Tambaram,
DEPARTMENT OF MECHANICAL ENGINEERING
ME8361 - MANUFACTURING TECHNOLOGY LABORATORY
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III SEMESTER - R 2013
LABORATORY MANUAL
Name : _________________________________
Register No. : _________________________________
Section : _________________________________
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VISION
College of Engineering is committed to provide highly disciplined, conscientious and enterprising professionals conforming to global standards through value based quality education and training.
MISSION
- To provide competent technical manpower capable of meeting requirements of the industry
- To contribute to the promotion of Academic Excellence in pursuit of Technical Education at different levels
- To train the students to sell his brawn and brain to the highest bidder but to never put a price tag on heart and soul
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DEPARTMENT OF MECHANICAL ENGINEERING
VISION
Rendering the services to the global needs of engineering industries by educating students to become professionally sound mechanical engineers of excellent caliber
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MISSION
To produce mechanical engineering technocrats with a perfect knowledge intellectual and hands on experience and to inculcate the spirit of moral values and ethics to serve the society
PROGRAMME EDUCATIONAL OBJECTIVES (PEOS)
- Fundamentals
To impart students with fundamental knowledge in mathematics and basic sciences that will mould them to be successful professionals
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- Core competence
To provide students with sound knowledge in engineering and experimental skills to identify complex software problems in industry and to develop a practical solution for them
- Breadth
To provide relevant training and experience to bridge the gap between theory and practice which enable them to find solutions for the real time problems in industry and organization and to design products requiring interdisciplinary skills
- Professional skills
To bestow students with adequate training and provide opportunities to work as team that will build up their communication skills, individual, leadership and supportive qualities and to enable them to adapt and to work in ever changing technologies
- Life-long learning
To develop the ability of students to establish themselves as professionals in mechanical engineering and to create awareness about the need for lifelong learning and pursuing advanced degrees
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PROGRAMME OUTCOMES (POS)
On completion of the B.E. (Mechanical) degree, the graduate will be able
- To apply the basic knowledge of mathematics, science and engineering
- To design and conduct experiments as well as to analyze and interpret data and apply the same in the career or entrepreneurship
- To design and develop innovative and creative software applications
- To understand a complex real world problem and develop an efficient practical solution
- To create, select and apply appropriate techniques, resources, modern engineering and IT tools
- To understand the role as a professional and give the best to the society
- To develop a system that will meet expected needs within realistic constraints such as economical environmental, social, political, ethical, safety and sustainability
- To communicate effectively and make others understand exactly what they are trying to tell in both verbal and written forms
- To work in a team as a team member or a leader and make unique contributions and work with coordination
- To engage in lifelong learning and exhibit their technical skills
- To develop and manage projects in multidisciplinary environments
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ME8361 - MANUFACTURING TECHNOLOGY LABORATORY
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SYLLABUS
COURSE OBJECTIVES
To study and practice the various operations that can be performed in lathe, shaper, drilling, milling machines, etc. and to equip with the practical knowledge required in the core industries.
