1

PROJECT REPORT
ON
Bench Tapping Machine

Mechanical Engineering Project - I (4351904)

5th Semester Mechanical Engineering
(27th July 2023 to 30th December 2023)

Prepared By:
Valand Satyajit .R 216040319063

Guided By:
Prof. A . J . Patel
MECHANICAL ENGINEERING (GIA)

Bhailalbhai & Bhikhabhai Institute of Technology (BBIT)

Postbox No. 3, Opp. Shastri Maidan,
Vallabh Vidyanagar-388120
2

Dist. Anand (India)

CERTIFICATE
This is to certify that the project report for the project titled as

“ Bench tapping machine “

is successfully completed and submitted by the following student;

Valand Satyajit .R Enrollment No. 216040319063

of Mechanical Engineering division M5A/M5B for subject Mechanical

Engineering Project-I (3351908) during the academic term of 5th semester
from 27th July, 2023 to 16th December 2023 in partial fulfillment of Diploma in
Mechanical Engineering, according to the curriculum of Gujarat Technological
University - Ahmedabad. This project work has been carried out by him/her
under my supervision and guidance within the prescribed time limit and
prescribed boundary.

Date of Submission:

INTERNAL PROJECT GUIDE PROJECT CO-ORDINATOR

( Prof. A.J Patel ) (Prof. S. N. Chaudhari )

HOD
(Dr. R. D. Patel)
3

ACKNOWLEDGEMENT

At this pleasing moment of having successfully completed

our project, we wish to convey our sincere thanks and gratitude
to the management of our college and our beloved chairman
who provided all the facilities to us.
We would like to express our sincere thanks to our
principal K.M. makwana sir for forwarding us to do our project
and offering adequate duration in completing our project.
We are also grateful to the Head of Department Prof. R.D
patel sir for her constructive suggestions & encouragement
during our project.

With deep sense of gratitude, we extend our earnest &

sincere thanks to our guide A.J patel sir Department of
Mechanical for her kind guidance & encouragement during this
project.

We also express our indebt thanks to our TEACHING and

NON TEACHING staffs of MECHANICAL ENGINEERING
DEPARTMENT Bhailal & Bikhalal institute of technology.
4

ABSTRACT

Tapping is a process that is widely used in the field of

engineering, it entails cutting of screw threads onto or
into a work-piece. A tap is usually used to cut threads on
the female part of the nut part, for external threads a die
is usually used to obtain the desire thread size and form.
This project focuses on the design of a manually
operated bench tapping machine, the main problem that
is encountered during tapping process is usually
misalignment of threads which might occur due to
inadequate clamping forces and misalignment of tap
and work-piece. This design provides a solution by
providing a machine which ensures accurate alignment
of tap and work-piece during the threading process. The
machine is composed of supporting frame and shaft,
machine bed, bench holder, spindle shaft and a tab
holder, the combination of these components ensures
that a uniform torque is applied to the tap and as a
result the threading process is accurate and precise. The
machine also as the flexibility advantage because it
allows for attachment of various tap sizes and work-
piece forms and hence it can be used for numerous
applications within a limited space setting. The average
torque on the spindle rod was calculated to be
1.2252Nm which is the average value that an average
human being can produce, this torque can be handled by
5

the spindle shaft material and hence the machine

service life is improved and safety is assured.

INDEX

Sr title Page
no. no.
1 Course outcomes 5
2 Selection of Project Title 6-7
3 Identification of Needs Which Require Product 8-9
Development in your project.

4 Generation of at Least Three Questions of Following 10-

category for your Project:
11
i.productivity ii.quality iii.cost reduction

iv.value

5 Literature Survey of Selected Project 12-

14
6 Market Survey for Selected Project and/or Brief 15-
Industrial Visit Report
18
7 5 S Strategies and 7 S Frame Work Technique 19-
Applicable to the Selected Project
21
8 Detailed Production Drawing & Assembly Drawing 22-
23
9 Bill of Materials with Make or Buy Decision (As per 24-
ANNEXURE - 4)
37
10 Outline Process Chart (OPC) 38-
41
11 Flow Process Chart (FPC) 42-
46
12 Plant Layout with Dimension Applicable to the Selected 47-
6

Project 48
13 List Specification of Machineries, Equipments & Tools 49-
to be Used in the Project
50
14 List, Quantity & Specification of Consumables & its 51-
Consumption
52
15 Detailed Cost Estimation 53-
55
16 References 56
17 Presentation (PPT Slides) ------
7

Chapter – 1
Course Outcomes

1. Threaded Holes: The primary purpose of a bench tapping machine is

to create threaded holes in materials such as metal, plastic, or wood.
These threaded holes are essential for connecting components using
screws, bolts, or other threaded fasteners.
2. Increased Productivity: Bench tapping machines are typically faster
and more precise than manual tapping methods, which can
significantly increase productivity in manufacturing and assembly
processes.
3. Consistency: Tapping machines ensure that the threads created in
materials are consistent in size, depth, and pitch, which is essential
for proper assembly and the integrity of the final product.
4. Reduced Operator Fatigue: Using a bench tapping machine reduces
the physical strain and fatigue associated with manual tapping, as the
machine does the work automatically.
5. Improved Quality Control: The use of a tapping machine can result in
a higher level of quality control, as it helps prevent human errors and
inconsistencies in thread creation.
6. Increased Thread Strength: Bench tapping machines can often
produce threads with greater precision and strength compared to
manually tapped threads.
7. Versatility: Many bench tapping machines are adjustable, allowing for
the creation of threads in a variety of materials and thicknesses.
8. Operator Safety: By automating the tapping process, bench tapping
machines can enhance operator safety by reducing the risk of injuries
related to manual tapping methods.
9. Cost Savings: While there is an initial investment in purchasing a
bench tapping machine, the long-term cost savings in terms of labor
and increased productivity can be substantial.
10. Reduced Scrap: The consistency and precision of bench
tapping machines can reduce the occurrence of scrapped parts due
to improperly tapped threads.
8

