II YEAR, III SEMESTER

SUB.CODE:- ME6311
SUB. NAME:
MANUFACTURING TECHNOLOGY LAB MANUAL-I
Lab incharge:

ME6311 MANUFACTURING TECHNOLOGY LABORATORY

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:
1. Taper Turning
2. External Thread cutting
3. Internal Thread Cutting
4. Eccentric Turning
5. Knurling
6. Square Head Shaping
7. Hexagonal Head Shaping
TOTAL: 45 PERIODS
OUTCOMES:
Upon completion of this course, the students can able to demonstrate and fabricate
different types of components using the machine tools.

LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS

2

S. NO.

NAME OF THE EQUIPMENT

Qty.

Centre Lathes

7 Nos.

Horizontal Milling Machine

1 No

Vertical Milling Machine 1

No

Shaper

1 Nos.

GENERAL INFORMATION
In this laboratory you will be exposed to the common manufacturing
processes such as Metal cutting, Metal casting, metal forming, and metal
joining.You are required to submit the lab record on each laboratory session in
the following that session.
You will be provided with a question bank and quiz will be based on the
questions contained in the bank. You have to refer to the textbooks for
appropriate answers to the questions in the question bank.

GENERAL INSTRUCTIONS

1. Every student should obtain a copy of Laboratory Manual.

2. Dress Code: Students must come to the laboratory wearing (i) Lab Uniform
(ii) Leather Shoes. Half pants, loosely hanging garments and slippers are
not allowed.
3. To avoid injury, the student must take the permission of the laboratory
staff before handling any machine.
4. Students must ensure that their work areas are clean and dry to avoid
slipping.
5. A leather apron will be issued to each student during Welding Exercise.
Students not wearing the apron will not be permitted to work in the
laboratory. Students are required to clear off all tools and materials from
machine/work place.
6. At the end of each experiment, students must clear off all tools and
materials from the work area.
7. Careless handling of machines may result in serious injury.
8. Laboratory record must be submitted in standard form in the subsequent
lab class. Reports on ordinary sheet and computer papers will not be
accepted.
9. The Lab report should only contain: (i) Title of the experiment, (ii) Two to
three lines stating the objectives (Aim), (iii) Name of all equipments/tools
used, (iv) Procedure and (v) Result. The report should be neat and sweet.

INDEX
S.N
O

PAGE.N

EXP.NAME

FACING PLAIN TURNING AND

STEP TURNING

TAPER TURNING BY USING

COMPOUND REST METHOD

TAPER TURNING BY USING

TAILSTOCK SET OVER METHOD

ECCENTRIC TURNING

SINGLE AND MULTI START V

EXTERNAL THREAD CUTTING
AND KNURLING

BORING AND INTERNAL

THREAD CUTTING

ROUND TO SQUARE USING

SHAPER MACHINE

ROUND TO HEXAGON USING

SHAPER MACHINE

9
10
11
12

DATE OF
SUBMISSIO
N

SIGNATUR
E

LATHE
INTRODUCTION:
Lathe is the father of all machine tool. It is a basic machine tool
probably the most important one of all, lathe was actually the first
machine tool.
Lathe is a particular type of machine tool in which the work is held and
rotated against a suitable cutting tool for the purpose of producing surface
of revolution in any material.
LATHE SPECIFICATIONS:
In order to specify a lathe, a number of parameters could be used
on the specific applications. However, the major elements used for
specifications should invariably be based on the components that would
be manufactured in the lathe. The sum of lathe specifications is,
L=Distance between centers.
A=Swing diameter over bed.
B=Swing diameter over carriage.
R=Radius.
H=Height of center from bed
DISTANCE BETWEEN CENTERS (L):
This would be specifying the maximum length of the job that can be
turned in the lathe.
SWING DIAMETER OVER BED (A):
This specifies the maximum diameter of the job that can be turned in
the lathe machine generally restricted to small length jobs.
SWING DIAMETER OVER CARRIAGE (B):
This specifies the maximum diameter of job that can be turned in the
lathe machines with the job across the cross slide.

Other factors should also be specified to fully describe the lathe machine.
1.