LIST OF EXPERIMENTS
Machining and machining time estimations for:
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- Taper turning
- External thread cutting
- Internal thread cutting
- Eccentric turning
- Knurling
- Square head shaping
- Hexagonal head shaping
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COURSE OUTCOMES
- Able to produce a component by performing taper turning operation by compound rest method
- Able to produce a component by performing taper turning operation by compound rest method
- Able to produce a component by performing taper turning operation by tail stock offset method
- Able to produce the component by performing external thread cutting operation using lathe
- Able to produce the component by performing drilling, boring and thread cutting operation using lathe
- Able to turn a given work piece eccentrically in a lathe machine as per the given dimensions
- Able to make round work piece to square shape by using shaper
- Able to make a round work piece to hexagonal shape by using shaper
- Able to produce the component by performing knurling and grooving operation using lathe
- Able to machine the work piece to the given dimensions using capstan lathe
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CONTENTS
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| Ex. No. | Name of the Experiment | Page No. |
|---|---|---|
| EXPERIMENTS | ||
| 1 | Study of lathe | 7 |
| 2 | Taper turning using compound rest method | 17 |
| 3 | Taper turning by tail stock offset method | 20 |
| 4 | External thread cutting | 23 |
| 5 | Drilling, boring and internal thread Cutting | 26 |
| 6 | Eccentric turning | 29 |
| 7 | Square head shaping | 32 |
| 8 | Hexagonal head shaping | 34 |
| 9 | Study of welding | 36 |
| 10 | Single V butt joint | 38 |
| 11 | Double V butt joint | 40 |
| 12 | Lap joint | 42 |
| 13 | Tee fillet joint | 44 |
| 14 | Gas welding practice | 46 |
| 15 | Study of Foundry | 48 |
| 16 | Gear pattern | 53 |
| 17 | Stepped cone pulley | 55 |
| 18 | Study of sheet metal work | 58 |
| 19 | Rectangular tray | 67 |
| 20 | Cylinder | 69 |
| 21 | Funnel | 71 |
| ADDITIONAL EXPERIMENTS BEYOND THE SYLLABUS | ||
| 22 | Knurling and grooving | 74 |
| 23 | Capstan lathe | 76 |
Expt. No.01 STUDY OF LATHE
Aim:
To understand the working principle and operations done in lathe machine to identify the various components of lathe machine and its function
Machining processes:
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Machining is one of the processes of manufacturing in which the specified shape to the work piece is imparted by removing surplus material. Conventionally this surplus material from the work piece is removed in the form of chips by interacting the work piece with an appropriate tool. This mechanical generation of chips can be carried out by single point or multi point tools or by abrasive operations these are summarized below
Machining Processes
| Single point tool operations | Multi-point tool operations | Abrasive operations |
|---|---|---|
| 1. Boring | 1. Drilling | 1. Lapping |
| 2. Shaping | 2. Tapping | 2. Honing |
| 3. Planning | 3. Reaming | 3. Super-finishing |
| 4. Turning | 4. Hobbing | 4.Grinding |
| 5. Broaching | ||
| 6. Sawing | ||
| 7. Milling |
Multi-point tool operations:
The process of chip formation in metal cutting is affected by relative motion between the tool and the work piece achieved with the aid of a device called machine tool. This relative motion can be obtained by a combination of rotary and translator movements of either the tool or the work piece or both. The kind of surface that is produced by the operation depends on the shape of the tool and the path it traverses through the materials.
When the workpiece is rotated about an axis and the tool is traversed in a definite path relative to the axis, a surface of revolution is generated. When the tool path is parallel to the axis, the surface generated is a cylinder as in straight turning or boring operations. Similarly, planes may be generated by a series of straight cuts without rotating the workpiece as in shaping and planning operations (Fig.3).
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In shaping the tool is reciprocating and the work piece is moved crosswise at the end of each stroke. Planning is done by reciprocating the work piece and crosswise movement is provided to the tool.
Surface may be machined by the tools having a number of cutting edges that can cut successively through the work piece materials. In plane milling, the cutter revolves and moves over the work piece as shown Fig. 4. The axis of the cutter is parallel to the surface generated.
Similarly in drilling, the drill may turn and be fed into the work piece or the work piece may revolve while the drill is fed into it (Fig.5).
The machine tools, in general, provide two kinds of relative motions. The primary motion is responsible for the cutting action and absorbs most of the power required to perform the machining action.
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The secondary motion of the feed motion may proceed in steps or continuously and absorbs only a fraction of the total power required for machining. When the secondary motion is added to the primary motion, machine surfaces of desired geometric characteristics are produced.
Lathe:
Lathe is the machine tool which is used to perform several operations on the work piece. Lathe is useful in making several parts which is further assembled to make new machine. Hence lathe is known as "mother of machines".
Basic working principle of lathe:
In lathe, the work piece is held in the chuck, a work holding device. The cutting tool is mounted in the tool post. The chuck is rotated by means of power. When the chuck rotates, the work piece also rotates.
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The tool is moved against the rotating work piece by giving small amount of depth of cut. The material is removed in the form of chips. Continuous feed and depth of cut is given until the required dimensions are obtained in the work piece.
