RAJAGIRI SCHOOL OF

ENGINEERING & TECHNOLOGY

RAJAGIRI VALLEY, KAKKANAD, KOCHI - 682039

BASICS OF MECHANICAL ENGINEERING –

PRACTICAL PART
LAB MANUAL

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 INDEX

SL NAME OF PAGE
NO. EXPERIMENT NO.

1 GENERAL TOOLS 1

2 MEASURING AND MARKING TOOLS 8

3 WELDING 11

4 MACHINE TOOLS 15

5 3D PRINTING 22
College Vision

To evolve into a premier technological and research institution, moulding eminent professionals
with creative minds, innovative ideas and sound practical skill, and to shape a future where
technology works for the enrichment of mankind.

College Mission

To impart state-of-the-art knowledge to individuals in various technological disciplines and to

inculcate in them a high degree of social consciousness and human values, thereby enabling
them to face the challenges of life with courage and conviction.

The Vision of Department of Mechanical Engineering

To evolve into a centre of excellence by imparting professional education in mechanical

engineering with a unique academic and research ambience that fosters innovation, creativity
and excellence.

The Mission of Department of Mechanical Engineering

 To have state-of-the-art infrastructure facilities.

 To have highly qualified and experienced faculty from academics, research organizations
and industry.
 To develop students as socially committed professionals with sound engineering
knowledge, creative minds, leadership qualities and practical skills.
 PROGRAM OUTCOMES (PO)

Engineering Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
3. Design / development of solutions: Design solutions for complex engineering
problems and design system components or processes that meet the specified needs with
appropriate consideration for the public health and safety, and the cultural, societal, and
environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data,
and synthesis of the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and
write effective reports and design documentation, make effective presentations, and give
and receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to ones own work, as a member
and leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
change.
 COURSE OUTCOMES

CO5: Students will be able to understand the various manufacturing processes in the basic
mechanical engineering workshop trades

CO6: Students will be able to use various tools used in the basic mechanical engineering
workshop trades.

CO7: Students will be able to select appropriate measuring instruments according to the
work.

CO8: Students will be able to understand the operations of various machine tools and
advanced manufacturing techniques.

CO9: Students will be able to identify the different components of mechanical devices by
assembling & disassembling models.

CO10: Construct models by using various basic mechanical workshop operations

CO11: Apply appropriate safety measures with respect to the mechanical workshop trades.
 SAFETY PRECAUTIONS

1. Ensure that lab coat and shoes are worn before entering the workshop.

2. Never work in loose clothing, tie your sleeves up to the wrist and wear proper head dress
wherever necessary.

3. Girls should tie back their hair to avoid it coming contact with the machines and making
accidents.

4. Never use rings, chains or watches while working.

5. Extra books pouches, etc. should be kept away from work bench and equipment’s.

6. Concentrate on the work and do not talk unnecessarily while working.

7. Avoid shortcuts and use only gangways inside the workshop.

8. Do not attempt to operate the machines before receiving instructions.

9. Ensure that all machines have effective working guards that are always in place when
machines are operating.

10. Never leave any machine when it is running.

11. Be careful for the safety of the others as well as for yourself.

12. Do not try to stop machines with your hands or body.

13. Do not lean against the machine.

14. Always wear safety goggles or face shields designed for the type of work when operating
any machine.

15. Do not attempt to clean oil, adjust and repair any machine while it is running.

16. Ensure proper lighting in the workshop.

17. The work place should be kept clean and free from oil, grease or any other liquid in order
to avoid slipping the workers.

18. Get first aid immediately for any injury.

“Accidents do not occur, they are caused”

 General Tools

Introduction
The process of assembling is joining of finished parts together to form the required component or subassembly of a
machine or equipment. The parts produced may be in a batch production or mass production shop.
Hand tools
Spanners/Wrenches
To tighten and loosen nuts, bolts and studs, spanners are used. They are tools made of forged steel. In British English
“spanner” and in American English “wrench” describe the same tool. Spanners/Wrenches are different in shape to
provide ease of operation under certain conditions. They are manufactured from high tensile or alloy steel. The sizes of
metric spanners are identified by the distance across flats of a nut or bolt head as shown.

