ME III (3351903)

PRACTICAL NO: 1

Aim:
Demonstrate various cutting parameters, carbide inserts with ISO designation system and explain the
steps to calculate cutting speeds.

Objective:
1. Explain various cutting parameters such as Cutting Speed, Feed, Depthof Cut and Material Removal
Rate (MRR).

2. Tabulate various cutting tools materials with main elements, properties and applications.

3. Calculate RPM for lathe, milling cutter and drill spindle; based on given data. Use equations.
Students should be given different data for diameters and cutting speeds.

4. Calculate strokes/minute for shaping/planning machine based on given data. Use equations. Students
should be given different data for cutting speeds and length of jobs.

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 ME III (3351903)

1. Cutting parameters:
Cutting Speed:
 The distance travelled by the cutting tool per unit time is called cutting speed.
 It is the length of the chip in meter removed by tool in one minute.
 It is relative motion between tool and job during cutting.
 Its unit is meter/min.

Feed:
 The feed may be defined as the distance through the tool advanced through the tool advanced
into the work piece during one revolution of the work piece or the tool or cutter.
 Its unit is mm/rev.

Depth of Cut:
 The depth of cut may be which a tool or cutter is inserted into the work piece metal during one
cut; hence it is the thickness of the metal removed in one cut.
 It is measured in mm.

Metal Removal Rate:

 The metal removal rate is the volume of metal removed in unit time, it helps to calculate time
required to removed specify quantity of material from the work piece.
 Its unit is m3/min.

Machine Tool:
 A machine may be defined as a power driven metal cutting machine which charges the
shape of material or job by producing chips.

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 ME III (3351903)

2. Carbide Inserts with ISO Designation System:

ISO
APPLICATION OPERATION AND WORKING CONDITIONS
RANGE

Finishing of steel & steel casting at very high. Cutting speed & light feeds
P01
under stable working condition.

Finishing & light roughing of steel & steel casting at high cutting speed &
P10
moderate feed under favorable working condition.

Light & rough machining of steel & stainless steel at moderate cutting
P20
speeds & feeds under less favorable working condition.

Roughing of steel & steel casting at moderate cutting speed & heavy feeds
P 30
under unfavorable working conditions.

Roughing of carbon, stainless steel & steel castings at law working speeds
P 40
under particularly difficult working conditions.

Finishing & light roughing of high strength thermal resistance material

M 10
suitable for machining at comparatively high speed.

Machine of austenitic stainless castings. Permits the use of large positive

M 40
rakes & low cutting speeds under unfavorable conditions.

K 01 Finishing of cast iron most wear resistant grade.

Finishing of both tempered steel & C.I when high edge sharpness is
K 10
required.

Finishing & roughing of high & low alloy cast iron. An extremely fine
K 20
grain grade. Combining toughness with high wear resistance.

An alternative grade for C.I & other short clipping materials. Suitable as a
K 30
finishing grade for but strength alloy.

Roughing of C.I & hot strength alloys at heavy feeds & low cutting speeds
K 40
under unfavorable working conditions.

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 ME III (3351903)

3. Various Cutting Tools Materials with Main Elements, Properties and

Applications:
Sr
. Cutting Tool
Main Elements Properties Application
N Material
o
C: 0.9-1.2% - Low wear resistance. - Hand ToolsTools
Small quantities of - Maximum hardness is working at low motion.
Carbon Steel silicon,chromium, about HRC 62. - Lathe Tool, Dies and
1
manganese, and Taps, Reamers and
vanadium Broaches
Tungsten: 18% - Cold Hardness in the - Taps, drills, reamers,
Chromium:4% range of HRC 63-65 gear tools,
Vanadium: 1%, - Hot hardness value much - End cutters, slitting,
High-speed steel
Cobalt: 3-5 %, greater than carbon broaches,
2 (HSS) Molybdenum: 1%, steels. - Roughing Tool for rough
- High toughness and good machining of Forging &
wearresistance Casting.
Non ferrous Alloy - Red Hardness value of - Machining ductile
Tungsten: 12-19% 8000C. material at high speed.
Chromium:30-35% - Can provide better
Stellite Cobalt: 30-35 %, polished surface.
3 Molybdenum: 1%, - Prevent the formation of
built up edge on the tool
face.
Carbide Particles: 55- - Higher values of Red - P Grouping: To cut
90% Hardness. metal into the form of
- Higher Wear long chips.
Cemented Resistance& toughness. - K Grouping: To cut
4 Carbides - Thermal conductivity is metal into the form of
twice that of unalloyed short chips.
steels. - M Grouping: To cut
metal into the form of
medium chips.
Aluminum Oxide - Very high wear - Used for Grinding at
Al2O3: 90% resistance but low High Temperature.
Other 10 % toughness - Remove 20% more
Ceramics OR
Chromium Oxide - Remain stable in air up to metal hence the rate of
5 Cemented Oxide
(Cr2O3), MgO& 18000C. production increases.
Fe3O4 - Non Magnetic
- Resistant to Electricity

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 ME III (3351903)

Sr. Cutting Tool

Main Elements Properties Application
No Material
- The hardest - Non Metallic Tool - Used for truing &
substance ever Material. dressing of grinding
known of all - Resist Heat up to 15000C wheels.
materials. - Higher Wear Resistant - Used in grinding
- A coating material properties. wheels, dies, files,
in itspolycrystalline - Zero Top rake honing stone.
Diamond Tools
6 form angle&less clearance - In lapping paste for
angle. valve & valve seat
- It conducts heat very grinding.
rapidly.
- Co efficient of friction is
less.
- Columbium: 50% - Its vicker’s hardness is - Use is limited only for
- Titanium: 30% 2500-3000. turning, facing and
- Tungsten:20% - High thermal shock boring.
resistance - Not used for
Ucon - High hardness and machining of stainless
7 toughness. steel containing
- High resistance to nickel, cobalt,
diffusion and adhesion titanium etc and super
wear. alloys.
- Nitrogen and Boron - It is next harder to the - Grinding of Lead
diamond. screw, Splines, Ball
- High Hardness and and roller bearings,
thermal conductivity. Slide ways etc.
Cubic Boron
- Does not react with - Used for milling and
8 Nitride
oxygen. turning as indexible
- It is not chemically react inserts.
with iron even at high
temperatures

