Manufacturing Process PDF Cut

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Module
4
General Purpose
Machine Tools
Version 2 ME, IIT Kharagpur
Lesson
23
Construction,
Operation and Tool
layout in
Semiautomatic and
Automatic
lathes.
Instructional objectives
This lesson will enable the students ;
(i) Illustrate the constructional features and uses of semiautomatic and

automatic lathes.
(ii) Show the kinematic system and explain the working principles of
semiautomatic and automatic lathes of common use.
(iii) Plan and visualise tool layout for machining in semiautomatic and
automatic lathes.
(i) Constructional Features And Uses Of General Purpose

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Semiautomatic
And Automatic
Lathes.
Automation is incorporated in a machine tool or machining system as a whole
for higher productivity with consistent quality aiming meeting the large
requirements and overall economy. Such automation enables quick and
accurate auxiliary motions, i.e., handling operations like tool work mounting,
bar feeding, tool indexing etc. repeatably with minimum human intervention
but with the help of special or additional mechanism and control systems.
These systems may be of mechanical, electro-mechanical, hydraulic or
electronic type or their combination.
It is already mentioned that according to degree of automation machine tools
are classified as,
Non automatic where most of the handling operations irrespective
of processing operations, are done manually, like centre lathes etc.
Semiautomatic
Automatic where all the handling or auxilliary operations as well as
the processing operations are carried out automatically.
General purpose machine tools may have both fixed automation or flexible
automation where the latter one is characterised by computer Numerical
Control (CNC).
Amongst the machine tools, lathes are most versatile and widely used. Here
automation of lathes only have been discussed.
The conventional general purpose automated lathes can be classified as,
(a) Semiautomatic :
(b) Automatic
capstan lathe (ram type turret lathe)

turret lathe
multiple spindle turret lathe
copying (hydraulic) lathe
Automatic cutting off lathe
Single spindle automatic lathe
Swiss type automatic lathe
multiple spindle automatic lathes
The other categories of semiautomatic and automatic lathes are :

Vertical turret
lathe
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Special purpose lathes
Non conventional type, i.e., flexibly automatic CNC lathes, turning
centre etc.
(a) Semiautomatic lathes
The characteristic features of such lathes are ;
some major auxiliary motions and handling operations like bar
feeding, speed change, tool change etc. are done quickly and
consistently with lesser human involvement
the operators
need lesser
skill and putting lesser effort and
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attention
suitable for batch or small lot production
costlier than centre lathes of same capacity.
Capstan and Turret lathes
The semiautomatic lathes, capstan lathe and turret lathe are very similar in
construction, operation and application. Fig. 4.7.1 schematically shows the
basic configuration of capstan lathe and Fig. 4.7.2 shows that of turret lathe.
Fig. 4.7.1
Schematic configuration of capstan lathe.
Guide rod
Fig. 4.7.2 Schematic configuration of turret lathe.

In contrast to centre lathes, capstan and turret lathes
are semiautomatic
possess an axially movable indexable turret (mostly hexagonal) in
place of tailstock
holds large number of cutting tools; upto four in indexable tool post
on the front slide, one in the rear slide and upto six in the turret (if
hexagonal) as indicated in the schematic diagrams.
are more productive for quick engagement and overlapped
functioning of the tools in addition to faster mounting and feeding of
the job and rapid speed change.
enable repetitive production of same job requiring less involvement,
effort and attention of the operator for pre-setting of workspeed
and feed rate and length of travel of the cutting tools
are relatively costlier
are suitable and economically viable for batch production or small
lot production.
There are some differences in between capstan and turret lathes such as,
Turret lathes are relatively more robust and heavy duty machines
Capstan lathes generally deal with short or long rod type blanks
held in collet, whereas turret lathes mostly work on chucking type
jobs held in the quick acting chucks
In capstan lathe, the turret travels with limited stroke length within a
saddle type guide block, called auxiliary bed, which is clamped on
the main bed as indicated in Fig. 4.7.1, whereas in turret lathe, the
heavy turret being mounted on the saddle which directly slides with
larger stroke length on the main bed as indicated in Fig. 4.7.2
One additional guide rod or pilot bar is provided on the headstock of
the turretPDFZilla
lathes as shown
Fig. 4.7.2, to ensure rigid axial travel of
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the turret head
External screw threads are cut in capstan lathe, if required, using a
self opening die being mounted in one face of the turret, whereas in
turret lathes external threads are generally cut, if required, by a
single point or multipoint chasing tool being mounted on the front
slide and moved by a short leadscrew and a swing type half nut.
Fig. 4.7.3 and Fig. 4.7.4 are showing the pictorial views of a typical capstan
lathe and a horizontal turret lathe respectively.
Fig. 4.7.3 Pictorial view of a capstan lathe
Ram type turret lathes, i.e., capstan lathes are usually single spindle and
horizontal axis type. Turret lathes are also mostly single spindle and
horizontal type but it may be also
Vertical type and
Multispindle type
Some more productive turret lathes are provided with preoptive drive which
enables on-line presetting and engaging the next work-speed and thus help in
reducing the cycle time.
Ramp type turret lathes, i.e., capstan lathes are usually single spindle and
horizontal axis type. Turret lathes are also mostly single spindle and
horizontal type but itPDFZilla
may be also - Unregistered
Vertical type and
Multi-spindle type
Some more productive turret lathes are provided with pre-optive drive which
enables on-line presetting and engaging the next work-speed and thus help in
reducing the cycle time.
Multi-spindle Vertical Turret lathe
Fig. 4.7.4 Pictorial view of a turret lathe.

Multiple spindle Vertical Turret lathe
Turret lathes are mostly horizontal axis single spindle type. The multiple
spindle vertical turret lathes are characterised by :
Suitably used for large lot or mass production of jobs of generally ;
chucking type
relatively large size
requiring limited number of machining operations
Machine axis
vertical for
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lesser floor space occupied
easy loading and unloading of blanks and finished jobs
relieving the spindles of bending loads due to job
weight.
Number of spindle four to eight.
Fig. 4.7.5 visualise the basic configuration of multiple spindle vertical turret
lathes which are comprised mainly of a large disc type spindle carrier and a
tool holding vertical ram as shown.
Such vertical turret lathes are of three categories :