Types of lathe machines:
There are different types of lathe machines, they are
- Centre lathe
- Tool room lathe
- Bench lathe
- Capstan lathe
- Turret lathe
- Automatic lathe
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Description of lathe:
Lathe is a machine which has several parts in it. They are
Bed:
It is the base of the machine. On its left side, the head stock is mounted and on its right it has movable casting known as tailstock. Its legs have holes to bolt down on the ground.
Head stock:
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It consists of spindles, gears and speed changing levers. It is used to transmit the motion to the job. It has two types; one is the headstock driven by belt and the other one is the gear driven.
Carriage:
Carriage is used to carry a tool to bring in contact with the rotating work piece or to with draw from such a contact. It operates on bed ways between the headstock and tail stock.
Saddle:
It is an 'H' shaped part fitted on the lathe bed. There is a hand wheel to move it on the bed way. Cross slide, compound rest, tool post is fitted on this saddle.
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Cross slide:
It is on the upper slide of saddle in the form of dove tail. A hand wheel is provided to drive the cross slide. It permits the cross wise movement of the tool (i.e.) movement of tool towards or away from the operator.
Compound rest:
It is fitted over the cross slide on a turn table. It permits both parallel and angular movements to cutting tool.
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Tool post:
It is fitted on the top most part of the compound rest. Tool is mounted on this tool post. Cutting tool is fixed in it with the help of screws.
Apron:
It is the hanging part in front of the carriage. It accommodates the mechanism of hand and power feed to the cutting tool for carrying out different operations.
Lead screw:
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It is a long screw with ACME threads. It is used for transmitting power for automatic feed or feed for thread cutting operation.
Tail stock:
It is located at the right end of the lathe bed and it can be positioned anywhere in the bed. It is used for supporting lengthy jobs and also carries tool to carry out operations such as tapping, drilling and reaming.
Work holding devices:
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Lathe centers:
They are used to support work. It has two categories of centers. Live center is one which is fitted in the headstock spindle. Dead is another one which is fitted in the tail stock.
Chuck:
It is a device used to hold a job. It is easily fitted on the thread cut on the end of head stock spindle. Various types of chuck are Two jaw chuck, three jaw chuck, four jaw chuck collect chuck and magnetic chuck.
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Face plate:
Lathe carriers or dogs:
Steady rest:
Clamped to the lathe ways, it uses adjustable fingers to contact the work piece and align It Can be used in place of tailstock or in the middle to support long or unstable parts being machined.
Mandrel:
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Mandrel used to hold hollow jobs.
Follower rest:
Bolted to the lathe carriage, it uses adjustable fingers to bear against the work piece opposite the cutting tool to prevent deflection.
Cutting tools used:
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For making a finished job on lathe machine, various types of cutting tools are used. One of them is single point cutting tool which is used to perform several operations on the work piece. Various types of cutting tools are furnished below.
Facing Tool:
It is used for facing the longitudinal ends of the job. Its shape is like a knife.
Rough Turning Tool:
It is used to remove excess material from the work piece in quick time. It can be used to give large depth of cut and work at coarse feed.
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Finishing Tool:
It is used for getting smooth finish on the work piece. Its point is a little more round.
Radius Tool:
Jobs which need round cutting are done with this tool. Its types are Convex radius tool and concave radius tool.
Parting Tools:
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It is used to cut the jobs into two parts. It is also used for grooving.
Form Turning Tool:
It is used for jobs which require both convex and concave turning.
Thread Cutting Tool:
It is used for making internal or external threads on the work piece. The tool nose is designed with a definite profile for taking threads.
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Drill Tool:
It is used for making holes of various diameters on the job. Drill bit of various sizes of diameter are available.
Boring Tool:
It used for enlarging the drill hole.
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Tool materials:
The single point cutting tools are made of high speed steel(H.S.S). The main alloying elements in 18-4-1 HSS tools are 18% tungsten, 4% chromium and 1% vanadium. 5 to 10% cobalt is also added to improve the heat resisting properties of the tool. General purpose hand cutting tools are usually made from carbon steel or tool steel. Carbide tipped tools fixed in tool holders, are mostly used in production shops.
Cutting tool angles:
Top rake angle (back rake angle):
If the slope is given to the face or surface of the tool and if this slope is along the tools length then it is called top rake angle. It is usually from 15° to 20°.