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 ME III (3351903)

 Some other Tool Materials:-

1. Coated Carbide:
 The high wear resistance and toughness properties of carbide tools are improved by applying
coating of titanium carbide, titanium nitride having thickness of 4 to 8 mm by vapour deposition
techniques.
 It reduces friction hence cutting forces are reduced by 15 to 25%.
 Other coatings in use are multi coating, halfnium nitride, aluminum oxide etc.
 Tool life increases and more metal removal rate is obtained when these coated carbide tools are
used.

4. Equations For Calculate the Cutting Speed:

1. For Lathe Machine Tool:

Cutting Speed (V) = π x D x N

1000
Where,
D = Diameter of Work Piece in mm
N = Work Piece Speed OR Spindle Speed in rpm

Fig. 1.1

2.

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 ME III (3351903)
For Milling Machine Tool:

Spindle Speed (N) = SFM x 3.82

1000
Where,
N = Spindle Speed in RPM
SFM = Cutter Speed in Surface Feet per Minute
D = Diameter of Tool in inch.
λD∗N 3.82 = Constant relates the SFM to Work piece Dia.
Cutting speed V =
1000

Fig. 1.2

Fig.
1.3

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 ME III (3351903)
3. For Drilling Machine Tool:

Cutting Speed (V) = π x D x N

12
Where,
D = Tool Diameter in inch.
N = RPM
V = Cutting speed ft/min.

Fig. 1.4

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 ME III (3351903)
4. For Shaper Machine Tool:

Cutting Speed (V) = Length of Cutting Stroke

Time consumed in cutting stroke

V = n L (1+m)
1000
Where,
L = Length of cutting stroke in mm.
m = Ratio of return time and cutting time.
n = No of cycles of ram per min. (Cycle= One Cutting
and One Return Stroke)
V = Cutting speed m/min.

1. Machine Vice 2. Workpiece

3. Work Holding Device 4.Tool

Fig.1.5

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 ME III (3351903)

PRACTICAL NO: 4
Aim:
Grinding various cutting tool angles.

Objective:
1. Sketch single point cutting tool.

2. List various angles on single point cutting tool and state importance of each.

3. Sketch set up to grind each angle on tool and cutter grinder.

4. Grind the single point cutting tool on tool and cutter grinder.

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 ME III (3351903)

1. Tool Geometry:
 Successful design of cutting tools for material removal process required through Understanding
of function of cutting tools and effect of various angles and nose Radius to be given to tools to
obtain the optimum cutting conditions. The form & Angles to be given to tool is known as tool
geometry.

Single Point Cutting Tool Nomenclature:

Fig. 2.1

1. Shank:- The shank is that portion of the tool bit which is not ground to cutting
edge and is rectangular in cross section.
2. Face: - The face of the cutting tool is that surface against which the chip
slides.
3. Flank: - The flank of cutting tool is that surface which face the work piece.
4. Heel: - Heel of single point cutting tool is lowest portion of side cutting edge.
5. Nose Radius: - Nose of tool is conjunction of side & end cutting edge. As nose radius
increase the tool has lowest life and improves surface finish.
6. Base: - Base of cutting tool is under side of shank.
7. Rack: - Rack is slope of top away from cutting edge.

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 ME III (3351903)

Fig. 2.2 Single Point Cutting Tool Various Angle as Per I.S

Fig. 2.3 Rake Angle

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 ME III (3351903)

2. Various Angles on Single Point Cutting Tool and Its Importance:

Various Angles on
Sr.
Single Point Cutting Its Importance
No
Tool
The main function of clearance angle is to prevent flank
of the tool from rubbing against the surface of work
1 Clearance Angle
allowing the cutting edge only to come in contact with
work material.
The front clearance angle prevent the front flank of tool
2 Front Clearance Angle
from rubbing against the work.
It prevents the side of tool from rubbing against the
3 Side Clearance Angle
work when longitudinal feed applied.
The side cutting edge angle of turning tool is vary from
4 Side Cutting Edge Angle
0° to 90°.
The amount of lip angle determined cutting edge.
5 Lip Angle The lip angle depends upon the amount of rack &
clearance angle provided on tool.
The tool has a positive rack when face of the tool slopes
6 Positive Rack Angle away from the cutting edge & slants towards the back or
side of tool.
A tool has zero rack when face of tool has no slope & is
7 Zero Rack Angle in the same plane or parallel to upper surface of the
shank.
A tool has a negative rack when the face of the tool
8 Negative Rack Angle slopes away from the cutting edge & slants towards the
back or side of tool.

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 ME III (3351903)

PRACTICAL NO: 5
Aim:
To study about various machining methods and prepare a job.

Objective:

1. Sketch the production drawing of the part. Part should include plain/taper turning, knurling,
threading, cylindrical/surface grinding, etc.