Horse power of the motor

2.

Feed range

3.

Accuracy achieved

4.

Cutting speed range

5.

Screw cutting capacity

6.

Spindle nose diameter

PARTS OF ENGINE LATHE OR CENTER LATHE:

The principal parts of an engine lathe are,
1. Bed,
1. Head stock,
2. Tail stock,
3. Carriage,
8

3.1. Saddle,
1.1. Cross slide,
3.2. Compound rest,
3.3. Tool post,
3.4. Apron.
4. Feed Mechanism,
5. Thread cutting mechanism.
CARRIERS AND CATCH PLATES:
Carriers and catch plates are used to drive a work piece when it is held
between two centers. Carriers or driving dogs are attached to the end of the
work piece by a setscrew, and catch plates are either screwed or bolted to
the nose of the headstock spindle.
CHUCK:
A chuck is one of the most important devices for holding and rotating a
piece of work in a lathe. Work piece of short length, and large diameter or
irregular shapes, which cannot be conveniently mounted between centers,
are held quickly and rigidly in a chuck.

TYPES OF CHUCKS:
1. Four jaw independent chuck
2. Three jaw universal chuck
3. Air or hydraulic operated chuck
4. Magnetic chuck
5. Collet chuck
6. Combination chuck
7. Drill chuck
FACE PLATE:
A faceplate consists of a circular disk bored out and threaded to fit the
nose of the lathe spindle. This has the radial, plain and T slots for holding
work by bolts and clamps.
ANGLE PLATE:

This is a cast iron plate having two faces machined to make them
absolutely at right angles to each other. Holes and slots are provided on both
faces so that it may be clamped on a faceplate and can hold the work piece
on the face by bolts and clamps.
MANDRELS:
A mandrel is a device for holding and rotating a hollow piece of work
that has been previously drilled or bored. The work revolves with the mandrel
which is mounted between two centers.
PLAIN MANDREL:
The plain mandrel this type of mandrel is most commonly used in shops
and finds wide application where a large number of identical pieces having
standard size holes are required to be mounted on it.
STEP MANDREL:
A step mandrel having steps of different diameters may be employed to
drive different work pieces having different sizes of holes without replacing
the mandrel each time. This type of mandrel is suitable for turning collars,
washers and odd size jobs used in repairing workshops.

COOLER MANDREL:
A cooler mandrel having solid coolers is used for turning work pieces
having holes of larger diameter, usually above 100 mm. This construction
reduces weight and fits better than a solid mandrel of equal size.
SCREWED MANDREL:
A screwed mandrel is threaded at one end with a collar. Work pieces
having internal threads are screwed on to it against the collar for machining.
CONE MANDREL:
A cone mandrel consists of a solid attached to the one end of the body,
and a sliding cone, which can be adjusted by turning a nut at a threaded end.
GANG MANDREL:
10

This has a fixed collar at one end and a movable collar at the threaded
end, which may be adjusted, to this position by a nut. The mandrel is used to
hole a set of hollow work piece between two collars by tightening the nut.
EXPANSION MANDREL:
There are different types of expansion mandrels. The mandrel consists
of tapered pin, which is driven into a sleeve that is parallel outside and
tapered inside the sleeve has three longitudinal slots, two of which are cut
nearly through, and the third splits it completely.
RESTS:
A rest is a mechanical device which supports a long slender work piece,
which is turned between centers or by a clutch, at some intermediate point to
prevent bending of the work piece due to its own weight and vibrations set up
due to the cutting force that acts on it.
STEADY REST:
A steady rest shown in Fig consists of a cast iron base, which may be
made to slide on the loath bed ways and clamped at any desired position
where a support is necessary.
FOLLOWER REST:
A follower rest consists of a C like casting two adjustable jaws which
support the work piece. The rest is bolted to the back end of the carriage and
moves with it.
TYPES:
1.