Parallel processing type :
The spindle carrierPDFZilla
remains stationary.
Only the tool slides move with cutting
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tools radially and axially. Identical jobs (say six) are simultaneously mounted
and machined in the chucks parallely at all stations each one having same set
of axially and / or radially moving cutting tools.
Loading
unloading station
Fig. 4.7.5 Basic configuration of multispindle automatic vertical lathe
Progressively processing type :
The spindle carrier with the blanks fitted in the chucks on the rotating spindle
is indexed at regular interval by a Geneva mechanism. At each station the job
undergoes a few preset machining work by the axially and / or radially fed
cutting tools. The blank getting all the different machining operations
progressively at the different work stations is unloaded at a particular station
where the finished job is replaced by another fresh blank. This type of lathes
are suitable for jobs requiring large number of operations.
Continuously working type :
Like in parallel processing type, here also each job is finished in the
respective station where
it was loaded.
The set of cutting tools, mostly fed
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only axially along a face of the ram continuously work on the same blank
throughout its one cycle of rotation along with the spindle carrier. The tool ram
having same tool sets on its faces also rotate simultaneously along with the
spindle carrier which after each rotation halts for a while for unloading the
finished job and loading a fresh blank at a particular location. Such system is
also suitable for jobs requiring very few and simple machining operations.
Hydraulic copying (tracer controlled) lathes
Jobs having steps, tapers and / or curved profiles, as typically shown in Fig.
4.7.6, are conveniently and economically produced in batch or lot in
semiautomatically operated
tracer- controlled
hydraulic copying lathe. The
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movement of the stylus along the template provided with the same desired
job-profile) is hydraulically transmitted to the cutting tool tip which replicates
the template profile.
Fig. 4.7.6
(b)
A typical job suitable for copy turning.
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General Purpose
Automatic-lathes
Automatic lathes are essentially used for large lot or mass production of small
rod type of jobs. Automatic lathes are also classified into some distinguished
categories based on constructional features, operational characteristics,
number of spindles and applications as follows
Single spindle
Automatic cutting off lathes
Automatic (screw cutting) lathe
Multispindle automatic lathe
Automatic cutting off lathe

These simple but automatic lathes are used for producing short work pieces
of simple form by using
few crossfeeding
tools. In addition to parting some
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simple operations like short turning, facing, chamfering etc. are also done.
The general purpose single spindle automatic lathes are widely used for
quantity or mass production (by machining) of high quality fasteners; bolts,
screws, studs etc., bushings, pins, shafts, rollers, handles and similar small
metallic parts from long bars or tubes of regular section and also often from
separate small blanks.
Fig. 4.7.7 shows a typical single spindle automatic lathe.
Unlike the semiautomatic
lathes, single
spindle automats are :
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preferably and essentially used for larger volume of production i.e.,
large lot production and mass production
used always for producing jobs of rod, tubular or ring type and of
relatively smaller size.
run fully automatically, including bar feeding and tool indexing, and
continuously over a long duration repeating the same machining
cycle for each product
provided with upto five radial tool slides which are moved by cams
mounted on a cam shaft
of relatively smaller size and power but have higher spindle speeds
Fig. 4.7.7
A typical single spindle automatic lathe.
The characteristics and applications of these single spindle automatic lathes

are :
In respect of application :
Used for lot or mass production of thin slender rod or tubular jobs, like
components of small clocks and wrist watches, by precision machining;
o Job size (approximately)
Diameter range 2 to 12 mm
Length range 3 to 30 mm
Dimensional accuracy and surface finish almost as good as provided by
grinding
In respect of configuration
and operation
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The headstock travels enabling axial feed of the bar stock against the
cutting tools as indicated in Fig. 4.7.8
There is no tailstock or turret
High spindle speed (2000 10,000 rpm) for small job diameter
The cutting tools (upto five in number including two on the rocker arm)
are fed radially
Drilling and threading tools, if required, are moved axially using
swivelling device(s)
The cylindrical blanks are prefinished by grinding and are moved
through a carbide guide bush as shown.
Fig. 4.7.8
Basic principle of Swiss type automatic lathe.
Multispindle automatic lathes
For further increase in rate of production of jobs usually of smaller size and
simpler geometry. Multispindle automatic lathes having four to eight parallel
spindles are preferably used. Unlike multispindle turret lathes, multispindle
automatic lathes ;
are horizontal (for working on long bar stocks)
work mostly on long bar type or tubular blanks
Multiple spindle automats also may be parallel action or progressively working
type. Machining of the inner and outer races in mass production of ball
bearings are, for instance, machined in multispindle automatic lathes.
(ii)
KinematicPDFZilla
Systems And
Working Principles Of Semi
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Automatic And Automatic Lathes
The kinematic systems and basic principles of working of the following

general purpose semi-automatic and automatic lathes of common use have
been visualised and briefly discussed here :
(a) Semi-automatic lathes :
Capstan and single spindle turret lathe
Hydraulic copying lathe
(b) Automatic lathes
Single spindle automatic (screw cutting) lathe
Kinematic system and working principle of capstan lathe
Like general configurations and applications, the basic kinematic systems are
also very similar in capstan lathes and turret lathes (particularly single spindle
bar and horizontal types) in respect of their major functions, i.e.,
bar feeding mechanism
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turret PDFZilla
moving and indexing
speed and feed drives
Bar feeding mechanism of capstan lathe
Fig. 4.7.9 typically shows the kinematic arrangement of feeding and clamping
of bar stock in capstan lathes.
The bar stock is held and tightly clamped in the push type spring collet which
is pushed by a push tube with the help of a pair of bell-crank levers actuated
by a taper ring as shown in Fig. 4.7.9. Bar feeding is accomplished by four
elementary operations;
unclamping of the job by opening the collet
bar feed by pushing it forward
clamping of the bar by closing the collet
free return of the bar-pushing element
After a job is complete and part off, the collet is opened by moving the lever
manually rightward to withdraw the push force on the collet. Further moving of
the lever in the same direction causes forward push of the bar with the help of
the ratchet paul system
shown. After
the projection of the bar from the collet
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face to the desired length controlled by a pre-set stop stock generally held in
one face of the turret or in a separate swing stop, the lever is moved leftward
resulting closing of the collet by clamping of the barstock. Just before
clamping of the collet, the leftward movement of the lever pushes the bar
feeder (ratchet) back freely against the paul.
Turret indexing mechanism in capstan and turret lathes
Turret indexing mechanism of capstan and single spindle turret lathe is
typically shown schematically in Fig. 4.7.10.
The turret (generally hexagonal) holding the axially moving cutting tools have
the following motions
to be controlled
mechanically and manually ;
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forward axial traverse comprising;
quick approach manually done by rotating the pinion as
shown
slow working feed automatically by engaging the clutch
stop at preset position depending upon the desired length
of travel of the individual tools
o quick return manually done by disengaging the clutch and
moving the turret back
o indexing of the turret by 60o (or multiple of it) done manually by
further moving the turret slide back.
Fig. 4.7.9 Typical bar feeding mechanism in capstan lathe.
Just before indexing at the end of the

withdrawn by the lever which is lifted at
against the hinged wedge as indicated in
travel of the turret slide causes rotation of
return stroke, the locking pin is

its other end by gradually riding
Fig. 4.7.10 (a). Further backward
the free head by the indexing pin
and lever as indicated in Fig. 4.7.10 (b). Rotation of the turret head by exact
angle is accomplished by insertion of the locking pin in the next hole of the six
equispaced holes. After indexing and locking, the turret head is moved
forward with the next
cutting tool
at its
front face when the roller of the lever
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returns through the wider slot of the wedge without disturbing the locking pin
as indicated in the figure. The forward motion of the turret head is
automatically stopped when the set-screw corresponding to the working tool is
arrested by the mechanical stop. The end position and hence length of travel
of the tool is governed by presetting the screw. There are six such screws,
each one corresponds with particular face or tool of the turret. The drum
holding those equispaced six screw with different projection length is rotated
along with the indexing (rotation) of the turret head by a pair of bevel gears
(1:1) as indicated in Fig. 4.7.10 (a). The bottom most screw, which
corresponds with the tool on the front face of the turret, when hits or touches
the stop, the turret
movement is
stopped either manually by feeling or
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automatically by disengaging the clutch between the feed rod and the turret
slide.
stop
(a) sectional view
(b) top (inner) view