Distance across flats (s)

Spanner Types
1- Open-ended spanners
The ends of this type of spanners are generally oriented at an angle of 15º to the
longitudinal axis of the handle to allow greater range of movement in enclosed spaces.
Fig. shows open ended spanners of different sizes.

2- Ring spanners
Ring spanners or box-end wrenches are recommended to be used
when a better grip is needed and when the spanner swing is restricted.
Fig. shows ring spanners of different sizes.

3- Combination spanners
This type comes with an open end from one side and a ring end from the
other side and usually both ends are having the same size.

4- Adjustable spanners
Adjustable spanners are spanners that have a moving jaw to fit
different bolt/nut sizes.

5- Allen keys
Screws or bolts with allen heads ( hexagonal sockets) are tightened
or loosened by using L shaped tool called Allen key. They are made
of hard steel and have hexagonal cross-section.

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 6- Screw Drivers
To tighten or loosen different types of screws, Screw drivers are
used. It consist of a hard steel rod flattened at one end and a wooden or
plastic handle on the other end. The flat end of the tool is inserted in to
the slot provided on the head of the screw for rotating it. The length of
the screw driver is made larger to get high screwing loads without
slipping. Very small size screw drivers are some time called connecters,
since they are used to tighten small screws of electrical fittings.
Different types of screwdrivers, Flathead and Crosshead are shown
below

7- Pliers
Pliers are a hand tool used to hold objects firmly, or for cutting and bending tough materials such as wires. There are
different types such as flat nose pliers, long nose pliers, combination pliers and circlip pliers. These types are designed
to deal with different types of jobs.
Flat nose pliers : These are used to hold pins and small objects when working in confined spaces.
Long nose pliers:Long nose pliers are both cutting and gripping pliers used to bend, re-position and cut wire.
Combination pliers: These pliers incorporate side cutters, joint cutters and pipe grip.
Circlip pliers: Circlips are retaining devices They are fitted inside a groove on bores and shafts. The internal circlip has
to be squeezed to be removed and the external circlip which is fitted onto a shaft has to be opened out to be removed.
shows internal and external circlip pliers. The nose is either straight or bent depending on the type of job.

Long nose pliers

Combination pliers
Flat nose pliers

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 Angle grinder

An angle grinder is a handheld power tool that can be used for a variety of metal fabrication jobs that
include cutting, grinding, deburring, finishing and polishing. The most common types of angle grinder
tools are powered by electricity; either corded or battery powered. An abrasive or cutting or grinding disc is
mounted at a right angle and rotates rapidly to perform the task. There is an adjustable guard and a side-handle for
two-handed operation.

Hand drilling machine

A hand drilling machine, also known as a hand drill, is a portable and manually operated tool used for
drilling holes in various materials such as wood, metal, plastic, and more. It typically consists of the
following components:
1. Handle: The part you grip for control and stability.
2. Trigger or On/Off Switch: Used to start and stop the drilling action.
3. Chuck: The part where drill bits are inserted and secured.
4. Drill Bit: The cutting tool that creates the hole in the material.
5. Housing: The casing that contains the motor and mechanical components.
To use a hand drilling machine, you select the appropriate drill bit, insert it into the chuck, tighten it
securely, position the machine over the material to be drilled, and then activate the trigger or switch. As
you press the drill bit into the material and apply pressure, the machine rotates the drill bit, creating a
hole.

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 Bench Vice
The bench vice is a work holding device. It is the most commonly used vice in a fitting shop. It is fixed to the
bench with bolts and nuts. The vice body consists of two main parts, fixed jaw and movable jaw. When the
vice handle is turned in a clockwise direction, the sliding jaw forces the work against the fixed jaw. Jaw plates
are made of hardened steel. Serrations on the jaws ensure a good grip. Jaw caps made of soft material are used
to protect finished surfaces, gripped in the vice. The size of the vice is specified by the length of the jaws. The
vice body is made of cast Iron which is strong in compression, weak in tension and so fractures under
shocks and therefore should never be hammered.

