NIT JAMSHEDPUR
LAB MANUAL
MANUFACTURING PRACTICE II
Objective:
• To comprehend the elementary fundamentals of Conventional
machining.
• To provide an acquaintance platform to transfer concepts through
hands on practice.
• To investigate the machining potential of different conventional
machining.
• To provide insight concepts to comprehend computer numerical control
machine.
Outcome:
• Able to address machine and machining potential.
1
EXPERIMENT 1
Aim of the Experiment: To exercise numerous lathe operations to make a screw of M10Χ1.5
with taper turn head with in tolerance limit of ±0.05.
Machine tool, cutting tool and accessories required
• Lathe Machine Tool
• Facing Tool
• Turning Tool
• Threading Tool
Materials: A 32 mm diameter and 45 mm length cylindrical mild steel workpiece
Job Figure
Fig. 1.1 Job Figure.
Theory: A lathe is machine tool (Fig. 1.2) in which the workpiece is to be held in the revolving
chuck and the tool is fed past through it. While the workpiece revolves, the tool which remains
stationery cuts the material. The chips may be segmented, continuous or continuous with built
up edge.
Basic parts of a lathe: -
Bed: It is one of the indispensable parts of a lathe machine. All the moving parts are mounted
on the bed. It is made of cast iron.
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Headstock: It is also known as line centres. It is permanently fastened on the inner ways at the
left side of the lathe. The headstock, spindle, a hollow shaft supported by bearings provides a
drive from the motor to the work holding machine.
Chuck: It is work holding device attached to the lathe spindle. There are two common types of
chuck. They are: -
• Three jaw self-centred chuck: In this type, there is synchronous motion of the three
jaws. As we tighten or loosen on the jaws the other two jaws are also loosened /
tightened.
• Four jaw independent chuck: This contains 4 jaws which can adjusted individually
to the centre of workpiece. Due to independencies in jaws’ positioning the job of
irregular shape or eccentric shape can be machined easily.
Tail stock: It is situated on the right-hand side of the bed and is mounted on the inner
guideways. It is used to move the tail stock spindle in. An oil and lock lever is used to fix the
position.
Carriage: The carriage supports the moving parts like saddle, cross slide, apron etc.
Saddle: It is H-shaped casting mounted on top of the lathe so that it slides along the ways.
Cross slide: It is mounted on the saddle. It contains dovetails which fits over the saddle dove
tail. Cross slide moves across the axis of the machine i.e. depth of cut is given by it.
Compound rest: It is mounted on top of the cross slide. It can swivelled to any degree for taper
turning operation .
Apron: The hanging part of the carriage is called apron.
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Leg: The leg supports the entire load of the lathe machine and transfers all the working forces
to the ground.
Fig. 1.2 Constructional features of a centre lathe
OPERATIONS
Fig. 1.3 Numerous Lathe machine operations
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Procedure: -
• The workpiece is held in the three/ four jaw chuck
• First the turning is done to reduce the diameter of the workpiece from 32 mm to 30 mm
and also for finishing the outer surface.
• Then grooving operation is performed in which grooves of 0.2-0.3mm are formed on
the surface of the cylinder.
• Drilling operation is done using a 19 mm drill bit which is held in the tailstock and
brought forward at a length of 40mm
• Then the tool is changed and boring tool is added to increase the diameter of the drill
bit so that only about 5mm thickness of piston remains.
• Grinding operation is then done for finishing purposes.
Calculation: MRR= fdV mm3/s
Where, f = feed rate
d=depth of cut
V= cutting velocity
Result:
Precautions:
• The workpiece should be properly centred and tightened.
• Coolant should be used for cooling as well as to prevent formation of built-up-edge.
5
EXPERIMENT 2
Aim: To prepare a stepped internal hole with in tolerance limit of ±0.05 from a given job
(Experiment 1).
