NAGARJUNA INSTITUTE OF ENGINEERING

TECHNOLOGY & MANAGEMENT

DEPARTMENT OF MECHANICAL ENGINEERING

LABORATORY MANUAL

Machining
Processes

B.TECH. Fourth
Semester
 Department of Mechanical Engineering

Name of Student File:

Name of Subject File: Machining process
Name of Faculty:

Lab In charge:
Subject Code: BEME 401 P (CBCS)
Semester:4th(CBCS)
File No.:
 1. Course Objectives
1. This course is designed to provide students with an overview of a wide variety of
machining process for processing of engineering materials.
2. Students will learn principles, operations and mechanisms of various machines.
3. Students will develop an interest in manufacturing and machining processes.
4. Students will understand the tools and their applications
5. Students individually will make models after understanding the machining operations
6. Upon completion of this course, students shall understand the importance of machining
processes and beable to select and apply suitable processes for manufacturing an
engineering product.

Hours / Maximum Marks

Course Week
Semester Credits
Title(Subject) Continual University
L T P Total
Assessment Examination
Machining
IV 00 00 02 01 25 25 50
Processes
Course Outcomes

2. Course Outcomes
After successful completion of this course the student will be able to:
CO1 Understand basic cutting tools.
CO2 Working of lathe and turning operation
CO3 Shaping and planning operation
CO4 Milling and drilling operation
CO5 Grinding and surface finishing
Sr.No.
List of Practical’s
01 Study of Single Point Cutting Tool.
02 Studyof Various forces on single point cutting tools.
03 Study of multiple point cutting tools (milling, drilling)
04 Study of Lathe Machine.
05 Study of Shaper mechanisms.
06 Study of milling machine
07 One Job on Milling.
08 One Job on Drilling, Boring
09 One Job on Thread Cutting, Taper Turning.
10 One Job on Surface Grinding.
 EXPERIMENT NO. 01

Aim: Study of Single Point Cutting Tool.

THEORY/ WORKING PRINCIPLE:

Single Point Cutting Tool is a tool that helps to perform several operations (like Turning, Facing,
and Producing Flat surface) on Lathe, Shaper, and Planer Machine.
Single Point Cutting Tool:

This tool consists of a sharpened cutting part called its point and the shank.

The point of the tool is bounded by the face (along which the chips slides as they are cut by the
tool), the side flank or major flank the end flank or minor flank and the base.

Several operations on the lathe (like turning, facing) from thesingle-point cutting tool.

Design and fabrication are very easy for this tool.

This tool can be made at a very cheaper rate as compared to others.

Single point cutting tool

Single Point Cutting Tool Types:

There are only two types of tool:

1. Single and
2. Multi-Point cutting tool.

1. Single Point cutting tool:

One cutting point or tip is available

Example: Lathe Machine, Planning Machine tool
2. Multi-Point cutting tool:

More than One cutting point or tip is available

Example: Milling cutter, Grinding wheel, drill tool, extra.

Single Point Cutting Tool Material:

This tool can be made from several materials like:

High carbon steel

High-speed steel
Ceramics
Cerements
Diamonds
Ucon
Cemented carbide
CBN (Cubic boron nitrite)

Single Point Cutting Tool Geometry / Nomenclature:

1. Shank
2. Flank Face
3. Heel
4. Nose
5. Nose radius
6. Cutting Edges

Angle:

1. Side Cutting edge angle

2. End cutting edge angle
3. Side relief angle
4. End relief angle
5. Back Rack angle
6. Side rack angle
Here you can see in this diagram:

1. Shank:
 This is the main body of the tool. The shank is used to hold the tool (i.e tool holder).

2. Flank:
The surface or surface below and adjacent to the cutting edge is called flank of the tool.

3. Face:
The surface on which the chips slide is called the face of the tool.

4. Heel:
It is the intersection of the flan and the base of the tool. It is a curved portion at the bottom
of the tool.

5. Nose:
It is the point where the side cutting edge and end cutting edge intersects.

Notes you want to make:

6. Noise radius:
The nose radius will provide long life and also good surface finish with it a sharp point on the
nose.

7. Cutting edge:
It is the edge on the face of the tool which removes the material from the workpiece.

The tool cutting edge consists of side cutting edge (major cutting edge), end cutting edge (minor
cutting edge and the nose).

Angle:

1. Side cutting edge angle:

This angle also is known as the lead angle. This is the angle between the side cutting edge and
side of the tool shank.

2. End cutting edge angle:

This is the angle between the end cutting edge and a line normal to the tool shank.