Speed lathe
a. Woodworking
b. Centering
c. Polishing
d. Spinning
2. Engine lathe
a. Belt drive
b .Individual motor drive
c. Gear head lathe
11

3. Bench lathe
4. Tool room lathe
5. Capstan and turret lathe
6. Special purpose
a. Wheel lathe
a. T. Lathe
b. Gap. Bed lathe
c. Duplicating lathe
7. Automatic lathe
THE ENGINE LATHE OR CENTER LATHE:
The term engine lathe is associated with the lathe owing to the fed
that early lathe was driven by steam engines It has all parts.
THE BENCH LATHE:
This is a small lathe usually mounted on bench it has similarly all the
parts of an engine lathe or speed lathe and it only difference is being in the
size. This is used for small and precision work.
THE TOOL ROOM LATHE:
A tool room lathe having the features similar to an engine lathe is much
more accurately built and has wide range of spindle speed ranging from a
very few to quite high speed unto 2500 rpm. This lathe is mainly used for
precision works on tools, dies, and gauges and in machinery work.
THE CAPSTAN AND TURRET LATHE:
These lathes are developed of the engine lathe and are used for
product on work. The distinguishing features of this type of lathe is that the
tailstock of an engine lathe is replaced by a hexagonal turret on the face of
which multiple tools may be fitted and feed into the work in the proper
sequence.

SPECIAL PURPOSE LATHE:

As the name implies they are used for special purpose and the jobs,
which cannot be accommodated or conveniently machined on a standard
12

lathe.

The wheel lathe is made for finishing the journal and turning the

traded on the railroad carriage and locomotive wheel. The gab bed lathe in
which a section of the bed is adjacent to the headstock of the bed is
recoverable is used to sluing extra large diameter piece. The T lathe a new
member of the lathe family is intended for machining of rotor for jet engines.
AUTOMATIC LATHE:

These are high speed heavy duty mass production

lathe with complete automatic controls once the tools are set and the
machine started it performs automatically all the operation to finish the
job.
TOOLS:
A cutting tool may be used either for cutting a part as with a knife or for
remaining the chips parts are produced by removing the metal mostly in the
form of small ships removal in the metal cutting process may be performed
wither by cutting tools having distinct cutting edges or by abrasively sticks
abrasive cloth etc,
All cutting tools can be divided into 2 groups
1.

Single point cutting tool

2.

Multi point cutting tool

SINGLE POINT CUTTING TOOLS:

Single point cutting tool has a sharpened cutting part its point and
shaft; the point of the too bounded by the base. The side flank or major flank
or end slank or minor flank or and it base. The side cutting edges of a tool is
form by the interaction of the base and the side flank. The end cutting edge,
a tool into form by the intersection of the base and the flank, the chip and cut
from the work piece by the side cutting edges. The paint a where the end
and side cutting edge met is called nose of tool.
LATHE OPERATIONS:
TURNING:
Turning is the further most generally used operation is the lathe. In ties
the work held in spindle is rotated which the tool is fed part the work piece in
13

a direction parallel in the axis of rotation.

The surface generated is the

cylindrical shape
FACING:
Facing is the operation of machining the ends of a piece of work to
produce flat Surface Square with the axis. The operation involves feeding the
tool parallel to the axis of rotation of the work piece.
TAPER TURNING:
Taper may be turned in a lathe by feeding the tool at an angle to the
axis of the work piece. Which taper is essential that the tool cuttings edge
should be accurately on the centre line of the work piece otherwise correct
taper will not be obtained
By a broad nose form tool

By setting over to the tailstock center

By swiveling the compound rest

By a taper turning attachment.

By combing longitudinal and cross feed in a lather.

THREAD CUTTING:
Thread cutting is one of the most important operations performed in a
lathe.

When the job is reduced between centers or by a chuck.

The

longitudinal feed should be equal to the pitch of the thread to be cut per
revolution of the work piece.

