lab_report_of_fabrication[1]
lab_report_of_fabrication[1]
1. Introduction
The purpose of this lab report is to document the process of drawing and grinding a turning
tool on a rack at a specified angle for designated operations. Turning tools are essential in
machining processes, as they shape materials through cutting. Proper grinding techniques
ensure that tools maintain their effectiveness and precision.
2. Materials and Equipment
Turning tool blank (material: high-speed steel or carbide)
Tool grinding machine
Angle gauge
Calipers
Bench grinder
Safety goggles
Measuring tape
Marking tools (scribe, marker)
3. Procedure
Step 1: Drawing the Tool Design The first step involves creating a detailed drawing of the
turning tool. This drawing should include dimensions, angles, and profiles necessary for the
intended operation. The design must consider factors such as:
The type of material being machined.
The required surface finish.
The geometry of the cutting edge.
Using CAD software or manual drafting techniques, create a scale drawing that includes:
Overall length.
Cutting edge angle (typically between 5° to 15°).
Relief angles to prevent rubbing against the workpiece.
Step 2: Setting Up the Grinding Machine Before grinding, ensure that the grinding machine is
set up correctly:
Check that all safety guards are in place.
Ensure that the grinding wheel is appropriate for the material of the tool blank.
Adjust the height of the work rest to match the centerline of the spindle.
Step 3: Marking Reference Points Using calipers and marking tools, transfer critical
dimensions from your drawing onto the tool blank. Mark reference points for:
The cutting edge.
Relief angles. This will guide you during grinding.
Objective:
To study the drawing and grind the turning tool on the rack and specified angle on the
designated operation.
Procedure:
1. Check to see if the cutting edge of the tool bit is free from nicks, burns, etc. It is good
practice to home the cutting edge before you take a finish cut.
2. Set the lathe to the recommended speed and feed rate. The feed rate used depends
upon the surface finish required.
3. Take a light trial cut about .250 inch long at the right hand end of the work to produce
a true diameter, set the cutting tool bit to the diameter and set the graduated collar
to the right diameter.
4. Stop the lathe, measure the diameter.
5. Set the depth of cut for half the amount of material to be removed.
6. Cut along for .250 inch, stop the lathe and check the diameter.
7. Re-adjust the depth of cut, if necessary and finish turn the diameter. In order to
produce the truest diameter possible, finish turn work piece to the required size.
Should it be necessary to finish a diameter by filming or polishing, never leave more
than .002 to .003 inch for this operation.
FACING
Work pieces to be machined are generally cut a little longer than required, and faced to
the right length. Facing is an operation of machining the ends of a workpiece square with
its axis.
To produce a flat, square surface when facing, the lathe might be true.
The purpose of facing are:
To provide a true, flat surface, square with the axis of the workpieces.
To provide and accurate surface from which to take measurements.
To cut the work pieces to the required length.
Procedure:
1. Move the tool post to the left-hand side of the compound rest, and set the right hand
facing tool bit to the right height of the lathe center point. The compound rest may be
set at 30 degrees for accurate end facing.
2. Mount the work piece in the chuck to face. Use a line center in the tail stuck or
straight ruler if needed for true.
3. Insert a facing tool.
Objective:
To finish turning and start facing practice on the cylindrical metal work piece.
02 Secure the workpiece in the lathe chuck and set the speed and feed rate.
03 Position the facing tool slightly above the centerline of the workpiece.
04 Start the operation with low feed and speed and high depth of cut.
Procedure:
1. Set the lathe to the correct speed and feed rate for the type and size of the material being
cut.
2. Adjust the quick change gear box for a .010 to .030 inch feed, depending on the depth of cut
and condition of the machine.
3. For Example: .010, Move the tool holder to the left hand side of the compound rest and set
the tool bit to right height to center.
4. Tighten the tool post securely to prevent the tool holder from moving during the machining
operation.