V BLOCK WITH CLAMP

V‐block is rectangular or square block with a V‐groove on one

or both sides opposite to each other. The angle of the ‘V’ is usually 900
during layout of measurement, for measuring operations or for
drilling for this the bar is faced longitudinally in the V‐Groove and
the screw of V‐clamp is tightened. This grip the rod is firm with its
axis parallel to the axis of the v‐groove. V‐block with a clamp is used
to hold cylindrical work securely, during layout of measurement, for
measuring operations or for drilling for this the bar is faced
longitudinally in the V‐Groove and the screw of V‐clamp is tightened.
This grip the rod is firm with its axis parallel to the axis of the v‐
groove.

CUTTING TOOLS
Files
Filing is one of the methods of removing small amounts of material from the surface of a metal part. A file is
hardened steel tool, having small parallel rows of cutting edges or teeth on its surfaces. On the faces, the teeth
are usually diagonal to the edge. One end of the file is shaped to fit into a wooden handle. The figure shows
various parts of a hand file. The hand file is parallel in width and tapering slightly in thickness, towards the tip.
It is provided with double cut teeth. On the faces, single cut on one edge and no teeth on the other edge, which
is known as a safe edge.

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 Files are classified according to their shape, cutting teeth and pitch or grade of the teeth. The following figure
shows the various types of files based on their shape.

Flat File: It is rectangular in section and tapered for

1/3length in width and thickness towards the point. It is
a general purpose file.

Half Round File: it has one flat and on curved side. The
flat side is double cut and the curved side is single cut. It
is only about 1/3 of circle. This is extremely useful file
for flat surfaces and curved surfaces.

Square File: It is square in sections and carries double

cut teeth on the all four faces. It is tapered for 1/3 of its
length towards the point. It is used for filing corners and
slots. It is also used for cut key ways.

Round file: It is tapered for 1/3 length with double cut

on large coarse grades. Used for filing out round,
elliptical and curved openings.

Triangular file: It is equilateral triangular in sections

and tapered towards the tip. The faces are double cut and
edges sharp. These files are used to file angular hole and
recesses.
The spacing between teeth is known as the pitch (grade). And that has an importance in the performance of the
file. According to the spacing of the teeth, files classified as
1. Rough (R) 8teeth per cm.
2. Bastard (B) 12 teeth per cm.
3. Second cut(Sc) 16 teeth per cm.
4. Smooth (i) 24 teeth per cm.
5. Dead smooth (Ds) 35 teeth per cm.
6. Super smooth(Ss) 50teeth per cm.

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 Hack Saw
The Hack Saw is used for cutting metal by hand. It consists of a frame, which holds a thin blade, firmly in
position. Hacksaw blade is specified by the number of teeth for centimeter. Hacksaw blades have a number of
teeth ranging from 5 to 15 per centimeter (cm). Blades having lesser number of teeth per cm are used for cutting
soft materials like aluminum, brass and bronze. Blades having larger number of teeth per centimeter are used
for cutting hard materials like steel and cast Iron. Hacksaw blades are classified as (i) All hard and (ii) flexible
type. The all hard blades are made of H.S.S, hardened and tempered throughout to retain their cutting edges
longer. These are used to cut hard metals. These blades are hard and brittle and can break easily by twisting
and forcing them into the work while sawing. Flexible blades are made of H.S.S or low alloy steel but only the
teeth are hardened and the rest of the blade is soft and flexible. These are suitable for use by un‐skilled or semi‐
skilled persons.

Chisels
Chisels are used for removing surplus metal or for cutting thin
sheets. These tools are made from 0.9% to 1.0% carbon steel
of octagonal or hexagonal section. Chisels are annealed,
hardened and tempered to produce a tough shank and hard
cutting edge. Annealing relieves the internal stresses in a
metal. The cutting angle of the chisel for general purpose is
about 60°.
Ball‐ Peen Hammer

This is most commonly used for fitting works. Ball‐ Peen

Hammers are named, depending upon their shape and
material and specified by their weight. A ball peen hammer
has a flat face which is used for general work and a ball end,
particularly used for riveting.
Twist Drill
Twist drills are used for making holes. These are made of High speed steel. Both straight and taper shank twist
drills are used. The parallel shank twist drill can be held in an ordinary self – centering drill check. The tapper
shank twist drill fits into a corresponding tapered bore provided in the drilling machine spindle.

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 Reamers
Reaming is an operation of sizing and finishing a drilled hole, with the help of a cutting tool called reamer
having a number of cutting edges. For this, a hole is first drilled, the size of which is slightly smaller than the
finished size and then a hand reamer or machine reamer is used for finishing the hole to the correct size.

