MANUFACTURING TECHNOLOGY LAB

(U18LCAU4L2)

B.TECH AUTOMOBILE ENGINEERING

LAB MANUAL

DEPARTMENT OF AUTOMOBILE ENGINEERING

Bharath Institute of Higher Education and Research (BIHER)
173, Agaram Main Rd, Selaiyur, Chennai, Tamil Nadu, India-600073.

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 MANUFACTURING TECHNOLOGY LAB L T P C
Total Contact Hours - 45 0 0 2 1
U18LCAU4L2 Prerequisite – Workshop Technology

Course Designed by- Department of Automobile Engineering

OBJECTIVE
To make the student understand various process, capabilities of lathe, drilling machine,
milling machine and shaper machine

LIST OF EXPERIMENTS
1. Cylindrical surface process
2. Lathe – Taper turning and external thread cutting
3. Drilling machine – Drilling, Tapping & Reaming
4. Milling process – Surface milling
5. Gear manufacturing process – spur gear, gear hobbing
6. Shaping process – keyway cutting
7. Surface finishing process – surface grinding, cylindrical grinding

Course Outcomes
Ability to use different machines depending on job profile requirement
Ability to use different machine tools depending on job surface requirement
Ability to manufacture single point cutting tool using cutter grinder
Ability to manufacture gear through generation process
Ability to use different grinding machine process
Mapping of Course Outcomes with Program outcomes (POs)
(H/M/L indicates strength of correlation) H-High, M-Medium, L-Low
1 COs/POs a b c d e f g h i j k l PSO1 PSO2 PSO3
CO1 H M L M M M H H
CO2 H M L M H H
CO3 H H M M M M L H H
2
CO4 M H M L M L H H
CO5 M M H L L M M
CO6 M H H H
3 Category Professional Core (PC)
4 Approval 47th Meeting of Academic Council held in Aug, 2018

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 LIST OF EXPERIMENTS

1. Cylindrical surface process

2. Lathe – Taper turning and external thread cutting
3. Drilling machine – Drilling, Tapping & Reaming
4. Milling process – Surface milling
5. Gear manufacturing process – spur gear, gear hobbing
6. Shaping process – keyway cutting
7. Surface finishing process – surface grinding, cylindrical grinding

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 TABLE OF CONTENTS
Ex Name of Experiments Page
p. No.
No.
1 Introduction to lathe machine 6
2 Cylindrical surface process 10
3 Lathe- Taper turning 13
4 Lathe- External Thread cutting 17
5 Drilling Machine-Drilling, Tapping 20
and Reaming
6 Milling Process-Surface Milling 25
7 Gear manufacturing process – spur 29
gear
8 Gear manufacturing process- gear 31
hobbing
9 Shaping process – keyway cutting 33
10 Surface finishing process – surface 37
grinding
11 Surface finishing process –cylindrical 39
grinding

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 GENERAL INSTRUCTIONS

1. All the students are instructed to dress appropriately. Remove

any necklaces or other dangling jewelry, wristwatch or rings.
Secure any loose-fitting clothing and roll up long sleeves. Wear
an apron or a properly fitted shop coat. Safety glasses are a
must.
2. Do not attempt to operate a machine until you know the proper
procedures and have been checked out on its safe operation by
your instructor.
3. Keep the machine clear of tools and always stop the machine
before making measurements and adjustments.
4. Don't operate any machine without getting concerned staff
member's prior permission.
5. All the students are advised to come with completed record and
corrected observation book of previous experiment.
6. Extreme care must be taken to avoid any possible injury while
on laboratory work.
7. In case, anything occurs immediately report to the staff
members.

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 Experiment No-01
Introduction to Lathe Machine

LATHE (Turning Machine)

INTRODUCTION

A lathe is the father of all machine tools. It is a basic machine tool, probably the most important one
of all lathe was actually the first machine tool.

Lathe is a particular type of machine tool in which the work is held and rotated against a suitable
cutting tool for the purpose producing surface of revolution in any material.

The main function of a lathe is to remove metal in the form of chips from a workpiece to give it the
required shape and size. Generally, single point cutting tool is used as the cutting tool. The tool
material should be harder and stronger than the workpiece material.