14

FACING, PLAIN TURNING AND STEP TURNING

DRAWING:

All Dimensions are in mm

15

FACING PLAIN TURNING AND STEP TURNING

Ex. No:
Date:
AIM:
To machine the given cylindrical rod as per the sketch by using lathe.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter _______mm and length_________ mm
mild steel rod.
TOOLS / INSTRUMENTS REQUIRED:
1. Single point cutting tool

2. Parting tool
3. Steel rule
4. Vernier caliper
SEQUENCE OF OPERATIONS:
1. Checking of Work piece
2. Job setting
3. Tool setting
4. Facing
5. Plain Turning
6. Step turning
7. Chamfering
WORKING STEPS:
1. The mild steel rod is cut approximately to the given dimensions.
2. Then the work piece is held in the chuck such that no eccentricity
and run out occurs. It is done by using the marking block.
3. Then the work piece is fitted tightly with the help of

chuck key in

the chuck.
4. The single point cutting tool is placed on tool post and it is always
aligned such that it coincides with the axis of the dead centre
5. The tool is fixed tightly with the help of tool post key
6. Now the constant speed is applied to the work piece
7. Then the tool tip is brought to the centre of work piece
16

8. The facing operation is done by giving cross feed by moving carriage

and tool post by moving from centre and the turning operation is
done

by giving

longitudinal feed.The chamfering

is done to the

edges of work piece.

9. The work piece is clamped on the other side for machining.
10.

The operations are

repeated to make step turning to the given

size.
11.

Then the work piece is checked for required dimensions with the

help of

vernier caliper.

RESULT:
Thus the required size and shape of the given work piece is
obtained.

17

TAPER TURNING BY USING COMPOUND REST METHOD

DRAWING:

Taper angle calculation :

Tan = (D-d) / 2 L
= Tan-1 ( D-d ) / 2 L
Where

= Taper angle in degrees

D = Major diameter in mm
D = Minor diameter in mm
L = Length of job

All Dimensions are in mm

18

TAPER TURNING BY USING COMPOUND REST METHOD

Ex. No:

Date:

AIM:
To obtain the required shape and size of the work piece by taper turning
operation using compound rest.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_________mm and length_________ mm
mild steel rod.
TOOLS / INSTRUMENTS REQUIRED:
1. Single point cutting tool

2. Parting tool
3. Steel rule
4. Vernier caliper
SEQUENCE OF OPERATIONS:
1. Checking of Work piece
2. Job setting
3. Tool setting
4. Facing
5. Plain Turning
6. Taper turning
7. Chamfering
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the
job firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the
nuts using Tool post key.
4. Facing is done with cutting tool moving from the centre of work piece
towards outside. It is one until the required length of the job is
obtained.

19

5. Turning is done to reduce the diameter of the job. Sufficient depth of

cit is given and it is done until the required diameter of the job is
obtained.
6. Next step taper turning is done on the work piece, as per the taper
angle already calculated. Then the compound rest base is swiveled
and set at half taper angle. Cutting tool is moved at an angle to the
lathe axis. Tool is moved by the compound rest hand wheel.
7. For chamfering to be done at the end of the work piece, the tool is
held at 450 to the lathe axis and is fed against the rotating work
spice.
8. Finally the dimension of work piece is again checked.

RESULT:
Thus the required size and shape of the given work piece is
obtained.

20

21

TAPER TURNING BY USING TAILSTOCK SET OVER METHOD

DRAWING:

Tail stock set over calculation:

Set over S = LT x Tan
= LT x (D-d) / 2 L
Where

LT = Total length of job

D = Major diameter in mm
D = Minor diameter in mm
L = Length of tapered portion

All Dimensions are in mm

22

TAPER TURNING BY USING TAILSTOCK SETOVER METHOD

Ex. No:

Date:

AIM:
To obtain the required shape and size of the work piece by taper turning
operation using tailstock set over.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_________mm and length_________ mm
mild steel rod.
TOOLS / INSTRUMENTS REQUIRED:
1. Single point cutting tool
2. Parting tool
3. Steel rule
4. Vernier caliper
SEQUENCE OF OPERATIONS:
1. Checking of Work piece
2. Job setting
3. Tool setting
4. Facing
5. Plain Turning
6. Taper turning
7. Chamfering
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten
the job firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens
the nuts using Tool post key.
4. Facing is done with cutting tool moving from the centre of work
piece towards outside. It is one until the required length of the job
is obtained.