Chapter -2

TITTLE SELECTION
1. Define Your Project Requirements:
 Determine the specific needs of your project, such as
the type of materials you'll be tapping (e.g., metal,
plastic, wood), the size and depth of threads required,
and the expected production volume.
2. Budget Constraints:
 Establish a budget for the project, including the cost of
the bench tapper machine, tooling, and any necessary
accessories.
3. Machine Specifications:
 Consider the technical specifications of the bench
tapper machine, such as motor power, spindle speed,
and thread pitch range. Ensure these specifications
align with your project requirements.
4. Machine Type:
 Decide whether you need an automatic or semi-
automatic bench tapper machine, depending on the
volume of work and the level of automation required for
your project.
5. Thread Sizes and Types:
 Check if the machine can accommodate the specific
thread sizes and types you need for your project.
6. Material Compatibility:
 Ensure that the bench tapper machine is compatible
with the materials you'll be working with, as different
machines may be designed for different materials.
7. Tooling and Accessories:
 Determine if the machine comes with the necessary
tooling and accessories, such as tapping heads, collets,
or tapping chucks. If not, consider the additional cost
and availability of these items.
8. Ease of Operation:
 Evaluate the user-friendliness of the machine, including
features like controls, setup, and changeover
procedures.
9

9. Quality and Durability:

 Assess the build quality and durability of the machine. A
reliable machine is essential for consistent and trouble-
free operation.
10. Safety Features:
 Check for safety features such as emergency stop
buttons, guards, and safety interlocks to ensure the
safety of machine operators.
11. Manufacturer Reputation:
 Research the manufacturer's reputation, customer
reviews, and after-sales support to ensure you are
investing in a reputable and reliable brand.
12. Warranty and Support:
 Inquire about the warranty and availability of technical
support and spare parts for the machine.
13. Space and Installation:
 Ensure that you have the necessary space for the
machine and consider any special installation or power
requirements.
14. Energy Efficiency:
 Consider the energy consumption of the machine,
especially if you are concerned about operational costs
and environmental impact.
15. Future Expansion:
 Think about whether the machine can be easily
integrated into your production process and if it allows
for future expansion or modification.
16. Comparative Analysis:
 Compare multiple bench tapper machine models from
different manufacturers to make an informed decision.
17. Demonstrations and Trials:
 If possible, arrange demonstrations or trials of the
machines to assess their performance and suitability for
your project.
18. Consult with Experts:
 Seek advice from experts or industry professionals who
have experience with bench tapper machines.
10

CHAPTER – 3

IDENTIFICATION OF NEED WHICH REQUIRE

PRODUCT DEVLOPMENT IN YOUR PROJECT

1. Enhanced Automation: Developing a bench tapper machine

with advanced automation features can reduce the need for
operator intervention and increase productivity. This might
include automatic tool changes, automatic depth control, or
adaptive tapping based on material hardness.
2. IoT Integration: Incorporating Internet of Things (IoT)
technology can provide real-time monitoring and data
collection capabilities. This can help with predictive
maintenance, performance optimization, and remote
monitoring.
3. Improved Material Compatibility: Developing a machine that
can handle a wider range of materials or materials with
unique properties can broaden its application, making it
more versatile for various industries.
4. High Precision and Accuracy: Focusing on achieving higher
precision and accuracy in thread creation is essential for
applications where tolerances are critical, such as
aerospace or medical device manufacturing.
5. User-Friendly Interface: Developing a more intuitive and
user-friendly interface can reduce the learning curve for
operators and enhance overall ease of use.
6. Energy Efficiency: Designing a bench tapper machine that is
energy-efficient can reduce operational costs and minimize
environmental impact.
7. Safety Innovations: Incorporating advanced safety features,
such as collision detection systems or improved ergonomic
design, can enhance operator safety and reduce the risk of
accidents.
8. Modular Design: Creating a modular machine design that
allows for easy customization and adaptation to different
production requirements can be a significant advantage.
11

9. Quick Changeover: Developing systems for fast tool or

setup changeover can save time and increase machine
efficiency in a production environment with frequent product
changes.
10. Reduced Maintenance Needs: Designing the machine
with components that require less frequent maintenance or
have longer service life can reduce downtime and
maintenance costs.
11. Noise and Vibration Reduction: Addressing noise and
vibration issues can improve the working environment and
reduce wear and tear on the machine.
12. Cost Efficiency: Focusing on cost-effective design and
manufacturing processes can make the machine more
affordable and attractive to a wider range of customers.
13. Compact and Space-Saving Design: Developing a
more compact and space-saving machine can be
advantageous for smaller workshops or crowded production
environments.
14. Customization Options: Offering customization options
to cater to specific industry requirements or unique
customer needs can make the machine more appealing to a
diverse customer base.
15. Environmental Sustainability: Developing a bench
tapper machine with features that reduce environmental
impact, such as efficient energy usage and eco-friendly
materials, can align with the growing focus on sustainability.
12

CHAPTER – 4

Generation of at Least Three Questions of Following

category for your Project:

i.Productivity. ii. Quality. iii. Cost/waste reduction. iv. Value

analysis.

Productivity:
1. How can we improve the throughput and efficiency of the
Bench Tapper Machine to increase the number of threaded
holes it can create per hour?
2. Are there any automation features that can be integrated into
the machine to reduce manual intervention and enhance
overall productivity?
3. What strategies can be implemented to reduce setup times
and changeover times between different tapping operations
on the Bench Tapper Machine?