2. Outline the processes.

3. Calculate/select, set, observe and record the cutting parameters for each process.

4. List the cutting tools you have used. Also state specifications of each.

5. List the work holding devices you have used. Also state specifications of each.

6. Produce the part.

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 ME III (3351903)

 Basic machine tool process:

1) Lathe machine.
2) Drilling machine.
3) Boring machine
4) Milling machine
5) Shaping machine
6) Planning machine
7) Slotting machine

 Operation on Lathe machine:

1) Turning
2) Facing
3) Boring
4) Drilling
5) Reaming
6) Threading
7) Knurling
8) Grooving
9) Profiling
10) Parting off
11) Spinning

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 ME III (3351903)

Prepared By :Vipul Makwana

 ME III (3351903)

 Operation on drilling machine:

1) Drilling
2) Reaming
3) Boring
4) Counter boring
5) Counter sinking
6) Spot facing
7) Taping
8) Trepanning

 Operations on shaping machine:

1) Machining horizontal surface:

2) Machining vertical surface
3) Machining angular surface
4) Cutting slots, grooves and keyways
5) Machining irregular surface
6) Machining spines of cutting gears

 Operations on boring machine:

1) Chamfering
2) Cornering
3) Counter boring
4) Hole making
5) Counter sinking
6) Hole enlarging etc.

 Operations on milling machine:

1) Plain milling
2) Face milling
3) Side milling
4) Angular milling
5) Gag milling
6) End milling
7) Key way groove and slot milling
8) Gear cutting

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 ME III (3351903)

1. Sketch of Production Drawing:

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 ME III (3351903)

2. OPERATION STEPS:-

1. Take diameter 25mm* 105mm long M.S. round bar as per raw material reqd.
2. Hold the bar in the chuck.
3. Select facing tool & machining parameters for facing.
4. Carry out facing operation.
5. Remove facing tool, mount turning tool on the tool post.
6. Select machining parameters.
7. Now start turning operation roughing to produce 23mm diameter for in 100 mm
length.
8. For the taper turning operation at calculation angle of swivel for compound rest by
using,Tan φ = (D – d)/2l.
9. After calculate angle of swivel, compound rest should be swiveled as per angle & set
it.
10. Create taper by moving compound slide and cross slide for the depth of cut &
complete the taper operation.
11. Move slide compound rest at zero degree.
12. Remove turning tool & mount grooving tool.
13. Remove the grooving tool & mount the knurling tool.
14. Perform straight knurling operation for 25mm length & diameter 23mm.
15. Mount the drilling tool on tail stock.
16. Perform drilling operation for 10mm length & diameter 10mm
17. Perform Tapping operation for 10mm length & diameter 10mm
18. Remove the running tool from tool post & mount the threading tool.
19. Perform threading operation for thread on 20mm length & 16 mm diameter with 1
mm pitch.
20. Remove the threading tool.
21. Perform chamfering for 2 mm length at 45° angle.
22. Perform finishing operation with the help of emery paper.

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 ME III (3351903)

Sr. Depth
Description of Operation M/c used Remark
No. of Cut
Using raw material of Dia. 25 mm & 105 mm Hacksaw
1 --- Hacksaw blade
length. M/C

2 To hold work piece in the chuck. Lathe --- Three jaw chuck

3 Perform Facing operation on both side of job. Lathe 2.5 mm Single point cutting tool

Perform Roughing operation to reduce dia. of job.

4 Lathe 2 mm Single point cutting tool
i.e. dia. 28 mm.

5 Perform Step turning. Lathe --- Single point cutting tool

6 Perform Taper turning operation. Lathe --- Single point cutting tool

Grooving operation for 14 mm dia. in 10 mm

7 Lathe 3 mm Parting off tool
length and 20 mm dia. in 25 mm length.

Perform Drilling operation Drill dia. 10 mm

8 Lathe --- Drill Bit
in 10 mm length.
Perform Tapping operation Drill dia. 10 mm
9 Hand Tap --- Hand Tap
in 10 mm length.
Perform knurling operation for 23 mm dia. in 25
10 Lathe --- Straight Knurlier
mm length.

Threading operation for 16 mm dia. in 20 mm

11 Lathe --- Single point cutting tool
length.

Perform chamfering operation for 2 mm at 45°

12 Lathe --- Single point cutting tool
angle.

13 Perform finishing operation. Lathe --- Emery paper

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 ME III (3351903)

3. Outline The Processes:

Sr.
Operation Tool
No.
1. Facing Operation Single Point Cutting Tool

2. Turning Operation Single Point Cutting Tool

3. Step Turning Single Point Cutting Tool

4. Tapper Turning Single Point Cutting Tool

5. Grooving Operation Grooving Tool

6. Chamfering Operation Single Point Cutting Tool

7. Centering Drill Bit

8. Drilling Operation Drill Bit

9. Tapping Hand Tap

10. Knurling Knurling Tool

11. Threading Threading Tool

12. Grinding Grinding Tool

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 ME III (3351903)

PRACTICAL NO: 7

Aim:
To Study about Gear Cutting.

Objective:

1. Sketch the production drawing of the part.

2. State equations to find module, pitch circle diameter, outside diameter, circular pitch and
number of teeth.

3. Produce spur gear on milling machine using indexing head. Calculate/select, set, observe and
record the cutting parameters.

4. List the cutting tools you have used. Also state specifications of each.

5. List the work holding devices you have used. Also state specifications of each.

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 ME III (3351903)

 Gear Terminology:

Fig. 3.1

1) Module: - Length of each teeth of pitch circle diameter is called module.

m=D/N
m = Module
D = Pitch circle diameter
N = No. of Teeth

2) Circular Pitch: - Distance between two flanks of nearest teeth on pitch circle diameter is
called (C.P) circular pitch.

C.P = ᴫ * m

C.P = Circular Pitch.

M = Module.

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 ME III (3351903)

3) Addendum or Outside Diameter: - Height of tooth space above the pitch circle is called
addendum or outside diameter.

4) Dedendum: - Depth of tooth space below the pitch circle is called dedendum.

Dedendum = Addendum + Clearance

5) Diametric Pitch: - Ratio of no. of teeth to no. of inches of pitch diameter.