3. Side relief angle:

It is the angle between the portion of the side flank immediately below the side cutting edge
and a line perpendicular to the base of the tool and measured at the right angle to the end flank.

4. End relief angle:

It is the angle between the portion of the end flank immediately below the end cutting edge and
a line perpendicular to the base of the tool and measured at the right angle to the end flank.

5. Back rack angle:

It is the angle between the tool face and a line parallel to the base of the tool and
measured in a plane perpendicular through the side cutting edge.

The back rack angle is positive if the side cutting edge slopes downwards from the point towards
the shank and The back rack angle is negative if the slope is side cutting edge isreversed.

6. Side rack angle:

It is the angle between the tool face and a line parallel to the base of the tool and
measured in a plane perpendicular to the base and the side cutting edge.This angle gives
the slope of the face of the tool from the cutting edge.
The side rack angle is negative if the slope is toward the cutting edge. And the side rack angle is
positive if the slope is away from the cutting edge.

Single Point Cutting Tool Advantages:

The main advantages are:

1. Design and fabrication are easy.

2. This tool is a little cheaper in price.

Single Point Cutting Tool Disadvantages:

The main disadvantages are:

1. There is having little high tool wear rate.

2. Shorter tool life.
3. Low metal removal rate.
4. Low productive.

Single Point Cutting Tool Application:

This tool is used in several machines for producing a flat surface like:

Lathe machine
Shaper Machine
 EXPERIMENT NO. 02
Aim: Study of various forces on single point cutting tool
THEORY/ WORKING PRINCIPLE:
The cutting tool moves along the feed direction. The metal gets plastically deformed along the shear
plane. The chips move along the rake face of the tool. The chip being rough gets resistance in
movement and hence a frictional force F of the tool acting on the chip.
Cutting force is the resistance of the material against the intrusion of the cutting tool. The force
directions and amplitudes differ in different cutting processes such as turning, milling, drilling, etc.
performed in manufacturing machines

There are two types of metal cutting processes. One is oblique cutting process which is shown in Fig.
9.3 (b) and second is orthogonal cutting process as shown in Fig. 9.3 (a).

Force Relationship in Oblique Cutting:

Fig. 9.31 shows a turning process in oblique cutting. In oblique cutting, the principal cutting edge

(ab) makes an angle with the direction of the feed. Since the metal is being cut there must be a

cutting force (R). This cutting force (R) can be resolved in three mutually perpendicular directions.

Therefore, force relationship in oblique cutting is complex in nature and do not considered for force

analysis in cutting process. Only orthogonal cutting process is best suitable for ease of calculations
and lower complexity.

The cutting force (R) in oblique cutting can be resolved into three mutually perpendicular directions,

as given below:

(a) In the direction of feed of the tool (Fd):

It is the horizontal components of the cutting force. It is also called Feed Force (Fd).
In the direction perpendicular to feed direction (Fr):

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It is in the radial direction, i.e., in the direction perpendicular to the generated surface. It may be

considered due to the reaction between the tool and the workpiece. It is also called thrust force and is

represented by (Fr).

(c) In vertical direction (FC):

It is vertical component of the cutting force. It is the main cutting force. It is represented by (FC).
(ii) Force Relationship in Orthogonal Cutting:

Fig. 9.32 shows an orthogonal machining process. In this process, the cutting force has only two

components. One in the feed direction (Fd) and other in direction of cutting (Fc).

The cutting tool moves along the feed direction. The metal gets plastically deformed along the shear

plane. The chips move along the rake face of the tool. The chip being rough gets resistance in
movement and hence a frictional force F of the tool acting on the chip.

So, various forces acting are:

Force F:
Frictional resistance of the tool acting on the chip.

Force N:
Reaction provided by the tool, acting in a direction normal to the rake face of the tool. It is normal to
frictional force F.

Force Fs:
Shear force of the metal. It is due to resistance of the metal to shear in forming the chips.

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Force Fn:
Normal force to shear plane. It is a backing up force provided by the workpiece on the chip. It causes
compressive stress on the shear plane.

EXPERIMENT NO. 03

Aim: Study of multiple point cutting tools (milling, drilling)

THEORY/ WORKING PRINCIPLE:

Multiple-point cutting tools have two or more cutting edges and include milling cutters, drills, and
broaches. Multipoint cutting tools are a series of single-point cutting tools mounted in or integral
with a holder or body and operated in such a manner that all the teeth or cutting edges follow
essentially the same path across the work piece. Most multipoint cutting tools create discontinuous
chips that are carried for some distance before ejection. Adequate chip space must be provided to
prevent jamming and tool breakage. When designing multipoint tools, care must be taken to provide
sufficient chip space without losing too much rigidity in the tool. The amount and shape of the chip
space needed depends on the work piece material and type of cut. There are numerous multi-tooth
cutting. A few of the most common include: the broach, the twist drill, and face mill.The broach is
the most common multipoint, linear-travel cutting tool and is used for producing either external or
internal surfaces in a variety of profiles.

