DYNAMICS & MACHINE TOOLS LABORATORY

MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

Prepared by
C.Chandrasekhar Reddy,
Assistant Professor (Ad-hoc),
JNTUA College of Engineering Pulivendula,
Mechanical Engineering.

JNTUACOLLEGE OF ENGIEERING PULIVENDULA

MUDDANUR ROAD, PULIVENDULA–516390
ANDHRA PRADESH
 LIST OF EXPERIMENTS

1. INTRODUCTION TO GENERAL PURPPOSE MACHINES

2. LATHE OPERATIONS (FACING, CHAMFERING, PLANE TURNING AND

STEP TURNING)

3. LATHE OPERATIONS (FACING, CHAMFERING, PLANE TURNING,

KNURLING AND TAPER TURNING).

4. DRILLING, TAPPING AND GRINDING OPERATIONS

5. SHAPING OPERATION (V-CUT MODEL)

6. SHAPING OPERATION (RECTANGULAR CUT MODEL)

7. MILLING OPERATION (GROOVE CUT MODEL)

8. GRINDING OPERATIONS ( HEXAGONAL CUT MODEL)

9. PORTER GOVERNOR APPARATUS.

10. PROELL GOVERNOR APPARATUS.

11. HARTNELL GOVERNOR APPARATUS.

12. STATIC AND DYNAMIC BALANCING APPARATUS.

13. CAM SHAFT FOLLOWER APPARATUS (EXPERIMENT 1).

14. CAM SHAFT FOLLOWER APPARATUS (EXPERIMENT 2).

15. INVERSION FOUR BAR MECHANISM.

 1. INTRODUCTION TO GENERAL PURPOSE MACHINES

A Machine Tools Lab is a specialized workshop or facility where various machines and tools
are used to shape, cut, and finish materials, primarily metals, to create precise components and assemblies.
This lab is an essential part of engineering education, research, and industrial production, providing hands-
on experience with the machinery and techniques used in manufacturing processes.
Key Components of a Machine Tools Lab
1. Machine Tools:

o Lathes: Used for turning operations to create cylindrical parts. These machines can perform
various operations like facing, turning, threading, and tapering.
o Milling Machines: Used for cutting and shaping materials using rotating cutters. Milling
machines can perform operations such as slotting, drilling, and contouring.
o Drilling Machines: Used to create holes in materials. This includes various types such as bench
drills, pillar drills, and radial drills.
o Grinding Machines: Used to finish surfaces by removing small amounts of material with an
abrasive wheel, achieving high precision and surface finish.
o Shapers and Planers: Used for shaping flat surfaces, grooves, and keyways by moving a
cutting tool across the work piece.
Benefits of a Machine Tools Lab
 Skill Development: Provides practical experience and enhances skills in using machine tools,
interpreting technical drawings, and understanding machining principles.
 Quality and Precision: Teaches the importance of precision and accuracy in manufacturing, which is
crucial for creating high-quality parts and components.
 Innovation and Creativity: Encourages innovation by allowing users to experiment with different
machining processes and tool designs.
 Safety Awareness: Emphasizes the importance of safety practices and protocols in a manufacturing
environment, helping to minimize accidents and injuries.

.
 LATHE MACHINE

A lathe machine is a versatile and essential tool in the field of manufacturing and machining. It is primarily
used for shaping and machining various materials, such as metal, wood, and plastic, by rotating the work piece
against a cutting tool. The lathe is often considered the "mother of all machines" because many other machine
tools are derived from or influenced by it.
The main purpose of a lathe machine is to remove material from a work piece to create cylindrical shapes and
precise components. The lathe performs various operations, such as turning, facing, threading, drilling, and
boring, making it a fundamental tool in manufacturing, repair, and production settings.
Key Components of a Lathe Machine:

1. Bed: The bed is the sturdy base of the lathe that supports all other components and ensures stability.
2. Headstock: The headstock houses the spindle and various gears, providing power and rotation to the
work piece.
3. Tailstock: The tailstock slides along the bed to support the end of the work piece or hold tools like
drills.
4. Carriage: The carriage moves along the bed to hold and move the cutting tool against the rotating
work piece.
5. Spindle: The spindle is the rotating shaft that holds and spins the work piece during machining.
6. Chuck: The chuck is a clamping device attached to the spindle to securely hold the work piece.
7. Lead Screw: The lead screw drives the carriage for precise threading and longitudinal feed operations.
8. Feed Rod: The feed rod provides smooth and controlled movement of the carriage for general turning
operations.
Basic Operations of a Lathe Machine

1. Turning:
o In turning, the work piece rotates while a single-point cutting tool moves parallel to the axis of
rotation, removing material to reduce the diameter of the work piece and create cylindrical
shapes.

2. Facing:
o Facing involves moving the cutting tool perpendicular to the axis of rotation to create a flat
surface on the end of the work piece.

3. Threading:
o Threading creates screw threads on the work piece by moving the cutting tool along the rotating
work piece in a precise, controlled manner.

4. Drilling:
o Drilling uses a drill bit held in the tailstock to create holes along the center axis of the work
piece.

5. Boring:
o Boring enlarges an existing hole by removing material from its inner surface, typically to
achieve a precise diameter or to finish a drilled hole.

6. Knurling:
o Knurling creates a textured pattern on the surface of the work piece by pressing a hardened
knurling tool against it. This operation is often used to improve grip on handles and knobs.