Straight fluted reamer Machine reamer (spiral fluted)

Taps and Tap wrenches

A tap is a hardened and steel tool, used for cutting internal thread in a
drill hole. Hand Taps are usually supplied in sets of three in each
diameter and thread size. Each set consists of a tapper tap, intermediate
tap and plug or bottoming tap. Taps are made of high carbon steel or
high speed steel.

Dies and die‐holders

Dies are the cutting tools used for making external thread. Dies are
made either solid or split type. They are fixed in a die stock for holding
and adjusting the die gap. They are made of Steel or High Carbon
Steel.

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 MEASURING AND MARKING TOOLS
Surface plate
The surface plate is machined to fine limits and is used for testing the flatness of the work piece. It is also used
for marking out small box and is more precious than the marking table. The degree of the finished depends
upon whether it is designed for bench work in a fitting shop or for using in an inspection room; the surface
plate is made of Cast Iron, hardened Steel or Granite stone. It is specified by length, width, height and grade.
Handles are provided on two opposite sides, to carry it while shifting from one place to another.

Angle plate
It has two planed surfaces at right angle to each other and has various slots in both the surfaces for holding the
work firmly by means of bolts and clamps. It is used in conjunction with the surface plate for supporting the
work at right angles for marking. It is made of cast iron in different sizes.
Universal Surface Gauge
This is used for scribing lines for lay
out work and checking parallel lines.

Vernier Height Gauge

The Vernier Height gauge clamped
with a scriber. It is used for Lay out
work and offset scriber is used when
it is required to take measurement
from the surface, on which the gauge
is standing. The accuracy and working
principle of this gauge are the same as
those of the vernier calipers. Its size is
specified by the maximum height that
can be measured by it. It is made of
Nickel‐Chromium Steel.

Try square
It is measuring and marking tool for 900 of many types of small
works when extreme accuracy is not required. It is used for
checking the squareness of small works when extreme accuracy is
not required. The length of the blade specifies the size of the try
square.

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 Scriber
A Scriber is a slender steel tool, used to scribe or mark lines on
metal work pieces. It is made of hardened and tempered High
Carbon Steel. The Tip of the scriber is generally ground at 12 o to
15o . It is generally available in lengths, ranging from 125mm to
250mm .It has two pointed ends the bent end is used for marking
lines where the straight end cannot reach.

Punches
These are used for making indentations on the scribed lines, to make them visible clearly. These are made of
high carbon steel. A punch is specified by its length and diameter (say as 150’ 12.5mm). It consists of a
cylindrical knurled body, which is plain for some length at the top of it. At the other end, it is ground to a point.
The tapered point of the punch is hardened over a length of 20 to 30mm. Dot punch is used to lightly indent
along the layout lines, to locate center of holes and to provide a small center mark for divider point, etc.
for this purpose, the punch is ground to a conical point having 60° included angle. Center punch is similar to
the dot punch, except that it is ground to a conical point having 90° included angle. It is used to mark the
location of the holes to be drilled.
Steel Rule
Teel rule is the scale used in the fitting
shop for taking measurements up to
0.5mm accuracy. One side is marked in
millimeters and the other side is in inches.
The material used for making the scale is
stainless steel. Steel rules are usually of
150mm or 300mm in length.

Vernier Caliper
For more precise measurement of length, vernier
calipers to measure length with an accuracy of
0.02mm or 0.001 inch. A vernier caliper basically
consists of a bar having the main scale marked on
it and the fixed jaw for external and internal
measurements. The adjustable vernier head having
the vernier scale, is positioned over the main scale
and carries the movable jaw. There is an auxiliary
head, connected to the main head by micrometering
screw for fine adjustments. Both the heads are
provided with locking screws to lock them firmly
at any desired position.

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 MICROMETER

Micrometer is a precision instrument used to measure the

size up to an accuracy of 0.01 mm. It consists of a
semicircular frame having a cylindrical extension at its right
end and hardened anvil inside at the left end. To measurre
the size of a part using micrometer, the part is placed
between the measuring face (anvil ) and the spindle. Then
the spindle is advanced slowly by screwing the thimble
forward. As the anvil is about to touch the object, the further
movement of it and the pressure of touching is applied by
rotating the ratchet stop. The reading on the barrel as well
as thimble are noted to get the size.