Quality:
1. How can we ensure that the Bench Tapper Machine
consistently produces threads with the highest level of
precision and accuracy, meeting stringent quality standards?
2. What quality control measures can be implemented to detect
and prevent defects in the threaded holes created by the
machine, and how can these processes be automated?
3. Are there any innovations or technologies that can be
integrated to enhance the durability and strength of the
threaded holes created by the Bench Tapper Machine,
especially for critical applications?

Cost/Waste Reduction:
1. What strategies can be employed to reduce energy
consumption and operational costs associated with running
the Bench Tapper Machine while maintaining high
productivity?
13

2. How can we minimize material waste generated during the

tapping process, especially when working with expensive or
limited resources?
3. Are there opportunities to extend the maintenance intervals
and reduce overall maintenance costs for the Bench Tapper
Machine, without compromising performance or reliability?

Value Analysis:
1. How does the cost of acquiring and operating the Bench
Tapper Machine compare to the value it delivers in terms of
increased production capacity and efficiency?
2. What features or innovations can be added to the machine
to enhance its overall value proposition for customers,
considering factors like durability, ease of use, and
versatility?
3. Can a comprehensive value analysis be conducted to
assess the long-term return on investment (ROI) of the
Bench Tapper Machine for potential customers, including
savings in labor, improved product quality, and reduced
downtime?
14

CHAPTER - 5
Literature Survey of Selected Project

Although manual tapping is employed depending upon

the usage, the risk of human error is higher compared to
most automatic tapping machines. On the other hand, via
machine tapping alongside an arsenal of taps (of varying
materials, thread dimensions, and finishes) the work is
faster, accurate, and more reliable though care is to be
exercised when it comes to the lifetime of the equipment
as well as that of the taps employed in this process. Wear
and tear of taps either by improper spindle speed, under-
or over-feeding the tap causing axial failure, tap and
work-piece misalignment, chip clogging and the absence
of proper torque limitation are some of the problems that
still depicts the manual bench tapping process . Also,
without the aid of proper taps and dies, termed as
chasers, the formation of weaker threads with poor
durability is likely to occur. These threads usually have
non-uniform tolerances and always have loose fittings to
their respective female or male components. In tapping it
is important that only the required materials for the
formation of threads are removed and not any more than
that otherwise the efficiency of the threads is highly
affected, making the whole mechanism joint more
susceptible to failure. To ensure recurring usage of thread
screws the threads must maintain their strength in the
long run with recurring usage without falling prey to
breakage, too much material removal and improper
15

angularity as such even the minutiae of alteration can

devastate the joint strength resulting in unwanted, sudden
failures after overtime usage.
Prior to the availability of hand-powered benches, thread
cutting operations were carried out under the supervision
of skilled workers that could achieve limited accuracy in
their operations and were dominantly dependent on the
workers instead of on the tools. To further delve into the
history of the subject in this matter we must first go into
the history of screws with their design hypothesis dating
all the way back to Archimedes’ screw, then after going
through the hands of the great Greek mathematicians and
after being implemented in carpentry industry and also in
the advent of machines after the dawn of Industrial
revolution, thereafter lathes came forth and various forms
of rolling started to be developed . During the period
between 1760 and 1800, means for proper threaded
fastening increased through various attempts of
Standardization. Later, for the rolling of screw threads, the
first patent came about in 1836 by William Keane of
Monroe in New York, afterward in the 1940s, the ISO
standards came forth for screw threads and by that time
numerous methods for machining threads had become
the norm .Now from a few years back, specific hand
tapping benches have been made commercially available
for internal thread creation which is useful where hand
operations are to be performed.
Some of the recent studies available are reviews on
means of optimizing thread tapping process and the ways
that their improvement can be achieved. As of now there
remains substantial difficulty in having to perform tapping
on certain materials such as Titanium where ultrasonic
vibration tapping can be utilized thus reducing the tapping
torque requirements and thus decreasing the likelihood of
16

tap breakage. Punch Tapping is another hot topic in this

regard, this process is mainly employed in threading
aluminum and other light weight alloys work-pieces,
punch tapping is utilized in the automotive industry where
with single twisting and exiting motion threads are
generated. Currently, only Audi has the exclusive rights to
this technology. There’s also extensive research done
with regards to Cast Iron tapping where varying the
cutting speed, and application of cutting fluid and its
application method while monitoring the axial loads can
help in analyzing the tapping process in extensive detail
while comparing normal lubrication with minimal quantity
(MQF) methods.
17

CHAPTER - 6

Market Survey for Selected Project and/or Brief

Industrial Visit Report
Market Survey for Bench Tapper Machine:

1. Introduction:
• Briefly introduce the purpose and scope of the market
survey.
2. Industry Overview:
• Provide an overview of the metalworking or machining
industry, highlighting its growth trends, key players, and major
applications for bench tapper machines.
3. Competitive Analysis:
• Identify and analyze the major manufacturers and suppliers
of bench tapper machines, considering factors like market share,
product offerings, and customer base.
4. Market Size and Growth:
• Determine the current market size and growth rate for bench
tapper machines, along with anticipated trends in the industry.
5. Customer Needs and Preferences:
• Survey potential customers and gather information on their
requirements, preferences, and pain points related to bench
tapper machines.
6. Market Segmentation:
• Divide the market into segments based on factors such as
industry, geography, machine type, and applications.
18

7. Regulatory Environment:
• Discuss any relevant regulations or standards that impact
the production and use of bench tapper machines.