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12/6
Examples of multi-point cutting tool
Milling cutters are the common example for this category. Except fly milling cutter (a single point
cutter), others are usually multi-point cutter. It can contain three cutting edges (say small end mills)
to as high as 40 cutting edges for heavy duty large cutters. Apart from milling cutters, few other
examples of multi-point cutter are enlisted below.

 Reamer (tool for reaming operation)

 Broach (tool for broaching operation)
 Hob (tool for hobbing operation)
 Grinding wheel (abrasive cutter)
 Hone (tool for honing operation)

Advantages of multi-point cutting tool

 Since total feed rate or depth of cut is equally distributed among all cutting edges, so chip
load on each cutting edge reduces greatly. Thus higher feed rate or depth of cut can be
utilized to improve material removal rate for enhancing productivity.
 Because of the distribution of chip load, force acting on each cutting edge reduces
significantly. Sometime, one component of cutting force as a whole gets eliminated/reduced

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 automatically (resultant of one cutting force component in a particular direction may become
zero).
 During machining, none of the cutting edge remains in continuous contact with the work
piece; instead, engagement and disengagement occur repeatedly. This provides sufficient time
to disperse heat from the tool body, which protects the cutter from excessive heating and
plastic deformation. Thus lower rate of increase in tool temperature is observed due to
intermittent cutting action.

Disadvantages of multi-point cutting tool

 Due to intermittent cutting, cutting edges or teeth are subjected to fluctuating load. This
creates noise, vibration and endurance failure of the cutter.
 Design and fabrication of the cutter is comparatively difficult. This makes such cutter costlier

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 EXPERIMENT NO. 04

Aim: Study of Lathe Machine.

Lathe is one of the most versatile and widely used machine tools all over the world. It is
commonly known as the mother of all other machine tool. The main function of a lathe is to
remove metal from a job to give it the required shape and size. The job is securely and rigidly
held in the chuck or in between centers on the lathe machine and then turn it against a single
point cutting tool which will remove metal from the job in the form of chips.
TYPES OF LATHE Lathes are manufactured in a variety of types and sizes, from very small
bench lathes used for precision work to huge lathes used for turning large steel shafts. But the
principle of operation and function of all types of lathes are same. The different types of
lathes are: 1. Speed lathe 2. Centre or Engine lathe 3. Bench lathe 4. Tool Room Lathe 5.
Capstan and Turret lathe 6. Special purpose lathe 7. Automatic lathe
PRINCIPLE FUNCTIONS OF LATHE PARTS A simple lathe comprises of a bed made of
grey cast iron on which headstock, tailstock, carriage and other components of lathe are
mounted. Figure l shows the different parts of engine lathe or central lathe. The major parts
of lathe machine are given as under: 1. Bed 2. Head stock 3. Tailstock 4. Carriage 5. Feed
mechanism

Bed
The bed of a lathe machine is the base on which all other parts of lathe are mounted. It is
massiveand rigid single piece casting made to support other active parts of lathe. On left
end of the bed, headstock of lathe machine is located while on right side tailstock is
located. The carriage of the machine rests over the bed and slides on it. On the top of
the bed there are two sets of guideways - innerways and outerways. The innerways
provide sliding surfaces for the tailstock and the outerways for the carriage. The
guideways of the lathe bed may be flat and inverted V shape. Generally cast iron
alloyed with nickel and chromium material is used for manufacturingof the lathe bed.

Head Stock
The main function of headstock is to transmit power to the different parts of a lathe. It
comprises of the headstock casting to accommodate all the parts within it including

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gear train arrangement. The main spindle is adjusted in it, which possesses live centre
to which the work can be attached. It supports the work and revolves with the work,
fitted into the main spindle of the headstock. The cone pulley is also attached with this
arrangement, which is used to get various spindle speed through electric motor. The
back gear arrangement is used for obtaining a wide range of slower speeds. Some gears
called change wheels are used to produce different velocity ratio required for thread
cutting.