Fig.4.7.10
Turret indexing in capstan and turret lathe.
Kinematics and working principle of hydraulic copying lathe
Hydraulic drive is often preferably used in some machine tools for smooth
motions without jerk and noise, self lubrication, flexible transmission system
and stepless variation in speed and feed despite the limitations like larger
space requirement, oil leakage, difficult maintenance etc.
Fig. 4.7.11 typically shows the circuitry of a hydraulically driven (tool travel)
drilling machine. The direction and length of travel of the drilling head fitted on
the moving piston are controlled by movement of the spool of the direction
control valve which is actuated by the pilot valve and governed by the
electromechanical stop as indicated in the figure. The rate of travel of the drill
head i.e., the feed rate is governed by the throttle or metre controlling valve
which is again controlled
by a template
like cam and a follower coupled with
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the spool of the throttle valve as shown in Fig. 4.7.11. To keep feed rate
constant irrespective of the working force on the piston, a pressure reducing
valve is provided prior to the throttle valve. The pressure reducing valve helps
keep its exit pressure i.e., input pressure of the throttle valve fixed to a preset
value irrespective of the input pressure of the pressure reducing valve which
varies with the working load on the drill piston. Constant pressure difference
keeps constant fluid flow rate through the throttle valve resulting constant feed
rate irrespective of the cutting force.
Fig. 4.7.11 Circuitry and kinematic system of hydraulically

driven machine tool
Fig.4.7.12 schematically shows the principle of typical hydraulic copying lathe.

The cross feed is controlled, under fixed longitudinal feed, hydraulically. When
the stylus moves in the transverse direction slightly (by say x) due to slope
or profile in the fixed
template, theports
open enabling the high pressure fluid
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enter in the lower chamber. Since the piston is fixed, the sliding cylinder
holding the cutting tool will start moving down. When the tool also retracts by
x the ports get closed. This way the incremental or discrete motion of the
stylus is replicated by the tool tip resulting true copying of the profile from the
template to the job.
Fig.4.7.12
Principle of hydraulic copy turning.
Kinematic system and working principle of automatic lathes of

common use.

This general purpose and widely used autmatic lathe is also known as single
spindle automatic screw cutting lathe (ssASCL) because such lathes were
introduced aiming mainly mass production of fasteners having screw threads.
Fig. 4.7.13 schematically shows the typical kinematic system of single spindle
automat. The major characteristic functions that are automatically
accomplished in sequence and proper synchrony in such lathes are :
spindle speed change magnitude and direction of
rotation
bar feeding
transverse tools feeding
turret indexing and travelling
Single revolution clutch
Cylindrical cam
spindle
collet
turret
Finger collet
barstock
clutch
Tool slide
Cam follower
Trip dog
II
Cam
Trip dog
I
clutch
Fig. 4.7.13 Typical kinematic system of single spindle automatic lathe.
Change of spindle speed

Repetitive production in large volume and limted ranges of job tool materials
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and job diameter PDFZilla
necessitate a small
number of spindle speeds in automatic
lathes unlike centre lathes. However, at least two speeds, high and low (for
threading etc.) and provision of reversal of those speeds need to be provided
in automatic lathes. Power and speed are transmitted from the motor to shaft
I through belt-pulley and a speed gear box (SGB) if required as can be seen
in Fig. 4.7.13. The two gear loosely mounted on shaft I are in mesh with two
gears fixed on shaft II. Rotations are transmitted from shaft II to the spindle by
two pairs of chain and sprockets as indicated in the kinematic diagram (Fig.
4.7.13). The two sprockets are loosely mounted on the spindle and
simultaneously rotate at the same speed, low or high, but in opposite
directions. The spindle is made to rotate at high or low speed and clockwise
or anticlockwise by engaging the clutches on shaft I and the spindle
respectively. The clutch is shifted by a lever and cylindrical cam which is
rotated at the desired moment by one revolution only with the help of a single
revolution clutch which is again triggered by a trip dog controlled by the

camshaft as shown in the figure.
Bar feeding mechanism

For feeding the barstock to a desired projection length after completing
machining and parting a job, first the collet is opened by withdrawing the push
force by moving the taper ring outward by a lever automatically with the help
of the cylindrical cam. Then the cam at the other end of the cylinder pushes
the rod forward using the lever, a slide and finger collet. Next half of the
rotation of that cylindrical cam accomplishes clamping collet and return of the
finger collet by moving the levers in opposite direction.
Here again, the cylindrical cam is rotated by only one revolution by actuating
another single revolution clutch at the proper moment by a trip dog as
indicated in the figure.
Transverse tool feeds

The radially moving cutting tools (upto five) are fed sequentially at preset
timings and desired length and rate of travel by individual cams mounted on
the cam shaft which rotates slowly with one rotation for one machining cycle
i.e., one product.
All the single revolution clutches are mounted on the auxiliary shaft which
positively roates at a constant speed of 120 rpm. Rotation is transmitted from
that to the cam shaft through speed reduction and a feed gear box (FGB) to
vary the cam-shaft speed depending upon the cycle time for each job.
Feed motions of the axially fed cutting tools mounted on the turret
The end points, length and rate of travel of the six tools on the turret are
governed by a single plate cam having six lobes corresponding to the tools in
the turret as shown in the figure. The rotational speed of that cam is kept
same as that of the cam shaft.
Turret indexing mechanism
The hexagonal turret is rotated (for indexing) by a Geneva mechanism where

a Geneva disc having six radial slots is driven by a revolving pin. Before
starting rotation, the locking pin is withdrawn by a cam lever mechanism
shown in the diagram. The single rotation of the disc holding the indexing pin
is derived from the auxiliary shaft with the help of another single revolution
clutch as indicated
Kinematic system and operating principle of Swiss type automatic

lathe
The kinematic diagram of typical Swiss type automatic lathe is schematically