23

5. Turning is done to reduce the diameter of the job. Sufficient depth

of cit is given and it is done until the required diameter of the job
is obtained.
6. Next step taper turning is done on the work piece, as per the
tailstock setover already calculated. Then the tailstock is made to
slide on its base towards or away from the operator by a setover
screw. Cutting tool is moved parallel to the lathe axis by rotating
the carriage hand wheel.
7. For chamfering to be done at the end of the work piece, the tool
is held at 450 to the lathe axis and is fed against the rotating work
spice.
8. Finally the dimension of work piece is again checked.

RESULT:
Thus the required size and shape of the given work piece is
obtained.

24

ECCENTRIC TURNING
DRAWING

25

ECCENTRIC TURNING
Ex. No:

Date:

AIM:
To obtain the required shape and size of the work piece by ECCENTRIC
TURNING operation.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_________mm and length_________ mm
mild steel rod.
TOOLS / INSTRUMENTS REQUIRED:
5. Single point cutting tool
6. Parting tool
7. Steel rule
8. Vernier caliper
SEQUENCE OF OPERATIONS:
8. Checking of Work piece
9. Job setting
10.

Tool setting

11.

Facing

12.

Plain Turning

13.

Taper turning

14.

Chamfering

WORKING STEPS:
9. The given work piece is checked for its dimension.
10.

The work piece is held in the chuck. Chuck key is used to

tighten the job firmly, ensuring centering of work piece.

11.

The single point cutting tool is held in the tool post and

tightens the nuts using Tool post key.

12.

Facing is done with cutting tool moving from the centre of

work piece towards outside. It is one until the required length of

the job is obtained.
13.

Turning is done to reduce the diameter of the job. Sufficient

depth of cit is given and it is done until the required diameter of

the job is obtained.
26

14.

Next step taper turning is done on the work piece, as per

the tailstock setover already calculated. Then the tailstock is

made to slide on its base towards or away from the operator by a
setover screw. Cutting tool is moved parallel to the lathe axis by
rotating the carriage hand wheel.
15.

For chamfering to be done at the end of the work piece, the

tool is held at 450 to the lathe axis and is fed against the rotating
work spice.
16.

Finally the dimension of work piece is again checked.

RESULT:
Thus the required size and shape of the given work piece is
obtained.

27

SINGLE

AND MULTI START V THREAD

CUTTING AND KNURLING

DRAWING:

ALL DIMENSIONS ARE IN MM

28

SINGLE AND MULTI START V THREAD

CUTTING AND KNURLING
Ex.

No:

Date:
AIM:
To obtain the required shape and size of the work piece by turning and thread
cutting.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_________mm and length__________mm
mild steel rod.
TOOLS / INSTRUMENTS REQUIRED:
1. Single point cutting tool
2. Thread cutting tool

3. Knurling tool
4. Vernier caliper
5. Pitch gauge
SEQUENCE OF OPERATIONS:
1. Checking of Work piece
2. Tool setting
3. Facing
4. Plain Turning
5. Thread cutting
6. Chamfering
WORKING STEPS:
1. The given work piece is checked for its dimension.
2. The work piece is held in the chuck. Chuck key is used to tighten the
job firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the
nuts using spanner.

29

4. Facing is done with cutting tool moving from the centre of work piece
towards outside. It is one until the required length of the job is
obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of
cit is given and it is done until the required diameter of the job is
obtained.
6. For chamfering to be done at the end of the work piece, the tool is
held at 450 to the lathe axis and is fed against the rotating work
spice.
7. The cutting tool in the tool post is taken out. Thread cutting tool is
held in the tool post and tightened the nuts.
8. The gear ration is calculated and the suitable size gears are fitted in
the change gear train.
9. For right hand thread the lead screw rotates in clock wise direction
and for left thread, it rotates in anti clock wise direction.
10.
11.

The half nut is engaged after giving suitable depth of cut.

The tool is moved towards headstock in helical path and thread is

produced.
12.

At the end of each cut tool is withdrawn. Then the spindle of the

machine is reversed and the tool is moved towards tailstock.

13.

After the tool reaches the starting position the machine is

stopped.
14.

The required depth of cut is given and the cycle is repeated to

obtain the required depth.

15.

The dimension of work piece and pitch of the thread are again

checked.
16.