Tail Stock

Figure 5 shows the tail stock of central lathe, which is commonly used for the
objective of primarily giving an outer bearing and support the circular job being
turned on centers. Tail stock can be easily set or adjusted for alignment or non-
alignment with respect to the spindle centre and carries a centre called dead centre for
supporting one end of the work. Both live and dead centers have 60° conical points to fit
centre holes in the circular job, the other end tapering to allow for good fitting into the
spindles. The dead centre can be mounted in ball bearing so that it rotates with the job
avoiding friction of the job with dead centre as it important to hold heavy jobs.

Figure 5: Tail stock of central lathe

WORK HOLDING DEVICES:

1. Work is held between the centres
a. Live centre - head stock spindle and Dead centre - tail stock
spindle.
b. Driven by catch plate and carrier

2. Work piece held in chuck

a. four jaw independent chuck
b. three jaw universal self centering chuck
c. magnetic chuck
d. collet chuck

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 e. Drill chuck

3. Work held in face plate.

4. Work held in mandrel

a) Plain Mandrel e) Cope Mandrel
b) Step Mandrel f) Gang Mandrel
c) Collar Mandrel g) Expansion Mandrel
d) Screwed Mandrel

5. Work held in turning fixture

a) Steady Rest
b) Follower Rest

Figure 6: Three Jaw Universal Self Centering Chuck

Figure 7: Four Jaw Independent Chuck

LATHE OPERATIONS:
1. Straight Turning Or Plain Turning 8. Spinning
2. Facing 9. Eccentric
3. Shoulder turning turning
4. Chamfering 10. Drilling
5. Knurling 11. Boring
6. Forming 12. Centering
7. Parting off (grooving) 13. Thread cutting
14. Taper turning

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 A taper is defined as a uniform increase or decrease in diameter of a
piece of work measured along its length. In a lathe machine, taper
turning means to produce a conical surface by gradual reduction in
diameter from a cylindrical job. The taper angle (α) for conical surface
is given by;

Where,

D is diameter of the large end, d is the dia of the small end of

the cylindrical job, l isthe length of the taper of cylindrical
job.
A taper is generally turned in a lathe by feeding the tool at an angle
to the axis of rotation of the workpiece. The angle formed by the path
of the tool with the axis of the workpiece should correspond to the half
taper angle. A taper can be turned by anyone of the following methods:

1. By swiveling the compound rest,

2. By setting over the tailstock centre,
3. By a broad nose form tool,
4. By a taper turning attachment,
5. By combining longitudinal and cross feed in a special lathe and
6. By using numerical control lathe

Taper Turning by Swivelling the Compound Rest

This method uses the principle of turning taper by rotating the

workpiece on the lathe axis and feeding the tool at an angle to the axis
of rotation of the workpiece. The tool is mounted on the compound rest

which is attached to a circular base, graduated in degrees.

Figure 9: Taper turning by swiveling compound rest

The compound rest can easily be swiveled or rotated and clamped at any
desired angle as shown in Fig. 7. Once the compound rest is set at the desired

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half taper angle, rotation of the compound slide screw will cause the tool to be
fed at that angle and generate a corresponding taper. This method is limited to
turn a short but steep taper because of the limited movement of the cross-slide.
The positioning or setting of the compound rest is accomplished by swiveling
the rest at the half taper angle, if this is already known. If the diameter of the
small and large end and length of taper are known, the half taper angle can be
calculated

Thread Cutting

Figure 10: Thread Cutting

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Figure 8 shows the setup of thread cutting on a lathe. Thread of any pitch, shape and
size can be cut on a lathe using single point cutting tool. Thread cutting is operation
of producing a helical groove on spindle shape such as V, square or power threads on
a cylindrical surface. The job is held in between centres or in a chuck and the cutting
tool is held on tool post. The cutting tool must travel a distance equal to the pitch (in
mm) as the work piece completes a revolution. The definite relative rotary and linear
motion between job and cutting tool is achieved by locking or engaging a carriage
motion with lead screw and nut mechanism and fixing a gear ratio between head stock
spindle and lead screw. To make or cut threads, the cutting tool is brought to the start
of job and a small depth of cut is given to cutting tool using cross slide. The equation
for thread cutting calculation is given by;

DRILLING ON A LATHE
For producing holes in jobs on lathe, the job is held in a chuck or on a face plate. The
drill is held in the position of tailstock and which is brought nearer the job by moving the tailstock
along the guide ways, the thus drill is fed against the rotating job.