6) Pitch Circle: - A circle of radius equal to distance from gear axis to pitch point.

7) Pitch Circle Diameter: - This is main diameter of Gear. At the time of rolling action the
motion of diameter is same as gear motion is called (P.C.D) pitch circle diameter.

8) Pitch Point: - The tangent point of pitch circles of two matting gears.

9) Blank Diameter: - The diameter of blank for gear cutting is called blank diameter.

Blank diameter = P.C.D + (2*m)

P.C.D = Pitch circle diameter

m = Module

 PRINCIPLE OF GEAR GENERATING AND GEAR

FORMING:-
 The surface reproduced by shaper or planner works on generating principle. The tool used
for that in single point cutting tool. Thus the surface produced by providing definite
motion to cutting edge or the cutting tool is known as generating.
 The process of obtaining surface developed on the work piece made as the form tool
profile is known as forming.

 GEAR MILLING BY FORMING PROCESS:-

 Milling machine used for manufacturing all types of gears like spur gear, helical gear,
worm gear, bevel gear etc. In milling machine the cutter rotates on the spindle and work
reciprocates under the cutter, once the cutter finished the tooth profile the work is indexed
for next position.
 There are two types of cutters used like End mill cutter & Disc cutter. End mill cutter
used for big pitch of pinions & Disc cutter used for cutting big spur gear at which more
material is to be removed.

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 ME III (3351903)

Fig. 4.2 Basic Method of Machining Gears by Form Milling

Fig. 4.3 Gear Machining By Form Milling

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 ME III (3351903)

 GEAR BROCHING PROCESS:-

 Gear cutting by broaching machine is known as high production and high accuracy
process. It is mainly used for manufacturing internal gears and helical gears used for high
speed applications. It is also used for spur gear production.

Fig. 4.4 Gear Machining By Form Milling

1 – elongated body,
2 – teeth,
3 – gullets,
4 – teeth gaps,
5 – axis,
6 – follower end,
7 – pull end,
10 – outside shape of broach,

 GEAR SHAPING PROCESS:-

 The cutter used in gear shaping machine is one type of gear on which cutting edge
present. In this pinion or rack is used for gear cutter. This modification of the gear
shaping process is defined as a process for generating gear teeth by a rotating and
reciprocating pinion-shaped cutter. The cutter axis is parallel to the gear axis. The cutter
rotates slowly in timed relationship with the gear blank at the same pitch-cycle velocity,
with an axial primary reciprocating motion, to produce the gear teeth.

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 ME III (3351903)

 A train of gears provides the required relative motion between the cutter shaft and the
gear-blank shaft. Cutting may take place either at the down stroke or upstroke of the
machine. Because the clearance required for cutter travel is small, gear shaping is suitable
for gears that are located close to obstructing surfaces such as flanges.

Fig. 4.5 Gear Shaping

 The tool is called gear cutter and resembles in shape the mating gear from the conjugate
gear pair, the other gear being the blank. Gear shaping is one of the most versatile of all
gear cutting operations used to produce internal gears, external gears, and integral gear-
pinion arrangements.

 Shaping with a rack-shaped cutter

 In the gear shaping with a rack-shaped cutter, gear teeth are generated by a cutting tool
called a rack shaper. The rack shaper reciprocates parallel to the axis of the gear axis. It
moves slowly linearly with the gear blank rotation at the same pitch-cycle velocity: The
rack shaper is actually a segment of a rack. Because it is not practical to have more than
6-12 teeth on a rack cutter, the cutter must be disengaged at suitable intervals and
returned to the starting point, the gear blank meanwhile remaining fixed.

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 ME III (3351903)

Fig. 4.6 Gear Shaping Processes

Fig. 4.7 Gear Shaping by Rack Cutter

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 ME III (3351903)

 GEAR HOBBING PROCESS:-

 Hobbing is generally used for external gear cutting. By using special module number of
hob different number of teeth obtained in spur and helical gear manufacturing. Worm,
worm wheel, straight and involutes gears also generate by hobbing process.

Fig. 4.8 Gear Hobbing Process

 When hobbing a spur gear, the angle between the hob and gear blank axes is 90° minus
the lead angle at the hob threads. For helical gears, the hob is set so that the helix angle of
the hob is parallel with the tooth direction of the gear being cut. Additional movement
along the tooth length is necessary in order to cut the whole tooth length.

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 ME III (3351903)

Fig. 4.9 Gear Hob

Fig. 4.10 Gear Hobbing Process

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 ME III (3351903)

 GEAR FINISHING PROCESSES: -

 The gears produced may have some errors. E.g. Pitch circle process, helical errors, Tooth
profile errors etc. To eliminate these errors gear finishing is to be done. There are four
processes employed for gear finishing.

1. GEAR SHAVING:-
 Gear finishing operation is carried out by gear shaving cutter by this method index error
of gear tooth, helix angle error, profile error can be rectified and also distortion of gear
tooth due to heat treatment can be rectified.

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 ME III (3351903)

Fig. 4.11 Gear Shaving Process

2. GEAR GRINDING:-
 Gear grinding is generally used to finish a gear tooth profile which has been heat treated
to require hardness, other gears has been cutting out on grinding machine. Grinding
method use disc type grinding wheel having a shape corresponding to tooth profile by
using simple disc wheel the finishing of tooth is done.

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 ME III (3351903)

Fig. 4.12 Gear Grinding Process

3. GEAR LAPPING:-
 Gear lapping is done after heat treatment of gears. In this process soft lapping tool grind
on surface of gear tooth, by using abrasive compound between tools and surface from
which gear finishing is possible.