PARTS OF CENTRE LATHE:

1. Bed 2. Head stock 3. Tail stock.

4. Carriage (a) Saddle (b) Cross-slide (c) Compound rest (d) Tool post (e) Apron

SPECIFICATIONS:
Capacity
(i) Distance between centers (ii) Swing diameter over the bed (iii) Swing over Carriage

Other Factors
(a) Horse power of the motor (b) Cutting speed range (c) Feed range
(d) Screw cutting capacity (e) Accuracy achievable (f) Spindle nose diameter and hole size.

TYPES OF LATHE
1. Centre lathe
(a) Belt drive (b) Individual motor drive (c) Gear head lathe

2. Speed lathe.
(a) Wood working lathe (b) Centering (c) Polishing lathe (d) Metal spinning

3. Bench lathe
This is a small lathe, usually mounted on a bench. This is used for small and precision work.

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4. Tool room lathe
A tool room lathe is a very accurate lathe. This lathe mainly used for precision work on tools,
dies, gauges and in machining work where accuracy is needed.

5. Capstan and Turret lathe (Semi-automatic lathe)

These lathes are development of engine lathe and used for mass production. Instead of tail
stock it has hexagonal turret fixed in the carriage carrying six tools. The advantage is that
several different types of operations can be done on work piece a without re-setting of work
or tools.

6. Automatic lathe
In this, all the operations and all the tool movements are automatic, and changing of tools,
speeds are also done automatically. No participation of the operator is necessary during the
operation.

7. Special purpose lathe (a)

Wheel lathe (b) Gap bed lathe (c) T/- lathe (d) Duplicating lathe (e) Missible lathe

FEED MECHANISM
1. End of bed gearing 2. Feed gear box 3. Feed rod and lead screw 4 Apron mechanism,
THREAD CUTTING MECHANISM
1. Right hand thread 2. Left hand thread 3. Single start thread 4. Multi start thread

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 Study of Lathe
Introduction:

The most important machine used in workshop is Lathe. The main function of a lathe is to remove
metal from a piece of work to give the required shape and size. A lathe removes metal by rotating the
work piece against a single point cutting tool. Generally, lathe is used to machine cylindrical shapes.
The parts to be machined can be held between two rigid supports called live and dead centers. The
tool is moved perpendicular to the work piece axis to produce a cylindrical surface.

Principle parts of Lathe:

Principle parts of the Lathe are as follow:

1. Bed; 2. Headstock; 3. Tails stock; 4. Carriage; 5. Saddle ; 6. Compound rest;

7. Tool post; 8. Apron

Bed:

It is the base of the lathe. The head stock is mounted on the left end, the carriage in the middle and the
tailstock at the right end of the bed. The bed has flat and inverted ‘V’ guide ways which is ground
smooth finish to slide the carriage and tailstock smoothly along the guide ways over the bed.

Head Stock:

It consists of hallow spindle which rotates with the help of prime mover (motor) through belt drive. A
live center be fitted into the hallow spindle to hold the work piece along with dog ( Screw
clamp with elbow). A chain of gear drive is attached with the head stock to change the speed and
direction of the rotation of the lathe.

Tail Stock:

It is mounted on the bed at its right end and can slide along the bed and clamped rigidly as required
the length of work piece. It is used for supporting the right end of the work piece to hold by means of
a dead center.

Carriage:

It is fitted on the middle portion of lathe bed over the guide ways and can move in a direction parallel
to the lathe axis. It carries Saddle, Cross-slide, Compound rest, Tool post and Apron.

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(i) Saddle:

It carries the cross slide. compound rest and ‘tool post. It is a ‘H’ shaped casting fitted over the
bed and move along the guide ways.

(ii) Cross-slide:

It carries the compound rest and tool post. It is mounted on the top of the saddle. It can be moved
by hand or may be given power feed through apron mechanism.

(iii) Compound rest

It is mounted on the cross slide. It carries a circular base called swivel plate which graduated in
degrees. It is used during taper turning to set the tool for angular cuts. The upper part known as
compound slide can be moved by means of a hand wheel.

(iv) Tool post:

The tool post is fitted over the compound rest. The tool is clamped in the tool post. There are four
types of tool post.