8. Price and Cost Analysis:

• Analyze the pricing strategies of different manufacturers and
assess how pricing affects the purchasing decisions of
customers.
9. Technology Trends:
19

• Identify emerging technologies in bench tapper machines,

such as automation, IoT integration, or energy efficiency
improvements.
10. Opportunities and Challenges:
• Highlight potential market opportunities and challenges for a
new bench tapper machine project.
11. Competitive Positioning:
• Assess where your project could fit within the existing market
landscape.
12. Conclusion:
• Summarize key findings, emerging trends, and potential
opportunities for a bench tapper machine project.
Industrial Visit Report for Bench Tapper Machine:
1. Introduction:
• Provide an introduction to the industrial visit, including the
purpose and the company or facility visited.
2. Company Overview:
• Describe the visited company's history, mission, and its role
in the production of bench tapper machines.
3. Production Process:
• Detail the production process of the bench tapper machines,
from raw materials to assembly and quality control.
4. Technology and Innovation:
• Highlight any innovative technologies or automation used in
the manufacturing process and their impact on productivity and
quality.
5. Quality Control Measures:
• Explain the quality control procedures and measures
implemented to ensure the reliability and precision of the
machines.
20

6. Safety and Compliance:

• Discuss safety measures and regulatory compliance aspects
in the production facility.
7. Tour Highlights:
• Describe specific observations or highlights from the
industrial visit, such as unique features or practices in the
production process.
8. Interactions and Interviews:
• Share insights from discussions with employees or
managers during the visit, including their perspectives on industry
trends and challenges.
9. Recommendations and Learnings:
• Provide recommendations or insights that can be applied to
the project based on what was learned during the visit.
10. Conclusion:
• Summarize the key takeaways and the value of the industrial
visit to the Bench Tapper Machine project.
21

CHAPTER - 7
5 S Strategies and 7 S Frame Work Technique
Applicable to the Selected Project

5S Methodology:
1. Sort (Seiri): In the context of a Bench Tapper Machine
project, this step involves decluttering and organizing the
workspace. Ensure that all tools, materials, and components
needed for the project are organized and easily accessible.
Removing unnecessary items and optimizing the layout can
streamline the production process.
2. Set in order (Seiton): This step involves organizing items and
tools in a systematic and efficient manner. It is essential to ensure
that everything has its designated place and that operators can
easily locate and access the necessary tools or materials for the
Bench Tapper Machine assembly and operation.
3. Shine (Seiso): In the context of the Bench Tapper Machine
project, maintaining cleanliness and orderliness in the workspace
is essential for safety, product quality, and overall efficiency.
Regular cleaning and maintenance of the machine can prevent
downtime and defects.
4. Standardize (Seiketsu): Standardization ensures that
processes and procedures are consistent and well-documented.
For the Bench Tapper Machine project, this step involves
establishing standardized operating procedures and maintenance
schedules to ensure consistent quality and performance.
5. Sustain (Shitsuke): The final "S" involves developing a
culture of continuous improvement and discipline. For your
22

project, this means ensuring that the practices of sorting, setting

in order, shining, and standardizing are continually maintained
and improved upon.
7S Framework:
1. Strategy: Define the strategic goals of the Bench Tapper
Machine project. This includes identifying the target market,
competitive positioning, and long-term objectives. Consider how
the project aligns with the company's overall business strategy.
2. Structure: Assess the organizational structure of the project
team. Define roles and responsibilities, reporting relationships,
and decision-making processes. Ensure that the project team is
structured for maximum efficiency and accountability.
3. Systems: Evaluate the systems and processes in place for
the Bench Tapper Machine project. This includes product
development processes, supply chain management, quality
control, and project management systems. Identify areas where
improvements can be made.
4. Skills: Examine the skills and competencies of the project
team members. Ensure that the team has the necessary
technical, engineering, and project management skills to
successfully develop the Bench Tapper Machine.
5. Shared Values: Define the core values and principles that
guide the project. These values should align with the project's
objectives, such as quality, innovation, and customer satisfaction.
6. Style: Consider the leadership style and culture within the
project team. Effective leadership and a culture of collaboration
and continuous improvement are crucial for project success.
7. Staff: Evaluate the team composition and the availability of
skilled personnel. Ensure that the project team is adequately
staffed and that team members are motivated and aligned with
the project's objectives.
23
24

CHAPTER - 8
Detailed Production Drawing & Assembly
Drawing
25
26
27
28
29

CHAPTER - 9
30

BILL OF MATERIAL (BOM) (ANNEXURE-4)

Semester: 5th Subject: : Mechanical Engineering Project-I

(4351904) Term: 27/07/2023 to 16/12/2023

Title of Project: Bench Tapper Machine

Raw Materials (BOM)

M
a
t
e Tot
r al
i Wei
a ght Est.
Name Unit
l Size Cos
Sr. of Quantity (of Price
& t Remarks
No. Part/It (in mm) Nos. all
(Rs.) (Rs.
em piec
S )
e es)
c (in
t kg)
i
o
n

AS PER DRG AS TO MAKE

SHAF PROJECT
1
T
1 PER 350 650
DRG ROTATE

SPI AS PER DRG AS SPINDLE

NDL PE OF SHAFT
2 E 2 R 300 600
SHA DR
FT G
AS PER DRG AS TP MAKE
BEA PE ROTATIO
3 RIN 5 R 50 250
G DR N OF
G PARTS
31

AS PER DRG AS RAW

PE MATERIAL
4 PIPE AS REQ R 100 200
DR OR
OPERATION SYMBOL MACHINED TOOLSG SETTING MACHINING
FRAME
USED USED TIME TIME(MIN)
AS PER DRG AS IT HOLD
TAP PE (MIN)
TO TAP
5 HOL 1 R 450 450
Loading
DER D - - DR 1 -
G
Drilling O Drilling Drill - 10
AS PER DRG Tool ofAS IT HOLD
MAC PE THE
6 HINE 1 HSS ΦR 500 500
BED DR DEVICE
½” for
G
6 holes
SCR AS PER DRG AS TO MAKE
Drilling
EW O Drilling DrillPE - 3
JOINT
7 & 15 Tool ΦR 30 450
JOIN DR
TS 3/8” G
for 2
A. Total Raw Material
holes
Cost (Rs.) 2800