2. SHAPING MACHINE:
A shaping machine, also known as a shaper, is a versatile machine tool used primarily for producing flat
surfaces, grooves, and other straight-edged contours on work pieces. The shaping machine operates by
reciprocating a single-point cutting tool back and forth across the work piece in a linear motion, removing
material during the forward stroke and returning without cutting during the backward stroke. It is an essential
tool in machine shops, used for shaping and finishing various materials, especially metals.
The main purpose of a shaping machine is to create flat surfaces, slots, grooves, keyways, and other straight
profiles on materials with precision and efficiency. Shapers are particularly useful for machining parts with
simple geometry or when specific surface finishes are required.
Key Components of a Shaping Machine
1. Base:

o The base is the heavy and rigid part of the machine that supports all other components. It is
usually made of cast iron to absorb vibrations and provide stability during operation.
2. Column:

o The column is a vertical support mounted on the base that houses the ram and other internal
mechanisms, including the drive system that controls the movement of the cutting tool.
3. Ram:

o The ram is the reciprocating part of the shaping machine that holds the cutting tool and moves it
back and forth in a straight line to cut the work piece.
4. Tool Head:
 o The tool head is attached to the front of the ram and holds the cutting tool. It can be adjusted to
vary the depth of cut and the position of the tool relative to the work piece.
5. Table:

o The table is the flat surface on which the work piece is clamped during machining. It can move
horizontally and vertically to position the work piece correctly for cutting.
6. Clapper Box:

o The clapper box is a hinged mechanism attached to the tool head that allows the cutting tool to
lift during the return stroke, preventing contact with the work piece and avoiding tool wear.
7. Cross Rail:

o The cross rail is mounted on the column and can move vertically to adjust the height of the
table, allowing for different work piece sizes and thicknesses.
8. Feed Mechanism:

o The feed mechanism controls the movement of the table in small increments, allowing for
precise control over the depth of cut and positioning of the work piece during machining.
Basic Operations of a Shaping Machine
1. Flat Surface Shaping:
o The shaping machine is used to produce flat surfaces by moving the cutting tool horizontally
across the workpiece in a straight line, removing material layer by layer.
2. Grooving:

o Grooving involves cutting narrow channels or grooves into the workpiece surface, typically
used for keyways, slots, and other features requiring precise width and depth.
3. Slotting:

o Slotting is similar to grooving but usually involves wider cuts, creating slots in the workpiece
for various applications, such as assembly or fitting.
4. Form Cutting:

o Form cutting uses specially shaped tools to cut specific profiles or contours into the workpiece,
allowing for the creation of complex shapes and surfaces.
5. Angular Cutting:

o Angular cutting involves tilting the tool head to produce inclined surfaces or angular cuts,
useful for creating chamfers and other angled features.

3. DRILLING MACHINE:
A radial drilling machine is a versatile and powerful machine tool used for drilling holes in large and heavy
work pieces that cannot be easily moved. It is designed to handle drilling operations that require a high degree
of flexibility and precision. The radial drilling machine is distinct from other drilling machines because its drill
head can move along a radial arm, allowing it to drill holes at various locations on a large work piece without
repositioning it.
The primary purpose of a radial drilling machine is to drill holes of varying sizes in different types of
materials, such as metals, wood, and plastics. Due to its design, the machine is ideal for drilling, boring,
tapping, reaming, and counter boring operations, especially on large, heavy, or awkwardly shaped work pieces.

Key Components of a Radial Drilling Machine

1. Base:

o The base is the heavy, rigid foundation of the machine that supports all other components. It is
usually made of cast iron or steel to provide stability and absorb vibrations during drilling.
2. Column:

o The column is a vertical post mounted on the base that supports the radial arm. It is typically
cylindrical and can rotate around its axis, allowing the radial arm to swing horizontally.
3. Radial Arm:

o The radial arm is a horizontal beam attached to the column that can be moved up and down and
rotated around the column. It supports the drill head and allows it to be positioned over the
work piece at different locations and angles.
4. Drill Head:

o The drill head is the assembly that holds the spindle and the cutting tool. It moves along the
radial arm and can be adjusted vertically and horizontally to align the drill with the desired
location on the work piece.
5. Spindle:

o The spindle is a rotating shaft that holds the drill bit or other cutting tools. It is driven by an
electric motor and transmits rotational motion to the cutting tool to perform drilling operations.
6. Feed Mechanism:

o The feed mechanism controls the downward movement of the spindle, allowing the operator to
adjust the rate at which the drill bit penetrates the work piece for different materials and drilling
depths.
7. Table:

o The table is the flat surface on which the work piece is mounted and secured during drilling. It
can be adjusted vertically and rotated for precise positioning of the work piece under the drill
head.
8. Motor:

o The motor provides the power needed to rotate the spindle and drill bit. It can vary in size and
power depending on the specific model and application of the radial drilling machine.

Basic Operations of a Radial Drilling Machine

1. Drilling:

o The primary operation of a radial drilling machine is drilling holes in various materials. The
drill bit is positioned over the work piece, and the spindle is lowered to create the hole.
2. Boring:

o Boring is an operation where the radial drilling machine enlarges an existing hole to achieve a
precise diameter or to finish a drilled hole.
3. Reaming:

o Reaming is used to refine the surface finish and accuracy of an existing hole, ensuring it meets
precise dimensional tolerances.
4. Tapping:

o Tapping involves cutting threads inside a drilled hole to allow for the insertion of screws or
bolts. The drill head is equipped with a tapping attachment for this operation.
5. Counter boring:

o Counter boring creates a larger diameter section at the top of a hole to accommodate the head of
a bolt or screw, allowing it to sit flush with or below the surface of the work piece.

4. MILLING MACHINE :
A milling machine is a versatile machine tool used for shaping and machining solid materials, such as
metal, wood, and plastic. It utilizes rotary cutters to remove material from a work piece by advancing it
at various angles to the cutting tool. Milling machines are essential in manufacturing, fabrication, and
machining operations, where they produce a wide range of components, from simple shapes to
complex parts with intricate details.
The primary purpose of a milling machine is to create precise shapes and forms by removing material
from a work piece. This process involves feeding the work piece against a rotating cutting tool, which
can perform various operations such as cutting, drilling, slotting, and threading. Milling machines are
widely used in industrial manufacturing, prototype development, and custom part fabrication due to
their ability to produce high-quality, detailed components.