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Side rake angle:
If the slope is given to the face or top of the tool along the tools width then it is called side rake angle. It lies between 6° and 15°.
Clearance angle (relief angle):
Types: 1. Side clearance angle 2. End clearance angle.
They are provided to keep surface of the tool clear of the work piece.
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Cutting edge angle:
Types: 1. Side cutting edge angle – (generally 15°) it is an angle, the side cutting edge makes with the axis of the tool 2. End cutting edge angle – (from 7° to 15°) it is an angle made by the end cutting edge with the width of the tool.
Lip angle (cutting angle):
It is the angle between the face and the end surface of the tool.
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Nose angle:
It is the angle between the side cutting edge and end cutting edge.
Lathe operations:
Facing:
It is done for getting fine finish (good surface finish) on the face of the job. Facing tool is set at an angle to the work piece. The tool is fed from the centre of work piece towards the outer surface against the rotating work piece. Depth of cut is low for the facing operation.
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Plain Turning:
It is done for reducing the diameter of the work piece. A cutting tool with 70° setting angle is used for roughing operation. More feed is given for rough turning while less feed is given for finishing. Work piece is held in chuck and tool is set to center height of the work piece.
Step Turning:
It is similar to the process of turning but in this case different diameter in step of various sizes is taken on the work piece.
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Taper Turning:
It is different from the turning operation. Taper is defined as uniform change in the diameter of a work piece measured along its length.
Where
D – large diameter
d - small diameter
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I- length of taper
Knurling:
It is process of making serrations on the work piece. Knurling tools of different shape and size are used to make grip on the work piece. It has two hardened steel rollers. The tool is held in tool post and pressed against the rotating work piece. Work piece is rotated at lower speed and small amount of feed is given.
Drilling:
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It is a process of making a hole on the work piece Job is held in chuck while the drill is held in the tail stock sleeve. Feed is given by rotating the hand wheel in the tail stock which pushes the tailstock sleeve.
Cutting Speed:
It is the peripheral speed of the work past the cutting tool. It is the speed at which metal is removed by the tool from the work piece. It is expressed in meter / minute. Cutting speed= (p x diameter x R.P.M)/1000 = p DN/1000 in m/min
D - Diameter in mm
N - Spindle speed in rpm
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Feed:
It is defined as the rate of tool travel across a surface cutting it. It is the distance of the tool advances for each revolution of the work piece. It is expressed in mm/revolution.
Depth of Cut:
It is the perpendicular distance measured from the machined surface to the uncut surface of work. It is expressed in mm.
Depth of cut= (d1- d2)/2
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d1 - diameter of work before machining
d2 - diameter of work after machining
Expt. No.02 TAPER TURNING USING COMPOUND REST METHOD
Aim:
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To produce the component by performing taper turning using lathe
Materials required:
Mild steel $ 32 mm X 100 mm long
Tools required:
- Chuck key
- Tool post spanner
- Verneir caliper
- Steel rule
- Single point cutting tool
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Specimen drawing:
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All dimensions are in mm
Procedure:
- Check the size of raw material given and ensure the size.
- Hold the workpiece in the chuck and tight it properly.
- Clamp the tool on post properly and check the centre of work piece with cutting tool tip.
- Do the facing operation by giving cross feed to the cross slide and reduce length.
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- Do the turning operation by giving longitudinal feed to the carriage and reduce the diameter of the work piece.
- Two or three pass can be given for turning operation.
- Remove the work piece and hold in chuck on other side and do the turning operation for the remaining portion of the work piece.
- Calculate the taper angle and swivel the compound rest and clamp it properly.
- Do the taper turning operation by giving angular feed to the compound rest as per the dimension.
- Do the facing operation and get the required length.
- Remove the component carefully and check the dimension.
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Result:
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Thus the component is produced as per the given drawing using lathe.
Outcome:
Able to produce a component by performing taper turning operation by compound rest method
Viva - voce
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- What is meant by lathe?
- What are the various operations can be performed on a lathe?
- What are principle parts of the lathe?
- What are the types of headstock?
- What are the various parts mounted on the carriage?
- What are the four types of tool post?
- What is meant by an apron?
- What are the two specification of lathe?