Unloading D - - 1 -

Tapping O - Hand - 36
tap Φ
½” for
6 holes

Tapping O - Hand - 12
tap Φ
3/8”
for 2
holes
32

CHAPTER - 10
Outline Process Chart

Base:-

Total Time = 63 min

O SYM MACHINE TOOLS USED SETTING MACHI

P BOL USED TIME NE
E (MIN) TIME
R (MIN)
A
T
I
O
N
L D - Surface Gauge 2 -
o
a
d
i
n
g

F O Lathe Facing Tool of HSS - 5

a
ci
n
g

T O Lathe Turning Tool of HSS - 6

u
r
33

n
i
n
g

C O Lathe Chamfering Tool of HSS - 2

h
a
m
f
e
ri
n
g

U D - - 1 -
n
l
o
a
d
i
n
g

L D - Surface Gauge 2 -
o
a
d
i
n
g

F O Lathe Facing Tool of HSS - 3

a
ci
n
34

O Lathe Turning Tool of HSS - 4

T
u
r
n
i
n
g

C O Lathe Chamfering Tool of HSS - 2

h
a
m
f
e
ri
n
g

D O Lathe Drill Tool Φ 1 ½” - 14

ri
lli
n
g

B O Lathe Boaring Tool of HSS - 12

o
a
35

ri
n
g

C O Lathe Chamfering Tool of HSS - 2

h
a
m
f
e
ri
n
g

U D - - 1 -
n
l
o
a
d
i
n
g

COLUMN SUPPORT

Total Time = 56 Min.

COLUMN
36

Facing O Lathe Facing Tool - 2

of HSS

Turning O Lathe Turning - 12

Tool of HSS

Unloading D - - 2 -

Total Time = 32

b)TWO FLAT PLATES

Total Time = 42 Mins.

Total Time = 69 Mins.

c) SQUARE COLLAR:

OPERATION SYMBOL MACHINE TOOLS SETTING MACHINING

USED USED TIME TIME (MIN)
(MIN)

Loading D - Surface 3 -
Gauge

Facing O Lathe Facing - 3

Tool of
HSS

WORK TABLE:

Total Time = 88 Mi

RACK MOUNTING:
37

OPERATION SYMBOL MACHINE TOOLS SETTING MACHINING

USED USED TIME TIME (MIN)
(MIN)
Loading D - Surface 3 -
Gauge

Facing O Lathe Facing - 4

Tool of
HSS

Turning O Lathe Turning - 6

Tool of
HSS

Unloading D - - 2 -

Loading D - Surface 3 -
Gauge

Facing O Lathe Facing - 4

Tool of
HSS

Turning O Lathe Turning - 6

Tool of
HSS

Drilling O Lathe Drill Tool φ - 6

15 mm

Threading O Lathe Threading - 4

Tool

Unloading D - - 1 -

Loading D - - 2 -

Slotting O Slotting Slotting - 26

Tool of
HSS for 4
Slots
38

Unloading D - - 1 -

Welding O Arc Electrode - 10

Welding

Total Time = 78 Mins.

CONE HOUSING:

a) SQUARE BAR:

OPERATION SYMBOL MACHINE TOOLS SETTING MACHINING

USED USED TIME TIME (MIN)
(MIN)
Loading D - Surface 3 -
Gauge

Facing O Lathe Facing - 3

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 3

Tool of
HSS

Drilling O Lathe Drill Tool - 8

φ 1”

Boring O Lathe Boring - 12

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge
39

Facing O Lathe Facing - 14

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 14

Tool of
HSS

Unloading D - - 1 -

Total Time = 67 Mins.

b) CYLINDRICAL PART:

OPERATION SYMBOL MACHINE TOOLS SETTING MACHINING

USED USED TIME TIME (MIN)
(MIN)
Loading D - Surface 3 -
Gauge

Facing O Lathe Facing - 4

Tool of
HSS

Turning O Lathe Turning - 12

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 4

Tool of
40

HSS

Turning O Lathe Turning - 8

Tool of
HSS

Unloading D - - 1 -

Welding O Arc Electrode - 10

Welding

Chipping O - Chipping - 2
Tool

Finishing O - Emery - 2
Cloth

Loading D - Surface 3 -
Gauge

Drilling O Lathe Drill Tool - 12

Φ 30mm

Boring O Lathe Boring - 8

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 3 -
Gauge

Boring O Lathe Boring - 8

Tool of
HSS

Total Time = 84 Mins.

c) ARMS
41

OPERATION SYMBOL MACHINE TOOLS SETTING MACHINING

USED USED TIME TIME (MIN)
(MIN)

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 8

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 8

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 8

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 8

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 2

42

Tool of
HSS

Unloading D - - 1 -

Welding O Arc Electrode - 18

Welding

Chipping O - Chipping - 3
Tool

Total Time = 70 Mins.

d) MS CONE:

OPERATION SYMBOL MACHINE TOOLS SETTING

MACHINING
USED USED TIME
TIME (MIN)
(MIN)

Loading D - Surface 3 -
Gauge

Facing O Lathe Facing - 5

Tool of
HSS

Turning O Lathe Turning - 8

Tool of
HSS

Unloading D - - 1 -

Loading D - Surface 2 -
Gauge

Facing O Lathe Facing - 6

Tool of
HSS

Turning O Lathe Turning - 8

Tool of
HSS

Step Turning O Lathe Turning - 10

43

Tool of
HSS

Drilling O Lathe Drill Tool - 8

Φ 22mm

Taper O Lathe Turning - 22

Turning Tool of
HSS

Total Time = 73 Mins.

e) FIBRE CONE:

OPERATION SYMBOL MACHINE TOOLS SETTING MACHINING

USED USED TIME TIME (MIN)
(MIN)

Loading D - Surface 3 -
Gauge

Drilling O Lathe Drill Tool - 6

Φ 1”

Unloading D - - 1 -

Loading with D Lathe Surface 2 -

mandrel Gauge

Facing O Lathe Facing - 4

Tool of
HSS

Turning O Lathe Turning - 6

Tool of
HSS

Taper O Lathe Turning - 20

Turning Tool of
HSS

Total Time = 42 Mins.

