Me6311-Mt - 1 - Lab Manual

INDEX
S.No DATE NAME OF THE EXPERIMENT MARK SIGNATURE
10
11
12
13
14
15
16
17
Completed date:
Average Mark: Staff - in – charge
1
STUDY OF BASIC MACHINES
INTRODUCTION
Machining is the process of converting the given work piece into the required
shape and size with help of a machine tool. The most widely used machine tool is
lathe. In simple words machining is the process of removing certain material from
the work piece.
1.LATHE
Lathe is the machine tool which is used to perform several operations on the
work piece. Lathe is useful in making several parts which is further assembled to
make new machine. Hence lathe is known as “mother of machines”.
1.1 BASIC WORKING PRINCIPLE OF LATHE
In lathe, the work piece is held in the chuck, a work holding device. The cutting
tool is mounted in the tool post. The chuck is rotated by means of power. When the
chuck rotates, the work piece also rotates. The tool is moved against the rotating
work piece by giving small amount of depth of cut. The material is removed in the
form of chips. Continuous feed and depth of cut is given until the required
dimensions are obtained in the work piece.
2
1.2 TYPES OF LATHE MACHINES
There are different types of lathe machines, they are
1. Centre lathe
2. Tool room lathe
3. Bench lathe
4. Capstan lathe
5. Turret lathe
6. Automatic lathe
1.3 DESCRIPTION OF LATHE
Lathe is a machine which has several parts in it. They are
1. Bed
It is the base of the machine. On its left side, the head stock is mounted and
on its right it has movable casting known as tailstock. Its legs have holes to
bolt down on the ground.
2. Head stock
It consists of spindles, gears and speed changing levers. It is used to
transmit the motion to the job. It has two types one is the headstock driven
by belt and the other one is the gear driven.
3. Carriage
Carriage is used to carry a tool to bring in contact with the rotating work
piece or to with draw from such a contact. It operates on bed ways between
the headstock and tail stock.
4. Saddle
It is a ‘H’ shaped part fitted on the lathe bed. There is a hand wheel to move
it on the bed way. Cross slide, compound rest, tool post are fitted on this
saddle.
a) Cross slide
It is on the upper slide of saddle in the form of dove tail. A hand wheel is
provided to drive the cross slide. It permits the cross wise movement of
the tool (i.e.) movement of tool towards or away from the operator
3
b) Compound rest
It is fitted over the cross slide on a turn table. It permits both parallel and
angular movements to cutting tool.
c) Tool post
It is fitted on the top most part of the compound rest. Tool is mounted on
this tool post. Cutting tool is fixed in it with the help of screws.
5. Apron
It is the hanging part in front of the carriage. It accommodates the
mechanism of hand and power feed to the cutting tool for carrying out
different operations.
6. Lead screw
It is a long screw with ACME threads. It is used for transmitting power for
automatic feed or feed for thread cutting operation.
4
7. Tail stock
It is located at the right end of the lathe bed and it cn be positioned
anywhere in the bed. It is used for supporting lengthy jobs and also carries
tool to carry out operations such as tapping, drilling, reaming.
1.4 WORK HOLDING DEVICES
1. Lathe centers
They are used to support work. It has two categories of centers. Live center is one
which is fitted in the headstock spindle. Dead is another one which is fitted in the
tail stock.
2. Chuck
It is a device used to hold a job. It is easily fitted on the thread cut on the
end of head stock spindle. Various types of chuck are
a) Two jaw chuck b) three jaw chuck c) four jaw chuck d) collet chuck
e) Magnetic chuck
Three Jaw Universal self- Four Jaw Independent

5
centering chuck chuck
3. Face plate
4. Catch plate
5. Lathe carriers or dog’s
6. Steady rest
7. Mandrel
8. Follower rest
1.5 CUTTING TOOLS USED
For making a finished job on lathe machine, various types of cutting tools are used.
One of them is single point cutting tool which is used to perform several operations
on the work piece. Various types of cutting tools are
1. FACING TOOL
It is used for facing the longitudinal ends of the job. Its shape is like a knife.
2. ROUGH TURNING TOOL
It is used to remove excess material from the work piece in quick time. It can
be used to give large depth of cut and work at coarse feed.
3. FINISHING TOOL
It is used for getting smooth finish on the work piece. Its point is a little
more round.
4. RADIUS TOOL
Jobs which need round cutting are done with this tool. Its type is
a) Convex radius tool b) concave radius tool
5. PARTING TOOLS
It is used to cut the jobs into two parts. It is also used for grooving.
6. FORM TURNING TOOL
6
It is used for jobs which require both convex and concave turning.
7. THREAD CUTTING TOOL