5. Take a light trial cut at the right hand end of the work piece for about .250 inch length.
6. Measure the work piece and adjust the tool bit for the proper depth of cut.
7. Cut along for about .250 inch, stop the lathe and check the diameter for size. The diameter
should be about .030 inch over the finish side.
8. Re-adjust the depth of cut, if necessary.
For exercise turning, the operator will engage the lathe at a low speed to practice basic
operations such as facing, straight turning, and chamfering. The cutting tool should be
adjusted to achieve the desired depth of cut while maintaining proper feed rates.
Measurements are taken frequently using calipers or micrometers to ensure accuracy
throughout the process.
In step turning, multiple diameters are created along a single workpiece by adjusting the
position of the cutting tool after each pass. This requires careful planning of dimensions before
starting the operation. The operator will mark reference points on the workpiece to guide
where each diameter change occurs. After setting up these reference points, successive cuts
are made until all required diameters are achieved.
Finishing operations involve using finer cutting tools or adjusting parameters such as speed
and feed rate to enhance surface quality further. This stage may also include polishing or
applying coatings if necessary for specific applications. Throughout all steps, continuous
monitoring of tool wear and adjustment of cutting parameters ensures optimal performance.
OBJECTIVE:
To operate and learn the functions of lathe machine. To handle cylindrical work piece, check its
dimensions and properly clamp work piece.
02 Secure the workpiece in the lathe chuck and set the speed and feed rate.
04 Conduct step turning by adjusting the cutting tool for each required diameter.
06 Perform finishing operations for desired surface finish and Clean the workpiece.
EXERCISE NO. 05:
THREADING (MANUAL ,AUTOMATIC):
5. THREADING( MANUAL,AUTOMATIC):
I. Introduction
Threading is a critical operation in machining that involves creating helical grooves on a
cylindrical or conical surface. This process is essential for producing screws, bolts, and other
fasteners that require precise dimensions and fit. Threading can be performed manually or
automatically, each method having its own advantages and applications.
Measurement:
Use a thread pitch gauge to check accuracy after each cut.
Adjust settings as necessary based on measurements taken.
VI. Procedure for Automatic Threading
Setup:
Load program into CNC machine specifying thread dimensions and parameters.
Secure workpiece in CNC chuck.
Tool Preparation:
Select appropriate tooling based on material and thread specifications.
Cutting Process:
Initiate program; machine automatically performs threading operation based on pre-set
parameters.
Monitor operation through CNC interface for any adjustments needed during processing.
Measurement:
Post-process measurement using automated gauging systems integrated within CNC
machinery to ensure precision.
03 Select and prepare the appropriate hand threading die and holder.
04 Align the die with the workpiece and manually start the threading operation.
05 Alternate between clockwise and counterclockwise rotations to loosen chips and ensure
precise threading.
5.DICE FORMATION
(AUTOMATIC&MANUAL)
1. Introduction
The fabrication of dice involves precise machining processes to ensure that each die is uniform
and fair in its design. This report outlines the procedures followed in a fabrication workshop
for creating dice using both manual and automatic lathe machines. The aim is to compare the
effectiveness, efficiency, and accuracy of both methods.
3. Methodology
Manual Lathe Machining Process
Preparation:
Select the appropriate material block for the dice.
Secure the block in the lathe chuck.
Setting Up the Lathe:
Adjust the speed of the lathe according to the material being used.
Ensure all safety measures are in place before starting.
Turning Process:
Begin by turning down the outer diameter of the block to achieve a cylindrical shape.
Gradually reduce the diameter until it reaches approximately 16mm (standard size for dice)
Shaping Edges:
Use cutting tools to create flat surfaces on opposite sides of the cylinder.
This process is repeated until a cube shape is formed.
Drilling Pips:
Switch to a drill bit suitable for creating pips (the dots on dice).
Carefully drill holes at specified locations on each face of the cube according to standard die
designs.
Finishing:
Sand down any rough edges using sandpaper.
Polish surfaces for aesthetic appeal and smoothness.