Key Components of a Milling Machine

1. Base:
 o The base is the foundation of the milling machine, providing stability and support for all other
components. It is typically made of cast iron to absorb vibrations and maintain machine
accuracy.
2. Column:

o The column is a vertical structure mounted on the base that houses the machine's spindle and
cutting tool. It provides support for the head and allows vertical movement of the cutting tool.
3. Knee:

o The knee is a vertically adjustable component mounted on the column. It supports the saddle
and table, allowing for vertical movement of the work piece towards or away from the cutting
tool.
4. Saddle:

o The saddle is attached to the knee and moves horizontally in the transverse direction (Y-axis). It
supports the table and allows precise positioning of the work piece.
5. Table:

o The table is a flat surface that holds and secures the work piece during machining. It can move
longitudinally (X-axis) and, in some machines, can also be swiveled to different angles.
6. Spindle:

o The spindle is a rotating shaft that holds and drives the cutting tool. It is powered by a motor
and can be adjusted for different speeds, depending on the material and type of operation.
7. Over arm (Arbor Support):

o The over arm or arbor support is a horizontal beam extending from the column. It supports the
arbor, which holds the cutting tools, providing additional stability for horizontal milling
operations.
8. Arbor:

o The arbor is a shaft attached to the spindle, used for mounting various cutting tools such as
milling cutters. It is supported by the over arm and allows for precise positioning and alignment
of the tool.
9. Head:

o The head is the part of the milling machine that holds the spindle and the motor. It can be
adjusted vertically and rotated, allowing for angular and intricate cutting operations.
10. Quill:
 o The quill is a part of the spindle assembly that allows the spindle to move vertically. It is used
for precise drilling and boring operations, enabling fine adjustments of the cutting depth.

Basic Operations of a Milling Machine

1. Face Milling:

o Face milling is the process of creating a flat surface on the top of a work piece. It involves
feeding the work piece against a rotating cutter with multiple teeth, removing material layer by
layer to achieve a smooth finish.
2. End Milling:

o End milling involves using a cutting tool called an end mill to produce slots, grooves, pockets,
and complex contours. The end mill can cut in multiple directions, making it versatile for
creating detailed shapes.
3. Slot Milling:

o Slot milling creates slots or grooves in a work piece by using a side-and-face cutter or an end
mill. It is commonly used for keyways, gear teeth, and other applications requiring precise
grooves.
4. Drilling:

o Drilling on a milling machine involves using a drill bit mounted on the spindle to create holes in
the work piece. The machine's precision and control allow for accurate hole placement and
depth.
5. Boring:

o Boring enlarges an existing hole by removing material from its inner surface. It is used to
achieve precise diameters and fine surface finishes, often in conjunction with drilling
operations.
6. Thread Milling:

o Thread milling creates threads inside a hole using a specialized cutting tool. It allows for
precise thread cutting with adjustable thread pitch and depth.

5. BENCH GRINDING MACHINE:

Grinding is a machining process that involves the use of a rotating abrasive wheel to remove material from
a work piece, achieving a high level of surface finish and dimensional accuracy. Unlike other machining
 processes like turning or milling, which use cutting tools with sharp edges, grinding utilizes abrasive grains
bonded together to form a grinding wheel. Each abrasive grain acts as a cutting edge, removing small chips
of material from the work piece.
The primary purposes of grinding are to:
1. Achieve a Fine Surface Finish: Grinding can produce very smooth surface finishes that are often
required for high-precision components.
2. Achieve High Dimensional Accuracy: Grinding is used to achieve tight tolerances and precise
dimensions that are difficult to achieve with other machining processes.
3. Sharpen Cutting Tools: Grinding is commonly used to sharpen and recondition cutting tools such as
drills, end mills, and saw blades.

4. Remove Material: It is used to remove excess material or to refine the final shape of the work piece.

A bench grinding machine is a compact and versatile tool used for sharpening, shaping, and finishing metal
parts. It is typically mounted on a workbench or pedestal and features two grinding wheels, one on each side of
the machine. Bench grinders are common in workshops and garages for various tasks, including tool
maintenance, deburring, and polishing.
Purpose of a Bench Grinding Machine
The primary purposes of a bench grinding machine include:
1. Sharpening Tools: Bench grinders are used to sharpen cutting tools such as chisels, knives, and drills,
restoring their cutting edges.
2. Shaping Metal: They can shape metal parts by grinding away material to achieve desired contours and
dimensions.
3. Deburring: Bench grinders remove burrs and sharp edges from metal parts after machining or
fabrication, improving safety and functionality.
4. Polishing: They can be used with polishing wheels to achieve a smooth, shiny finish on metal surfaces.
Key Components of a Bench Grinding Machine
1. Base:
o The base is the sturdy, heavy part of the machine that provides stability and support. It is
usually made of cast iron or heavy steel to reduce vibrations during operation.
2. Grinding Wheels:
o Bench grinders typically have two grinding wheels, one for coarse grinding and one for finer
finishing. The wheels are made of abrasive materials like aluminum oxide or silicon carbide.
3. Tool Rest:
o The tool rest is a support platform located in front of the grinding wheel. It helps hold and
position the work piece during grinding, allowing for precise control.
4. Adjustable Eye Shields:
o Eye shields are safety features mounted above the grinding wheels. They protect the operator's
eyes from flying debris and sparks generated during grinding.
5. Spark Guards:
o Spark guards are positioned near the grinding wheels to catch and deflect sparks and debris,
reducing the risk of fire and improving safety.
6. Wheel Guards:
o Wheel guards are protective covers around the grinding wheels. They prevent debris and spark
from escaping and protect the operator from accidental contact with the rotating wheels.
7. Motor:
o The motor powers the grinding wheels and provides the necessary rotational force. Bench
grinders usually have a single-phase electric motor that drives the wheels at high speeds.
8. Adjustable Tool Rest:
o This component allows the operator to adjust the angle and position of the tool rest to
accommodate different grinding tasks and work piece sizes.
EXPERIMENT 2: LATHE OPERATIONS

FACING, CHAMFERING, PLANE TURNING AND STEP TURNING

OPERATIONS ON A LATHE MACHINE
Aim: To perform and understand the operations of facing, chamfering, plane turning, and step turning on a
lathe machine, achieving accurate dimensions and surface finishes on a cylindrical work piece.
MATERIAL REQUIRED
 A mild steel bar of 20 mm diameter and 110 mm length.
TOOLS AND EQUIPMENT USED
 H.S.S. single point cutting tool,
 Chuck key,
 Tool post key,
 Outside caliper,
 Steel rule.
SEQUENCE OF OPERATIONS
1. Facing H.S.S Single Point tool
2. Chamfering H.S.S Single Point tool.
3. Plane turning H.S.S Single Point tool.
4. Step Turning H.S.S Single Point tool.
Facing: Facing is a fundamental machining operation performed on a lathe to create a flat surface at the end of a
cylindrical work piece. This operation is crucial for achieving accurate and smooth end faces that are perpendicular to
the axis of the work piece. Facing is commonly used to prepare a work piece for further machining processes, ensuring a
clean and flat surface that serves as a reference for subsequent operations.