44

CHAPTER – 11

Flow Process Chart

Title: Bench Tapping Machine Operation

1. Start

- At the beginning of the operation, the operator arrives at the

machine station and prepares to use the bench tapping machine.

2. Prepare the Workpiece

- Before beginning the actual tapping operation, the operator

places the workpiece on the bench. This workpiece could be a
metal component that requires threading, such as a bolt or a stud.
45

It's important to ensure that the workpiece is properly positioned

and stable.

3. Prepare the Tapping Tool

- Selecting the right tapping tool is crucial to ensure a

successful tapping operation. The operator chooses the
appropriate tapping tool based on the thread size and type
needed for the workpiece. Once selected, the tapping tool is
securely mounted in the machine's chuck. Proper installation of
the tool is vital to prevent any accidents during the operation.

4. Set Machine Parameters

- To customize the tapping operation for the specific job, the

operator needs to adjust various machine settings, which may
include:

- Tapping depth: This determines how deep the threads will be

cut into the workpiece.

- Tapping speed: Controlling the speed at which the tap

rotates is essential for achieving the desired thread quality.

- Direction of rotation: The operator must ensure that the

machine rotates the tap in the correct direction (clockwise or
counterclockwise) depending on the thread type (e.g., right-hand
or left-hand threads).

- Any other specific settings required for the particular job.

46

5. Position the Workpiece

- Proper alignment of the workpiece is critical for accurate

threading. The operator carefully aligns the workpiece under the
tapping tool and may use clamps or fixtures to securely hold the
workpiece in place. This ensures that the workpiece doesn't shift
during the tapping process, which could result in misaligned or
damaged threads.

6. Tapping Operation

- With all preparations complete, the operator starts the

machine by turning it on. The machine's power activates the
chuck holding the tapping tool, allowing it to engage with the
workpiece.

- The tapping tool begins cutting threads into the workpiece as it

moves downward. The operator should closely monitor this
process to check for any unusual noises, vibrations, or other
issues that could indicate problems with the operation.

7. Inspect the Threads

- Once the tapping operation is complete, the operator stops the

machine and carefully removes the workpiece.

- The operator inspects the threads created in the workpiece to

ensure they meet quality and accuracy standards. This may
47

involve using thread gauges or other measuring tools to verify the

correctness of the threads.

8. Finish

- Depending on the results of the inspection, the operator may

need to make adjustments or repeat the tapping process. If the
threads meet the required specifications, the workpiece is marked
as completed.

- As a final step, the operator shuts down the tapping machine

and ensures the work area is clean and orderly. Tools are
returned to their designated places.

9. End

- The entire bench tapping machine operation is concluded, and

the workpiece with properly threaded holes is ready for further
assembly or use.

This detailed flow process chart highlights each step involved in

operating a bench tapping machine, emphasizing the importance
of preparation, safety, and quality control throughout the process.
Adjustments and additional steps can be incorporated based on
the specific requirements of your mechanical diploma project.
48

CHAPTER - 12

PLANT LAYOUT WITH DIMENSION APPLICABLE TO

THE SELECTED PROJECT

Creating a plant layout for a bench tapping machine involves

designing a workspace that accommodates the machine,
provides adequate space for the operator, and ensures safety
and efficiency. The specific dimensions will depend on the size
and model of the tapping machine, as well as any unique
requirements of your workspace. Here's a general outline of how
to create a plant layout with dimensions for a bench tapping
machine:

1. Measure the Tapping Machine:

- Measure the length, width, and height of the tapping machine.

Note any specific clearance requirements or recommended
distances from walls or other equipment provided in the
machine's manual.
49

2. Operator Workspace:

- Ensure that there's enough space around the machine for the
operator to work comfortably and safely.

- Allow adequate space for the operator to stand or sit,

depending on the machine and operator's preference.

- Include a sturdy workbench with appropriate dimensions for

the machine to sit on. The bench should be at a comfortable
working height.

3. Safety Considerations:

- Provide sufficient space to ensure safety. There should be

clear pathways for the operator to move around the machine and
access emergency shut-off switches.

- Ensure that there's enough space for the machine's tool

changes or maintenance.

4. Power and Utilities:

- Plan for power outlets, air compressors (if needed), and other
utilities required for the machine. These should be conveniently
located near the machine.

5. Material Handling:
50

- Consider the placement of raw materials and finished

products. Ensure there's a logical and safe flow of materials to
and from the machine.

6. Lighting:

- Provide adequate lighting in the work area to ensure the

operator can see clearly.

7. Noise and Vibration Control:

- If the tapping machine generates significant noise or vibration,

take this into account when positioning it in the layout. Consider
using vibration-damping materials or isolation solutions.

8. Ergonomics:

- Ensure the machine's controls are easily accessible to the

operator without straining or stretching.

9. Storage and Tooling:

- Designate space for storing tools, tooling components, and

any other accessories related to the tapping machine.
51

10. Marking and Safety Signs:

- Clearly mark areas for safety equipment, such as fire

extinguishers or first aid kits, as well as any required safety
signage.

11. Maintenance Access:

- Ensure there's adequate space for maintenance personnel to

access the machine for repairs and routine maintenance.

12. Fire Safety and Exits:

- Make sure the layout complies with fire safety regulations,

and keep pathways to exits clear.