4. GEAR HONNING:-
 Gear finishing by gear honing process is done after shaving and heat treatment of gears
from which small burrs remove from gears. This process is used to grind gears with
abrasive tools used for special design of high speed machine.

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 ME III (3351903)

PRACTICAL NO: 6

Aim:
To Study about process planning, workshop layout and route sheet for complex job.

Objective:

1. Sketch the production drawing of the part. Part should include shaping, milling, drilling,

taping, boring, slotting, surface grinding, etc.

2. Outline the processes. Prepare process plan for the same.

3. Prepare workshop layout and route sheet.

4. Produce the part, Calculate/select, set, observe and record the cutting parameters for each

process.

5. List the cutting tools you have used. Also state specifications of each.

6. List the work holding devices you have used. Also state specifications of each.

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 ME III (3351903)

 Process Planning:
 Process planning is also called: manufacturing planning, process planning, material
processing, process engineering, and machine routing.
 Which machining processes and parameters are to be used (as well as those machines
capable of performing these processes) to convert (machine) a piece part from its initial
form to a final form predetermined (usually by a design engineer) from an engineering
drawing.
 The act of preparing detailed work instructions to produce a part.
 How to realize a given product design.

PROCESS
PLANNING

Design Machine
Tool

Process
Planning

Scheduling and Production Control

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 ME III (3351903)

 Process Plan:
 Also called: operation sheet, route sheet, operation planning summary, or another similar
name.
 The detailed plan contains:
 Route
 Processes
 Process parameters
 Machine and tool selections
 Fixtures
 How detail the plan is depends on the application.
 Operation: a process
 Operation Plan (Op-plan): contains the description of an operation, includes tools,
machines to be used, process parameters, machining time, etc.
 Op-plan sequence: Summary of a process plan.

 Requirements in Manual Process Planning:

 Ability to interpret an engineering drawing.
 Familiar with manufacturing processes and practice.
 Familiar with tooling and fixtures.
 Know what resources are available in the shop.
 Know how to use reference books, such as machinability data handbook.
 Able to do computations on machining time and cost.
 Familiar with the raw materials.
 Know the relative costs of processes, tooling, and raw materials.

 Process Planning Steps:

 Study the overall shape of the part. Use this information to classify the part and
determine the type of workstation needed.
 Thoroughly study the drawing. Try to identify every manufacturing features and notes.
 If raw stock is not given, determine the best raw material shape to use.
 Identify datum surfaces. Use information on datum surfaces to determine the setups.

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 ME III (3351903)

 Select machines for each setup.

 For each setup determine the rough sequence of operations necessary to create all the
features.
 Sequence the operations determined in the previous step.
 Select tools for each operation. Try to use the same tool for several operations if it is
possible. Keep in mind the trade off on tool change time and estimated machining time.
 Select or design fixtures for each setup.
 Evaluate the plan generate thus far and make necessary modifications.
 Select cutting parameters for each operation.
 Prepare the final process plan document.

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 ME III (3351903)

PRACTICAL NO: 3

Aim:
Demonstration of Kinematics and motion transmission systems of machine tool.

Objective:

1. Sketch and label main elements of machine kinematics.

2. Demonstrate and explain machining process with position/motion of work piece and tool.
Video may also be used.

3. Sketch cutting tools with nomenclature.

4. Sketch tool holders.

5. Explain methods of work and tool mounting systems.

6. Tabulate cutting parameters for commonly used tool materials and work piece materials.

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 ME III (3351903)

 GRINDING MACHINE:-
 Grinding machines are broadly classified into cylindrical grinding machine internal
grinding machines surface grinding machine and tool and cutter grinding machine.
Depending on the shape of the ground surface and type of grinding they do.

1. CYLINDRICAL GRINDING MACHINE:

 Cylindrical grinding is performed to remove material to produce a precise geometry and
to obtain the desire surface finish on external these surface may be cylindrical tapers,
fillets, grooves, shoulder and other formed surface of revolution.
 Three basic types of cylindrical grinding machine:
I. center type
II. chucking type
III. center less type

I. Centre type cylindrical grinding machine:-

 center type grinding is use for single and multi-diameter .shaft especially .when the
concentrically must be head between diameter ground in sperate operation .in these type
of machine the work piece is supported in between centers consists of a bed a wheel .
 Head stock and tail stock are mounted on a scoriae table which in turn is mounted on a
sliding table which moves to and fro in the bed guide way center type cylindrical grinding
machine be manually operated of fully automatic.
 Thecenter type cylindrical grinding machine as classified as universal plain &plane types.
Universal cylindrical grinding machine these machine are usually of the manually
operated it possible to do internal grinding and surface grinding operation the capabilities
can be further enhanced by making semi-automatic.
 It could also the used as a clucking type grinder.

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 ME III (3351903)

 The different operations possible one universal cylindrical grinding machine are in direct
in fig. the feature of the universal machine is general are:-
1. Work head mounted on the survived base which can be also displaced longitudinal
along the table.

2. Work head spindle can be converted from dead center from dead center to rotating
spindle type operation or vice vessel.

3. The work head and the wheel head can be survived to facilities taper grinding.

4. An internal drilling device in the machine with facilities taper to fit any of the several
different types of spindle.

5. Wheel turning devices for straight radius angle staring.

6. Provision is made for variety of work holding &supporting devices like 3 jaw chuck,
4jaw chuck independent chucks magnetic chuck&different type of steady rests.

II. PLAN CYLINDRICAL GRINDING MACHINES

 The design emphasis in this category machine is more on productivity than on versatility
without compromising on the work accuracy these plain grinder are equally adaptable
for transvers and plunge grinding.in plunge grinding machine facility to profile training of
wheels is invariably provided.