Chamfering: Chamfering is a machining process used to create a beveled edge or an angled surface on a work piece.
In lathe operations, chamfering involves cutting away a portion of the edge at an angle to remove sharp corners or to
prepare surfaces for assembly. This operation enhances the appearance, functionality, and safety of the work piece.
Plane Turning is a lathe machining operation aimed at producing a smooth, flat surface along the length of a
cylindrical work piece. This process involves reducing the diameter of the work piece to achieve a uniform surface,
making it suitable for various applications where a precise, even cylindrical shape is required.

Metal cutting: 1. Depth of Cut

Definition: Depth of cut refers to the thickness of the material removed in a single pass of the cutting tool
during machining. It is measured perpendicular to the surface of the work piece.
Formula: Depth of Cut(d) = Initial Diameter − Final Diameter
where:
 Initial Diameter: Diameter of the workpiece before cutting.
 Final Diameter: Diameter of the workpiece after cutting.
2. Feed
Definition: Feed is the distance the cutting tool advances into the work piece for each revolution of the
spindle. It determines the rate at which material is removed and affects the surface finish and tool life.
Formula: Feed Rate(f) = Feed per Revolution(fr) × Spindle Speed(N)
where:
 Feed per Revolution (fr): Distance the tool advances for each revolution of the spindle.
 Spindle Speed (N): Number of revolutions per minute (RPM) of the work piece.

3. Cutting Speed
Definition: Cutting speed, or surface speed, is the speed at which the cutting edge of the tool engages the
work piece material. It is expressed in terms of the linear speed of the work piece surface.
Formula: Cutting Speed (Vc)= π× Diameter(D)× Spindle Speed(N) / 1000
where:
 Diameter (DDD): Diameter of the workpiece.
 Spindle Speed (NNN): Number of revolutions per minute (RPM) of the workpiece.
 The result is typically in meters per minute (m/min).

PROCEDURE
 The work piece is fixed in a 3 – jaw chuck with sufficient overhang.
 Adjust the machine to run the job to a required cutting speed.
 Fix the cutting tool in the tool post and centering operation is performed so that the
 axis of the job coincides with the lathe axis.
 Give the feed and depth of cut to the cutting tool.
 Facing operation is performed from the center of the job towards outwards or from
the circumference towards the center.
 Chamfering is done at the end of the work piece on both sides.
 Plain turning operation is performed until the diameter of the work piece reduces to
16 mm.
 Check the dimensions by using vernier calipers.
 Perform the plain turning operation on the same work piece for the required length
in order to reduce the diameter to 12 mm so as to get the step turning.
 Using a V – cutting tool grooving operation is performed according to the given
dimensions and finishes the groove using parting tool.
 Finally check the dimensions using outside calipers.
Safety Precautions:
 Wear : Safety glasses, gloves, and hearing protection.
 Inspect Machine: Ensure all guards and safety devices are in place and functioning.
 Secure Work piece: Verify the work piece is properly clamped in the chuck.
 Avoid Contact: Keep hands and tools away from rotating parts.
 Use Coolant: Apply coolant to prevent overheating and maintain proper tool operation.

Result: Hence the Facing, chamfering, plane turning and step turning operations has been performed on the
given work piece using Lathe machine.

EXPERIMENT 3: LATHE OPERATIONS

 FACING, CHAMFERING, PLANE TURNING, TAPER TURNING AND
KNURLING OPERATIONS ON A LATHE MACHINE
Aim: To perform and understand the operations of facing, chamfering, plane turning, Knurling and Taper
turning on a lathe machine, achieving accurate dimensions and surface finishes on a cylindrical work piece.
MATERIAL REQUIRED
 A mild steel bar of 20 mm diameter and 110 mm length.
TOOLS AND EQUIPMENT USED
 H.S.S. single point cutting tool,
 Chuck key,
 Tool post key,
 Outside caliper,
 Steel rule.
SEQUENCE OF OPERATIONS
1. Facing H.S.S Single Point tool
2. Chamfering H.S.S Single Point tool.
3. Plane turning H.S.S Single Point tool.
4. Taper Turning H.S.S Single Point tool.
5. Knurling H.S.S Single Point tool.
Theory:
Knurling is a machining process used to create a textured pattern on the surface of a work piece, typically a cylindrical
one. This pattern can enhance the grip, improve the appearance, or provide functional benefits to the part. The knurling
operation is commonly performed on a lathe using a specialized knurling tool that presses into the work piece to form the
desired texture.
Purpose of Knurling:
1. Improved Grip: Knurling creates a textured surface that enhances the grip of handles, knobs, or other
components where user interaction is required.
2. Aesthetic Enhancement: Provides a decorative finish that can improve the visual appeal of the work piece.
3. Functional Features: Knurled patterns can be used for functional purposes, such as providing a surface for easy
rotation or engagement in mechanical assemblies.

Types of Knurling Patterns:

1. Straight Knurling: Features parallel lines that run along the length of the work piece.
2. Diamond Knurling: Displays a crisscross pattern that forms diamond shapes, often used for a more decorative
appearance.
3. Cross Knurling: Combines multiple patterns to create a more complex texture.
Taper Turning: Taper Turning is a lathe machining process used to create a conical shape on a cylindrical work piece.
This operation involves gradually reducing the diameter of the work piece along its length to produce a tapered surface.
Taper turning is essential for producing parts that fit precisely into assemblies, facilitating proper alignment and
functioning.
To calculate the taper angle of a work piece in a taper turning operation, you can use the following formula:

Taper Angle Formula

Formula: Taper Angle (θ) = Tan−1(Difference in Diameter / (2×Length)
where:
 Difference in Diameter: The difference between the large end diameter (D1) and the small end diameter (D2) of
the work piece.
 Length: The length of the tapered section of the work piece.
PROCEDURE:
 The work piece is fixed in a 3 – jaw chuck with sufficient overhang.
 Adjust the machine to run the job to required cutting speed.
 Fix the cutting tool in the tool post and centering operation is performed so that the
axis of the job coincides with the lathe axis.
 Facing is performed by giving longitudinal depth of cut and cross feed.
 Perform plain turning operation until the diameter of the work piece reduced to 16 mm.
 Use the compound rest or tailstock to set the tool at the desired angle. For the compound rest, set it to the
taper angle directly. For the tailstock, adjust it to tilt and align the tool to create the taper.
Tapered angle Tanα = (D – d) / 2L)