It is used for making internal or external threads on the work piece. The tool
nose is designed with a definite profile for taking threads.
8. DRILL TOOL
It is used for making holes of various diameters on the job. Drill bit of
various sizes of diameter are available.
9. BORING TOOL
It used for enlarging the drill hole.
10.KNURLING TOOL
Drawing slanting or square projecting lines on the surface of a job is known

as knurling. It is used for making better grip on the surface of a job.
7
1.6 TOOL MATERIALS
 The single point cutting tools are made of high speed steel. (H. S. S)
 The main alloying elements in 18 – 4 – 1 HSS tools are 18 % tungsten, 4%
chromium and 1 % Vanadium. 5 to 10 % cobalt is also added to improve the
heat resisting properties of the tool.
 General purpose hand cutting tools are usually made from carbon steel or
tool steel.
 Carbide tipped tools fixed in tool holders, are mostly used in production
shops.
1.7 NOMENCLATURE OF SINGLE POINT CUTTING TOOL
1.8 CUTTING TOOL ANGLES
 Top rake angle (back rake angle)

If the slope is given to the face or surface of the tool and if this slope is along
the tools length then it is called top rake angle. It is usually 15 to 20.
 Side rake angle
If the slope is given to the face or top of the tool along the tools width then it
is called side rake angle. It lies between 6 and 15.
8
 Clearance angle (relief angle)
Types: 1. Side clearance angle 2. End clearance angle.
They are provided to keep surface of the tool clear of the work piece.
 Cutting edge angle
Types: 1. Side cutting edge angle – (generally 15) it is an angle, the side
cutting edge makes with the axis of the tool 2. End cutting edge angle –
(from 7 to 15) it is an angle, the end cutting edge makes with the width of
the tool.
 Lip angle (cutting angle)
It is the angle between the face and the end surface of the tool.
 Nose angle
It is the angle between the side cutting edge and end cutting edge.
1.9 LATHE OPERATIONS
1. FACING
 It is done for getting fine finish (good surface finish) on the face of the
job.
 Facing tool is set at an angle to the work piece.
 The tool is fed from the centre of work piece towards the outer surface
against the rotating work piece.
 Depth of cut is low for the facing operation.
2. PLAIN TURNING
 It is done for reducing the diameter of the work piece.
 A cutting tool with 70 setting angle is used for roughing operation.
 More feed is given for rough turning while less feed is given for
finishing.
 Work piece is held in chuck and tool is set to center height of the
work piece.
9
3. STEP TURNING
 It is similar to the process of turning but in this case different
diameter in step of various sizes is taken on the work piece.
4. TAPER TURNING
 It is different from the turning operation.
 Taper is defined as uniform change in the diameter of a work piece
measured along its length.
Where D – large Diameter

d – Small diameter
l – Length of taper
5. KNURLING
 It is process of making serrations on the work piece.
 Knurling tools of different shape and size are used to make grip on the
work piece. It has two hardened steel rollers.
 The tool is held in tool post and pressed against the rotating work
piece.
 Work piece is rotated at lower speed and small amount of feed is
given.
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6. DRILLING
 It is a process of making a hole on the work piece
 Job is held in chuck while the drill is held in the tail stock sleeve.
 Feed is given by rotating the hand wheel in the tail stock which
pushes the tailstock sleeve.
1.10 CUTTING SPEED
 It is the peripheral speed of the work past the cutting tool.

 It is the speed at which metal is removed by the tool from the work piece.
 It is expressed in meter / minute.
𝝅 × 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 × 𝑹. 𝑷. 𝑴 𝝅𝑫𝑵
𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒔𝒑𝒆𝒆𝒅 = = 𝒊𝒏 𝒎/𝒎𝒊𝒏
𝟏𝟎𝟎𝟎 𝟏𝟎𝟎𝟎
D – Diameter in mm
N – Spindle speed in rpm
1.11 FEED
 It is defined as the rate of tool travel across a surface cutting it.