Figure 11: Drilling on lathe

CUTTING PARAMETERS

Cutting speed

Cutting speed for lathe work may be defined as the rate in meters per
minute at which the surface of the job moves past the cutting tool.
Machining at a correct cutting speed is highly important for good tool
life and efficient cutting. Too slow cutting speeds reduce productivity
and increase manufacturing costs whereas too high cutting speeds

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 result in overheating of the tool and premature failure of the cutting
edge of the tool. The following factors affect the cutting speed:

i. Kind of material being cut

ii. Cutting tool material
iii. Shape of cutting tool
iv. Rigidity of machine tool and the job piece and
v. Type of cutting fluid being used.

Cutting speed is the speed at which metal is removed by the tool from the work.

.
Where, D is

diameter of

job in mmN

is speed in

RPM

Feed
It is the distance the tool advances for every revolution of the workpiece.
It is expressed inmm/rev.

Depth of Cut
It is perpendicular distance measured from the machined surface to the
uncut surface of work.It is expressed in mm

Where,

D1 is diameter of work before machining, D2 is diameter of work after machining.

Machining Time

DIFFERENT MECHANISMS:
2.7.l Apron Mechanisum:
when a spindle rotates, the LEAD screw and the feed rod will rotate through the
tumbler gear. This, Apron Mechanism provided in the carriage is connected to the

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LEAD Screw through the half nut engaged in the carriage, from which auto feed of the
longitudinal and the cross feed mechanism is obtained.

Back Gear Mechanism:

Back gear arrangement is used for reducing the spindle speed, which is necessary for
thread cutting and knurling.

Figure 12: Back Gear Mechanism

There is one stepped cone pulley in the lathe spindle. This pulley can freely rotate on
the spindle. A pinion gear Pl is connected to small end of the cone pulley. Pl will
rotate when cone pulley rotates. Bull gear Gl is keyed to lathe spindle such that the
spindle will rotate when Gear Gl rotates. Speed changes can be obtained by changing
the flat belt on the steps. A bull gear Gl may be locked or unlocked with this cone
pulley by a lock pin. There are two back gears Bl and B2 on a back shaft. It is
operated by means of hand lever L; back gears Bl and B2 can be engaged or
disengaged with Gl and Pl. For getting direct speed, back gear is not engaged. Thestep
cone pulley is locked with the main spindle by using the lock pin. The flat belt is
changed for different steps. Thus three or four ranges of speed can be obtained directly.
For getting slow or indirect speeds, back gear is engaged by lever L and lock pin is
disengaged. Now, power will flow from Pl to Bl. Bl to B2 (same shaft), B2 to Gl to
spindle. As gear Bl is larger than Pl, the speed will further be reduced at Bl. Bl and B2
will have the same speeds. The speed will further be reduced at Gl because gear Gl is
larger than B2. So, the speed of spindle is reduced by engaging the back gear.

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Tumbler Gear Mechanism
Tumbler gear mechanism is used to change the direction of lead screw and feed rod.
By changing tumbler gear, the carriage can be moved automatically from tailstock
end to headstock end or moved from head stock end to tailstock end. Usually during
thread cuttingand automatic feed, tumbler gear is used.

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 EXPERIMENT NUMBER 5
Aim: Study of Shaper mechanisms.

The shaper is a machine tool used primarily for:

1. Producing a flat or plane surface which may be in a horizontal, a vertical or an

angular plane.
2. Making slots, grooves and keyways
3. Producing contour of concave/convex or a combination of these

WORKING PRINCIPLE
The job is rigidly fixed on the machine table. The single point cutting tool held properly in the
tool post is mounted on a reciprocating ram. The reciprocating motion of the ram is obtained
by a quick return motion mechanism. As the ram reciprocates, the tool cuts the material during
its forward stroke. During return, there is no cutting action and this stroke is called the idle
stroke. The forward and return strokes constitute one operating cycle of the shaper.

Figure 13: Standard Shaping Machine

Shapers can be classified as below;

1) Based on the reciprocating Mechanism

a) Crank type

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 b) Geared type
c) Hydraulic type
2) Based on the ram travel
a) Horizontal
b) Vertical
c) Traveling head
3) Based on the table design
a) Standard shaper
b) Universal shaper
4) Based on the cutting stroke
a) Push cut type
b) Draw cut type

DRIVE MECHANISM:
It provides the reciprocating motion to the ram, hence to the tool. In a standard shaper, the
cutting action is provided in the forward stroke of the ram and the reverse stroke is the idle/
non-cutting stroke. For proper cutting action with minimum vibrations it needs a slower
forward stroke and to save machining time a faster' idle reverse stroke of the ram. A shaper
drive, mechanism is always designed to serve this purpose, and this is known as Quick Return

Mechanism: This type of drive can be obtained by any of the following mechanisms

1) Crank and slotted link mechanism .