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 WELDING

INTRODUCTION
Arc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode
and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating
(AC) current, and consumable or non-consumable electrodes. The welding region is usually protected by some
type of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully
automated.
WORKING PRINCIPLE
Shielded metal arc wielding is a manual arc wielding process in which the heat required for melting the joining surfaces
is generated by maintaining an electric arc between a flux-coated consumable electrode and the base metal. The flux
coating burns along with melting of a tip of the electrode and produces a gaseous shield to protect the electric arc, weld
puddle and from neighboring areas from atmospheric contamination.

POWER SUPPLY
To supply the electrical energy necessary for arc welding processes, a number of different power supplies can be used.
The most common classification is constant current power supplies and constant voltage power supplies. In arc
welding, the voltage is directly related to the length of the arc, and the current is related to the amount of heat input.
Constant current power supplies are most often used for manual welding processes such as gas tungsten arc welding
and shielded metal arc welding, because they maintain a relatively constant current even as the voltage varies. This is
important because in manual welding, it can be difficult to hold the electrode perfectly steady, and as a result, the arc
length and thus voltage tend to fluctuate. Constant voltage power supplies hold the voltage constant and vary the
current, and as a result, are most often used for automated welding processes such as gas metal arc welding, flux cored
arc welding, and submerged arc welding. In these processes, arc length is kept constant, since any fluctuation in the
distance between the wire and the base material is quickly rectified by a large change in current. For example, if the
wire and the base material get too close, the current will rapidly increase, which in turn causes the heat to increase and
the tip of the wire to melt, returning it to its original separation distance.To convert the standard 3 phase line supply to
the required form any one of these are used
AC Transformer set for A C output
DC Motor Generator set for D C output
DC Transformer rectifier set for D C output

Welding position
There are five recognized positions for wielding
1.Flat or down hand position
2.Inclined position
3.Horizontal-vertical position
4.Vertical position
5.Overhead position

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 Functions of flux covering on electrode
Flux coating over the core wire of an electrode perform the following important functions to produce good
welded joints
1. To strike and maintain the arc
2. To produce protective gaseous shield around the arc
3.To produce a slag blanket on the welded metal
4. To deoxidize and refine the weld metal
5. To add alloying elements to the welded metal
6.To concentrate the arc for better penetration
7.To prevent spatter of metal and thus to get rounded appearance to the weld bead.
Electrode Specification
Electrodes are usually produced in lengths of 250,300,350 and 450mm .About 20mm of core wire length is kept as
bare at one end for inserting into the electron holder to give the power supply. The common size of electrode(diameter)
are 1.6mm ,2mm ,2.5mm,3.2mm,4mm,5mm,6mm
Types of weld
Butt weld - This weld is formed by joing the surfaces of two plates or rods.
Fillet wield - this weld is formed by joining surfaces of plates usually at right angles by filling metal.
Slot weld - to join 2 plates of large area , slots are made on the plate and wielding is done inside these
slots to fill the gap.
Plug weld - this joint is similar to slot weld . Here the slots are replaced by round holesto form the plugs
by welding.
Types of joints
The welded joints usually produced can be classified as
1.Butt joint
2.lap joint
3.Tee joint
4.Corner joint
5.Edge joint

Welding machines
Three types of welding machines are in use:-
a.Welding transformer
It is used to change voltage-current to suitable values for welding, ie low voltage –high current. It operates on AC
Only and it has no rotating parts. Actually it is a step down transformer which reduces the main supply voltage (220 or
440V) to the welding supply open circuit voltage (O.C.V) between 40 and 100V.

b.Welding generator
It is used to generate DC for arc welding. It may be motor driven on engine driven. In the first type, the generator is
driven by an AC motor and main supply is essential to run the machine. In the second type the generator is driven by a
petrol or diesel engine. It can be used anywhere in field work, away from electric lines.