Quality Check:
Measure dimensions using calipers to ensure compliance with standards.
Verify that pips are evenly spaced and correctly sized.
Automatic Lathe Machining Process
Preparation:
Load material into an automatic lathe machine equipped with CNC capabilities.
Programming:
Input design specifications into the CNC software, including dimensions and pip placements.
Machining Cycle:
The machine automatically performs turning operations similar to manual machining but with
higher precision.
It can execute multiple operations such as drilling, cutting, and finishing without manual
intervention.
Quality Control During Operation:
Sensors monitor dimensions during machining, allowing for real-time adjustments if necessary.
Post-Processing:
After machining, parts may undergo additional automated processes like polishing or coating if
required.
Final Inspection:
Conduct a thorough inspection using digital measuring tools to ensure all specifications are
met accurately.
03 Form the dice shape using a bastard file to rough out the edges.
04 Smooth and level the surface of the dice using a smooth file.
EXERCISE NO.07:
THREADING AND TAPPING:
03 Select the appropriate tap and die set for the desired thread size.
04 Align the tap with the pre-drilled hole at the corner of the dice.
05 Clean the threaded hole and the dice to remove any metal shavings or
debris.
EXERCISE NO . 08:
MILLING (CONVENTIONAL & CLIMB MILLING)
8.MILLING (CONVENTIONAL & CLIMB):
1. Introduction
Milling is a fundamental machining process used to remove material from a workpiece using
rotary cutters. This report focuses on two primary milling techniques: conventional milling
(also known as up milling) and climb milling (down milling). Understanding the differences
between these methods, their advantages, disadvantages, and applications is crucial for
optimizing machining operations.
2. Methodology
Machining Efficiency:
Climb Milling required less power compared to conventional milling because it generated
downward forces that helped stabilize the workpiece during cutting.
Conventional Milling required more power due to upward forces that could potentially lift or
shift the workpiece.
4. Discussion
The results indicate that while both conventional and climb milling have their respective
advantages, climb milling generally provides superior outcomes in terms of surface finish and
tool longevity when performed on machines with minimal backlash. However, caution must be
exercised when using climb milling on older manual machines where backlash may lead to
dangerous situations such as tool breakage or injury.
02 Select the appropriate milling cutter and secure the workpiece on the
milling machine.
03 Choose between climb and conventional milling based on the material and
desired finish.
04 Set the feed rate and spindle speed, then begin the milling process,
monitoring for accuracy.
05 Inspect the workpiece for surface finish and dimensional accuracy after
milling.
EXERCISE NO.09:
Etching and Engraving ,Bending,Finishing
Practice:
Etching and Engraving ,Bending,Finishing
Practice:
Etching:
Etching is the process of using strong acid or mordant to cut into the unprotected parts of a
metal to create a design in intaglio in the metal (the original process —in modern
manufacturing other chemicals may be used on other types of material). As an intaglio method
of printmaking it is, along with engraving, the most important technique for old master surface
prints, and remains widely used today.
Process:
1. Sheet metal or coil is selected from a comprehensive metal (0.07mm to 1.5mm thickness)
and is cut to the required size.
2. The copperplate is first coated with an acid-resistant substance, called the etching ground,
through which the design is drawn with a sharp tool. The ground is usually a compound of
beeswax, bitumen, and resin.
3. The plate is then exposed to nitric acid or Dutch mordant, which eats away those areas of
the plate unprotected by the ground, forming a pattern of recessed lines.
4. These lines hold the ink, and, when the plate is applied to moist paper, the design transfers
to the paper, making a finished print.
5. In the variety of etching known as aquatint, a copperplate is exposed to acid through a layer
of melted granulated resin, leaving an evenly pitted surface that yields broad areas of tone
when the grains are removed and the plate is printed.
6. Etching and aquatint are often combined in a print by means of successive workings of its
plate.