2) Whitworth quick return mechanism

3) Hydraulic quick return mechanism

Whitworth - quick return mechanism

Figure 15: Whitworth - quick return mechanism

The Fig. 13 shows the whirtworth – quick return mechanism. The crank OC is fixed and OQ
rotates about O. The slider slides in the slotted link and generates a circle of radius CP. Link 5
connects the extension OQ provided on the opposite side of the link 1 to the ram (link 6). The
rotary motion of P is taken to the ram R which reciprocates. The quick return motion

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 mechanism is used in shapers and slotting machines. The angle covered during cutting stroke
from P1 to P2 in counter clockwise direction is α or 360 -2θ. During the return stroke, the angle
covered is 2θ or β.

Crank and Slotted Link Mechanism

In this mechanism the ram is actuated by gear drives associated with electric motor. First, the

electric motor drives the pinion gear. Next, the pinion gear drives the bull gear which rotates
in opposite direction due to external gear meshing. A radial slide is provided on the bull gear.
A sliding block is assembled on this slide. The block can be positioned in radial direction by
rotating the stroke adjustment screw. The sliding block has a crank pin. A rocker arm is freely
fitted to this crank pin. The rocker arm sliding block slides in the slot provided in the rocker
arm called as slotted link. The upper end has fork which is connected to the ram block by a pin
while the bottom end of the rocker arm is pivoted. When the pinion gear rotates along with the
bull gear, the crank will also rotate. Due to this, the rocker arm sliding block also rotates in the
same circle. Simultaneously, the sliding block slides up and down in the slot. This movement
is transmitted to the ram which reciprocates. Hence, the rotary motion is converted in
reciprocating motion.

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 Figure 16: Crank and slotted link mechanism
SHAPER OPERATIONS:
Generally a shaper is used to machine flat horizontal surfaces. However, a shaper can be used
also to machine vertical surfaces, inclined surfaces, splines, key ways, gear teeth and irregular
contoured blanks. The operations performed in a shaper are as follows

1) Machining horizontal surface

2) Machining vertical surface

3) Machining inclined (angular) surface

4) Machining key ways

5) Machining splines and gear teeth

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28/6
WORK HOLDING DEVICES
i. Clamped in a vise
ii. Clamped directly on the table
a. Using T-bolt and strap clamp
b. Using strip and stop pins
c. Using a wedge strip and stop pin
iii. Clamped on an angle plate
iv. Clamped over a vee block
v. Fixture

SHAPER TOOLS CLASSIFICATIONS

Shaper tools can be classified as;

i. According to the shape – straight, cranked, goose necked tool.

ii. According to the direction of cutting – left hand and right hand tool.
iii. According to the finish required – roughing tool, finishing tool. iv. According to
type of operation – down cutting, parting, squaring, side recessing tools.
v. According to the shape of cutting edge – round nose, square nose tool.

Figure 18: Shaper tools

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CUTTING PARAMETERS
Cutting Speed
It is rate of speed at which the metal is removed by the tool. It is expressed in meter per
minute.

Where, L is length of cutting storke in mm , m is ration between return time and cutting
time, n is RPM of the bull gear

Feed
Relative movement of the tool in a direction perpendicular to the movement of ram.
Expressed in mm per stroke. Feed is given at the end of the stroke.

Depth of Cut
It is the thickeness of metal removed in one cut. It is expressed in mm.

Machining Time.

Where, L is length of stroke in mm

B is width or breadth of the workpiece in mm, S is the feed expressed in

mm/double strok, m is the ratio between return and cutting time. v is cutting speed

in meters/min.

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 Experiment Number 6

Aim: Study of milling machine

Milling is a machining process in which metal is removed by a rotating multiple-tooth cutter

against a fixed work piece, each tooth removing a small amount of metal witheach revolution
of the spindle. In this operation the cutter rotates at high speeds, and metal removal is very fast.
Milling machines are employed for machining flat surfaces, contoured surfaces, external and
internal teeth on gear blanks and helical surfaces.

CLASSIFICATION OF MILLING MACHINES:

1. Column and knee type
a) Plain or Horizontal milling Machine
b) Universal milling machine
c) Vertical milling machine

2. Fixed bed type

a) Simplex milling machine
b) Duplex milling machine
c) Triplex milling machine
3. Planer type
4. Special type.
a) Rotary fable milling machine
b) Drum milling machine
c) Planetary milling machine.
d) Profile tracer milling machine

Spindle orientation is one of the means of classifying milling machines. Horizontal milling
machines have horizontal spindle and are most commonly used. Vertical milling machines
have their spindle in vertical direction. Special milling machines have horizontal, vertical
and angular spindles, which operate either one after the other, or all at the same time.
Column and Knee type Milling Machines:

These are so named because of two of their main structural elements, a column shaped
main frame and knee shaped projection. Six principal parts of these machines are

1) The base, on which the milling machine structure is built.