 It is the distance of the tool advances for each revolution of the work piece.
 It is expressed in mm/revolution.
1.12 DEPTH OF CUT
 It is the perpendicular distance measured from the machined surface to the

uncut surface of work. It is expressed in mm.
𝒅𝟏− 𝒅𝟐
𝒅𝒆𝒑𝒕𝒉 𝒐𝒇 𝒄𝒖𝒕 =
𝟐
d1 = diameter of work before machining
d2 = diameter of work after machining
2. DRILLING MACHINE
The drilling machine is one of the most important machine tools in a
workshop. In a drilling machine holes may be drilled quickly and at a low cost.
The hole is generated by the rotating edge of a cutting tool known as the drill,
which exerts large force on the work clamped on the table.
The different parts of a radial drilling machine have been illustrated in Fig.
They are as follows:
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1. Base,
2. Column,
3. Radial arm,
4. Drill head
5. Spindle speed and feed mechanism
2.1 BASE
The base of a radial drilling machine is a large rectangular casting that is
finished on its top to support a column on its one end and to hold the work table
at the other end. In some machines T-slots are provided on the base for clamping
work when it serves as a table.
2.2 COLUMN
The column is a cylindrical casting that is mounted vertically at one end of
the base. It supports the radial arm which may slide up or down on its face. An
electric motor is mounted on the top of the column, which imparts vertical
adjustment of the arm by rotating a screw passing through a nut attached to the
arm.
2.3 RADIAL ARM
The radial arm that is mounted on the column extends horizontally over the
base. It is a massive casting with its front vertical face accurately machined to
provide guide ways on which the drill head may be made to slide. The arm may
be swung round the column. In some machines this movement is controlled by a
separate motor.
2.4 DRILL HEAD
The drill head is mounted on the radial arm and drives the drill spindle. It
encloses all the mechanism for driving the drill at multiple speeds and at
different speed. All the mechanisms and controls are housed within a small drill
head, which may be made to slide on the guide ways of the arm for adjusting the
position of drill spindle with respect to the work.
2.5 SPINDLE DRIVE AND FEED MECHANISM
A constant speed motor is mounted at the extreme end of the radial arm,
which drives a horizontal spindle, which runs along the length of the arm, and
the motion is transmitted to the drill head through bevel gears.
By train of gearing within the drill head, the speed of the spindle may be
varied. Through another train of gearing within the drill head, different feeds of
the spindle are obtained. In some machines, a vertical motor is fitted directly on
the drill head and through gearbox multiple speed and the feed of the spindle can
be obtained.
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.
Radial drilling machine
1.Base, 2.Column, 3.Radial arm, 4.Motor for elevating the arm, 5.Elevating
screw, 6.Guide ways, 7.Motor for driving the drill
3. MILLING MACHINE
Milling is the process of removing metal by feeding the work piece through
a rotating multipoint cutter. Milling machine can be used for machining flat
surfaces, complex and irregular areas, surface of revolution, external and
internal threads, gear cutting, helical surface of cross sections.
The different parts of a Milling machine have been illustrated in Fig (3.0). They
are as follows:
1. Base
2.Column
3.Knee
4.Saddle
5.Table
6.Spindle
7.Arbor
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1
2
3
4 5
7
9
10
MILLING MACHINE
1. Over arm 2.Arbor support 3.Arbor 4.Spindle 5.Table 6.Saddle 7.
Knee 8. Elevating screw. 9. Column 10. Base
3.1. BASE:
It is the foundation of the machine and is that part upon which all parts
are mounted. It gives the machine rigidity and strength.
3.2. COLUMN:
It is the main supporting frame. The motor and other driving
mechanisms are contained with in it.
3.3 KNEE:
The knee projects from the column and slides up and down on its face.
It supports the saddle and table and partially supported by the elevating screw
which adjusts its height.
3.4. SADDLE:
The saddle supports and carries the table and is adjustable
transversely on ways on top of the knee. It is provided with graduations for exact
movement and operated by power or hand.
3.5. TABLE:
The table rests on ways on the saddle and travels longitudinally in a
horizontal plane. It supports the works piece, fixtures and all other equipments.
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3.6. SPINDLE:
The spindle obtains its power from the motor through motors.
Cutters are mounted directly in the spindle nose.
3.7. ARBOR:
The arbor is an accurately machined shaft for holding and driving
the arbor cutter. It is tapered at one end to fit the spindle nose and two slots to fit
the nose keys for locating and driving it.
4. SHAPER
The shaper is a reciprocating type of machine tool intended primarily to
produce flat surfaces. These surfaces may be horizontal, vertical, or inclined.
The different parts of typical shaper are shown in fig (4.0).
The principal parts of a standard shaper are:
1. Base
2. Column
3. Cross rail
4. Saddle
5. Table
6. Ram
7. Tool head
Shaping machine
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1. Table support,
2. Table,
3.Clapper box
4.Apron clamping bolts
5. Down feed hand wheel
6.Swivel base degree graduations
7.Position of stroke adjustment hand wheel
8.Ram block locking handle
9.Ram
10. Column
11. Driving pulley
12. Base
13. Feed disc
14. Pawl mechanism
15. Elevating screw.
4.1 BASE
The base is the necessary bed or required for all machine tools. The base
may be rigidly bolted to the floor of the shop or on the bench according to the size
of the machine. It is so designed that it can take up the entire load of the
machine and the forces set up by the cutting tool over the work. It is made of cast
iron to resist vibration and take up high compressive load.
4.2 COLUMN
The column is a box like casting mounted upon the base. It encloses the ram
driving mechanism. Two accurately machined guide ways are provided on the top
of the column on which the ram reciprocates. The front vertical face of the
column, serves as the guide ways for the cross rail. The lid on the left side of the
column may be opened for inspection and oiling of the internal mechanism.
4.3 CROSSRAIL
The cross rail is mounted on the front vertical guide ways of the column. It
has two parallel guide ways on its top in the vertical plane that is perpendicular
to the ram axis. The table may be raised or lowered to accommodate different
sizes of jobs by rotating elevating screw, which causes the cross rail to slide up
and down on the vertical face of the column. A horizontal cross feed screw, which
is fitted within the cross rail and parallel to the top guide ways of the cross rail
actuates the table to move in a crosswise direction.
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4.4 SADDLE
The saddle is mounted on the cross rail, which holds the table firmly on its
top. Crosswise movement of the saddle by rotating the cross feed screw by hand
or power causes the table to move sideways.
4.5 TABLE
The table is bolted to the saddle receives crosswise and vertical movements
from the saddle and cross rail. It is a box like casting having T-slots both on the
top and sides for clamping the work. In a universal shaper the table may be
swiveled on a horizontal axis and the upper part of the table may be tilted up or
down.
4.6 RAM
The ram is the reciprocating member of the shaper. This is semi cylindrical
in form and heavily ribbed inside to make it more rigid. It slides on the accurately
machined dovetail guide ways on the top of the column and is connected to the
reciprocating mechanism contained within the column. It houses a screwed shaft
for altering the position of the ram with respect to the work and holds the tool
head at the extreme forward end.
4.7 TOOLHEAD
The tool head of a shaper holds the tool rigidly, provides vertical and angular
feed movement of the tool and allows the tool to have an automatic relief during
its return stroke. The vertical slide of the tool head has a swivel base, which is
held on a circular seat on the ram. The swivel base is graduated in degrees, so
that the vertical slide is set perpendicular to the work or at any desired angle.
RESULT :
Thus the construction, working principle and sequence of operations of