Machine tool, cutting tool and accessories required
• Lathe
• Twist drills (as shown in Fig. 2.1)
• Revolving centre or dead centre
• Inside callipers
Fig 2.1 Drill bit of different diameters
JOB Drawing:
Fig. 2.2 Details of Figure
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Theory:
A lathe is machine tool in which the workpiece is to be held in the revolving chuck and the
tool is fed past through it. While the workpiece revolves, the tool which remains stationery cuts
the material. The chips may be segmented, continuous or continuous with built up edge of
lathes :-
Basic parts of a lathe :-
Bed: It is one of the indispensable parts of a lathe machine. All the moving parts are mounted
on the bed. It is made of cast iron
Headstock: it is also known as line centres. It is permanently fastened on the inner ways. At
the left side of the lathe. The headstock, spindle, a hollow shaft supported by bearings provides
a drive from the motor to the work holding machine
Chuck: It is work holding device attached to the lathe spindle. There are two common types of
chuck. They are: -
• Three jaw self-centred chuck: In this type, there is synchronous motion of the three
jaws. As we tighten or loosen on the jaws the other two jaws are also loosened /
tightened.
• Four jaw independent chuck: This contains 4 jaws which can adjusted individually
to the centre of workpiece. Due to independencies in jaws’ positioning the job of
irregular shape or eccentric shape can be machined easily.
Tail stock: it is situated on the right-hand side of the bed and is mounted on the inner
guideways. It is used to move the tail stock spindle in and oil and lock lever is used to fix the
position.
Carriage: the carriage supports the moving parts like saddle, cross slide, apron etc.
Saddle: It is H-shaped casting mounted on top of the lathe so that it slides along the ways.
Cross slide: It is mounted on the saddle. It contains dovetails which fits over the saddle dove
tail. cross slide moves across the axis of the machine i.e., depth of cut is given by it.
Compound rest: It is mounted on top of the cross slide. It can swivel to any degree for taper
turning operation.
Apron: The hanging part of the carriage is called apron.
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Leg: The leg supports the entire load of the lathe machine & transfers all the working forces to
the ground
The constructional features of a centre lathe are shown in Fig. 2.3.
. Fig. 2.3 Constructional features of a centre lathe
Procedure:
• The workpiece is held in three or four jaws of chuck and held stationery.
• The drill of particular diameter (1st the smallest diameter) is held in the tailstock and
brought closer to the workpiece.
• The spindle is started and workpiece rotates.
• The drill makes contact with workpiece and feed is given to drill
• The same process is repeated for other two drills.
Results: The job with required dimensions of hole is formed as shown in Fig. 2.4.
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Fig. 2.4 Top (left) and bottom ( right) view of the final product
Precautions:
• The workpiece should be properly tightened.
• Cutting fluid should be used for cooling and lubrication
• Measurement should be taken carefully.
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EXPERIMENT 3
Aim of the Experiment: To exercise shaper operation and planner operation to make a groove.
Machine tool, cutting tool and accessories required
• Shaper
• Grooving tool
• Steel ruler
• Chalk
• Marker
• Hammer
• Spanner set
• Vernier calliper
Materials required: Cubical block of mild steel of 50 mm ×50 mm ×50 mm.
JOB Figure
Fig. 3.1 Job details
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Shaper machine
Fig. 3.2. Shaper machine
Theory:
Shaping is a process of removal of metal from surfaces in horizontal plane by the use a single
point cutting tool held in a ram that reciprocates the tool in a linear direction across workpiece.
Working principle:
Operation: In a shaper a single point cutting tool reciprocates over the stationary workpiece.
The workpiece is rigidly held in a vice/ clamped directly on the table. The tool is held in the
tool head mounted on the ram of the machine. When the ram moves forward cutting of material
takes place called as cutting stroke. When the ram moves backward n cutting takes place this
is called die stroke. The time taken during return stroke is less compared to forward stroke and
this is obtained by quick return mechanism. The depth of cut is obtained by moving the tool
downward towards the workpiece.
Principle of quick return mechanism (Crank and slotted lever type)
A quick return mechanism is used to produce a reciprocating motion in which the time taken
for return stroke is less than that for forward stroke. It is driven by a circular motion source
(typically a motor of some sort) and uses a system of links and sliding joints.
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Fig. 3.3 Quick return motion mechanism
Main components of a shaper
• Base: It is heavy cast iron body that supports all other parts of machine.
