Experiment 3

Title:
To perform Drilling, Boring, knurling and parting on specimen of
Mild Steel.

Objectives:
1. To perform internal and external threading on an aluminum specimen using a lathe
machine.
2. To understand the differences in thread formation, tool selection, and machining
processes for internal and external threads.
3. To analyze the effect of RPM, feed rate, and cutting depth on thread accuracy and
surface finish.
4. To ensure correct pitch, depth, and fit between the internal and external threads
using measurement tools.
5. To evaluate the importance of boring before tapping in internal threading and
turning before external threading.

Apparatus:
1. Lathe Machine.
2. Drill Bit (8 mm) – To create the initial hole for internal threading.
3. Boring Tool – To enlarge the drilled hole to 8.5 mm before tapping.
4. Tapping Tool (1.5 Tap Set) – To create internal threads.
5. External Thread Cutting Tool – Single-point tool used for external threading on a
lathe.
6. Vernier Caliper & Micrometer
7. Cutting Fluid (Optional)
8. Parting Tool

Apparatus Picture

Figure 1 Lathe Machine

Theory

Threading
Threading is a machining process used to create helical grooves (threads) on the internal or
external surface of a workpiece. These threads allow parts to be joined together using
fasteners such as screws, bolts, and nuts. Threads can be cut using a lathe machine, taps and
dies, or thread milling tools.

Types of Threads (1)

There are various types of threads, classified based on shape, standard system, and purpose.
The two most common thread profiles used in machining are:

V-Threads (Unified & Metric)

 These have a 60° included angle and are the most widely used threads in mechanical
assemblies.
 Examples include ISO Metric (M) threads and Unified Thread Standard (UNC,
UNF, UNEF).
 Metric threads are specified in millimeters (mm), while Unified threads are specified
in inches (TPI – Threads Per Inch).

Square and Acme Threads

 Square threads are used in power transmission applications (e.g., lead screws).
 Acme threads have a 29° angle and are stronger than square threads, often used in
machine tools and jacks.

Buttress Threads
 Designed for high axial loads in one direction, commonly used in hydraulic presses.

Pipe Threads (BSP, NPT)

 Used for fluid-tight sealing in pipes and fittings.

Internal vs. External Threading (2)

 Internal Threading:
Threads are cut inside a pre-drilled hole using a tap or a boring bar with a threading
tool. (Example: Nut, tapped holes).
  External Threading:
Threads are cut on the outer surface of a cylindrical workpiece using a threading tool
or a die. (Example: Bolts, screws).

Metric vs. Inch Threading

 Metric Threads (mm):

Pitch is measured in millimeters (distance between two consecutive threads).

Example: M8 × 1.25 (8 mm diameter, 1.25 mm pitch).

 Inch Threads (TPI - Threads Per Inch):

Instead of pitch, they use Threads Per Inch (TPI). Example: 1/4-20 UNC (¼ inch
diameter, 20 threads per inch). (3)

Pitch of the Threads in Our Experiment (4)

Since we performed threading in metric units, the pitch (P) is measured in mm. Pitch is
defined as:

For example, for M8 × 1.25, the pitch is 1.25 mm, meaning each thread is 1.25 mm apart.

Experimental Procedure
Internal Threading

1. Mounting the Workpiece:

o Secure the 16 mm diameter aluminum rod in the lathe chuck.
2. Facing: doing facing at 590rpm to make the facing surface plane
3. Drilling the Hole:
o Use an 8 mm drill bit in the lathe tailstock chuck.
o Set the spindle speed to 590rpm and drill a through-hole of 8 mm diameter.
 4. Boring the Hole to 8.5 mm:
o Replace the drill bit with a boring tool in the tool post.
o Set the spindle speed to 590rpm and enlarge the hole to 8.5 mm to allow easy
tapping.
5. Tapping the Internal Thread:
o Remove the workpiece from the lathe.

o Use the tapping tool by clamping it in he tail stock and rotating the tail stock at 38
RPM
o Reverse the tap slightly after every turn to break chips and prevent jamming.
6. Parting the Workpiece:
o Mount the workpiece back in the lathe.
o Use a parting tool to separate the threaded section.

External Threading on a Turned Rod

1. Mounting a New Workpiece:

o Fix another 16 mm diameter aluminum rod in the lathe chuck.
2. Turning the Diameter to 10 mm:
o Use a turning tool to reduce the diameter from 16 mm to 10 mm.
o Maintain slow and steady feed at 590 RPM for a smooth finish.
3. Setting Up for Thread Cutting:
o Mount an external threading tool at 60° to the workpiece axis.
o Engage the lead screw and set the thread pitch to 1.5 mm using the lathe’s gear
settings.
4. Cutting the External Thread:
o Reduce spindle speed to 230 RPM to prevent tool damage.
o Feed the tool into the workpiece gradually, making multiple passes to reach full
thread depth.

o Take a final light pass to refine the thread profile.

Observations & Calculations
Internal Threading Observations:

Parameter Value
Initial Hole Diameter 8 mm
Bored Hole Diameter 8.5
mm
Tap Used 8.5mm
Thread Pitch (P) 1.5
mm
RPM Used 38
RPM
Machining Time 45 sec

External Threading Observations:

Parameter Value
Initial Rod Diameter 16 mm
Turned Diameter for Threading 10 mm
Threading Pitch (P) 1.5 mm
RPM Used 230 RPM
Machining Time 50 sec

Discussion
 Internal threading required precise alignment of the tap to ensure uniform
threads. A bored hole of 8.5 mm (instead of 8 mm) allowed smooth tapping without
excessive force.
 External threading was performed using the lead screw and threading dial,
ensuring accuracy in thread pitch.
 Low RPM (~200 RPM) was crucial to prevent tool breakage and achieve clean
threads.
 Multiple passes were necessary in external threading to avoid excessive tool
pressure in a single cut.
 The external and internal threads fit correctly, confirming accurate machining.

Conclusion
 We successfully performed internal and external threading on aluminum
specimens using a lathe machine
 Thread pitch accuracy was verified using a thread pitch gauge.
 The combination of boring and tapping improved internal thread quality.
 Low RPM and multiple passes were essential for clean and precise external
threading.
 The results confirm that proper tool selection and cutting parameters ensure
accurate thread formation.
References
1. Kalpakjian, S., & Schmid, S. R. (2014). Manufacturing Processes for Engineering Materials.
Pearson Education.

2. Groover, M. P. (2020). Fundamentals of Modern Manufacturing: Materials, Processes, and

Systems. Wiley.

3. Ghosh, A., & Mallik, A. K. (2010). Manufacturing Science. East-West Press.

4. Rao, P. N. (2013). Manufacturing Technology: Metal Cutting and Machine Tools. Tata McGraw
Hill.