(a) Single screw tool post

(b) Open side tool post
(c) Four bolt tool post
(d) Four way tool post

(v) Apron:

The hanging part in front to the carriage is termed as the apron. It is attached the saddle and hangs
in front of the bed. It contains gears, clutches and levers for moving the carriage by a hand wheel
or power feed.

Operations performed on Lathe:

Some of the typical operations performed on the lathe are listed and briefly explained below.

Facing: It is the machining of the end of the work piece to produce the flat surface. This
operation may be performed by using facing tool or ordinary turning tool.

Turing: It is the process of removing excess material from a work piece to produce a cylindrical
surface. For ’Rough Turning’ the rate of feed of tool is fast and the depth of cut is heavy. For
‘Finish Turning feed and depth of cut will be small and it is to bring the work piece to the required
size and to produce a good surface finish.

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Taper turning: Producing a conical or taper surface is called taper turning. This taper turning is
achieved by any one of the following methods

 Forming tool method

 Compound rest method
 Tail stock set over method
 Taper turning attachment method.

Drilling: In lathe the work rotates and the drill is fixed in tail stock and fed. The job is
held in a chuck or face plate. An impression is first made at the center of the job then drilling is
proceed by hand feed by rotating the tail stock wheel, where the drill penetrates horizontally to
the work piece.

Thread cutting: The principle of thread cutting is to produce helical groove on a cylindrical or
conical surface by feeding the tool longitudinally, The job is held between centers or by a chuck.
The tool used is called threading tool.

Knurling: It is the process of producing straight or diamond shaped impression on the

surface of the work piece. A knurling tool is used to produce knurled surface.

Grooving: It is the machining of reducing the diameter of work piece on a particular

position by a grooving tool as forming method. Recessing, Undercutting, Necking are all the
same type of operation done different kind of tools.

Chamfering: It is the operation of turning as taper at the end of work. It removes the sharp
edge. It is done by chamfering tool or side edge cutting face of ordinary turning tool.

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 Experiment No-02
Cylindrical Surface Process
OBJECTIVE: Finishing of a surface on surface –grinding machine.

APPARATUS: Steel rule Try square, Vernier caliper

THEORY: Surface grinding machines are useful to produce and finish flat and plane surface.

Types of grinding machines: Transverse grinding, Plunger grinding

PROCEDURE: (take square section)

1. The given work piece is taken and checked for its dimensions.

2. The job is placed on the grinding magnet at opened position.

3. Then each face is grinded to the required accuracy by constant speed.

4. The job is removed from the required accuracy. It is checked by using

vernier caliper and squareness is checked by using try square.

Result: Thus the square section is grinded to the required accuracy in grinding machine.
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 Experiment No-02
Lathe – Taper Turning and External Thread Cutting
1. Step Turning and Taper Turning On Lathe
AIM:
To perform Step turning and Taper turning operations on the given work piece.

MATERIAL REQUIRED:

Mild steel rod of 25 mm diameter and 100 mm long.

TOOLS REQUIRED:
Vernier calipers, steel rule, spanner, chuck spanner, and H.S.S. single point
cutting tool.
SPECIFICATION OF LATHE:
Length of bed 1390 mm
Width of bed 200 mm
Height of centers 165 mm
Admit between centers 700 mm
Lead screw pitch 4TPI
Power of the motor 1 hp.
THEORY:
Lathe removes undesired material from a rotating work piece in the form of chips with the help
of a tool which is traversed across the work and can be fed deep in work. The tool material
should be harder than the work piece and the later help securely and rigidly on the machine. The
tool may be given linear motion in any direction. A lathe is used principally to produce
cylindrical surfaces and plane surfaces, at right angles to the axis of rotation. It can also produce
tapers and bellows etc.
A lathe (shown in fig.) basically consists of a bed to provide support, a head stock, a cross side to
traverse the tool, a tool post mounted on the cross slide. The spindle is driven by a motor through
a gear box to obtain a range of speeds. The carriage moves over the bed guide ways parallel to
the work piece and the cross slide provides the transverse motion. A feed shaft and lead screw
are also provided to power the carriage and for cutting the threads respectively.