13. Work-In-Progress (WIP) Area:

- Allocate space for workpieces that are in various stages of

completion.

Remember that the exact dimensions and layout will depend on

the specific bench tapping machine you are using, local building
codes, and your operational requirements. It's crucial to consult
52

the machine's manual and any relevant safety guidelines during

the layout design process. Additionally, involving a safety
engineer or industrial designer may be beneficial to ensure the
layout is optimized for both safety and efficiency.
53

CHAPTER – 13
List Specification of Machineries, Equipments &
Tools to be Used in the project.

Project Motivation
The motivation for doing this project was primarily to focus on
an easier and simpler way of acquiring precise, accurate and
aligned threads using the manual approach. During the first
years of our engineering course we did workshop practice
where we focused on thread cutting process using dies and
taps, the process was however not as accurate and precise as
needed, this made us think of simpler and cheaper ways of
acquiring perfect internal threads, the solution was to design a
manual bench tapping machine.

Project Specifications
The machine is a shaft-driven machine that consists of a strong
frame to hold the tapping shaft in place. The shaft is rotated
through a smooth bearing mechanism for easy operation and
its tip is fitted with a tap holder. The holder can be mounted
54

with taps as and when desired. The machine bed consists of a

work-piece holder to hold it in place for tapping. This machine
allows for accurate tapping results for perfectly aligned screw
threads.

The key marketing strategies will revolve around it being

economic, less power consuming and delivering perfect
threads. The idea behind the novelty here is that it would be
operable under minimum power requirements while at the
same time

ensuring proper lubrication throughout. Though being battery

and motor operable in the future, it is not employed here; this
project will stick to a manually operated bench tapping
machine.
It will also be easier to have it transported from one bench
location to another, wherever thread generation may be needed.
With respect to the standards the ones employed here are ISO
Metric Screw Thread Systems similar to those employed in
Europe and the rest of the world excluding North America [3]. For
manufacturing, it possible that we may employ shafts of polymers
or plastics as a way for a lighter bench apparatus as well as strain
sensors to ensure that the taps do not undergo higher levels of
strain beyond their set limit. The calculation takes a sample from
existing models available and
55

CHAPTER – 14

List, Quantity & Specification of

Consumables & its Consumption

A) Spindle Shaft
The is a shaft that runs down from the turning mechanism of
the tapping machine and connects to the tap holder, the main
function of this component is to transmit the circular motion to
the tap holder and thereafter to the tap itself.
B) Bearing
The bearing is located between the spindle shaft and the
supporting frame, it provides for the circular motion of the
spindle shaft within a stationary enclosure of the supporting
frame.
C) Supporting frame
The supporting frame connects the supporting shaft to the
spindle shaft, its geometry has an extended part which
56

increases its ability to sustain higher loads and cyclic stresses.

D) Supporting shaft
The base of the supporting shaft is connected to the machine
bed whereas the top end is connected to the supporting frame,
its main function is to provide support for the supporting frame,
bearing, pipe and the tap holder.
E) Tap Holder
The component is connected at the base of the spindle shaft
and rotates at the same speed as the spindle shaft. It provides
for the mounting of various sizes of taps on the bench tapping
machine.
F) Machine Bed
The machine bed is at the base of the bench tapping machine
and provides room for mounting of the supporting shaft and the
work piece holder. It also provides support for all the other
parts of the machine and hence it must be rigid and strong.
G) Turning Pipe
18
This allows the spindle shaft to be rotated at a desired speed,
provision of the pipes allows for the circular motion to be
obtained via a simple turning of the pipe.
H) Mounts
This includes screws and joints which provides for attachment
of various components into the main parts of the bench tapping
machine, they provide a firm and rigid assembly of subsystems
and components into the base of the machine.
1) Bench Holder
The acts as the work piece holder, it has a vice like mechanism
which provides for simpler rigid attachment and detachment
57

work pieces onto the machine bed. It also has mechanisms for
lubricant drainage and chip removal.

CHAPTER - 15
Detailed Cost Estimation

1. MATERIAL COST:

S. No. Description Material Qty. AMOUNT(RS)

1. BASE CAST IRON 1 OFF 500

2. COLUMN MILD STEEL 1 OFF 600

3. CONE HOUSING MILD STEEL 1 OFF 600

4. CONE MILD STEEL 2 OFF 1200

5. CONE FIBER 1 OFF 1000

6. TABLE HOUSING MILD STEEL 1 OFF 1000

7. TABLE CAST IRON 1 OFF 1500

8. RACK & PINION MILD STEEL 1 OFF 1500

9. MAIN DRIVE SHAFT MILD STEEL 1 OFF 1000

10. VERTICAL SPINDLE MILD STEEL 1 OFF 1000

58

11. LINEAR BUSH GUN METAL 1 OFF 1200

12. 3 JAW SELF CENTERING - 1 OFF 800

CHUCK (0-12MM)

13. TAPPER ROLLER BEARING - 2 OFF 1600

14. MOTOR (0.5 HP) - 2 OFF 6000

15. BOLTS MILD STEEL 8 OFF 1200

16. C.S.SCREW MILD STEEL 8 OFF 200

17. GRUB SCREW MILD STEEL 8 OFF 200

18. V-BELT - 1 OFF 500

19. PULLEYS (2.5”, 3.5” & 4.5”) CAST IRON 2 OFF 1000

1.Prime cost=direct material cost + Labour cost

=13440+1500
=14940
2.Factory cost=Prime cost + Factory overhead
=14940+750
=15690
3.Administrative overhead=1525
4.Production cost=Factory cost + administrative overhead
=15690+1625
=17315
5.Sales and distribution overhead=30% of production cost
=17315•30/100
59

=5185
6.Total production cost=production cost+ sales and
distribution overhead
=17315+5185
=22600