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 2) The column, which contains the spindle and its driving mechanism.
3) The over arm mounted on the column, which supports the. other end of the arbor.

4) The knee, which is a structural member attached to the column and which moves
vertically on the column. .

5) The saddle, which is mounted on the knee and moves horizontally.

6) The table mounted on the saddle, which moves at right angles to the saddle. Work is
clamped on the table. The column and knee type milling machines can have manual or
power control for all movements. By the use of stops & other control devices the
machine can be adopted for Automatic cycles.

Figure 19: Column and Knee type Milling Machines

Horizontal Milling Machine:

Horizontal knee type milling machines are classified as plain or universal depending upon
whether or not the table can be swiveled in a horizontal plane. The table on the universal
machine can be swiveled up to 459 to the right or left, making possible angular and helical
milling. These machines can also be converted into vertical type, if they have vertical
spindle head. The feature of a horizontal or plain milling machine is illustrated in figure
below.

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 Figure 20: Horizontal Milling Machine

Parts:

Base, Column, Table. Saddle (upper and lower), Knee, arbor, adjustable bearing block.

Vertical Milling Machine:

Vertical knee type milling machines have a vertical spindle. They may be either of the
fixed head, sliding head, swivel head type or they may be a combination of the last two.
Vertical milling machines have neither over arm nor brace. All other features are
substantially the same as in the Horizontal Milling Machine. A Vertical Milling Machine
is especially suitable for operations with end mills and face mills. The basic feature of a
vertical milling machine is illustrated in figure below:

Figure 21: Vertical Milling machine

MILLING CUTTERS
Milling cutters are the rotating type cutting tools that are used in milling machines. They
have multiple cutting teeth of similar shape equally spaced on the circumference of the
cutter. These teeth intermittently engage with the work piece and cause cutting action upon
continuous feeding. Milling cutters may be made of High Speed Steel, cast alloys or
cemented carbide tips. Generally HSS, tools are used for regular operations.
The different types of milling cutters, classified based on their constructional
features and the type of operation performed, are as follows:

1) Plain Milling Cutters

a) Straight teeth cutter

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 b) Helical teeth cutter
2) Milling cutters
a) Plain teeth
b) Staggered teeth
c) Half side teeth
3) Metal slitting Saw
a) Plain teeth
b) Staggered teeth
4) Angle Milling cutters
a) Single angle type

b) Double angle type

5) End Milling Cutters
a) Straight shank
b) Taper shank
c) Shell end 6) Slot Milling Cutters 7) Fly cutters.
8) Formed cutters
9) Tip and Reamer cutters

Figure 22: Different types of milling cutters

MILLING CUTTER NOMENCLATURE

Figure 21 shows two views of a common milling cutter with its parts and angles identified.
These parts and angles in some form are common to all cutter types.

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 Figure 23: Nomenclature of Milling Cutter

• The pitch refers to the angular distance between like or adjacent teeth.
• The pitch is determined by the number of teeth. The tooth face is the forward
facing surface of the tooth that forms the cutting edge.
• The cutting edge is the angle on each tooth that performs the cutting.
• The land is the narrow surface behind the cutting edge on each tooth.
• The rake angle is the angle formed between the face of the tooth and the
centerline of the cutter. The rake angle defines the cutting edge and provides a
path for chips that are cut from the workpiece.
• The primary clearance angle is the angle of the land of each tooth measured
from a line tangent to the centerline of the cutter at the cutting edge. This angle
prevents each tooth from rubbing against the work piece after it makes its cut.
• This angle defines the land of each tooth and provides additional clearance for
passage of cutting oil and chips.
• The hole diameter determines the size of the arbor necessary to mount the
milling cutter.
• Plain milling cutters that are more than 3/4 inch in width are usually made with
spiral or helical teeth. A plain spiral-tooth milling cutter produces a better and
smoother finish and requires less power to operate. A plain helical-tooth milling

cutter is especially desirable when milling an uneven surface or one with holes in
it.