shown in Fig. 4.7.14.
Both the high speed of the spindle and the low speed of the cam shaft are
derived from the motor as indicated in the diagram. All the cutting tools
mounted on the transverse slides are travelled to desired depth and at desired
feed rate by a set of plate cams mounted on the cam shaft. The headstock
with the spindle having the barstock clamped in it is moved forward and
returned at desired feed rate by a set of plate cams mounted on the camshaft
as shown.
Fig. 4.7.14
Kinematic system of Swiss type automatic lathe.
Feeding of the bar, after completion and parting of a job is done sequentially
by
Opening the collet by shifting the taper ring by a cam as shown
Pushing the bar, against the last working tool, by a gravitational
force
Collet clamping by return of the ring
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(iii) Process Planning
And
Tool Layout For Machining A
Product In Semi-Automatic And Automatic Lathes.
The procedural steps to be followed in sequence for batch or lot production of
a job by machining in semi-automatic and automatic general purpose machine
tools are :
(a) Thorough study of the job to be produced: in respect of :
volume of production, i.e., number of pieces of the specific
job to be produced
material and its properties
size and shape
surfaces to be machined
required dimensions with tolerances and surface finish
end use of the product
(b) Selection of machine tool (after studying the job): in respect of ;

type
size
precision
kind and degree of automation
(c) Selection of blank (based on job and machine selected): in respect of;
bar chucking or housing type
preformed by; casting, forging, rolling etc.
if bar type; cross section (circular, tubular, square, hexagon
etc.)
nominal size based on largest dimensions and availability
preformed by hot working or cold working
(d) Identification and listing of the elementary machining operations
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required, depending
upon the
product configuration
(e) Combine elementary machining operations as much as possible for
saving time
(f) Sequence the operations (after combining)
(g) Select cutting tools: in respect of;
type
material
size
geometry
availability
depending upon the machining operations (after combining) and work
material
(h) work scheduling or preparation of the instruction sheet or operation
chart giving column-wise :
description of the machining work to be done in sequence
cutting tools : type and location
speed and feed for each operation
length of travel of the tools
cutting fluid application;
o yes or not required
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o type of cutting
fluid
(i) Tool layout : schematically showing the type and configuration of the
cutting tools and their location and mounting.
A typical tool layout for a particular job being machined in a single spindle
automatic lathe is schematically shown in Fig. 4.7.15.
Fig. 4.7.15 Tool layout for a typical job in single automatic lathe.
(Iv) Case Study : As An Example
Task (say) : 2500 pieces of hollow hexagonal headed mild steel

bolts
, as shown -in Unregistered
Fig. 4.7.16, are to be produced by
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machining.
Machine tool selected :

Single spindle automatic lathe for
Lot production (for smaller volume of production capstan lathe is
better)
Circular bar type job
Common machinable material
Simple machining operations required
Fig. 4.7.16 Shape and dimension of the specific job

Blank selected :
Hot rolled hexagonal section mild steel bars for;
saving machining of the hexagonal head portion
the hexagonal head is of standard size which is available
job size reasonable for single spindle automatic
not being precision job
Elementary machining operations identified and listed :
Facing
Centering
Chamfering
(1) front - Unregistered
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Chamfering (2) middle portion
Chamfering (3) bolt head
Rough turning (1) to make circular from hexagon
Rough turning (2) to reduce diameter to 12 mm
Finish turning to 10
Drilling
Grooving (forming)
Thread cutting
Initial parting
Parting
Combining elementary operations

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combining
operations
to be done by a compound tool in a
single travel from one tool position
paralleling or overlapping operations to be done by different
tools moving in different directions.
The listed elementary operations can be combined and sequenced as follows
:
1
2
3
4
5
6
7
Rough turning (1), initial parting and rear chamfering (3)

Rough turning (to 12) and drilling and centering (for the next job)
Finish turning (10)
Spot facing
and front chamfering
(1)
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Grooving and central chamfering (2)
Thread cutting
Parting
Scheduling operation chart indicating tools and tool positions and

machining conditions.
N = spindle speed (rpm), s = feed (mm/rev), L = tool travel, CF = cutting fluid

HT (1) = hexagonal turret face 1, RS = Rear slide, FS = front slide, VS =
vertical slide
Table 1 : Scheduling; operation chart
Sl.
S
L
CF
Operation
Tool
Tool
N
No.
position
1
Stop stock & bar Stop
HT (1)
N
feed
2
Rough turning (1)
Turning tool HT(2)
640 0.10
30
Y
Initial parting
Formed
RS
0.05
6
Y
Chamfering (3)
Parting tool
3
Rough parting (2)
Turning tool
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HT(3)
640 0.10
50
Y
Drilling (6) PDFZilla
centering
4
Finish turning
Turning tool HT(4)
640 0.05
25
Y
5
Spot facing
Compound HT(5)
640 0.05
5
Y
Chamfering (1)
tool
6
Grooving
Form tool
FS
640 0.05
10
Y
Chamfering (2)
7
Threading
Solid die
HT(6)
56
2
20
Y
8
Parting
Parting tool VS
640 0.05
12
Y
]
]
Tool layout
The possible tool
layout made
on the scheduling made for the
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based
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product is schematically shown in Fig. 4.7.17.
Fig. 4.7.17 Tool layout for machining the given job

in single spindle automatic lathe
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
ME2258- MANUFACTURING TECHNOLOGY-II
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LABORATORY
MANUAL
FOR IV SEMESTER MECHANICAL
(FOR PRIVATE CIRCULATION ONLY)
ANNA UNIVERSITY CHENNAI
DEPARTMENT
OF MECHANICAL
ENGINEERING
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DR. NAVALAR NEDUNCHEZHIYAN COLLEGE OF ENGINEERING
THOLUDUR 606 303, CUDDALORE DISTRICT
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
LIST OF EQUIPMENTS
1. Centre Lathe with accessories 2
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2. Turret and capstan
lathes 2 Unregistered
3. Horizontal milling machine 1
4. Vertical milling machine 1
5. Surface grinding machine 1
6. Cylindrical grinding machine 1
7. Shaper 2
8. Slotter 1
9. Planner 1
10. Radial drilling machine 1
11. Tool dynamometer 1
12. Gear hobbing machine 1
13. Tool makers microscope
1
PDFZilla
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UNIVERSITY PRACTICAL EXAMINATION
Allotment of Marks
Internal Assessment
Practical Examination
Total
= 20 marks
= 80 marks
=100 marks
INTERNAL ASSESSMENT [20 Marks]