PLUNGECUT CENTRE TYPE GRINDING MACHINE: -

 In plunge type grinding machine the wheel is plunged into the work at a predetermine
feed rate and it’swithdrawn at the time the work piece reaches the correct size angular
wheel slide and straight plunge machine fall into this category these machine. Find
application in high volume. Production machine find application face or showed by the
wheel produce a scrape pattern on the shoulder which is under servable pattern on trout
bearing surface.
 In traverse grinding this can be improved by using a dished wheel there the cutting is
effected only may by these external edge of the wheel .limiting the no of grins particular
in castings and the length of contact of the grain with the work piece is more this results
in excessive wear at the edge the contact surface between the wheel the work piece s large
to overcome these draw chuck as angular when obtained as regarded to quality of the
ground component.

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 ME III (3351903)

1. The manual perpendicular of the ground surface is inherent in the shape of the trued
wheel faces otherwise a converting a step grinding the length the other on the
should this may not quality a perfect perpendicular.

2. The wheel contact on the flat shoulder, surface. Generally per mints a fit work surface
stock remove without damaging the work surface of the wheel, the contact of the
wheel, rotating around an axis inclined to the both work surface produces a smooth
surface pattern on the shoulder.

 Angular grinders are usually quipped with precisely operating power driven wheel
training device which use profile templates to generate the required profit.

2. CHUCKING TYPE CYLINDRICAL GRINDING:-

 Chucking type cylindrical grinders are used to grain external diameter on work piece
which are relatively short having no center holes no convenient surface for driving.
 The work head of the chucking grinder includes a rotating spindle on which the chuck is
mounted when the machine is provided with on automatic chuck and loaders it become an
extremely productive grinding machine. If the length of the job is more the job can be
supported by a center.
COSTRACTION DETAIL:-

 The appear surface of the bed has the general from of an along the use of this are the
ways for carrying the table mounted with work head on its slide is carried on the vertical
limb of that usually it is arranged that machine base follows the three condensed shape
with respect to the points upon which it rests If four point of support are use there is
always the possibility of one us un support.
 The direction that this might cause in the machine frame would fatal to the precision
grinding machine.

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 ME III (3351903)

Wheel head and slide

 On the universal machine this is mounted on an internal turn table permitting it to be
swiveled and feed at any angle on the plain machine the head is fixed and moved
perpendicular to the table. The head may be moved by wheel place in the front of the
machine as in the type of the wheel. The movement ratio wheel mountain on it.by this
means contact is always side of the operation mechanism in which even way the
operating wheel is turn the slide response immediately without any lost motion.
The Table

 The table is carried on the of at the top of front and carried the work head automatic
length travel is provided for of stroke and release being work after by adjustable type
which operate flat in section the letter shape often being found on plain machine
because of this types of machine has graduated.
 The table is secreted from the slide which carries it clamping nuts at the end at one and
adjusted screw front rotating in one means.
 The axis of the table may be set at angle for table may be set a taper work and corrected
taper permitted. A scaled of degree taper per unit length etc.

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 ME III (3351903)

 What is broaching:-
 Broaching m/c is a machining process in which a cutting tool that has multiple
transverse cutting edges is pushed or pulled through a hole or over surface remove
metal by axial catting because broaches are multi-toothed catting tools produced close
tolerance, they are expensive, consequently the process usually is employs only for high
production.
 Some part configurable however are practical to produce only by branches, for parts of
this type, thebroaching of low production quantities maybe warned because several
edges of a broach are cutting at one, force are much greater than in other machining
methods and broaching is rated as the most swirl of all machining operation.

 Application:-
 Broaching maybe employed in a wide range of application and where application at
leastseveral advantages over other making process, because both roughing and finishing
can be done in a single pass of the broach broaching m/c is rapid and efficient. More over
because close tolerance can be held and smooth surface provided.

 Subsequentoperation are seldom required. Almost any irregular shape can be broached if
is regular in the direction of broach travel. Large surface can be reached flat in on pars.

 For many applicationbroaching is selected because it is cheaper or faster, even though

acceptable result could be obtained by other-machiningmethod such as milling, boring,
shaping or reaming.

 Broaching Machine:-
 Broaching m/c are required for machiningexternal and internal surface of various
contours in mass and large lot production. There m/c are distinguished for their
exceptionally high wt. put they produce surface that are highly in shape and size.

 Machine employed for internal broaching can make holes of and shape and of a length
there or more times the transverse dimension.

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 ME III (3351903)

 M/c used for external broaching can efficiencyproduce, not only flat surface, but other
rated surface, including those of complex controls. Example include the external of main
bearing caps, connecting rods and many other similar part.

 The attainable and economically feasible accuracy and surface finish obtained in broach.

 The application of broaching m/c is not limit to large-lot and mass production. Certain
models of broaching m/c are suitable for small lot end eyepiece production conditions.
One there is the m/c for broaching key ways in the holes of parts of various shapes and
sizes with only seven sets of interchangeableparts, these m/c can broach keyways from 3
to 125 mm wide in holes from 12 to 60mm in dia.

 In comparison with other types of m/c tools, broaching m/c are notable for their simple
contact and o/p. This is due to fact that the shape of the surface produced in broaching
depends upon arrangement of the catting edges on the branch.

 The primary catting motion in branch is a straight line motion of either the branch, having
cutting edges of shape corresponding to the contour of the required surface or of the work
while the tools is held stationary. Broaching m/c have no feed mechanism since the feed
feature provided for by the gradual larger than has of the broach teeth.

 Horizontal Machines:-
 A general purpose m/c and maybe used for high or low production quantities. For m/c
interruptingextremely long stokes horizontal moment is the most practical.