• Column/pillar: It houses the driving motor, controlled devices, mechanisms of ram
and mark table. At top of the column ram reciprocation moves rail vertically along the
guideways.
• Cross rail: It is heavy cast iron construction attached to the column at it front of the
vertical guideways. It carries two mechanisms one for elevating the table and one for
table to be stable.
• Table: The table is provided with T slots on its slides for clamping the workpiece. The
front face of the table is supported to withstand the cutting forces of the workpiece
during cutting operation.
• Ram: The ram is rigidly screwed casting which reciprocates on the guide
• Elevating screw: It is used for vertical involvement of tools.
• Spindle for crosshead: Cross feed movements of the table by hand, power and match
drive mechanism.
• Down feed handle wheel: Used to give depth of cut to the workpiece.
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Fig. 3.4 Schematic diagram of a typical shaper machine
Procedure:
• A cubical block (50 mm×50 mm×50 mm) is taken
• The job is held on the work holding device on the work table of shaper.
Result:
Precaution:
• Chips should be removed only by means of brush
• It should be ensured that job and tool are rigidly secured in their position.
• Stroke length of the shaper should be checked before starting.
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EXPERIMENT 4
Aim: Manufacturing of a spur gear using form milling cutter in a horizontal milling machine
Machine tool, cutting tool and accessories required
• Horizontal milling machine
• Vernier callipers
• Holding Equipment
• Form Milling tool
Workpiece used
A performed blank of Aluminium of cylindrical shape of diameter 50.8 mm and thickness 12.7
mm, as shown in Fig. 4.1 is used. The internal diameter of hole in blank is 14 mm.
Fig. 4.1. Aluminium blank used for manufacturing gear
Experimental description
For gear cutting on milling machine, the gear blank is mounted on a mandrel which is supported
between the centre of the dividing head and other centre at the opposite end. One tooth space
is cut by the milling cutter and an indexing head is used to index the job to the next required
tooth space. Simple indexing method is followed to index the job. The centre is chosen
according to the diametral pitch and number of teeth of the gear to be cut. This cutter is mounted
on the milling arbour. It is very important to perform centering before the gear cutting process.
The form milling cutter used for cutting gear is shown in Fig. 4.3.
Milling Machine
It is used for machining flat surfaces, complex shapes and surfaces gears and thread cutting
operations, helical surface generation. There are two types of milling machine namely
Horizontal milling machine and Vertical milling machine. A typical horizontal milling machine
is shown in Fig. 4.2. Parts of a milling machine are listed below:
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1. Column & Base
Column including base is the main casting that supports all other parts of milling machine. The
column contains an oil reservoir and a pump which lubricates the spindle.
2. Knee
It is a casting that supports the saddle and table. All gearing mechanism is enclosed within the
knee. It is fastened to the column by dovetail ways. The knee is supported and adjusted by a
vertical positioning screw (elevating screw).
3. Saddle and Swivel Table
The saddle supports and carries the table and is adjusted transversely on the top of knee. It is
provided with graduation for exact movement and operated by power on hand.
4. Power Feed Mechanism
It is the knee which contains the power feed mechanism. It is used to control the longitudinal
(left and right), transverse ( in and out) and vertical (up and down) feeds.
5. Table
It is a rectangular casting which is present on the top of the saddle. It is used to hold the work
or work holding devices. It contains several T-slots for holding the work and work holding
devices (i.e. jigs and fixtures).
6. Spindle
It is the shaft which is used to hold and drives the cutting tools of the milling machine. Spindle
is driven by the electric motor through gear trains. The gear trains are present within the
column.
7. Arbor Support
It is a casting with bearing that supports the outer end of the arbor. It also helps in aligning the
outer end of the arbor with the spindle.
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Fig. 4.2. Horizontal Milling Machine
INDEXING
It is defined as the method of dividing the circumference of the circular work piece into equally
spaced divisions. Indexing head are of three types
• Plain or Simple Indexing Head
• Universal Dividing Head
• Optically Dividing Head
Methods of Indexing:
• Direct or Rapid Indexing Simple or plain Indexing
• Compound Indexing
• Differential Indexing
• Angular Indexing
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Simple or Plain Indexing: In this Indexing, the work piece is rotated by turning the crank as
shown. When the crank is rotated the worm shaft rotates causing the worm to drive the worm
wheel and consequently the spindle to turn. As spindle rotates, the work piece that is secured
to spindle by means of a suitable holding device which also rotates.