Staff should maintain the assessment Register and the Head of the Department
should monitor it.
SPLIT UP OF INTERNAL MARKS
Observation = 3 marks
Record Note = 7 marks
Model Exam = 5 marks
Attendance = 5 marks
_________
Total = 20 marks
___________
UNIVERSITY
Marks)
PDFZillaEXAMINATION(80
- Unregistered
The examination will be conducted for 100 marks. Then the marks will be
converted to 80 marks.
Split up of Practical Examination Marks
Aim and Procedure
Job Finishing
Viva -Voce
Total
= 20 marks
= 70 marks
= 10 marks
___________
= 100 marks
___________
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
GENERAL INSTRUCTIONS FOR LABORATORY CLASSES
PDFZilla
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Enter Lab with
CLOSED FOOTWEAR
Boys should TUCK IN the shirts
Students should wear uniform only
LONG HAIR should be protected, let it not be loose especially near

ROTATING MACHINERY.
Any other machines/ equipments should not be operated other than the
prescribed one for that day.
POWER SUPPLY
to your test-table
should be obtained only through the LAB
PDFZilla
Unregistered
TECHNICIAN
Do not LEAN and do not be CLOSE to the rotating components.
TOOLS, APPARATUS & GUAGE Sets are to be returned before leaving

the Lab.
HEADINGS & DETAILS should be neatly written

1. Aim of the experiment
2. Apparatus / Tools/ Instruments required
3. Procedure / Theory / Algorithm / Program
4. Model Calculations
5. Neat Diagram/ Flow charts
6. Specifications/ Designs details
7. Tabulation
8. Graph
9. Result/ Discussions
Before doing the experiment, the student should get the circuit/ Program
approval by the
FACULTY-IN-CHARGE
Experiment date should be written int the appropriate place
After completing the experiments, the answer to the VIVA-VOCE Questions
should be neatly written in the workbook
Be PATIENT, STEADY, SYSTEMATIC, & REGULAR
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
ME2258 MANUFACTURING TECHNOLOGY LABORATORY II

LTPC
0032
1. Two or more measurements in metal cutting Experiment [Example: Shear angle,
cutting force, Tool Wear etc.]
2. One or more exercises in Shaper, Slotter, Planner, Drilling, Milling machines
[Example: Round to Square, Dovetail in shaper, internal keyway cutting in Slotter,
Round to square in Planner, Drilling, reaming and tapping in Drilling machine, Gear
milling and key way milling in Milling machine]
3. Two or more exercises in Grinding/Abrasive machining [Example: Surface
grinding, cylindrical grinding]
4. Two or more exercises in assembly of machined components for different fits.

[Example: parts machined using lathes, shapers, drilling, milling and grinding
machines etc.]
5. One or more exercises in Capstan or Turret lathes.
6. One or more exercises in Gear machining. [Example: Gear milling, Gear Hobbing
etc.]
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
CONTENTS
S. No.
L1ist of experiments
Page No.
Making square from round rod using Shaper
15
Drilling, Tapping & Reaming in Radial drilling

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machine
18
Making dovetail from C.I. Block using Shaper
21
Making Internal key way cutting using Slotter
24
Making spur gear using Milling machine
27
Machining for press fit
29
Grinding to the required accuracy by Surface

grinding
32
8
9
34
Machining for clearance fit
36
Beyond the syllabus

10
Making bevel gear
39
11
Straddle milling
42
12
PDFZilla
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Machine a cast
iron bevel gear
Question bank
45
48
Signature of the Lab In charge

(N.GANESH)
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
STUDY OF MILLING MACHINE

AIM
To study the working principle of milling machine.
MILLING MACHINE
A milling machine is one of the most important machine tools. It remove metals
from the work piece it fed against rotating cutting tool used. In milling machine it has
multiple cutting edge which removes metal at a faster rate milling machine point of
application in the production of gears and cutting tool.
TYPES OF MILLING MACHINE
The milling machinePDFZilla
classified as follows:
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1)Column and knee type
2)Horizontal milling machine
a)vertical milling machine
b)Universal milling machine
3)Bed type milling machine
4)planer type
PRINCIPLE OPERATIONS AND PARTS OF A MILLING MACHINE
The principle parts of the column and knee type milling machines are as follows:
BASE
It is a foundation of machine. It carries the column and give strength and rigidity to
the machine it serves as the reservoir for cutting fluid.
COLUMN
It is the main supporting frame movement vertically on the base.
KNEE
It projects from column and sides up and down on the vertical guide ways of column
in turns support the saddle and knee table. The vertical position of the knee can be
PDFZilla
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adjusted by an elevating
screw provided
at the bottom of the knee.
SADDLE
It support the table and can be adjusted transversely on the guide ways provided on
the top surface of the knee. These guide ways are exactly at 90o to the face of the
column.
TABLE
It slides on the guide ways of saddle and travels longitudinally in a horizontal plane.
It supports the work piece and other features on it.
OVERHANGING ARM
It is mounted on the top of the column in turn extend beyond the column face.
ARBOR
It may be considered as extension of the spindle.
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
MILLING OPERATIONS:
The different types of operations that can be performed in milling machine are given
below:
Plain milling
Angular milling
Face and side milling
Gang milling
End milling
Straddle milling.
PLAIN MILLING
It is a method of producing flat surface. It is parallel to the axis of the cutter. It is
held in the milling arbor.
FACE AND SIDE MILLING
It is a method of producing flat surface right angle to the axis of cutter and in turn in
this method large flat surface can be obtained.
GANG MILLING
It is a method of milling by using two or more cutters arrangement together on one
arbor. It is used the similar pieces must be made.
ANGULAR MILLING
It is a method if producing a flat surface at an angle to the axis of the cutter. Angular
surface are milled by tilting the spindle.
END MILLING
It is a method of milling slots keyway surface by end mills and also it is used in
milling cutters.
STRADDLE MILLING
It is a method of milling to parallel slides at a work by employing to side milling.
SHAPER
PRINCIPLE OF OPERATION:
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The shaper which isPDFZilla
having a reciprocating
type of machine tool with single point
cutting tool used to produce flat surface. The flat surface may be horizontal, vertical
or inclined. It has three important parts such as
1.Table, 2.Tool head, 3. Ram
The tool head is fitted on the front on the ram while the job is rightly fixed on the
table. The tool is mounted on the tool post or head. The ram reciprocates along with
the tool to remove the metal in the forward stroke called as cutting stroke. The tool
does not cut the metal in the return stroke called as idle stroke. Therefore one pass is
nothing but the combination of one forward and return stroke or one cutting and one
idle stroke. So we are in a position to reduce idle stroke time by increasing the speed
of the return stroke. That is the speed of cutting stroke will be lower than the speed of
the return stroke.
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
10
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
CLASSIFICATION OF SHAPERS:
Generally, shapers are classified as follows
1. According to the type of driving mechanism
a. crank drive type
b. Whitworth driving mechanism type
c. Hydraulic drive type
2. According to the position of ram
a. Horizontal shaper
b. Vertical shaper
c. Travelling head shaper
3. According to the table design
a. standard or plain
shaper
PDFZilla
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b. Universal shaper
4. According to the type of cutting stroke
a. Push out type
b. Draw cut type
SHAPER SPECIFICATIONS:
Generally, the specifications of a typical shaper are listed below:
1. Maximum length of stroke.
2. Maximum crosswise movement of the table.
3. Maximum vertical adjustment of the table.
4. Type of driving mechanism
5. Power of the motor
6. Speed and feed available
7. Type of shaper-plain or universal
8. Floor space required
9. Total weight of the shaper.
10. Ratio of cutting stroke time to return stroke time.
UPRIGHT OR PILLAR DRILLING MACHINE