- What are the types of lathe?
- What is meant by semi-automatic lathe?
- What is meant by capstan lathe?
- Write down the formula used for taper turning by compound rest method.
- What is the purpose of compound rest?
- How to give angular feed in lathe
- What is the purpose of three jaw chuck?
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Expt. No.03 TAPER TURNING BY TAIL STOCK OFFSET METHOD
Aim:
To produce the component by performing taper turning using lathe
Material required:
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Mild steel $ 32 mm X 100 mm long
Tools required:
- Chuck key
- Tool post spanner
- Verneir caliper
- Steel rule
- Single point cutting tool
- Revolving centre
- Drill chuck with centre drill bit
- Catch plate with dog carrier
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Specimen drawing:
All dimensions are in mm
Procedure:
- Check the size of raw material given and ensure the size.
- Held the work piece in the chuck and tight it properly.
- Clamp the tool on tool post properly and check the centre of work piece with cutting tool tip.
- Do the facing operation by giving cross feed to the cross slide and reduce the length.
- Do the turning operation by giving longitudinal feed to the carriage and reduce the diameter of the work piece.
- Two or three passes can be given for turning operation.
- Remove the work piece and hold in chuck on other side. Does the turning operation for the remaining portion of the work piece also do the facing operation and get the required length.
- Make a centre drilling operation on both sides by tail stock.
- Calculate the offset distance and offset the tail stock from the lathe axis.
- Hold the work piece between lathe centers on both side using catch plate with dog carrier.
- Do the taper turning operation by giving longitudinal feed to the carriage as per the dimension.
- Remove the component carefully and check the dimension.
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Result:
Thus the component is produced as per the given drawing using lathe.
Outcome:
Able to produce a component by performing taper turning operation by tail stock offset method
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Viva - voce
- Define - Conicity
- What are the different operations performed on the lathe?
- What are the holding devices?
- What are the various feed mechanisms used for obtaining automatic feed?
- What is copying lathe?
- What are the advantage of capston lathe & turret lathe?
- What is meant by tooling?
- What are the three stage of a tool-layout?
- What are the different drives used in copying lathe?
- What are the two specifications of capstan and turret lathe?
- What are the methods used for taper turning in lathe?
- What are various feeds in lathe?
- Which method is suitable for steep turning?
- Which method is suitable for taper turning on lengthy workpiece?
- What is meant by lead screw?
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Expt. No.04 EXTERNAL THREAD CUTTING
Aim:
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To produce the component by performing threads cutting operation using lathe
Material required:
Mild steel $ 32 mm X 100 mm long
Tools required:
- Chuck key
- Tool post spanner
- Verneir caliper
- Steel rule
- Single point cutting tool
- V thread cutting tool
- Pitch gauge
- Grooving tool
- Drill chuck with centre drill bit
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Specimen drawing:
All dimensions are in mm
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Procedure:
- Check the size of raw material given and ensure the size.
- Hold the work pieces in the chuck and tight it properly.
- Clamp the tool on tool post properly and check the centre of work piece with cutting tool tip.
- Do the facing operation by giving cross feed to the cross slide and reduce the length.
- Do the turning operation by giving longitudinal feed to the carriage and reduce the length.
- Two or three pass can be given for the turning operation.
- Remove the work piece and hold in chuck on the other side and do the turning operation for the remaining work piece.
- Engage the back gear mechanism to reduce the speed of the work piece.
- Check the pitch required, calculate the tumbler gear, and engage it with head stock.
- Move the carriage towards tail stock and make a mark on the dial.
- Give small depth of cut and engage the half nut so that the carriage will move automatically towards head stock and cut the v-thread on the work piece.
- After reaching the required length of thread, release the tool by rotating cross slide in opposite to the depth of cut by counting the number of rotation.
- Move the carriage towards tail stock, give depth of cut and engage the half nut.
- Repeat the procedure to produce complete form of v-thread. After finishing remove the work piece from the chuck.
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Result:
Thus the component is produced as per the given drawing using lathe.
Outcome:
Able to produce the component by performing external thread cutting operation using lathe
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Viva - voce
- What are the components that can
This download link is referred from the post: Anna University B.Tech Lab Manual
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