, land, outside dia, root dia, cutter
1. Cutter with higher rake angle can be used. This reduces power requirements.
2. Cutter wear is less because chip thickness is maximum at the start of cut.
2. Face milling.
3. Angular milling.
4. Gang milling.
5. End milling.
6. Gear cutting.
Indexing is the process of dividing the periphery of a job into equal number of
divisions.
1. Plain or simple.
2. Universal.
3. Optical.
Cam milling is operation of producing cams in the milling machine by the use
universal dividing head &a vertical milling attachment.
60. What are the other forming methods for manufacturing gears?
3. Gear broaching.
4. Template method.
1. Gear shaping used for generating both internal & external spur gears.
1. Gear shaving.
2. Gear burnishing.
3. Gear grinding.
4. Gear lapping.
Advantage:
The process can be used for both internal & external gears.
Limitations:
Gear lapping is also employed for hardened gear teeth by an abrasive action.
The required shape of metal is obtained by removing the Unwanted material from the
work piece in the form of chips is called cutting shaping. Ex: turning, drilling, milling,
boring, etc...
1. Shank
2. Face
3. Flank
4. Base
5. Nose
6. Cutting edge
Back rake angle of tool is increases the strength of cutting tool& cutting action. It can
be classified in to two types
Positive rake angle
Negative rake angle
74. What are all the conditions for using positive rake angle?
Orthogonal cutting:
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.
The ratio of chip thickness before cutting to chip thickness after cutting is called chip
thickness ratio.
The chip breakers are used to break the chips in to small pieces for the removal,
safety & to prevent to machine & work.
Machinability is defined as the ease with which the material can be satisfactorily
machine.
Tool life is defined as time elapsed between two consecutive tool resharpening.
During this period tools serves effectively and efficiently.
1. Cutting speed
3. Tool geometry
4. Tool material
VTn=C