 Move the tool along the work piece while maintaining the set angle to cut the taper. Ensure steady
feeding to achieve a smooth, consistent taper.
 Choose the appropriate knurling tool with the desired pattern (straight, diamond, etc.) and mount the
knurling tool in the tool post
 Adjust the knurling tool so that the knurling wheels are perpendicular to the work piece surface. Slowly
feed the knurling tool into the rotating work piece.
 For every operation check the dimensions using vernier calipers.
Safety Precautions:
 Wear : Safety glasses, gloves, and hearing protection.
 Inspect Machine: Ensure all guards and safety devices are in place and functioning.
 Secure Work piece: Verify the work piece is properly clamped in the chuck.
 Avoid Contact: Keep hands and tools away from rotating parts.
 Use Coolant: Apply coolant to prevent overheating and maintain proper tool operation.

Result: Hence the Facing, chamfering, plane turning and step turning operations has been performed on the
given work piece using Lathe machine.

EXPERIMENT 4: Date:
 4. DRILLING, TAPPING AND GRINDING
AIM
To perform drilling, tapping and grinding operations on the given M.S Flat work piece.

APPARATUS
1. Drilling Machine with standard accessories
2. Work piece.
3. Tapping Tools.
4. Bench grinding machine.
MATERIAL REQUIRED:
Mild Steel flat plate 50 mm × 50 mm ×6 mm
SEQUENCE OF OPERATIONS:
S.No OPERATION TOOLSUSED
1 Marking Surface plate, Vernier height gauge
2 Punching Center punch, ball peen hammer
3 Pilot hole drilling Drill bit of ϕ3mm
4 Drilling Drill bit of ϕ8.5mm, ϕ9.8mm
5 Tapping(1stStage) M10 taper tap
6 Tapping(2ndStage) M10 intermediate tap
7 Tapping(3rdStage) M10 bottoming tap

THEORY:

MARKING:
Before drilling any hole on the given work piece, the center of the hole is located by drawing
Two lines at right angles to each other by means of Vernier height gauge placed on the surface plate.
PUNCHING:
After locating a center, an indentation is made at the point where the hole is to be drilled.
Punching is done by means of center punch and ball peen hammer.
DRILLING:
Drilling is the operation of producing a cylindrical hole by removing metal by the rotating edge of a cutting tool
called the drill. The drilling is one of the simplest methods of producing a hole. Drilling does not produce an
accurate hole in a work piece and the hole location is not perfect. The internal surface of the hole so generated
by drilling becomes rough and the hole is always slightly oversize than the drill used due to the vibration of the
spindle and the drill.
TAPPING:
Tapping is the operation of cutting internal threads by means of a cutting tool called a tap.
Tapping may be performed by hand or machine drill.
TAP:
A tap may be considered as a bolt with accurate threads cut on it and 3 or 4 flutes cut across the
thread. The edges of the thread formed by the flutes are the cutting edges which are hardened and ground. The
lower part of the tap is some what tapered, so that it can dig into the walls of the drilled hole. The upper part of
the tap consists of a shank ending in a square for holding the tap in the machine spindle or by a wrench.
Taps are made from carbon steel or H.S.S and are hardened and tempered. Taps are classified as
a) Hand tap and
b) Machine tap
Hand taps are usually made three sets as shown in figure.
i) Taper tap(rougher),
ii) Second tap(intermediate),
iii) Bottoming tap(finisher).
TAPER TAP (ROUGHER):
The end of the rougher has about 6 threads tapered. This is used to start the thread so that the threads are formed
gradually as the tap is turned in to the hole.
SECONDTAP (INTERMEDIATE):
The intermediate is tapered back from the edge about 3or 4 Threads. This is used after the rougher tap has been
used to cut the thread as far as possible.
BOTTOMINGTAP (FINISHER):
This tap has full threads for the whole of its length. This is used to finish the work prepared by the other two taps.
 PROCEDURE
 The given work piece is first filed to get required length, breadth and thickness wet
chalk is applied on four sides and with the scriber lines are drawn to get center hole at
required location.
 The centers are punched with a Punch and hammer.
 The work piece is fixed firmly in the vice of the Radial Drilling Machine
 10 mm diameter drill bit is fixed firmly in the chuck and drilling is performed giving uniform
depths.
 The drill bit is removed from the drill chuck.
 The Tapping operation is performed on the hole which has been previously drilled.
 The work is removed from the vice for performing tapping operation.
 The job is fixed firmly in a bench vice.
 Tap is fixed in the tap handle and pressure applied on the taps to obtain internal thread.
 After tapping operation make fillets model with any radius on the corners of the work piece with
Pencil.
 The finishing fillet operation on the work piece is done on the Bench grinding machine with the
help of cutting plier.
PRECAUTIONS
 Marking is done without parallax error
 Care should be taken while cutting and drilling.
 While performing drilling and tapping operations lubricant should be used to minimize the
friction.
 Always wear safety glasses or a face shield to protect your eyes from flying debris and sparks in
doing grinding operation.
RESULT: Hence, the drilling, tapping and Grinding (fillet model) operations has been performed on the
given work piece using Drilling machine, Different sets of taps and Bench grinding machine successfully.
EXPERIMENT 5: Date:

5. SHAPING MACHINE (V-CUT MODEL)

AIM: To perform a job on shaping machine and make a V- cut model on the given wooden work piece.
MATERIALS REQUIRED: Wood work piece. 100 mm × 50 mm × 25 mm,
Depth of V-Piece: 10mm and length: 10 mm
APPARATUS REQUIRED:

 Shaping machine

 M.S V-shape cutting tool.

 Metal jack plane and wood rasp file,

 Try square and Vernier calipers

 Steel rule.

THEORY:

A shaping machine, also known as a shaper, is a versatile machine tool used primarily for producing flat
surfaces, grooves, and other straight-edged contours on work pieces. The shaping machine operates by
reciprocating a single-point cutting tool back and forth across the work piece in a linear motion, removing
material during the forward stroke and returning without cutting during the backward stroke. It is an essential
tool in machine shops, used for shaping and finishing various materials, especially metals.
The main purpose of a shaping machine is to create flat surfaces, slots, grooves, keyways, and other straight
profiles on materials with precision and efficiency. Shapers are particularly useful for machining parts with
simple geometry or when specific surface finishes are required.