MILLING OPERATIONS
Milling operations can be classified as follows:

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 1. Plain milling 9. End milling
2. Face milling 10. Slot milling
3. Side milling 11. Saw milling
4. Straddle milling 12. Helical
5. Angular milling milling
13. Cam milling
6. Gang milling
14. Thread
7. Form milling
milling
15. Gear cutting
8. Profile milling
INDEXING
The different methods of indexing are
1. Direct indexing
2. Plain or simple indexing
3. Compound indexing
4. Differential indexing
5. Angular indexing
Direct Indexing:
This consists of a index plate with an indexing arm connected directly to the work spindle
without any gearing. Hence, rotation of the indexing arm is equal to the rotation of the
work piece. The required number of divisions on the work is obtained directly by rotating
the index arm through the index plate. Since, the method is very quick and direct it is
termed as rapid or direct indexing.
When a rapid index plate with 24 holes is used, it is possible to index _he work piece
into equal parts of 2, 3,4,6,8, 12 and 24. Generally the index plate is provided with different
number of holes on concentric circles to make' it convenient to obtain all possible divisions.
To determine the number of holes to be moved in a direct indexing, the expression is

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 n = number of holes to be moved on the index plate
N = number of divisions required on the work
T = total number of holes available in one indexing circle.
Simple Indexing
Simple or plain indexing incorporates a worm gear arrangement between the index crank
and the spindle. This is suitable for divisions beyond the range of direct indexing. In this,
method the crank arm is mounted on a single threaded worm, which meshes with a worm
gear with 40 teeth. Thus 40 turns other crank (worm) are required to rotate the spindle
(work) through one revolution. That is, one complete turn of the index crank will make the
work to rotate through 1/40 of a revolution.

Spindle

Figure 24: Index plate Figure 25: Spring loaded pin

Figure 26: Simple Indexing Mechanism

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The expression for using plain Indexing is

Where,
n = Number of turns of index crank
N = Number of divisions required (No of teeth)

Here, the constant 40 represents the gear ratio 40: 1. For a dividing head with another gear
ratio, another constant corresponding to the other Gear ratio should be used.

Figure 27: Indexing Head

Procedure for gear cutting

1. Fix the work piece (blank) in a mandrel.
2. Select the proper cutter & fix it on the arbor.
3. Switch on the power supply & select proper speed, feed, depth of cut.
4. As per the calculations go for indexing.

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 5. Perform the gear cutting operations.
Indexing Calculations

Where N is no. of division required.

Assume 15 teeth are to be cut.

Index plates are available in three standard with set of different index holes.
PLATE 1 15 16 17 18 19 20
PLATE 2 21 23 27 29 31 33
PLATE 3 37 39 41 43 47 49

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 Experiment Number 7

Aim: One job on milling machine

Apparatus: - Milling cutter, indexing head, ernier caliper etc.

Procedure: -

a. Fix the work piece on the worktable and then fit the milling cutter on the tool holder
b. Select a suitable cutting speed and feed.
c. Work piece is fed to the cutter automatically or manually.
d. The work piece is fed against the direction of the milling cutter.
e. The surface is cleaned with the help of brush to remove the chips.
f. This procedure is followed until the required dimension is obtained.
\

30

60

Note: All dimensions are in mm

Result: The model is prepared as per the drawing given.

Verification: The measurement of the model reveals that there is a deviation of

\
X mm in L1, Y mm in L2 and Z mm in L3 & L4.

Conclusion: The model prepared is within /

beyond the tolerance.

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 Experiment Number 8

Aim: One Job on Drilling, Boring

Materials required Mild steel Plate of Length 50x50 mm
Tools required Steel rule, Flat file (rough and smooth), Drill bit (8 mm, 10 mm, 10.5 mm)
Procedure
1. The work piece was fitted in the vice and filed to the required dimensions.
2. The squareness of the work piece was checked.
3. Drawing punches were made for various drills.
4. The job was fitted on the radial drilling machine.
5. The 10 mm & 8 mm drill bit were used for drilling in the required place and drilling
operation was made on the work piece.
6. Boring was done on the 10mm hole using the boring tool.
8. The work piece was removed from the radial drilling machine.

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 Experiment Number 9

Aim: One Job on Thread Cutting, Taper Turning.

Tools Required: Right Hand Single Point Cutting Tool, Knurling Tools, Parting Tool, Chuck Key, Tool Post
Key, Out Side Caliper

Procedure:
1. Facing is done on both sides of the work piece.
2. The work piece is held between the live center and the dead center.
3. The plain turning operations are done and the work piece is marked as per the given dimensions.
4. The step turning is done.
5. Taper turning, knurling and chamfering are done respectively using the corresponding tools.
6. Hence the model is completed.

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