Engraving:
Engraving is the practice of cutting a design into a hard surface such as metal. This process is
often used to produce decorative objects made of such materials as silver, gold, steel, lacquer,
or glass. In addition, the process may be applied to produce intaglio printing plates, of copper
or other metal, for printing images on paper, which are called engraving
Process:
1. A burin produces a unique type of line characterized by its steady, deliberate appearance
and clean edges. Usually made of hardened steel, the burin is traditionally used to engrave
copper plates.
2. The angle tint tool has a slightly curved tip that is commonly used in printmaking.
3. Florentine liners are flat-bottomed tools with multiple lines incised into them, used to do
fill work on larger areas.
4. Flat gravers are used for doing fill work on letters, as well as most musical instrument
engraving work. 5. Round gravers are commonly used on silver to create bright cuts (also
called bright cut engraving), as well as other hard-to-cut metals such as nickel and steel.
5. Round gravers are commonly used on silver to create bright cuts (also called bright cut
engraving), as well as other hard-to-cut metals such as nickel and Steel.
Bending Process
Preparation of Material: Select appropriate thickness of sheet metal (typically between 0.4mm
to 6mm).
Marking Lines: Use a ruler and scriber to mark bend lines on the sheet metal accurately.
Cutting: Cut excess material using snips if necessary before bending.
Bending Operation:
Position the marked sheet metal in the bending machine.
Adjust settings according to material thickness and desired angle (usually between 30° to 90°).
Finishing Process
Deburring: Remove sharp edges from cut areas using files or sanders to ensure safety and
improve aesthetics.
Smoothing Surfaces: Use sanding pads or polishing wheels to smooth out any rough areas
created during cutting or bending.
Cleaning: Clean the finished product with a suitable solvent to remove any oils or residues
from machining processes
Objective:
To practice etching on metal plate and engraving by engraving machine.
02 Mark the Center and Secure the metal sheet on the worktable.
03 Perform a dry run for alignment, then initiate the engraving process.
04 Monitor the engraving process for accuracy and clean the metal sheet
after finished
EXERCISE NO.10:
CNC MACHINE:
10: CNC MACHINE:
1. INTRODUCTION
The purpose of this lab report is to document the fabrication process using a Computer
Numerical Control (CNC) machine. CNC machining is a manufacturing process that utilizes
computer-controlled tools to create parts and components with high precision. This report
outlines the objectives, methodology, results, and conclusions drawn from the fabrication
process.
Setup of CNC Machine
Machine Preparation: The CNC machine was powered on and calibrated according to
manufacturer specifications.
Tool Installation: Required tools were installed in the tool holder of the CNC machine based
on the operations planned (facing, drilling, pocketing).
Workpiece Setup: The workpiece was securely mounted onto the machine table using clamps
or vises to prevent movement during machining.
Zero Point Setting: Using an edge finder or probe, the zero point for all axes (X, Y, Z) was
established to ensure accurate machining.
Components of CNC Machine
Computer Control Unit: The brain of the CNC machine that interprets the G-code and controls
the machine’s movements.
Drive Mechanism: Includes motors (servo or stepper) that move the machine’s components
according to the instructions from the control unit.
Feedback System: Sensors that provide real-time data to ensure accuracy in positioning and
movement.
Machine Tool: The actual cutting tool or spindle that performs the machining operations.
Workpiece Holder: Fixtures or clamps that secure the material being machined.
Power Supply: Provides electrical energy necessary for operation.
4. MACHINING PROCESS
The following operations were performed sequentially:
Facing Operation: A facing cutter was used to flatten one side of the workpiece to achieve a
uniform thickness.
Pocketing Operation: An end mill was employed to create pockets in specified areas as per
design requirements.
Drilling Operation: Drill bits were used to create holes at designated locations with precise
depths as defined in G-code.
Tapping Operation: Tapping was performed on drilled holes where threads were required for
assembly purposes.
Finishing Operations: Any additional finishing processes such as sanding or deburring were
conducted post-machining to enhance surface quality.