Fig. 4.3 Indexing Head
Compound Indexing: In this type of indexing is employed in those cases when the number of
divisions required on the work piece cannot be obtained with the simple or plain index method.
This method involves two separate indexing movements that give the name compound
indexing method. This is performed in two stages: 1. The first movement is obtained by turning
the work a definite amount in one direction in same way as in simple indexing. 2. The second
index movement is obtained by turning the indexing plate along the crank.
Differential Indexing: This is similar to compound indexing where the required division of
the periphery of job is obtained by the combination of two movements 1) The movement of
Indexing crank through the required number of spaces in one of whole circle of index plate as
in case of simple indexing. 2) The simultaneous movement of index plate along with cranks
either in same direction or reverses direction.
Procedure:
Module M = D/T (D : diameter and T : number of teeth)
Indexing calculation: ICR = 40/Z = 40/30
where , Z = no. of teeth which is to be cut (here, Z = 30)
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Depth of cut= 2.25M = 2.25 mm (Addendum: 1 M and dedendum: 1.25M)
where, dp= diametral pitch
1) The gear blank is held between the dividing head and the tailstock using a mandrel. The
mandrel is connected with the spindle of the dividing head by a carrier & a catch plate.
2) The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.
3) The speed and feed of machining is selected.
4) For guiding depth of cut, table is raised till the periphery of the gear blank just touches
the cutter.
5) The micrometre dial of the vertical feed screw is set to zero in this position.
6) Then the table is raised further to give the depth of cut
7) After the machine is started and the first groove is cut on the blank, the table is brought
back to starting position.
8) Then cutter is indexed for next tooth space.
9) This process is continued till all gear teeth are created.
Fig. 4.4. Form milling cutter employed
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Result: The given blank is cut in the form of gear using form milling cutter, as shown in Fig.
4.5.
Fig. 4.5 Gear manufactured from blank
Precautions:
• The milling cutter should be mounted on the arbor rigidly.
• The indexing should be very precise to prevent tooth error.
Safety
DO’S
✓ Do get thoroughly familiar with the stop lever.
✓ Do make sure that the work is held securely before engaging the cutter with it.
✓ Do make sure that all tools and machine parts are clear of the cutter before starting the
machine.
✓ Do keep all cutters carefully to guard against any injury to yourself or others.
✓ Do keep the shirt sleeves rolled up above the elbows and wear close fitting shop aprons
and coats.
DON’TS
❖ Don’t under any circumstances attempt to operate any machine unless you are
thoroughly familiar with it.
❖ Don’t attempt to remove chips from the machine with your bare hand or fingers. Use
brush or other suitable implement.
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❖ Don’t go away leaving machine running. If not then shutdown the machine.
❖ Don’t attempt to oil the machines while it is in operation.
❖ Don’t wear rings or long neckties while on the job
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EXPERIMENT 5
Aim of the Experiment: To produce perfect square plate of required dimension with tolerance
of ±0.05 mm and evaluate machining time and material removal rate respectively.
APPARATUS: Milling Machine tool
DRAWING:
Fig. 5.1 Job details
PROCEDURE:
It is indispensable to address machining time to optimize the whole production line in order to
reduce the cost of manufacturing. It must be exercise to evaluate productive time.
𝐿
Machining time = 𝑓𝑁
Where L is length of the job, f is feed and N is RPM.
Sometime for accurate evaluation approach length and over travel length added for the
calculation of machining time.
Result:
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EXPERIMENT 6
Aim of the Experiment: To drill 4 holes of 10 mm diameter at PCD of 35 mm and a central
hole of Ø 14mm in MS plate, using a pillar drilling machine.
Machine tool, cutting tool and accessories required
• Pillar drill machine
• Twist drill
• Chalk
• Hammer
• Punch
Work material required: A mild steel plate of dimension (45 mm×45mm×10 mm) as shown
in Fig. 6.1 is used as the workpiece material.