PROCEDURE:
 1. Select the wooden work piece and Ensure the wooden work piece is clean, free of defects, and properly
sized for the operation.

2. Do the cutting action with metal jack plane and wood rasp file for getting the required dimensions. 100
mm × 50 mm × 25 mm.

3. Fixing of wooden specimen in the machine vice of the shaping machine

4. Choose a V-shaped cutting tool or a tool bit with the desired angle for the V-cut. The angle of the tool
should match the angle of the V-cut required.

5. Mount the V-cutting tool securely in the tool holder of the shaping machine.

6. Position the work piece so that the area to be V-cut is correctly aligned with the cutting tool.

7. Adjust the feed rate according to the hardness of the wood and the desired finish. Generally, a moderate
feed rate is suitable for wood to avoid splintering.

8. Power on the shaping machine and set it to the appropriate speed for cutting wood. Engage the tool to
make the initial cut. Move the tool slowly and steadily along the surface of the work piece, following
the intended V-cut path.

9. Once the V-cut is complete, turn off the shaping machine and wait for all moving parts to come to a
complete stop. Carefully unclamp and remove the work piece from the machine.
PRECAUTIONS:
1. The shaping machine must be stopped before setting up or removing the work piece
2. All the chips should be removed from the cutter.
3. Turn off and unplug the machine before making adjustments or changing tools.
RESULT: Hence, the V-cut model on the given wood work piece has been performed by using Shaping
Machine.

EXPERIMENT 6: Date:
 6. SHAPING MACHINE (RECTANGLE-CUT MODEL)
AIM: To perform a job on Shaping machine and make a Rectangle cut model on the given wooden work piece.
MATERIALS REQUIRED: Wood work piece. 100 mm × 50 mm × 25 mm,
Depth of rectangle: 10 mm and length of rectangle model: 30 mm
APPARATUS REQUIRED:

 Shaping machine

 M.S Rectangle -shape cutting tool.

 Metal jack plane and wood rasp file,

 Try square and Vernier calipers

 Steel rule.
THEORY:

A shaping machine, also known as a shaper, is a versatile machine tool used primarily for producing flat
surfaces, grooves, and other straight-edged contours on work pieces. The shaping machine operates by
reciprocating a single-point cutting tool back and forth across the work piece in a linear motion, removing
material during the forward stroke and returning without cutting during the backward stroke. It is an essential
tool in machine shops, used for shaping and finishing various materials, especially metals.
The main purpose of a shaping machine is to create flat surfaces, slots, grooves, keyways, and other straight
profiles on materials with precision and efficiency. Shapers are particularly useful for machining parts with
simple geometry or when specific surface finishes are required.
PROCEDURE:
1. Select the wooden work piece and Ensure the wooden work piece is clean, free of defects, and properly
sized for the operation.
 2. Do the cutting action with metal jack plane and wood rasp file for getting the required dimensions.
100 mm × 50 mm × 25 mm.

3. Fixing of wooden specimen in the machine vice of the shaping machine

4. Choose a Rectangle-shaped cutting tool or a tool bit with the desired angle for the rectangle-cut. The
angle of the tool should match the angle of the rectangle-cut required.

5. Mount the rectangle-cutting tool securely in the tool holder of the shaping machine.

6. Position the work piece so that the area to be rectangle-cut is correctly aligned with the cutting tool.

7. Adjust the feed rate according to the hardness of the wood manually and the desired finish.
Generally, a moderate feed rate is suitable for wood to avoid splintering.

8. Power on the shaping machine and set it to the appropriate speed for cutting wood. Engage the tool to
make the initial cut. Move the tool slowly and steadily along the surface of the work piece, following
the intended rectangle-cut path.

9. Once the rectangle-cut is complete, turn off the shaping machine and wait for all moving parts to
come to a complete stop. Carefully unclamp and remove the work piece from the machine.
PRECAUTIONS:
1. The shaping machine must be stopped before setting up or removing the work piece
2. All the chips should be removed from the cutter.
3. Turn off and unplug the machine before making adjustments or changing tools.
RESULT: Hence, the rectangle-cut model on the given wood work piece has been performed by using
Shaping Machine.

EXPERIMENT NO: 07 DATE:

 JOB ON MILLING MACHINE (GROOVE-CUT MODEL)

AIM: To cut the slots and make a groove cut model on the given wooden work piece by using the Horizontal
Milling machine.

APPARATUS:

1. Horizontal Milling Machine

2. Steel rule,
3. Milling cutter
4. Spanner
5. Mandrel.

MATERAIL REQUIRED: Wooden piece of dimensions 150×50×25 mm

THEORY:
Milling is the machining process of using rotary cutters to remove material from a work piece advancing
(or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different operations
and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of
the most commonly used processes in industry and machine shops today for machining parts to precise sizes
and shapes.
Main Components of milling machine:
Base, column, knee, saddle, table
Types of milling machine:
Plain milling machine, vertical milling machine, universal milling machine,
simplex milling machine, triplex milling machine
Types of Milling Cutter:
Plain milling cutter, slide milling cutter, arbor cutters, shank cutters, face cutters.

PROCEDURE:

1. Cut the work piece as per required dimensions.

2. Plane the surface of the work piece smoothly using metal jack plane.
 3. on the work piece draw the slots with 6 mm depth. Now fix the milling cutter on the arbour by using
spacing collars.
4. Now fix the work piece in between the jaws of the milling machine vice.
5. Start the machine and give the load, feed and depth of cut.
6. Cut the slots by varying feed and depth of cut in both up milling and down milling operations.
7. For every slot observe the type of surface finish. Continue this procedure at different speeds and feeds
and make other slots with the depth of 6 mm and identify the type of surface finish.
8. After completion of the job remove the work piece and check the dimensions of each slot and switch
off the machine.