 Broach of large length would be excessively heavy and would require a more expensive
m/c for vertical then for horizontal o/p. Therefore a horizontal m/c with accessories to
assist in supporting the weight the broach would be more practical. In addition, smaller
work handing equipment is required for lifting a heavy-broach in to position in a
horizontal m/c then in a vertical m/c. Horizontal m/c for internal broaching classified as
''poll'' or "pus" m/c depending on how force is applied to the broach. Cutting fluid supply
requires more attentionhorizontal broaching.

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 ME III (3351903)

 It is often easier to supply catting fluid to the full length of catting fluid to the full length
of cutting section of a vertically operated broach especially of the poll-down type.
However supplying catting fluid to the catting areas sometimes requires considerable
ingenuity.

 Vertical broaching m/c are further classified as "poll up" pull down or push broach m/c
depending on the direction movement when the broach is cutting.

 What is Broaches:-
General:
 Broaches are tools that are used for the shapping of work pieces by means of the removal
of shavings.

 The overall appearance of the tool is that of toothed rod.

 Broaching i.e the rectilinear working movement between the tool and the work piece, is
followed by a corresponding variation in the section of the piece. The essential feature of
this type of o/p therefore is that the tool is self-fed. This means that the broaching m/c. It
self is simple to operate.

 According to the purpose for which they are used broached are divided in to internal and
external types. For the working of holes and external surfaces respectively. Both type can
be used on any m/c tool whose basic features include a horizontal or vertical movement
producing poll or compression free in the tool itself.

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 ME III (3351903)

 Manufacturingdistinguish two forms of broach on the basic of the working system

employs

a. Circularcore Broaches:-with these broaches the main working stages are carried out
by means of rotary motion of the broach about its longitudinal axis.

b. Rectangular core broaches: - here the main o/p are carried out by the alternate
rectilinear movement of the pool. Broaches belong to this category.

Types of broaches:-
 There are three broaches 1) sold, shell and lancer type within these categories broaches
afurtherclassified by the type of cut. They are design to make and by the method of cut
they are design no to make and by the method by which they are actuated.

Solid broach:-
 Solid broach are on piece broaches produced from bar stock. They can be provided
greater dimensional accuracy and concentricity than shell broaches. The chief
disadvantage of solid broaches lie in the cost of replacement when wear or elsenecessities
it.

Shell broaches:-
 Consist of a main broach body on arber section are which a removable shell &it and
removal shell that is the finishing section. A broach can have man than one removable
shell. Shell broaches can be used for internal broach half bores. Shell broaches are
superior to solid broaches in that worn or broken sections can be replaced without
discarding other sections.

Insert type broaches:-

 Are made up of a tool holder and inserts of high speed steel or carbide which do the
catting. Although these broaches maybe used or broaching contrivedshapes, both internal
and external, their main use is for broaching large flat surfaces, such as the machined
faces of automotive engine block.

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 ME III (3351903)

Pull broaches:-
 As the name implies are pulled thorough or against the surface of the work piece most
internal broaching is done with pull broaches can be longer than push broaches for the
same size of hole, and they also can remove more stock in one pass although pull
broaches can be made to long length, their cost usually limits solid pull broaches to a
length of about 7 f.t.

Push Broaches:-
 For internal broaching are necessary shorter than pull broaches, because of the problem of
bending under load. Push broaches are used to broach blind holes or for multiple station
broaching m/c where in swirl short broaches rather than a single long broach are used to
reduce the time rigid for a given operation.

Broach material:-
 Hardened high speed steel is by for the most widely used material for solid broaches or
for the cutting teeth of other types of broaches. The tool usually are ground to find
dimensions after hardening. The grade of him speed steel is normally chosen on. The
basic of minimum overall cost balancing tool life end. Production rate against tool cost.

Special broaches:-
 Technological or commercialreusing very often exist for the use of special profiles. A few
example are illustrated below.

 Toothed profile for male coupling reverses to hood the balls are provided inside the
coupling tooth, the latter, regulate the relative radial end axial position.

 The series of broach used for this type of working has a diameteral step for the first step
in the second stage. The broach works on the, sides only so as to obtain the required and
rest profile.

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 ME III (3351903)

 Gear Hobbing:
 The generating process require on accurate relationship between arias element of the m/c
in order to achieve desired result. The work table rotates in a desired relationship with the
rotation of the job.

 This relation is timed by index chasing gears for hobbing helical gears the rotation of the
work table is slight advanced or related in relation to rotate of the axial feed crew by
means at another set of change gears called different gear.

 Basic Types of Hobbing M/C:

 Hobbing machines are available in a number of forms sizes and configuration, through
the principal remains the same. The mast popular arrangement is the vertical m/c where
the axis of the work pic. And the feed motions are vertical. This configure is suitable for
the must size of workpiece from the small to large diameter and permits easy work
handing. A typical vertical gear hobbing m/c is shown fig.

 Advantages & Limitations of Hobbing Process

Advantages:
 The main advantage of the hobbing process is its veracity in that it can cover a verity of
work in chiding spur gear worm and worm gear and helical gears. Sapling and Serrations
very and helical gear saplings and serrations and a variant of special from.

 The indexing is continues and there is no intermission to give rise to errors. There is no
loss of time due to non-cutting on the return stake.

 It is also possible to generate internal gear but the application is very limited end a special
hold head on the m/c and special cutting.

Limitation:
 The limitation is that some gears are respected by adjacent showier large them the root
dia of the gear and close once to restrict the approach or run out of the hub.

 Sling and serration are sometimes rears with one tooth blocked or remove this tape of
component hovered is not suitable for hobbing although it is idea for gear shaping.

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 ME III (3351903)

 Hobbing Techniques:
 Shows in fig. two condition of hobbing and the type of chip removed for spear or helical
tooth forms where the hob switch setting angel is relation small the type of cutting actions
can be either condemnation or climb depending upon the rotation of the hub and the feed
direction for helical tooth forms where the job swaged setting angle is usually large the
type of cutting action is deferment by the rotation direction of workpiece rotation.