Fig. 6.1 Mild steel plate taken for drilling holes
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Fig. 6.2. Pillar Drill Machine
Theory:
There are two types of machine drill, the bench drill and the pillar drill. The bench drill is used
for drilling holes through materials including a range of woods, plastics and metals. It is
normally bolted to a bench so that it cannot be pushed over and that larger pieces of material
can be drilled safely.
The larger version of the machine drill is called pillar drill. This has a long column which stands
on the floor. This can do exactly same work as the bench drill but because of its larger size it
is capable of being used to drill larger pieces of materials and produce larger holes.
Fig. 6.3 Twist drill geometry
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Procedure:
• Holes to be drilled are marked using a chalk on the material.
• The centre was punched using a hammer
• The job fitted on the table of the machine and the hole was drilled.
Result: The desired product is created using pillar drill machine as shown below:
Fig. 6.4. Workpiece after drilling operation
Precautions:
• Evacuate the chips produced by drilling after regular intervals
• Add sufficient cutting fluid for cooling and lubrication.
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EXPERIMENT 7
Aim of the Experiment: To study basic fundamental of Computer numerical machine (Lathe
Machine).
Machine tools: CNC Lathe
Theory
CNC lathes are preferred over the older production lathes (multi-spindle, etc.) due to their ease
of setting, operation, repeatability and accuracy. They are designed to use modern carbide
tooling and fully use modern processes. The part may be designed and the tool
paths programmed by the CAD/CAM process or manually by the programmer and the resulti
ng fileuploaded to the machine, and once set and trialled the machine will continue to turn out
parts under the occasional supervision of an operator.
The machine is controlled electronically via a computer menu style interface;
the program may be modified and displayed at the machine, along with a simulated view of t
he process. The design of a CNC lathe varies with different manufacturers, but they all have
some common elements. The turret holds the tool holders and indexes them as needed, the
spindle holds the work-piece and there are slides that let the turret move in multiple axes
simultaneously. The machines are often totally enclosed, due in large part to Occupational
health and safety (OH&S) issues.
Programming fundamentals:
Machining involves an important aspect of relative movement between cutting tool and
workpiece. In lathe this is accomplished by moving the tool with respect to workpiece. A
program defining motion of tool / workpiece in this coordinate system is known as a Part
Program.
The main parts of the CNC machine are:
1. Input devices
2. Machine control unit (MCU)
3. Machine tool
4. Driving system
5. Feedback system
6. Display unit
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Fig. 8.1 Basic parts of CNC system
1. Input Devices:
These are devices that are used to input the part program into a CNC machine. There are three
generally used input devices and these are punch tape reader, magnetic tape reader and
computer via RS-232-C communication.
2. Machine Control Unit (MCU):
The machine control unit is called the heart of the CNC machine. It performs all the control
functions of the CNC machine, there are various tasks performed by MCU that are
• It reads the coded instructions given in it.
• Machine control unit decodes the coded instruction.
• This axis implements interpolation (linear, circular and helical) to generate
motion commands.
• Machine control unit feeds the axis motion command to the amplifier circuit to
drive the axis mechanism.
• It takes a feedback signal of position and speed for each drive axis.
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• It implements the auxiliary control functions such as coolant or spindle on/off
and tool change.
3. Machine Tool:
A CNC machine tool always has a sliding table and a spindle to control the position and speed.
The table of the machine is controlled in the X and Y-axis direction and the spindle is controlled
in the Z-axis direction.
4. Driving System:
The driving system of a CNC machine include of an amplifier circuit, drive motors, and ball
lead screws. The MCU supplies the signals (ie, of position and speed) of each axis to the
amplifier circuits. The control signals are then augmented (increased) to actuate the drive
motors. And the actuated drive motors rotate the ball lead screw to put in position the machine
table.
5. Feedback System:
The feedback system has transducers that act as sensors. It is also called a measuring system.
It consists of position and speed transducers that continuously monitor the position and speed
of the cutting tool located at any given moment.
The MCU receives signals from transducers and it uses the difference in reference signals and
feedback signals to generate control signals to correct position and speed errors.
6. Display Unit:
The monitor is employed to display programs, commands and other useful data of the CNC
machine.