Then the knurling tool is fixed and required pattern of knurling is

made on the job.

17.

Finally both ends of the job are chamfered by using chamfering

tool.

RESULT:
30

Thus the required size and shape of the given work piece is
obtained.

31

BORING AND

INTERNAL THREAD CUTTING

DRAWING:

32

33

All DIMENSIONS ARE IN MM

BORING AND

INTERNAL THREAD CUTTING

Ex.
Date:

No:

AIM:
To obtain the required shape and size of the work piece by Facing, plain
turning and Boring and internal threading.
MATERIALS SUPPLIED:
Cylindrical work piece of diameter_______ mm and length_______
mild steel rod.
TOOLS / EQUIPMENTS / INSTRUMENTS REQUIRED:
1. Single point cutting tool
2. Parting tool
3. Boring tool and internal thread cutting tool.
4. Drill chuck
5. Drill bit
6. Mandrel
7. Steel rule
8. Vernier caliper
9. Vernier height gauge
SEQUENCE OF OPERATIONS:
1. Checking of work piece
2. Work piece setting
3. Tool setting
4. Facing
5. Turning
6. Boring
7. Thread cutting.
WORKING STEPS:
1. The given work piece is checked for its dimension.
34

mm

2. The work piece is held in the chuck. Chuck key is used to tighten the
job firmly, ensuring centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the
nuts using spanner.
4. Facing is done with cutting tool moving from the centre of work piece
towards outside. It is one until the required length of the job is
obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of
cit is given and it is done until the required diameter of the job is
obtained.
6. Fix the boring tool in the tail stock.
7. Slowly given the feed by rotating the wheel in the tailstock which
moves the tool longitudinally to producing a boring.
8. Fix the internal threading tool, to cut the internal thread.
9. Finally the dimension of work piece is again checked.

RESULT:
Thus the required size and shape of the given work piece is
obtained.

35

SHAPER MACHINE
Shaping among the oldest techniques,
1. Shaping is where the work piece is fed at right angles to the cutting
motion between successive strokes of the tool. These processes
require skilled operators and for the most part have been replaced
by other processes.
Classifi cation of Shaper Machine
i. Horizontal-push cut
ii. Plain (Production work)
iii. Universal (Tool room work)
iv. Horizontal-draw cut St. Vertical S l o t t e r Key seater
v. Special purpose-as for gear cutting
Horizontal Push Cut Shaper
The shaper is a relatively simple machine. It is used fairly often in the tool
room or for machining one or two pieces for prototype work. Tooling is
simple, and shapers do not always require operator attention while cutting.
The horizontal shaper is the most common

type, and its principal

components are shown below, and described as follows:

36

Ram: The ram slides back and forth in dovetail or square ways to
transmit power to the cutter. The starting point and the length of the
stroke can be adjusted.
Tool head: The tool head is fastened to the ram on a circular plate
so that it can be rotated for making angular cuts. The tool bead can
also be moved up or down by its hand crank for precise depth
adjustments.
Clapper Box: The clapper box is needed because the cutter drags over
the work on the return stroke. The clapper box is hinged so that the
cutting tool will not dig in. Often this clapper box is automatically raised
by mechanical, air, or hydraulic action.
Table: The table is moved left and right, usually by hand, to position
the work under the cutter setting up. Then, either by hand or more
often automatically, the table moved sideways to feed the work under
the cutter at the end or beginning of each stroke.
Saddle: The saddle moves up and down (Y axis), usually manually, to
set
the
rough
position of the depth of cut. Final depth can be set by the hand crank on
the tool head.
Column: The column supports the ram and the rails for the saddle. The
mechanism for moving the ram and table is housed inside the column.
37