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 c. Welding rectifiers
It is used to convert AC into DC supply and does not have any rotating parts. Basically, it is an AC welding
transformer, but the output of this transformer is connected with a rectifier to change the AC into DC.
Tools & Equipment for arc welding
1) Chipping hammer
It is used to remove the slag from the weld. It resembles a hammer
2) Wire brush
It is used for cleaning the surface of metal and slags from the welds. It is made of steel wires fitted on a
wooden piece.
3) Hand screen(face shield )
It is used for protection of operator’s eyes and face from arc light and molten metal spatter.
4) Safety goggles
This is a pair of eye glasses to protect welder’s eyes from light and spatter of molten metal, similar to face
shield.
5) Hand gloves
It is used to protect hand from heat and arc. They are usually made of chrome leather.
6) Apron
For protecting operator’s clothes and body from heat and arc. It is usually made of heat resistant chrome
leather.

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 Advantages of Arc welding

• Versatility - readily applied to a variety of applications and a wide choice of electrodes

• Relative simplicity and portability of equipment

• Low cost

• Adaptable to confined spaces and remote locations

• Suitable for out-of-position welding

Disadvantages of Arc welding

• Not as productive as continuous wire processes

• Likely to be more costly to deposit a given quantity of metal

• Frequent stop/starts to change electrode

• Relatively high metal wastage (electrode stubs)

• Current limits are lower than for continuous or automatic processes (reduces deposition rate)

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 MACHINE TOOLS
STUDY OF MACHINE TOOLS

SHAPING MACHINE

A shaping machine is used to machine surfaces. It can cut curves, angles and many other shapes. It is a popular
machine in a workshop because its movement is very simple although it can produce a variety of work. The
tool feed handle can be turned to slowly feed the cutting tool into the material as the 'ram' moves forwards and
backwards. The strong machine vice holds the material securely. The vice rests on a steel table which can be
adjusted so that it can be moved up and down and then locked in position. Pulling back on the clutch handle
starts the 'ram' moving forwards and backwards.

Fig A: The tool post has been turned at an angle so

that side of the material can be machined
Fig. B: The tool post is not angled so that the tool can
be used to level a surface.
Fig C: The top slide is slowly feed into the material so
that a ‘rack’ can be machined for a rack and pinion
gear system.

SLOTTING MACHINE

The slotting machine is a reciprocating machine tool in which,

the ram holding the tool reciprocates in a vertical axis and the
cutting action of the tool is only during the downward stroke.
The base of the slotting machine is rigidly built to take up all
the cutting forces. The ram supports the tool head to which the
tool is attached. The workpiece is mounted on the table which
can be given longitudinal, cross and rotary feed motion.
The slotting machine is used for cutting grooves, keys and
slotes of various shapes making regular and irregular surfaces
both internal and external cutting internal and external gears
and profiles The slotter machine can be used on any type of
work where vertical tool movement is considered essential and
advantageous.

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 MILLING MACHINE

Milling: is a metal cutting operation in which the excess material from the work piece is removed by
rotating multipoint cutting tool called milling cutter.
Milling machine: is a power operated machine tool in which work piece mounted on a moving table is
machined to various shapes when moved under a slow revolving serrated cutter.

Horizontal Milling Machine Vertical Milling Machine

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 Up Milling & down milling

The up milling is also called as Climb up milling. In which the cutter and feed moves in opposite direction
i.e the rotary cutter moves against the feed. In down milling the cutting tool is fed with the direction of
rotation. Down milling is always the preferred method wherever the machine tool, fixture and workpiece
will allow.

MILLING OPERATIONS

 Plain or slab milling

 Face milling
 End milling
 Side milling
 Slot milling
 Angular milling
 Form milling
 Straddle milling
 Gang milling
 Slitting or saw
milling
 Gear cutting

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 Types of milling Cutters
1. Plain milling cutter 2.Face milling cutter 3. End milling cutter 4.Angle milling cutter 5.T-slot milling cutter
6.Slitting milling cutter 7.Form milling cutter 8.Fly cutter 9.Woodruff key slot milling cutter

DRILLING MACHINE

Drilling machine is a power operated machine tool which holds the drill in its spindle rotating at high speeds
and when actuated move linearly against the work piece produces a hole.