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SEQUENCE OF OPERATIONS:
 Centering
 Facing
 Plain turning
 Chamfering
 Step turning
 Grooving
 Taper turning

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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.
 Plain turning operation is performed until the diameter of the work piece reduces to 23
mm.
 Check the dimensions by using vernier calipers.
 Then chamfering is done on the 23mm diameter surface.
 Reverse the work piece in the chuck and facing operation is performed to reduce the
length of work piece to the required dimensions.
 Again Plain turning operation is performed until the diameter of the work piece reduced
to 18mm.
 Using V-cutting tool grooving operation is performed according to the given dimensions
and finish the groove using parting tool.
 Swivel the compound slide to the required angle and taper turning operation by rotating
the compound slide wheel.
 The angle can be measured by using the formula.
 Finally check the dimensions by using vernier calipers.

PRECAUTIONS:
 The work piece should be held rigidly in the chuck before operating the machine.
 Tool should be properly ground, fixed at correct height and properly secured, and work
also be firmly secured.
 Before operating the machine see whether the job and tool is firmly secured in devices or
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 not.
 Optimum machining conditions should be maintained.
 Chips should not be allowed to wound around a revolving job and cleared as often as
possible
 Apply cutting fluids to the tool and work piece properly.

RESULT: The job is completed successfully and safely.

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 Experiment No-03
Lathe – Taper Turning and External Thread Cutting
2. Thread Cutting and Knurling on Lathe

AIM:
To perform Thread cutting and Knurling operation on the given work piece.
MATERIAL REQUIRED:
Mild Steel rod of 25 mm diameter and 100 mm long
TOOLS REQUIRED:
Vernier calipers, steel rule, spanner, chuck spanner, and H.S.S. single point
cutting tool, parting tool and V- cutting tool.
SPECIFICATION OF LATHE:
Length of bed 1390 mm
Width of bed 200 mm
Height of centers 165 mm
Admit between centers 700 mm
Lead screw pitch 4TPI
Power of the motor 1 H.P.
THEORY:
Lathe removes undesired material from a rotating work piece in the form of chips with the help
of a tool which is traversed across the work and can be fed deep in work. The tool material
should be harder than the work piece and the later help securely and rigidly on the machine. The
tool may be given linear motion in any direction. A lathe is used principally to produce
cylindrical surfaces and plane surfaces, at right angles to the axis of rotation. It can also produce
tapers and bellows etc.

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A lathe basically consists of a bed to provide support, a head stock, a cross side to traverse the
tool, a tool post mounted on the cross slide. The spindle is driven by a motor through a gear box
to obtain a range of speeds. The carriage moves over the bed guide ways parallel to the work
piece and the cross slide provides the transverse motion. A feed shaft and lead screw are also
provided to power the carriage and for cutting the threads respectively.
SEQUENCE OF OPERATIONS:
 Centering
 Facing
 Plain turning
 Chamfering
 Step turning
 Grooving
 Thread cutting
 Knurling

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 20mm.
 Chamfering operation is done according to the given dimensions.
 Then reverse the work piece in the chuck and plain turning operation is performed
according to the given dimensions.
 Using V-cutting tool and parting off tool perform grooving operation to the required
dimensions.
 Reduce speed of the spindle by engaging back gear and use Tumbler
 feed reversing mechanism to transmit power through the lead screw.
 And calculate the change gears for the required pitch to be made on the work piece.

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 Using half nut mechanism perform thread cutting operation(right hand threading)
according to the given dimensions and continues it until required depth of cut is obtained.
 At the same speed knurling operation is performed using knurling tool.
 For every operation check the dimensions using vernier calipers.

PRECAUTIONS:

 Before starting the spindle by power, lathe spindle should be revolved by one revolution
by hand to make it sure that no fouling is there.
 Tool should be properly ground, fixed at correct height and properly secured, and work
also be firmly secured.
 Chips should not be allowed to wind around a revolving job and cleared as often as
possible.
 Before operating threading operation, V-tool should be properly ground to the required
helix angle.
 Apply cutting fluids to the tool and work piece property.
 No attempt should be made to clean the revolving job with cotton waste.
 On hearing unusual noise, machine should be stopped.

RESULT: The job is completed successfully and safely.