Future scope

Our project was mainly based on the tapping process and

how it can be made simpler and easier to perform, this
project enabled as to acquire the following life-long
learning that will be helpful to us in the future;

a) The use of modeling software in obtaining the 3D model

of the bench tapping machine has enabled as to acquire
the much needed knowledge on such software. Our world
is constantly shifting the use of improved technologies to
solve life-long issues and therefore have enough
knowledge can be highly advantageous. Our group
members were able to acquire some knowledge on
software's such as CAD, Autodesk Inventor and
Solidworks.

b) Due to the short project duration it was essential for the

team to learn on how to make the most out of a limited
time period. This enabled us to manage our time better
and be able to do all the required tasks within this duration
of time.
60

c) Material selection is a crucial design process which

ensures the materials selected are best suited for a
particular application while at the same time maintaining
the least possible cost. Our team was able to learn from
experience how to best select the materials within the
design constraints while ensuring we are within our project
budget.
d) Since the project was to be done by a group of five
individuals, it was crucial for the team members to learn
on how to best relate to each other and also what
motivations can be used to bring the best out of each team
member.

e) The project also acted as a refresher on some

engineering skills and knowledge which included welding,
turning, tapping process, and a few mathematical
calculations.

f) The project was a huge step in applying what we had

learnt in class into a real life problem, and in the end we
were able to provide an improved version on a bench
tapping machine which increases the efficiency and
effectiveness of the tapping process.
61

Advantages of bench tapping machine

1. Precision: Bench tapping machines offer high

precision and accuracy in drilling and tapping
operations, ensuring consistent results.

2. Efficiency: They are faster and more efficient than

manual tapping, reducing labor costs and fatigue.

3. Versatility: These machines can handle a variety of

materials, including metal, plastic, and wood, making
them versatile for different applications.

4. Consistency: They produce uniform threads and hole

depths, which is essential for quality control in
manufacturing.

5. Reduced risk of injury: Bench tapping machines

reduce the risk of repetitive strain injuries associated
with manual tapping.
62

Disadvantages of bench tapping machine

1. Cost: Bench tapping machines can be expensive to

purchase and maintain, making them less suitable for
small-scale or budget-conscious operations.

2. Limited mobility: They are typically stationary, which

can be a limitation in settings where mobility is
required.

3. Setup time: Changing the setup for different

workpieces can be time-consuming.

4. Maintenance: Regular maintenance is necessary to

ensure these machines operate smoothly, which adds
to the cost of ownership.

5. Skill requirement: Operating these machines

effectively may require training and skill, which can be
a barrier for some users.
63

6. The choice between a bench tapping

machine and other tapping methods depends on your
specific needs and budget.

Application of bench tapping machine

1. Metalworking: Bench tapping machines are frequently

used in metalworking operations for creating threaded
holes in metal components. This is essential in
manufacturing processes for products like automotive
parts, machinery, and aerospace components.

2. Woodworking: They can be employed in woodworking

to create threaded holes in wooden pieces for
assembly and joinery, such as in the construction of
furniture and cabinets.

3. Plastic Fabrication: Bench tapping machines are used

in plastic fabrication to produce threaded holes in
plastic components, which are found in various
industries, including electronics and consumer goods.

4. Electrical and Electronics: These machines are

employed in the production of electrical panels and
electronic enclosures where threaded holes are
needed for mounting components.
64

5. Maintenance and Repair: In maintenance and repair

workshops, bench tapping machines are used to
repair damaged threads or create new threaded holes
in a wide range of materials.
6. Prototyping: They are useful in prototyping and small-
batch production, where precision and consistency
are essential.

7. DIY and Hobbyist Projects: Enthusiasts and hobbyists

also use bench tapping machines for DIY projects,
such as creating custom parts for cars or motorcycles.

8. Educational Institutions: Educational institutions use

these machines in mechanical engineering and
vocational training programs to teach students about
threading operations.

9. Overall, bench tapping machines are

versatile tools that play a crucial role in many
industries where creating precise threaded holes is
necessary for assembly and production processes.
65

CHAPTER - 16
References

[1]Hand tapping and thread cutting. Canberra: A.G.P.S.,

1975.
[2]V. Yaroslavtsev, "Thread cutting using thread taps and
with preliminary plastic deformation of the material of the
layer to be cut", Science and Education of Bauman MSTU,
vol. 13, no. 8, 2013. Available: 10.7463/0813.0570897.
[3]Y. Li and S. Zhao, "The Key Technology in Extrusion
Tapping of Internal Thread", Advanced Materials
Research, vol. 295-297, pp. 2636-2641, 2011. Available:
10.4028/www.scientific.net/amr.295-297.2636.
[4]"A Portable Thread-Cutting Machine", Scientific
American, vol. 83, no. 19, pp. 292-292, 1900. Available:
10.1038/scientificamerican11101900-292b.
[5]"Bench Tapping Machine", Nevon Projects, 2021.
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tapping-machine/. [Accessed: 19- Apr2021].
[6]J. Hayashi, K. Okuda and H. Kodama, "A Study on Tool
Damage of Threading Tap in Screw Cutting of Stainless
Steel 15-5PH", Key Engineering Materials, vol. 656-657,
pp. 164-167, 2015. Available:
10.4028/www.scientific.net/kem.656-657.164.
66

[7]R. Bahadure, "Regeneration of Tapping Machine with

Effective Utilization", International Journal for Research in
Applied Science and Engineering Technology, vol. 7, no.
3, pp. 1569-1571, 2019. Available:
10.22214/ijraset.2019.3290.
[8]F. Colvin, Threads and thread cutting. [Place of
publication not identified]: Nabu Press, 2012.
[9]Thread forming and thread cutting tapping screws and
metallic drive screws (inch series). New York: American
Society of Mechanical Engineers, 1999.