various basic machines like lathe, shaper, drilling machine and milling machine
were studied.
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GIVEN WORK PIECE (FIG: 1)
FINISHED WORK PIECE (FIG: 2)
18
EX.NO: 01 DATE:
FACING, PLAIN TURNING AND STEP TURNING
AIM:
To machine a given work piece by facing, plain turning and step
turning operations by using a lathe machine.
TOOLS REQUIRED:
1. Lathe machine
2. Cutting tool
3. outside Caliper
4. Steel Rule
5. Vernier Caliper
PROCEDURE:
1. The given work piece is held firmly in a lathe chuck.
2. The cutting tool is set in a tool post such that the point of the cutting tool
coincides with the lathe axis.
3. The machine is switched on to revolve the work piece at the selected speed.
4. By giving Cross feed and longitudinal feed to the cutting tool, the facing and
turning operations are done respectively.
5. The machine is switched off.
6. The work piece is removed from the chuck and all the dimensions are
measured and checked.
RESULT:
Thus the facing, plain turning and step turning operations are done
as per the required dimensions on the given work piece by using a lathe
machine.
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20
EX.NO: 02 DATE:
TAPER TURNING
AIM:
To machine a work piece by taper turning operation (compound rest
method) by using a lathe machine and also calculate the time estimation for the
work.
TOOLS REQUIRED:
1. Lathe machine 4.Steel Rule
2. Cutting tool 5.Vernier Caliper
3. Outside Caliper 6.Spanner
FORMULA USED:
1) The taper angle is calculated using the following formula:
1 Dd 
Taper angle () = tan  
 2l 
Where
D = large diameter of taper in mm
d = small diameter of taper in mm
l = length of tapered part in mm
 = angle of taper
2) Time taken for taper turning:
Length of the cut