How CNC Machine Works?
The Fig. shows the CNC machine working:
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Fig. 8.2 working principle of CNC
First, the part program is entered into the MCU of the CNC.
The MCU processes all the data and according to the program prepared, it prepares all the
motion commands and gives them to the driving system.
The drive system acts as motion commands sent by the MCU. The drive system manages the
motion and velocity of the machine tool.
The feedback system records the position and velocity measurements of the machine tool and
gives a feedback signal to the MCU.
In the MCU, the feedback signals are compared with reference signals and if errors occur, it
corrects it and sends new signals to the machine tool to be corrected.
The display unit is used to see all the programs, commands, and other data. It works like the
eye of the machine.
Working Principle of CNC Machine
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It consists of two separate controls, a CNC controller that doses the function of program
decoding interpolation, diagnostics machine actuation, etc. Another is the programmable logic
controller (PLC), which does spindle on-off, coolant on-off, turret operation, etc.
Slides are transferred via their own feed drive (AC or DC) servomotors or ball screws and nut
drives. The feed drive controllers the feed drive motors. Suitable transducers have been fitted
to either the table or the motor, which measures the slide position.
Also, the position is monitored and checked through the feedback transducers to ensure the
accuracy of positioning. The spindle is provided with stepped motors of AC or DC. A suitable
control is used to vary is the speed of the spindle motor. A suitable feedback device connected
to the shaft monitors the speed. This is how the CNC machine works.
Advantages of CNC Machine
Following are the advantages of CNC machine:
1. CNC machine can produce jobs with highest accuracy and precision than any
other manual machine. It eliminates human errors.
2. It can be operated for 24 hours of a day. Higher flexibility also.
3. The parts manufactured by it have the same accuracy. There is no variety in
parts manufactured by CNC machines.
4. A highly skilled operator is not needed to run a CNC machine.
5. A semi-skilled operator can also operate accurately and more precisely.
6. Operators can easily make changes and improvements and reduce the delay time
and Reduce inspection cost.
7. It has the capability to produce a complex design with high accuracy in
minimum possible time with minimum wastage.
8. Modern design software allows the designer to emulate the creator of his idea.
9. And this removes the need for making a prototype or model a saves time and
money.
10. Fewer workers are required to operate a CNC machine and save labour cost.
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11. It is suitable for batch production.
12. It requires less space for its operations.
13. More operational safety.
Disadvantages of CNC Machine
Following are the disadvantages of CNC Machine:
1. The cost of a CNC machine is much higher than a manually operated machine.
2. The initial cost is high.
3. The parts of the CNC machines are costly.
4. Maintenance costs are significantly higher in the case of CNC.
5. It does not eliminate the need for costly tools.
6. CNC machine requires skilled programmers.
7. It is not suitable for small scale production
8. Maintenance cost is more.
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EXPERIMENT 8
Aim: Turning of a cylindrical job on CNC turning machine.
Machine tool, cutting tool and accessories required
• CNC turning center
• Single point turning tool
• Chalk
• Steel ruler
• Vernier callipers
Materials required : Cylindrical job made of mild steel.
Theory
Computer numeric control machine (CNC) is the automation of machine tools by means of
computer executing pre- programmed sequences of machine control commands. The design of
a mechanical part and its manufacturing program is highly automated. In CNC lathes,
workpieces are cut while they are rotated. These are suitable for complex [Link] are
generally 2 axes (X & Z). The turning operation can be done easily on these machines.
Fig 9.1 CNC Turning Center
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Example of CNC turning Program
02323;
G21 G98;
G28 UOWO;
T0505;
M03s500;
G00 X30.0 Z3.0;
G71 U0.2 R0.3;
G71 P22 Q23 F0.25;
N22 G01 X15.0;
G01 Z-30.0;
G01X20.0;
G01 X25.0 z -35.0;
N33 G01 X30.0;
G00 Z3.0;
T0000;
G28 U0 W0;
M05; #Spindle stop
M30; #end of program
Result: The Aluminium job of required dimension is produced
Precautions:
• The machine being expensive should be handled carefully.
• The code should be correctly written and the situation is to be checked for any errors
so that it can be corrected
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