Tool holders: Tool holders are the same as the ones used on at engine
lathe, though often larger in size. The cutter is sharpened with rake and
clearance angles similar to lathe tools though the angles are smaller
because the work surface is usually flat. These cutters are fastened into
the tool holder. Just as in the lathe, but in a vertical plane.
Work holding...Work holding is frequently done in a vise. The vise is
specially designed for use in. shapers and has long ways which allow
the jaws to open up to 14" or more, therefore quite large work pieces
can be held. The vise may also have a swivel base so that cuts may be
made at an angle. Work that cannot be held in the vise (due to size or
shape) is clamped directly to the shaper table in much the same way as
parts are secured on milling machine tables.
Shaper Size: The size of a shaper is the maximum length of stroke which it
can take. Horizontal shapers are most often made with strokes from 16- to
24" long, though some smaller and larger sizes are available. These shapers
use from 2- to 5-hp motors to drive the head and the automatic feed.
Shaper Width: The maximum width which can be cut depends on the
available movement of the table. Most shapers have a width capacity equal
to or greater than the length of the stroke. The maximum vertical height
available is about 12" to 15".
MACHINE metal surfaces especially where a large amount ot metal has to be
removed. Other machines such as milling machines are much more
expensive and are more suited to removing smaller amounts of metal;
very accurately. The reciprocating motion of the mechanism inside the
shaping machine can be seen in the diagram. As the disc rotates the top
of the machine moves forwards and backwards, pushing a cutting tool.
The cutting tool removes the metal from work which is carefully bolted.

Types of Work: The tool post and the tool slide can be angled as seen below.
This allows the shaper to be used for different types of work.

38

(i) The tool post has been turned at an angle so that side of
the material can be machined.
(ii) The tool post is not angled so that the tool can be used to
level a surface.
(iii) The top slide is slowly feed into the material so that a
'rack' can be machined for a rack and pinion gear system.

39

Round to Square Using Shaper Machine

Ex. No:
Date:
Aim: To make the square shape from the cylindrical work piece on a
shaper machine.
Tools required:
Single Point Tool (H.S.S), Vernier caliper, Adjustable spanner, key,
hammer, etc...

Materials required:
A cylindrical work piece of diameter ............mm and mm
length of cast iron rod.
Procedure:
1. The single point cutting tool is clamped in the tool post.
2. The surface of the material to be machined is marked.
3. The work piece is fixed in the machine vice, ensuring that it is parallel to the
stroke of the ram. By elevating screw it is brought to the required height.
4. The ram stroke is adjusted depending on the length of the work piece to
account for speed variation.
5. Ram stroke = length of job + length of approach + length of over travel.
6. The table and the clapper box are moved so that the tip of the tool just
touches the work piece.
7. Start the machine and the let the ram reciprocates, cutting during the
forward stroke. During the return stroke depth of cut is set by rotating
the handle. Feed is also set simultaneously by cranking table feed
screw. Feeding can be automated if required.
8. After machining a groove on the work piece the "V" tool is removed and
the parting tool is fixed.

9. Finishing cut is given on the Square Shape and 4 sides.

10. Procedure is repeated for required size and shape.

Result:
Thus a square shape from the cylindrical work piece on a shaper
machine

Round to Hexagon Using Shaper Machine

Ex. No:
Date:
Aim: To make the square shape from the cylindrical work piece on a
shaper machine.
Tools required: Single Point Tool (H.S.S), Vernier caliper, Adjustable spanner, key,
hammer, etc...
Materials required:
A cylindrical work piece of diameter ...........mm and length
mm of cast iron rod.
Procedure:
1. The single point cutting tool is clamped in the tool post.
2. The surface of the material to be machined is marked.
3. The work piece is fixed in the machine vice, ensuring that it is parallel to the
stroke of the ram. By elevating screw it is brought to the required height.
4. The ram stroke is adjusted depending on the length of the work piece to
account for speed variation.
5. Ram stroke = length of job + length of approach + length of over travel.
6. The table and the clapper box are moved so that the tip of the tool just
touches the work piece.
7. Start the machine and the let the ram reciprocates, cutting during the
forward stroke. During the return stroke depth of cut is set by rotating
the handle. Feed is also set simultaneously by cranking table feed
screw. Feeding can be automated if required.
8. After machining a groove on the work piece the "V" tool is removed and
the parting tool is fixed. '
9. Finishing cut is given on the Square Shape and 4 sides.
10. Procedure is repeated for required size and shape.

Result:
Thus a square shape from the cylindrical work piece on a shaper
machine