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 Experiment No-04
Drilling, Reaming and Tapping

1. AIM:
To perform Drilling, reaming and tapping operations on a mild steel flat work piece
2. MATERIAL REQUIRED:
Mild steel flat of 70x50x14mm.
3. TOOLS REQUIRED :
i) Drill bits of 3 mm, 8.5mm,  9.8 mm,
ii) Floating reamer of  10 mm,
iii) M10 hand tap set,
iv) Vernier height gauge, surface plate,
v) Center punch and ball peen hammer.
4. MEASURING INSTRUMENTS REQUIRED:
Vernier caliper, outside caliper,steel rule
5. EQUIPMENT REQUIRED:
Radial Drilling Machine
6. SEQUENCE OF OPERATIONS CHART:
Si No. Operation Tool s used
1. Marking Surface plate , vernier height gauge

2 Punching Center punch ,ball peen hammer

3. Pilot hole drilling Drill bit of  3 mm.

4. Drilling Drill bit of  8.5 mm,  9.8 mm.

5. Reaming Floating reamer of  10 mm

6. Tapping( 1st stage) M10 taper tap.

7. Tapping(2nd stage) M10 intermediate tap.

8. Tapping(3rd stage) M10 bottoming tap.

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6.1. 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.

6.2. 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.

6.3. Pilot hole drilling:

Before drilling a hole of larger diameter, a pilot hole of approximately > 3 mm

which is slightly greater than the width of the chisel edge must be drilled. The reason is that,
the action of the chisel edge during drilling is more pr less an extrusion process, so 80 to 85%
of total thrust i.e., vertically upward force will come on chisel edge which increases the
power requirement and decreases the tool-life. Therefore, to eliminate the thrust acting on the
chisel edge, a pilot hole has to be drilled.

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6.4. 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 is as shown in figure no.4.1.

6.5. Reaming:

Reaming is an accurate way of sizing and finishing a hole which has been
already drilled. In order to finish a hole and to bring it to the accurate size, the hole is drilled
slightly under size. The speed of the Reamer is made half that of drilling and automatic feed
may be employed. The tool used for reaming is known as the reamer which has multiple
cutting edges. Reamer cannot originate a hole. It simply follows the path which has been
previously drilled and removes a very small amount of metal. The Material removed by this
process is around 0.375 mm and for accurate work this should not exceed 0.125mm drill is
as shown in figure no.4.2.

6.6. 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 is as shown in figure
no.4.3.

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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 somewhat tapered, so that it can dig in to
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 hi three sets as shown in Fig (9.4).
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.

Second tap (intermediate):

The intermediate is tapered back from the edge about 3 or 4

Threads .This is used after the rougher tap has been used to cut the thread as far as possible.
Bottoming tap (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.

Tap drill size:

The size of the tap being the outside diameter of its threads, it is necessary that the drilled
hole must be smaller than the tap. The drill size which is sufficiently accurate for most cases
= Out side diameter X 0.8.

7. PROCEDURE:

i) Before drilling holes, centers of the holes are located on the work Piece by
drawing two lines at right angles to each other using vernier height gauge and surface
plate,
ii) The indentations are made at the points where the holes are to be drilled using
center punch and ball peen hammer.
ii) The Work piece is firmly fixed in the vice on a drilling machine and drill bit of
 3 mm is held firmly by the self centering chuck rotated along with the spindle,
iv) Two pilot holes of  3 mm are drilled at the chosen locations by starting
theDrilling machine.
v)  3 mm drill bit is replaced by 8.5 mm drill bit and the drilling is performed in
one of the previously drilled pilot hole.
vi)  8.5 mm drill bit is replaced by  9.8 mm drill bit and the drilling is performed
in the second pilot hole.
vii)  9.8 mm drill bit is replaced by the reamer of  10 mm and the subsequent
sizing and finishing of the hole is done by performing reaming operation in the second
hole by giving hand feed.

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 viii) Finally tapping operation is performed manually in three stages using taper
tap, Intermediate tap and bottoming tap one after the other holding by a wrench.

8. PRECAUTIONS:

1. Ensure that edges of the flat are perfectly square.

2. Slightly lower speeds of the order of 25% less than drilling should be used in
reaming operation,
3. Drilling should be performed only after pilot hole is made.