 In contention hobbing when the job swivel setting angel is small the hob is feed along the
work piece in a direction which is in argument with the tangential vector demoting the
direction of the hob rotation.

 The condition exist in the cutting zone as allegory in for component having large hail
angel, conversation type of hobbing exits when a component of hood rotation is oppose to
the work piece rotation. The holds tare when the work pieceheld are a like with a work
piece helix the axis of the work piece since the direction of the work piece rotation
depends solely upon the rotation of hob and its hand oh helix the hand of the work piece
helix deforming whether the job rotation oppose the work piece rotation.

 GEAR SHAPPING M/C:

 Gear can be shaped using the followers process which is the most versatile of all the gear
cutting process the shaping process make use of a hardness pinion as actuate ground with
top rack and clears fig. shown pinion cutter diagram. The cutter required the blank face
and can cut either on the unstock or down stock. A reliving m/c enable the cutter to clear
the work on the return stock.

THE M/CING CYCLE IS:

(a) GearCutter feed into fall depth, with cutter reciprocating and blank station.
(b) Cutter and blank slowly rotate until all the teeth are generated upon the blank.

 As with most gear cutter the blank is usually rouged to say there quote depth follows by
finishing external and internal spear gear and racks if used with a rack cutting attachment.

PINCIPAL OF SHAPPING M/C:

 Most single spindle gear shaper are of vertical configuration though. Essentially the
pinion type cutter is a gear with cutting edges and measure are provided to roared the
cutter is reciprocated along its alone axis at high speed at the same time a feed avoid
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 ME III (3351903)

motion is applied to one the other of the two number those presently diff. parts of the
flanks of the cutter to the gear to from the inviolate profile.

 The feed motion is measuring as the advantage per stork around the pitch circumference it
makes stock given by the ratio.

£=pitch dia /feed per stroke * π

 This value is often reference to as the rotary feed ‘F’ stoke per revolution of the cutter
following there for that if the gear was of the feed 0.314mm pre stoke and is the number
of teeth in the gear then.

❑ 100 π
£= ❑ =100
0.314

 Those the gear is produced in low stokes of cutter or each tooth been produced by 25
stocks of the cutter.

 It can be seen therefore that on external fine finish can be obtain by the shaper process as
the feed has a direct by on the number of cutter edges used to product the involve which
is not the core with the hobbing process. If the feed rate in about mended example is
change to 0.314mm per stokes and tooth of the gear would then be produced by 250
strokes of the cutter. The pitch circle dia of the cutter therefore often both the index and
o/p smoke by after note the dia.

 The other machining include cutter is feed and riving diving the return stock feeding
mechanism should be verify to thetwo –three or four cross depending upon the size of the
gear.

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 ME III (3351903)

PRINCIPAL OF GEAR SHAPPING PROCESS:

 Gear shaping is a generating process the sapper cutter is virtually a gear provides with
cutting edges the tool is rotated at the required velocity ratio relative to the gear tooth.
Consoling only errors on the cutter tooth are required directly in the corresponding gear
teeth space.

 As the cutter rotates with the gear it forms the tooth space by incremental cats depending
upon the used feed rate since by cats incremental depending upon the used feed rate since
two teeth are formed by a series of closely speed individual cuts and the involute on the
gear is in feat a series of finally spaced cuts .

 The depth of those cuts is however exceeding small even for relatively high feed rotes
and for all practical purpose the involve can be regarded as a smooth come.

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 ME III (3351903)

PRACTICAL NO: 8
Aim:
To Study about thread cutting procedure
Introduction:
Thread is ridge of uniform cross section in the form of a helix provided on the outside or inside of a
cylindrical or conical surface.External threads are provided on bolts, screws while internal threads
are on corresponding nuts or any machine members.Functionally fasteners are threaded for holding
component securely.Thread manufacturing is a very important manufacturing activity because of
huge demand of high precision fastening devices and power transmission systems.

Elements of Screw thread:

 Major Diameter
 Minor Diameter
 Pitch Diameter
 Pitch
 No. of start ( Independent thread on job surface)
 Lead hand
 Thread depth
 Thread angle
 Crest
 Root
 Addendum
 Dedendum

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Methods of Thread manufacture:

a. Thread cutting on Lathe
b. Thread Chasing
c. Die threading
d. Tapping
e. Thread Milling
f. Thread rolling
g. Thread Grinding
h. Thread casting
i. Thread Whirling

Thread cutting on Lathe

 Principle is to produce helical groove on a cylindrical or conical surface by feeding tool
longitudinally when job is rotating.
Steps :
 Selection of cutting tool
 Mounting of cutting tool and workpiece
 Establish relation between longitudinal movement of cutting tool and work piece rotation.
 Thread Cutting
 Tool feeding and Thread catching

Die Head Threading

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 ME III (3351903)

External threads cutting On a cylindrical or taper surface by means of Solid and self opening dies is
called die threading. Dies are look like nuts but it is made of Hardened Steel or HSS with sharp
cutting edges.This dies are coaxially rotate around the blank.
Types of Die
 Solid die
 Self opening die

In Spring dies elastically reduction in bore is possible and cut threads in number of passes. In Split
die , die is made in two pieces. One is fixed and other is moving within cavity of wrench.

Tapping:
Tapping is Thread cutting process for producing internal threads. Multipoint cutting ( Tap ) is used
like die threading and cutting may be done manually or on machines. In machine, process is similar
as manual tapping except feed being automatic and threads will be high accurate and uniform.
During machining features like fast retraction of the tool, automatic loading or unloading, use of
multiple spindles; machining rate will considerably increased. Taps are classified as Solid taps and
Collapsible taps.

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