Types of drilling machine are:

1. Portable drilling machine

2. Bench drilling machine

3. Radial drilling machine

4. Pillar drilling machine

5. Gang drilling machine

6. Multiple drilling machine

Drilling machine operations

Drilling: is a metal cutting process carried out by a

rotating cutting tool to make circular holes in solid
materials. Tool which makes hole is called as drill bit
or twist drill.
Reaming: is a process of smoothing the surface of
drilled holes with a tool. Tool is called as reamer.
Surface finish of the hole will be increased after
reaming.
Boring : It is process carried on a drilling machine to
increase the size of an already drilled hole. Initially
a hole is drilled to the nearest size and using a boring
tool the size of the hole is increased.
Counter boring: Provides a stepped hole, in which a
larger diameter follows smaller diameter partially
into the hole.
Counter sinking : This is an operation of making
the end of a hole into a conical shape. Cutting
speed will be half of the cutting speed of drilling
for a same hole.
Tapping : is the process of cutting internal threads
with a thread tool called as tap. Tap is a fluted
threaded tool, used for cutting internal threads
Cutting speed is very slow.

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 LATHE

Principle of lathe machine

The lathe is a machine tool which holds the work piece between the two rigid & strong supports called centres
or in a chuck or in face plate which revolves. The cutting tool is held and fed against the revolving work.
Cutting tool fed either parallel or at right angles to the axis of work piece. Or may also at an angle.

Principle parts of lathe

Headstock: The headstock is fixed on the machine and it consists of many pulleys, lever, spindle, chuck,
and gear box.
Spindle: The spindle is in the head box which rotates a shaft which is connected to the chuck. This chuck
holds awork piece, so the work pieces also rotate.
Gear box: The gear box is in the head stock which rotates the chuck at different speeds.
Chuck : is used for mounting of metal pieces which are not round shape while having a triangular or a
square shape.
Tailstock: is a moveable part and could be locked. It consists of a barrel that can move forward and
backward. Barrel consists of a Dead Centre which is used to support a work piece.
Carriage: is also a movable part which moves on bed ways. It moves on left and right. It consists of the
saddle, cross slide, compound rest, top slide or tool post and the apron. It is used as mounting and for the
position of tool post.

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 Saddle: The saddle has H shaped. It is on the carriage which helps cross slide to move back and forth on the
machine.
Cross slide: is on the carriage and moves on the saddle. It moves back and forth to give depth of cut to
the metal specimen by using hand wheel.
Compound rest: is on the cross slide which can rotate. It gives support to tool post. It is used in taper turning
by giving an angle.
Tool post: is on the compound rest and used to clamp the cutting tool.
Apron: The apron is on the front of the saddle which has hand wheel and levers. It is used to control the
movement of carriage on the bed: The bed is the main part of the machine which is fixed. It gives support
to all parts of machine like Head stock, Tail stock, Carriage etc. Way: Way is machined on bed which is
actually the rail and provide the movement to tailstock and carriage.
Lead screw: It is a long threaded rod on the bed which provides an automatic feed to carriage from head
stock to tail stock. It is used for giving threads to the work piece.

Lathe Machine operations

Turning: The process in which diameter of a work piece reduces is called turning. It also used to give
finishing the surface of the rod by the diameter of the rod. It can be done by giving feed from tail stock to
head stock and by giving depth of cut.

Facing: The process which is used to reduce the length of a work piece is called FACING. It also used to
give finishingalong the face. It is done by giving feed from forward to backward (cross slide movement).

Step turning: The process which is used to remove excess material from the work piece is called step
turning. It is done by giving depth of cut continuously left and right.

Taper turning: The process which is used to reduce diameter along length gradually is called taper turning.
It is used to make metal surface inclined at an angle to a fixed length. It is done by fixing compound slide
on a given angle.

Knurling: The process which is used to give straight lines angled lines and curved lines to a work the
piece is called knurling. It is used to give different patterns on the fixed length of the work piece. It is done
by knurling tool (havingtwo rollers of opposite pattern) touching it to work the piece at low speed.

Threading: The process which is used to make threads is called threading. It is used to make threads of
required length and depth on a work piece. It is done by fixing tool perpendicular to the axis of work piece
and by giving automatic feed at low speed.

Boring: The process in which material is removed from the inside of work piece is called boring. It is used
to enlarge the inner diameter of the hole. It is done by using a tool called boring bar along the axis of the
work piece.

Drilling: The process which is used to make a cylindrical hole in the work piece is called drilling. It is done
by a tool drill bit fixed it on the tail stock revolving against the revolution of work piece.