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 Experiment No-05
Milling Process-Surface Milling
Spur Gear Cutting in Milling Machine
Aim: To produce a spur gear out of the given work piece using milling machine
Apparatus Required:

Horizontal Milling machine

M10 – End Mill Cutter ( HSS )
Gear tooth Vernier
Materials Required:

Cast Iron Work piece – 55mm diameter, 20mm thickness

Milling Machine

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Procedure:

The gear blank is held between the dividing head and tailstock using a mandrel.
The cutter is mounted on the arbor and the cutter is centred accurately with the
gear blank
Set the speed and feed for machining. For giving depth of cut, the table is raised
till the
periphery of the gear blank just touches the cutter
The Micrometre dial of vertical feed screw is set to zero at this position. Then
the table is raised further to give the required depth of cut
The machine is started and feed is given to the table to cut the first groove of
the blank.
After the cut, the table is brought back to the starting position. Then the gear
blank is indexed for the next tooth space.This is continued till all the teeth are cut
Dimensions of the gear teeth profile are checked using the gear tooth Vernier.

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Calculation:

After Machining
Pitch circle Diameter DP = Diameter of the Blank(D) – ( 2 X Module(m)) =
65-(2X2.5)=60
Number of teeth Z = Pitch circle Diameter / module = 60 / 2.5 = 24
Circular Pitch PC = πDP / Z
The relationship between normal pitch and transverse pitch is given by
PN = PC X cosα
Helical Gear considerations:
Helix Angle α is related to Pitch circle diameter (DP) and the lead of the helix
(L) by the following relation
Tan α = πDP / L

With any of the two known values, the third value can be found

Indexing Calculation: Indexing = 40 / Z

Result: Thus a spur gear is made from the given work piece using milling
machine.

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 Experiment No-06
Gear Manufacturing Process
1. Spur gear

OBJECTIVE: Gear cutting on milling machine (Spur Gear).

APPARATUS: Steel rule, Milling cutter, Spanner, Mandrel, Dog carrier

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

Type of milling machine:

Plain milling machine, vertical milling machine, universal milling machine, simplex milling

machine, triplex milling machine

Type of Milling Cutter:

Plain milling cutter, slide milling cutter, arbor cutters, shank cutters, face cutters.

PROCEDURE:

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 1. The raw blank is selected with reference to the number of teeth to be cut.

2. Indexing number is calculated to the position of the blank.

3. Gear blank is mounted on mandrel in milling machine.

4. Centering of the blank is done by upward and cross feed.

5. The depth of the cut is calculated for the given module.

Result: Thus the gear cutting is performed in a milling machine.

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 Gear Manufacturing Process
2. Hobbing Machine

GEAR HOBBING PROCESS

In gear generating process the gear are formed by machining by means

of form cutter the cutting teeth of the gear have the shape and size of
the teeth of gear to be cut.

In generating process the gear teeth are machined as a result of

some relative motion between gear blank and cutter. A cutter of
pitch of capable of generating gear hobbing different number of
teeth.
The common generaating process used for cutting teeth are as follows.

GEAR HOBBING
Hobbing is a gear generating process by means of a rotating cutter
hob. The hob resemble a worm with straight and helical thread
parallel to the axis.
This will form reach shaped cutting teeth with proper rake and
clearance angle of the holes are either single threaded or
multithreaded.
A single threaded hob will complete one revolution for the
generation of each teeth when as threaded the gear cutting with a
hob involves the basic motions.
1) Rotation of hob and gear blank
2) Radial movement of gear blank
3) Down ward feed of job.

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RESULT
Thus the study of gear hobbing process is studied.

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 Experiment No: 7
Key Way By Using Slotting Machine Date
AIM :

To make a key way in the given hollow cylindrical

work piece. MATERIAL REQURED

Cylindrical work piece.

TOOLS REQUIRED

1. Single point cutting tool

2. Allen Key
3. Chuck key
4. Work piece
5. Outside caliber
6. Vernier Caliber

PROCEDURE

1. Hold the work piece on the table by using boltand nut.

2. Set the tool in the tool post.

3. Arrange for slotting movement.

4. Give 0.1 mm depth of cut.

5. Finish to dimensions

6.Switch of the machine

Check the work piece for dimensions.

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RESULT

Thus the Key way is machined in the given hollow cylindrical work piece by
using slotting machine.