Upright drilling machine is a higher capacity version of sensitive drilling
machine. It is a stationary floor mounted drilling machine. It is used for
medium sized work pieces having medium speed. The spindle head and the
drive arrangement in this machine are similar to a sensitive drilling
machine.
BASE:
It is a supporting member on which all the parts of the machine are
mounted. It is generally made of cast iron.
11
Dr.NNCE
MECH/IV SEM
12
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
13
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
COLUMN:
It is a vertical member mounted on the base and carries table, Spindle and pulley
drive mechanism. It should be very strong to take the heavy cutting forces. It may be
round type or box type.
TABLE:
The worktable is attached to the column by means of clamping screw. It has T-slots
on the surface to hold the work pieces. It can move vertically along the column and
can be adjusted radially about the column.
SPINDLE HEAD AND DRIVE MECHANISM:
The spindle head is mounted
on the top
of the vertical column. It is driven by a
PDFZilla
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motor through belt and step cone drive.
RESULT:
Thus the tools of Special Machines were studied in this experiment.
14
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Experiment Number: 1
Title of the exercise
Date of the exercise
: Making Square from round rod using Shaper

:
OBJECTIVE OF THE EXEPERIMENT

To generate a square from rounded on the given work piece in a shaper
machine.
FACILITIES REQUIRED AND PROCEDURE
a. Facilities/material required to do the exercise:
S.No. Facilities/Material
PDFZillarequired
- Unregistered
1.
Punching machine
2.
Steel rule
3.
Hammer
4.
Shaper tool
5.
Try Square
Quantity
1
1
1
1
1
bProcedure for doing the exercise:

Steps
1.
The job was checked to the given dimensions.
2.
The square was scribed in the outer circle of diameter of 50mm and
punching was done.
3.
The job was attached in the vice of a shaper
4.
The job was checked for perpendicular dimension.
5.
Then the square from round was obtained in the shaper
6.
The work piece was removed and burns are removed with accuracy
was checked.
15
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
c. Figure
d.Result
Thus the square from round was performed on the given dimension in a shaper
machine with the required dimensions.
16
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Viva questions
PDFZilla
Unregistered
1. What are the specifications
of shaper?
Maximum length of the stroke, power of the motor, floor space required, total
weight of the shaper.
2. Define cutting stroke?
The ram reciprocates along with the tool to remove the metal in the forward
stroke called cutting stroke.
3. What are the types of shaper?
Horizontal shaper, vertical shaper, travelling shaper.
4. What are the main components of shaper?
Base, column, cross rail, table.
5. Why the time for forward stroke is greater than return stroke?
Unregistered
The metal is PDFZilla
removed in the -forward
stroke, but no metal is cut during the
return stroke. So the time for forward stroke is high.
17
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
: Drilling, Tapping, and Reaming in Radial drilling machine

:

To make drilling, tapping and Reaming in the given work piece for the
required dimensions.
S.No.
1.
2.
Facilities/Material required
Steel rule
Flat file(rough and smooth)
Quantity
1
1
3.
Drill bit(8 mm, 10 mm, 10.5 mm)
4.
Reaming tool
5.
Try square
b.Procedure for doing the exercise:

Steps
1.
The work piece was fitted in the vice and filed to the required
dimensions.
2.
The squareness of the work piece was checked.
3.
Drawing punches were made for various drills.
4.
The job was fitted on the radial drilling machine.
5.
The 20 mm ,10.5 mm,8 mm, 6.5 mm-drill bit were used for drilling in
- Unregistered
the PDFZilla
required place and
drilling operation were made on the work piece.
6.
Reaming was done on the 8 mm hole using the Reaming tool size of 8
mm diameter. And tapping was done on the 6.5 mm drill and 10.5 mm
drill. The work piece was removed from the radial drilling machine.
18
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
c. Figure
d.Result
Thus the given job was drilled, tapped and Reaming to the required
dimensions.
19
Dr.NNCE
Viva questions:
MECH/IV SEM
MFT Lab-II LM
1. What are the components in radial drilling?

Base, column, radial arm, drill head.
2. What is meant by tapping?
Tapping is the operation of cutting internal threads in hole by cutting tool .
3. What is meant by counter boring?
The operation of enlarging of end of hole cylindrically is known as counter
boring.
4. What is meant by counter sinking?
The operation of making a cone shaped enlargement of end a hole known as
counter sinking.
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of radial
drilling machine?
Maximum size of drill head, Maximum spindle travelling, Power input of the
machine(H.P), Floor space required m2 .
20
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Dove tail machining in shaper
Date of the exercise :
To perform a dove tail fitting on the given work piece by shaper machine.
S.No.
1.
2.
3.
4.
5.
Facilities/Material
PDFZillarequired
- Unregistered
Steel rule
Scriber
Dot punch
Try square
Parting tool
Quantity
1
1
1
1
1
b.Procedure for doing the exercise:

Steps
1.
Initially the given work piece is checked for its dimensions.
2.
The dove tail surfaces are marked using scriber to given dimensions,
then punched.
3.
The job is fixed on a vice of the shaper to name external dove tail.
4.
The vertical slide of the tool head is swiveled to the required angle
from vertical position.
5.
The apron is further swiveled away from the work so that the tool will
clear
the work during
stroke.
PDFZilla
- return
Unregistered
6.
The angular down feed is given to the required depth of cut and length
of stroke is adjusted.
7.
The above procedure is respected to obtain an internal dove tail part.
8.
Then the work piece is removed and assembled for dove tail fit.
21
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
c. Figure
d. Result:
Thus the dove tail [internal and external] part were made to the given
dimensions and assembled to obtain dove tail fit assembly.
22
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Viva questions:
PDFZilla
Unregistered
of shaper?
Maximum length of the stroke, power of the motor, floor space required, total
weight of the shaper.
2. Define cutting stroke?
The ram reciprocates along with the tool to remove the metal in the forward
stroke called cutting stroke.
3. What are the types of shaper?
Horizontal shaper, vertical shaper, travelling shaper.
4. What are the main components of shaper?
Base, column, cross rail, table.
5. Why the time for forward stroke is greater than return stroke?
The metal is PDFZilla
removed in the -forward
stroke, but no metal is cut during the
Unregistered
return stroke. So the time for forward stroke is high.
23
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
: Internal key way cutting in slotter

:

To cut Internal key to the required dimensions in slotting machine to
accommodate key.

a. Facilities/material
required
do the exercise:
PDFZilla
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S.No. Facilities/Material required
1.
Steel rule
2.
Tipped tool
3.
Scriber
4.
Dot punch
5.
Anvil
6.
Surface gauge
7.
Steel rule
Quantity
1
1
1
1
1
1
1
b. Procedure for doing the exercise:

Steps
1.
The dimensions of the given work piece are checked as per the
requirements.
2.
Key and key way dimensions in proportionate to shaft diameter found.
3.
Key way dimensions are marked over the shaft then permanent mark
are made using dot punch.