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 CNC Machines
CNC (Computer Numerical Control) machines are automated manufacturing tools that use
computer programming to control the movement of cutting tools and other machinery. They are
widely used in various industries, including manufacturing, aerospace, automotive, and electronics.
Working of CNC machines
1. Computer Programming: The CNC machine is programmed using specialized software that
generates instructions (G-code) for the machine's movements. These instructions specify the
coordinates and paths that the cutting tool or work piece must follow.
2. Machine Setup: Before operation, the operator loads the program into the CNC machine's
control unit and sets up the workpiece or cutting tool. This may involve securing the workpiece to
the machine's table or installing the cutting tool in the spindle.
3. Automation: Once the program is initiated, the CNC machine automatically executes the
programmed instructions. This includes moving the cutting tool along specified paths, controlling
spindle speed and direction, and adjusting cutting parameters such as feed rate and depth of cut.
4. Precision and Accuracy: CNC machines offer high precision and accuracy, as they can follow
programmed instructions to within microns or even smaller tolerances. This makes them ideal for
tasks requiring intricate details and tight tolerances.
5. G codes And M Codes: G codes control the movement of the CNC machine, such as tool
positioning and machining operations. M codes control auxiliary functions or operations, like
spindle control and coolant activation.
Overall, CNC machines play a crucial role in modern manufacturing by enabling precise,
automated, and efficient production of complex parts and components.

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 3D PRINTING
3D printing, also known as additive manufacturing, is a technology that creates physical
objects by adding material layer by layer, as opposed to traditional subtractive manufacturing
methods that involve cutting or shaping materials. It is a technology that allows you to produce
physical objects from digital 3D models.

A 3D printer consists of several main parts, which work together to create three-
dimensional objects
from digital designs. These parts typically include:
1. Frame: This is the structural component of the printer, providing stability and support for
other components. It often comes in various designs, such as Cartesian, Delta, or Core XY.

2. Extruder: The extruder is responsible for melting and depositing the 3D printing material,
often plastic filament, onto the build platform. It consists of a hot end (heating element and nozzle)
and a cold end (motor and gear assembly).

3. Build Platform/Bed: The build platform is where the object is created. It may be heated to help with
material adhesion and prevent warping.

4. Print Head: The print head moves in the X, Y, and Z axes, precisely positioning the extruder and
material deposition. It is controlled by stepper motors and guided by rails or belts.

5. Controller and Motherboard: This component manages the printer's functions, interpreting the
digital design files (usually in G-code format) and sending commands to the stepper motors for precise
movement and extrusion.

6. Display/Interface: Most 3D printers have a user-friendly interface, often with an LCD screen,
buttons, or a touch screen, allowing users to control and monitor the printing process.

7. Power Supply: This provides the necessary electrical power for the printer's components, including
the heated bed and hot end.

8. Filament or Resin Reservoir: Depending on the type of 3D printer, it may have a spool for
filament (Fused Filament Fabrication) or a reservoir for liquid resin (Stereo lithography).

9. Cooling System: Fans and heat sinks are used to cool the hot end, prevent material from dripping,
and maintain consistent printing temperatures.

10. Connectivity: Many 3D printers can connect to a computer or network via USB, Wi-Fi, or SD card
to receive printing instructions and firmware updates.

These are the primary components of a 3D printer, and they can vary in design and sophistication
depending on the type and brand of the printer.

Working

1. Digital Design: You start with a 3D computer model or a digital design of the object you want to
create. This design is typically created using 3D modeling software.

2. Slicing: The digital model is divided into very thin horizontal cross-sectional layers using
specialized software. This process is called slicing.

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 3. Printing: The 3D printer reads the sliced design and begins to build the object layer by layer. The
material (often plastic, metal, or resin) is deposited or solidified according to the design, with each
layer fusing or adhering to the layer below.

4. Layer by Layer Stacking: The printer repeats this process, gradually stacking and solidifying
layers on top of one another, until the entire object is complete.

3D printing offers numerous advantages, including the ability to create complex and customized
objects, rapid prototyping, and reduced material waste. It is used in various industries, including
manufacturing, healthcare, aerospace, and education, for producing prototypes, replacement parts,
and even intricate art and jewelry.

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