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 Experiment No-9
Surface Finishing Process

INTRODUCTION:

It consists of the main driving motor situated over the housings. This motor drives the
countershaft through an open V- belt. The countershaft, at its extreme carries two
driving pulleys; one for open belt and the other for cross belt. The main driving shaft is
provided below the bed. One end of it passes through the housing and carries a pinion,
which meshes with the rack provided under the table of the machine as shown. The
other end of this shaft carries two pairs of pulleys – each pair consisting of a fast pulley
and loose pulley. One of these pairs is connected to one of the driving pulleys by means
of a open belt and the other to the second driving pulley by means of a cross belt. A
speed reduction gear box is mounted on the main driving shaft and the same is
incorporated between the pinion and the pairs of driven pulleys. One set of the above
pulleys is used for the forward motion of the table and the other set for backward or
return motion. the cross belt will be used for forward motion and the open belt for return
motion. Note that the driving pulley on the counter shaft for cross belt is smaller than
the pair of fast and loose pulleys for the same. Against this the driving pulley on the
countershaft for open belt is bigger than the pair of fast and loose pulleys for the same.
Consequently therefore for the same speed or number of revolutions of the countershaft
the main driving shaft will run faster when connected by open belt than when the cross
belt is used. It is obvious therefore that the return stroke will be faster than the forward
stroke. It should also be noted here that the pulleys are so arranged that when the cross
belt is on the fast pulley, i.e. in forward stroke the open belt will be on the loose pulley
and its reverse will take place during the return stroke. In order that this relative shifting
of belt may take place automatically at the end of each stroke, without stopping the
machine, a belt shifter and its operating lever are provided on the machine. Trip dogs
are mounted one each at both ends, on the table. At the end of each stroke these dogs
strike against the operating lever alternately and the belt shifted accordingly. Thus the
table movement is reversed automatically.

OPERATION DONE ON A PLANER:

The common operations performed on a planer include the following:
 Machining horizontal flat surfaces.
 Machining vertical flat surfaces.
 Machining angular surfaces, including dovetails.
 Machining different types of slots and grooves.
 Machining curved surfaces.

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 Machining along pre-marked contours.

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 Experiment No: 10
Surface Finishing Process
1. Plain Surface Grinding
Aim: To perform plain surface grinding on the given work piece to the
required dimensions.

Apparatus required:

Grinding machine
Grinding Wheel
Vernier Caliper
Material Required:

MS / CI plate 12mm X 50mm X 75mm

Procedure:

First the work piece is placed on the magnetic chuck

The positioning of the work piece is aligned at right angles to the
grinding wheel and exactly parallel to the sides of the magnetic chuck by
using slip gauges if necessary
The magnetic chuck is switched on and the powerful electromagnet
holds the job firmly in position
Now the spindle is turned on and the grinding wheel is just touched the
work piece surface to mark its zero / reference position
Now the required feed, either totally or in steps, is given to the grinding
wheel and the wheel is traversed all over the work piece
Same procedure is repeated until the required dimensions are achieved
Care should be taken for maintaining the surface finish
Finally the dimensions are checked using either a Vernier calliper or a
screw gauge.

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Result: Thus plain surface grinding is performed on the given work piece up
to the required Dimensions.

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 Surface Finishing Process
3. Cylindrical Grinding
Aim: To grind the cylindrical surface of the given work piece by cylindrical
grinding.

Apparatus Required:

Grinding machine
Cylindrical grinding wheel setup
Steel Rule
Vernier Calliper
Materials Required:

Cast iron work piece

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Procedure:

First the given work piece is preliminarily finished to the pre-required

dimensions on a lathe before beginning the grinding process
Now the work piece is fitted in the chuck of the cylindrical grinding
machine
The grinding wheel is just touched with the work piece and is taken as
the zero reference
Coolant circulation is switched on and the grinding wheel is engaged
with the work piece.
Both the work piece and the grinding wheel roll on contact with each
other like two gears in mesh
Now slowly the wheel is moved over the entire length of the work piece
to get the grinded finish
After one feed is over, the grinding wheel is moved further towards the
axis of the work piece and the process is repeated until the required
dimensions are achieved
Finally the dimensions are checked using a Vernier caliper.

Result: Thus cylindrical grinding is performed on the given work piece to

the given dimensions.

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