4.
Key way is machined in slotter machine to the required dimensions.
24
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
c. Figure
d.Result:
Thus the internal key way to the required dimension is cut in slotter.
25
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Viva questions:
1. Write any six specifications in slotter machine?
PDFZilla
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Maximum stroke
length, Diameter
of rotary table, Type of drive used, Power
rating motor, Net weight of machine, Floor area required.
2. What are the uses of slotter?
Key way, Bit tool, Heavy tool holders.
3. Why the time for forward stroke is greater than the return stroke?
In slotter, down stroke is the cutting stroke. The return stroke is idle. To
reduce the idle return time, quick return mechanism is used.
4. What is the difference between shaper and slotter?
PDFZilla
Sl.No
Shaper - Unregistered
Slotter
1.
Rotary table along with tools will remove.
Slides will remove to
perform slotting.
2.
Vertical shaper is not fixed in the vertical plane. Slotter is fixed in the
vertical plane.
5. What are the main components in slotting machine?
Base, Column, Saddle, Rotary table, Ram and tool head.
26
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Spur Gear milling


To perform a spur gear milling operation in milling machine.
Quantity
1.
Steel rule
1
2.
Milling cutter
1
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3.
Spanner
1
4.
Mandrel
1
5.
Dog carrier
1
Steps
1.
The raw blank is selected with reference to the number of teeth to be
cut.
2.
Indexing number is calculated to the position of the blank.
3.
Gear blank is mounted on mandrel in milling machine.
4.
Centering of the blank is done by upward and cross feed.
5.
The depth of the cut is calculated for the given module.
c. Figure
27
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
d. Result:
Thus the spur gear cutting is performed in a milling machine.
Viva questions:
1. What are the main components in milling machine?
Base, column, knee, saddle, table.
2. Write any six specifications in milling machine?
The table length and width, power of driving motor, spindle nose taper size,
type of milling machine, floor space and net weight.
3. What are the types of milling machine?
Plain milling machine, vertical milling machine, universal milling machine,
PDFZilla
- Unregistered
simplex milling machine,
triplex milling
machine.
4. What are the types of milling cutter?
Plain milling cutter, slide milling cutter, arbor cutters, shank cutters, face
cutters.
5. What is the purpose of indexing head?
The work piece held between centre of head stock and tail stock. Short work
pieces are held in chuck fitted to head stock spindle.
28
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Machining for press fit


To perform a machining operation for press fit in lathe machine.
1.
HSS Single point cutting tool
2.
Vernier caliper
3.
Steel rule
4.
5.
6.
Quantity
1
1
1
Chuck key
Tool post key
Drill bit socket
1
1
1

Steps
1.
The given work piece is cut into two pieces to make an assembly with
chuck key for its dimensions.
2.
The end is faced and chucked for the centering of the tool.
3.
The cutting tool is tighted by 30 for facing operation.
4.
The step turning operation is repeated in the shaft to get accurate

dimension by giving the gradual depth of cut and feeds,
The dimensions are checked by using the vernier caliper as per the
5.
specifications.
6.
ThePDFZilla
above procedure- isUnregistered
repeated with drill bit of 14 mm dia.
29
Dr.NNCE
MECH/IV SEM
c. Figure
d. Result:
Thus the job was finished and checked for assembly.
30
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Viva questions:
Unregistered
1. What is meant byPDFZilla
lathe?
Lathe is a machine which removes the metal from a piece of work to the
required shape and size.
2. Write any six specifications in lathe machine?
The length of bed, swing over bed, swing over the cross slide, width of bed,
spindle bore, spindle speed.
3. What are the main operations in lathe?
Turning, Facing, Forming, Reaming, chamfering, Boring, Knurling.
4. Why lathe bed is made up of cast iron?
To improve high strength.
5. What are the components of a lathe?
PDFZilla
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Bed, head stock,
tail stock, carriage,
feed mechanism.
31
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Grinding to the required accuracy by surface grinding
To perform a grinding operation in surface grinding machine.
1.
Steel rule
2.
Try square
3.
Vernier caliper
Quantity
1
1
1

Steps
1.
The given work piece is taken and checked for its dimensions.
2.
The job is placed on the grinding magnet at opened position.
3.
Then each face is grinded to the required accuracy by constant speed.
4.
The job is removed from the required accuracy. It is checked by using

vernier caliper and squareness is checked by using trysquare.
c. Figure
32
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
d. Result:
PDFZilla
Unregistered
Thus the square
section is grinded
to the required accuracy in grinding
machine.
Viva questions:
1. What is meant by surface grinding?
Surface grinding machines are useful to produce and finish flat and plane
surface.
2. What are the types of grinding machines?
Transverse grinding, Plunger grinding.
3. How the grinding wheel is made?
PDFZilla
- Unregistered
It is made up of
abrasive material.
4. What is the purpose of magnetic chuck?
Magnetic chuck is one type work holding devices. The chucks get magnetic
power from electro magnet.
33
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise :
To perform a cylindrical job using cylindrical grinding machine.
1.
Steel rule
2.
Vernier
caliper
PDFZilla
- Unregistered
3.
Outside caliper
4.
Surface plate
Quantity
1
1
1
1