TABULAR COLUMN:

Speed Type of Surface

S.NO Depth (mm) Feed
(rpm) milling finish

PRECAUTIONS:

1. Make sure that the work piece and cutter are mounted securely before taking a cut.
2. Move table as far as possible from cutter while setting up work to avoid injuring your hands.
3. Use a vacuum, brush or rake to remove cuttings only after the cutters have stopped moving.
RESULT:
Hence the slots (groove cut model) on the given wooden work piece has been performed successfully
using horizontal milling machine.

Experiment No: 08 Date:

8. JOB ON BENCH GRINDING MACHINE (HEXAGONAL MODEL)
AIM: To perform a job on the Bench grinding machine and prepare a Hexagonal model on the given work
piece.
REQUIRED WORK PIECE:

APPARATUS:

1. Mild steel work piece

2. Bench grinding machine
3. Drilling machine
4. Tapping tools
5. Cutting plier
6. Vernier calipers

MATERIAL REQUIRED: Mild steel work piece dimensions 60×60×3 mm

THEORY:
Grinding is a metal cutting operation performed by means of abrasive particles rigidly mounted on a

rotating wheel. Each of the abrasive particles act as a single point cutting tool and grinding wheel acts as a

multipoint cutting tool. The grinding operation is used to finish the work pieces with extremely high quality of

surface finish and accuracy of shape and dimension. Grinding is one of the widely accepted finishing

operations because it removes material in very small size of chips 0.25 to 0.50 mm. It provides accuracy of the

order of 0.000025 mm.

Work piece is fed against the rotating abrasive wheel. Due to action of rubbing or friction between the

abrasive particles and work piece material is removed.

PROCEDURE:

1. Choose a work piece that is appropriate for grinding into a hexagon. Typically, this would be a square bar of

metal or other machinable materials.

2. Using a marker or scribe, mark the work piece where the six faces of the hexagon will be ground.

3. For a square bar, mark the diagonal lines and measure to find the midpoints of these diagonals, then draw lines

to guide the grinding.

4. Hold the work piece on bench vice and apply filing operation and make small dot punches with hammer on the

excessive edges of the work piece.

5. Hold the work piece firmly with both hands or use a vice or clamp if available.

6. Gently press the work piece against the grinding wheel, allowing the wheel to remove material without forcing

it. This prevents overheating and excessive wear on the wheel.

7. Grind along the marked line until you achieve a flat surface that extends the full length of the work piece. This

will be the first side of the hexagon.

8. Repeat the grinding process for the other sides also. Ensure each face is flat and the angles between them are

consistent. After grinding all six sides, check the work piece to ensure all faces are even.

9. Turn off the bench grinder and wait for the wheel to come to a complete stop before making any adjustments or

moving the work piece.

PRECAUTIONS:

1. Wear goggles for all grinding machine operations.

2. Bring work into contact with the grinding wheel slowly and smoothly, without bumping.
 3. Apply gradual pressure to allow the wheel to warm up evenly. Use only the pressure required to
complete a job.

RESULT:

Hence, the Job on the Bench grinding machine has been performed and a Hexagonal model has been
prepared.
Experiment No: 09 Date:
09. PORTER GOVERNOR
AIM: To perform experiment on Porter governor and to determine the characteristics curves of the Porter
governor.
APPARATUS: 1. Digital rpm indicator with sensor
3. Sleeve weights
2. Porter arm setup
4. Measuring tape.
THEORY:
The function of a governor is to regulate the mean speed of an engine, when there are variations in the load
e.g. when the load on an engine increases, its speed decreases, therefore it becomes necessary to increase the
supply of working fluid. When the load on the engine decreases, its speed increases and thus less working
fluid is required. The governor automatically controls the supply of working fluid to the engine with the
varying load conditions and keeps the mean speed within certain limits.
The governors may, broadly, be classified as
1. Centrifugal governor
2. Inertia governor
The centrifugal governors, may further be classified as follows :
1. Pendulum type (Watt governor)
2. Loaded type

 Dead weight governor (Porter governor and Proell governor)

 Spring controlled governors (Hartnell governor, Hartung governor, Wilson-Hartnell governor and
Pickering governor)

The centre sleeve of the Porter and Proell governors incorporates a weight sleeve to which
weights may be added. The Hartnell governor provides means of varying spring rate and initial compression
level and mass of rotating weight. This enables the Hartnell governor to be operated as a stable or unstable
governor.

DC motor with drive: ½ HP motor and DC drive control for speed variation. Separate linkages for
governor arrangements ( Porter, Proell and Hartnell ) are provided using same motor and base.
Porter Governor: - The porter governor is a modification of a Watt’s governor, with central load attached
to the sleeve. The load moves up down the central spindle. This additional downward force increases the
speed of revolution required to enable the balls to rise to any to any pre-determined level.
FORMULAE:

1.Controlling Force, F = m ω2 R in N
Where, m = mass of each ball in kg ;
ω = angular velocity = ( 2πN ) / 60 rad /sec
 N = speed in rpm ;
R = radius of rotation of the ball in m ; R = 50 + (L . sin α)
2. Angle of the upper arm with reference to axis (α) = cos-1 (h/L)
3. Height of the Governor = H = h0 – (x/2)
OBSERVATIONS:

a) Length of each link, L = 130 mm

b) Initial height of the governor, h0 = 90 mm,
c) Initial radius of rotation, r0 = 135 mm,
d) Mass of the ball assembly, m = 0.5 kg,
e) Mass of the sleeve, M = 0.5 kg,

PROCEDURE:
1. Mount the required governor assembly over the spindle.
2. Tighten the necessary bolts.
3. Start the motor and gradually increase the speed.
4. The flyweight will fly outward due to which the sleeve will rise.
5. Note down the speed and sleeve rise or calculate by theoretical method.
6. Repeat the experiment at different speeds till the balls fly to maximum position.
7. Bring back the sleeve down by reducing the speed gradually and stop.

TABULAR COLUMN:

S.N Sleeve Speed Height of the Angle of Radius of Centrifug

o displaceme (N) governor inclination rotation al force (F)
nt (x)
in rpm H = (ho – x/2) α= Cos-1(H/l) r =50 + l Sin α ( m ω2 r )

PRECAUTIONS :
1. Do not keep the mains on when trial is complete.
2. Increase the speed gradually.
3. Take the sleeve displacement reading when the pointer remains steady.
4. See that at higher speed the load on sleeve does not hit the upper sleeve of the governor.
5. While closing the test bring the dimmer to zero position and then switch OFF.
 GRAPH:
1. Sleeve displacement vs. Speed.
2. Controlling force vs. Radius of rotation.