Steps
1.
2.
The work piece is fired in between the live and dead centre and is
rotated.
3.
Machining is done by the movement of grinding wheel head into the

work piece.
4.
Remove the job and check its dimensional accuracy.
c. Figure
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Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
d. Result:
Thus the cylindrical job was done to the required accuracy in a cylindrical
grinding machine. PDFZilla Unregistered
Viva questions:
1. What is meant by surface grinding?
Surface grinding machines are useful to produce and finish flat and plane
surface.
2. What are the types of grinding machines?
Transverse grinding, Plunger grinding.
3. How the grinding wheel is made?
It is made up of abrasive material.
4. What is the purpose of magnetic chuck?
Magnetic chuck is one type work holding devices. The chucks get magnetic
power from electro magnet.
35
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Machining for clearance Fit
To perform a machining operation for clearance fit in lathe machine.
1.
HSSPDFZilla
Single point cutting
tool
- Unregistered
2.
Quantity
1
1
Vernier caliper
3.
Steel rule
1
4.
Chuck key
1
5.
Drill bit socket
1
6.
Surface gauge
1
Steps
1.
2.
In the shaft facing, turning, grooving, thread cutting operation were

done to the required dimensions.
3.
To obtain the required hole dimension pilot drill is properly fixed in

the tail stock. The drill is moved along the axis of the job to carry out
the drilling operation.
4.
External thread cutting operation is carried out to the required TPI.
5.
Finally the matching parts are fitted together to check assembly.
36
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
c. Figure
d. Result:
The jobs were finished to the required dimensions and assembly.
37
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Viva questions:
Unregistered
1. What is meant byPDFZilla
lathe?
Lathe is a machine which removes the metal from a piece of work to the
required shape and size.
2. Write any six specifications in lathe machine?
The length of bed, swing over bed, swing over the cross slide, width of bed,
spindle bore, spindle speed.
3. What are the main operations in lathe?
Turning, Facing, Forming, Reaming, chamfering, Boring, Knurling.
4. Why lathe bed is made up of cast iron?
To improve high strength.
5. What are the components of a lathe?
PDFZilla
- Unregistered
Bed, head stock,
tail stock, carriage,
feed mechanism.
38
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Making Bevel Gear
To make a bevel gear in milling machine.
1.
Horizontal
miller - Unregistered
PDFZilla
2.
Quantity
1
1
Dividing head
3.
7/8 Arbor
4.
12 Pitch No.5 in volute gear cutter
5.
Spacing collars
Steps
1.
Mount the gear blank in the chuck on the dividing head.
2.
Set the work to the cutter.
3.
Take the first cut on the gear.
4.
Finish cutting the teeth.
5.
File the surfaces of the teeth.
c. Figure
39
1
1
1
Dr.NNCE
MECH/IV SEM
d. Result:
Thus the bevel gear has make in a milling machine.
40
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Viva questions:
Unregistered
Base, column,PDFZilla
knee, saddle, table.
simplex milling machine, triplex milling machine.
cutters.
The work piece
held between centre
of head stock and tail stock. Short work
PDFZilla
- Unregistered
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Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Straddle milling
To perform straddle milling in milling machine.
1.
Horizontal
PDFZilla
2.
Quantity
1
1
Dividing head
3.
7/8 Arbor
4.
5.
Spacing collars
Steps
1.
2.
3.
4.
5.
42
1
1
1
Dr.NNCE
c. Figure
MECH/IV SEM
Straddle Milling on Flatwork
43
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
d. Result: PDFZilla Unregistered

Thus the straddle milling was performed in a milling machine.
Viva questions:
Base, column, knee, saddle, table.
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- Unregistered
The table length
and width, power
of driving motor, spindle nose taper size,
cutters.
44
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Title of the exercise : Machine a cast iron bevel gear
To machine a cast iron bevel gear in milling machine.
1.
Horizontal
PDFZilla
2.
Quantity
1
1
Dividing head
3.
7/8 Arbor
4.
5.
Spacing collars
Steps
1.
2.
3.
4.
5.
45
1
1
1
Dr.NNCE
MECH/IV SEM
c. Figure
46
MFT Lab-II LM
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
d. Result:
Thus the cast iron bevel gear is performed in a milling machine.
Viva questions:
- Unregistered
Base, column,PDFZilla
knee, saddle, table.
cutters.
47
Dr.NNCE
MECH/IV SEM
MFT Lab-II LM
Question Bank
1.
Making square from round rod using Shaper.
2.
Drilling, Tapping &Counter sinking in radial drilling

machine.
3.
Making dovetail from round rod using shaper.
4.
Making external key way cutting using slotter.
5.
Making spur gear using milling machine.
6.
Machining for press fit.
7.
8.
Grinding to-the
required accuracy by surface grinding.
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Unregistered
Grinding to the required accuracy by cylindrical grinding.
Machining for clearance fit.
9.
Beyond the syllabus
10.
Making bevel gear
11.
Straddle milling
12.
Machine a cast iron bevel gear
48

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(i) Illustrate the constructional features and uses of semiautomatic and

(i) Constructional Features And Uses Of General Purpose

capstan lathe (ram type turret lathe)

Version 2 ME, IIT Kharagpur

The other categories of semiautomatic and automatic lathes are :

Schematic configuration of capstan lathe.

Version 2 ME, IIT Kharagpur

Fig. 4.7.2 Schematic configuration of turret lathe.

Version 2 ME, IIT Kharagpur

Fig. 4.7.3 Pictorial view of a capstan lathe

Version 2 ME, IIT Kharagpur

Multi-spindle Vertical Turret lathe

Fig. 4.7.4 Pictorial view of a turret lathe.

Version 2 ME, IIT Kharagpur

Such vertical turret lathes are of three categories :

Progressively processing type :

Version 2 ME, IIT Kharagpur

Continuously working type :

A typical job suitable for copy turning.

Version 2 ME, IIT Kharagpur

Automatic cutting off lathe

A typical single spindle automatic lathe.

Version 2 ME, IIT Kharagpur

Swiss type automatic lathe

The characteristics and applications of these single spindle automatic lathes

Basic principle of Swiss type automatic lathe.

Version 2 ME, IIT Kharagpur

Multispindle automatic lathes

The kinematic systems and basic principles of working of the following

Version 2 ME, IIT Kharagpur

Fig. 4.7.9 Typical bar feeding mechanism in capstan lathe.

Just before indexing at the end of the

return stroke, the locking pin is

(a) sectional view

(b) top (inner) view

Turret indexing in capstan and turret lathe.

Version 2 ME, IIT Kharagpur

Kinematics and working principle of hydraulic copying lathe

Fig. 4.7.11 Circuitry and kinematic system of hydraulically

Version 2 ME, IIT Kharagpur

Fig.4.7.12 schematically shows the principle of typical hydraulic copying lathe.

Principle of hydraulic copy turning.

Kinematic system and working principle of automatic lathes of

Single spindle automatic lathe

Single revolution clutch

Fig. 4.7.13 Typical kinematic system of single spindle automatic lathe.

Change of spindle speed

Version 2 ME, IIT Kharagpur

revolution clutch which is again triggered by a trip dog controlled by the

Bar feeding mechanism

Transverse tool feeds

The hexagonal turret is rotated (for indexing) by a Geneva mechanism where

Kinematic system and operating principle of Swiss type automatic

The kinematic diagram of typical Swiss type automatic lathe is schematically

Version 2 ME, IIT Kharagpur

Kinematic system of Swiss type automatic lathe.

Version 2 ME, IIT Kharagpur

(b) Selection of machine tool (after studying the job): in respect of ;

Version 2 ME, IIT Kharagpur

(Iv) Case Study : As An Example

Task (say) : 2500 pieces of hollow hexagonal headed mild steel

Machine tool selected :