RESULT:

Hence the performance characteristics curves of the Porter governor have been determined
successfully.
Experiment No: 10 Date:

PROELL GOVERNOR

AIM: To perform experiment on Proell governor and to determine the characteristics curves of the Porter
governor.
APPARATUS: 1. Digital rpm indicator with sensor
2. Sleeve weights
3. Proell arm setup
4. Measuring tape.
THEORY:
Governors are used for maintaining the speeds of engines with in prescribed limits from no load to
full load. In petrol engines, the governor controls the throttle of carburetor and in diesel engines they control
the fuel pump. Most of the governors are of centrifugal type. These governors use flyweights. Depending
upon the speed, the position of weights change. Which is transmitted to a sleeve through links. Ultimately the
sleeve operates throttle or fuel pump. The dynamic apparatus consists of a spindle mounted in a vertical
position. Four types of governors can be mounted over the spindle, namely watt, porter, proell and hartnell. A
sleeve attached to governor links is lifted by outward movement of balls due to centrifugal force. Lift of
sleeve is measured over a scale.
The centre sleeve of the Porter and Proell governors incorporates a weight sleeve to which
weights may be added. The Hartnell governor provides means of varying spring rate and initial compression
level and mass of rotating weight. This enables the Hartnell governor to be operated as a stable or unstable
governor.
DC motor with drive: ½ HP motor and DC drive control for speed variation. Separate
linkages for governor arrangements ( Porter, Proell and Hartnell ) are provided using same motor and base.
Proell Governor: - The porter governor is known as a Proell governor if the two balls (masses) are fixed on
the upward extensions of the lower links which are in the form of bent links
OBSERVATIONS:

a) Length of each link, L = 125 mm

b) Initial height of the governor, h0 = 90 mm,
c) Initial radius of rotation, r0 = 138 mm,
d) Mass of the fly ball, m = 0.5 kg.
e) Mass of the sleeve, M = 0.5 kg,

PROCEDURE:
1. Mount the required governor assembly over the spindle.
2. Tighten the necessary bolts.
3. Start the motor and gradually increase the speed.
4. The flyweight will fly outward due to which the sleeve will rise.
5. Note down the speed and sleeve rise or calculate by theoretical method.
6. Repeat the experiment at different speeds till the balls fly to maximum position.
7. Bring back the sleeve down by reducing the speed gradually and stop.
 TABULAR COLUMN:

S.No Sleeve Speed (N) Height of the Angle of Radius of Centrifugal

displacement governor inclination rotation force (F)
in rpm
(x)
H = (ho – x/2) α= Cos-1(H/L) r =50 + L Sin α ( m ω2 r )

GUIDANCE CALCULATION:

1. Height of the governor H = (ho – x/2)

2. Angle of inclination α = Cos-1(H/L)
3. Radius of rotation r =50 + L Sin α
4. Angular speed ω = 2πN/ 60
5. Centrifugal force F = m × ω2 × r

PRECAUTIONS :
a) DO NOT KEEP THE MAINS ON when trial is complete
b) Increase the speed gradually.
c) Take the sleeve displacement reading when the pointer remains steady.
d) See that at higher speed the load on sleeve does not hit the upper sleeve of the governor.
e) while closing the test bring the dimmer to zero position and then switch OFF

GRAPH:
2. Sleeve displacement vs. Speed.
3. Controlling force vs. Radius of rotation.

RESULT:

Hence the performance characteristics curves of the Proell governor have been determined
successfully.
Experiment No: 11 Date:

11 . HARTNELL GOVERNOR

Aim: To determine the characteristic performance curves of the Hartnell governor.

Apparatus Required:
1. Digital rpm indicator with sensor
2. Hartnell arm setup
3. Sleeve weights.
4. Measuring tape.
Description of the setup:
The drive unit consists of a DC electric motor connected through belt and pulley arrangement.
Motor and test setup are mounted on a M.S. fabricated frame. The governor spindle is driven by motor
through V belt and is supported in a ball bearing.
The optional governor mechanisms can be mounted on spindle. Digital speed is controlled by
the electronic control unit. A rpm indicator with sensor to determine the speed. A graduated scale is fixed to
the sleeve and guided in vertical direction. Sleeve displacement is to be noted on the scale provided.
The centre sleeve of the Porter and Proell governors incorporates a weight sleeve to which
weights may be added. The Hartnell governor provides means of varying spring rate and initial compression
level and mass of rotating weight. This enables the Hartnell governor to be operated as a stable or unstable
governor.
DC motor with drive: ½ HP motor and DC drive control for speed variation. Separate linkages
for governor arrangements (Porter, Proell and Hartnell) are provided using same motor and base.
Formulae:
1. Controlling Force, F = mω2 r , N
Where, m = mass of each ball, kg
ω = angular velocity = (2πN) / 60, rad/s
Where, N = speed, rpm
2. r = radius of rotation = ro + X (a / b), metres
Where, ro= initial radius of rotation, m
X= sleeve displacement, m
a =75 mm b = 116 mm

Observation:

a. Vertical length of bell crank lever (a) = 75 mm,

b. Horizontal length of the bell crank lever (b) = 116 mm.
c. Weight of each ball assembly, m = 0.5 kg.
d. Intial radius of rotation, r0 = 138 mm.
e. Spring stiffness, = 3.5 kg/cm
f. Free height of the spring = 110 mm
Tabulation:

Sl. Sleeve displacement , Controlling force ,

Speed , N Radius of rotation , r
X F
N
o. ( rpm ) (m)
(m) (N)
1
2
3
4
5

Precautions:
1) Take the sleeve displacement reading when the pointer remains steady.
2) See that at higher speed the load on the sleeve does not hit the upper sleeve of the governor.
3) While closing the test bring the pointer to zero position and then switch off the motor.

Graphs:
(i) Displacement vs Speed
(ii) Radius of rotation vs Controlling force

Result:
Hence the performance characteristics curves of the Hartnell governor have been determined
successfully
JNTUACOLLEGEOFENGINEERINGPULIVENDULA MACHINETOOLSLABORATORYMANUAL