T = --------------------------- X Number of cuts
[Feed x Rpm]
Where,
Depth of the cut should not exceed 4mm
Cutting speed, S = 75 mm/rev
Maximum feed, f = 0.05mm/rev
Rpm, N = [1000×S/ π × D]
PROCEDURE:
2. The cutting tool is set in a tool post such that the point of the Cutting tool
5. The compound rest is swiveled for the calculated taper angle.
21
CALCULATIONS:
22
6. By giving angular feed to the cutting tool through the compound slide the
taper turning operation is done.
RESULT:
Thus the taper turning operation was performed on the given work piece as
per the dimensions by using lathe machine and the machining time was calculated.
23
24
EX.NO: 03 DATE:
EXTERNAL THREAD CUTTING
AIM:
To machine a work piece by external thread cutting operation by
using a lathe machine and also calculate the time estimation for the work.
TOOLS REQUIRED:
1. Lathe machine 4.Outside Caliper
2. Turning tool 5.Steel Rule
3. External V – thread cutting tool 6.Vernier Caliper
FORMULAS USED:
1) The number of teeth on change gears is calculated using the following
formula:
Driver teeth Pitch of the work
------------------ = ---------------------------
Driven teeth pitch of the lead screw
2) Time taken for external threads:

Length of the cut
T = --------------------------- × Number of cuts
[Pitch x rpm]
3) Number of cuts
25
T = --------------------------- for external threads
Threads per ‘cm’
PROCEDURE:
5. The machine is switched off and the change gears of calculated teeth (as per
calculation) are connected.
6. Again the machine is switched on.
7. The external thread cutting operation is done using external V–thread
cutting tool by engaging thread cutting mechanism.
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CALCULATIONS:
Parting diameter calculation
Minor diameter = Major diameter – (2 x 0.613 x pitch)

 = 15- (2 x 0.613 x 2)
=15 - 2.452
=13 mm
1. Change Gear Calculation:
Driver teeth Pitch of the work in mm 5

= ×
Driven teeth Pitch of the lead screw in inch 127
2 5 5
= 1 × =2×4×
127 127
4
Driver teeth 40
=
Driven teeth 127
26
RESULT:
Thus the external thread cutting operation was performed on the given work
piece as per the dimensions by using lathe machine and the machining time was
calculated.
27
CALCULATIONS:
28
EX.NO: 04 DATE:
KNURLING
AIM:
To machine a work piece by knurling operation by using a lathe
machine and also calculate the time estimation for the work.
TOOLS REQUIRED:
3. Knurling tool 6.Vernier Caliper
FORMULAS USED:
Time taken for knurling:
Length of the cut
T = ---------------------------
[Feed x rpm]
PROCEDURE:
2. The cutting tool is set in a tool post such that the point of the
3. Cutting tool coincides with the lathe axis.
6. The speed of the work piece is reduced.
7. The knurling operation is done using knurling tool.
RESULT:
Thus the knurling operation was performed on the given work piece
as per the dimensions by using lathe machine and the machining time was
calculated.
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30
EX.NO: 05 DATE:
INTERNAL THREAD CUTTING
AIM:
To machine a work piece by internal thread cutting operation by using

a lathe machine and also calculate the time estimation for the work.
TOOLS REQUIRED:

3. Boring tool 7.Vernier Caliper
4. Internal V – thread cutting tool
FORMULAS USED:
1) The number of teeth on change gears is calculated using the following
formula:
Driver teeth Pitch of the work
------------------ = ---------------------------
Driven teeth pitch of the lead screw
2) Time taken for external threads:

Length of the cut
T = --------------------------- × Number of cuts
[Pitch x rpm]
3) Number of cuts
32
T = --------------------------- for internal threads
Threads per ‘cm’
PROCEDURE:

6. The boring operation is done using boring tool.
7. The machine is switched off and the change gears of calculated teeth (as per
calculation) are connected.
9. The internal thread cutting operation is done using internal V–thread cutting
tool by engaging thread cutting mechanism.
11. The work piece is removed from the chuck and all the Dimensions are
31
CALCULATIONS:
32
RESULT:
Thus the internal thread cutting operation was performed on
the given work piece as per the dimensions by using lathe machine and the
machining time was calculated.
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CALCULATIONS:
34
EX.NO: 06 DATE:
ECCENTRIC TURNING
AIM:
To machine a work piece by Eccentric Turning operation by using a

lathe machine and also calculate the time estimation for the work.
TOOLS REQUIRED:
1. Four jaw chuck lathe

2. Outside Caliper
3. Turning tool
4. Vernier caliper
5. Steel Rule
FORMULAS USED:
Time for eccentric turning
T= L / F x N
where
Speed , N = 1000 x s/π x D

No. of passes, F = D-d / 2 x depth of cut
PROCEDURE:

2. The cutting tool is set in a tool post such that the point of the Cutting
tool coincides with the lathe axis.
3. The machine is switched on to revolve the work piece at the selected
speed.
4. By giving Cross feed and longitudinal feed to the cutting tool, the facing
and turning operations are done respectively.
6. The four jaw chuck is manually adjusted for the offset purpose to make
the eccentricity.
RESULT:
Thus the internal thread cutting operation was performed on the given work
piece as per the dimensions by using lathe machine and the machining time was
calculated.
35
CALCULATIONS:
36
EX.NO: 07 DATE:
SQUARE SHAPING MACHINE
AIM:
To machine a work piece by square head shaping by using a shaping
TOOLS REQUIRED:
1. Shaping machine
2. Punching machine
2. Steel rule
3. Hammer
4. Shaper tool
5. Try Square
FORMULA
1) Time taken for shaping:
L (1 + K) W
T = --------------- X ----- X P
S X 1000 f
Where,
L = Length of forward stroke in ‘mm’
K = (time for return stroke / time for forward stroke)
w = width of the job in mm
S = Cutting speed in mm
F = feed per stroke
p = number of cuts ( or) passes required
2) No. of cuts P:
P = Depth of metal removed / Feed per stroke
PROCEDURE:
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.
RESULT:
Thus the square head shaping was performed on the given work piece as per
the dimensions by using shaping machine and the machining time was calculated.
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GIVEN WORKPIECE (FIG: 1)
38
EX.NO: 08 DATE:
HEXAGONAL HEAD MILLING
AIM:
To machine a work piece by hexagonal head milling by using a milling
TOOLS REQUIRED:
1. Milling machine 4. Vernier caliper
2. Plain milling cutter 5. Spanners
3. Dividing head
CALCULATION:
1) Index crank movement
40
Index crank movement =
N
where
N= Number of sides
2) Time taken for milling:
Length of the job + added table travel

T = ---------------------------------------------------------
(feed / rev ) X (r.p.m)
3) Feed / rev:
Feed / rev = {feed per teeth} X {no. of cutter teeth}
PROCEDURE:
1. The selected speed and feed of the machine is set.

2. The dividing head and the tailstock are bolted on the table after setting their
axis exactly perpendicular to the machine spindle.
3. The plain milling cutter is mounted on the arbor.
4. The work piece is mounted between the two centers by a mandrel.
5. The proper index plate is bolted on the dividing head and the positions of the
crank pin and the sector arms are adjusted.
6. The table is raised to give a required depth of cut.
7. The machine is started and the feed is applied to finish the first surface of
the blank.
8. After the end of the cut the table is brought to starting position and
then the blank is indexed for the next surface.
39
CALCULATIONS:
40
RESULT:
Thus the hexagonal head milling was performed on the given work piece as
per the dimensions by using milling machine and the machining time was
calculated.
41
LAP JOINT
42
EX.NO: 09 DATE:
LAP JOINT
AIM:
To join the given two work pieces as a “lap joint” by gas metal arc
welding / arc welding.
TOOLS REQUIRED:
1. Welding power supply 6. Flat file
2. Welding rod 7. Chipping hammer

3. Electrode holder 8. Wire brush
4. Gloves and apron 9. Earthing clamps
5. Shield and goggles

PROCEDURE:
1. The given work pieces are thoroughly cleaned, i.e. rust, scales are removed
and the edges are filed.
2. The electrode is held in an electrode holder and ground clamp is clamped to
the welding plates and the power is supplied.
3. The work pieces are positioned on the table to form a “Lab joint”.
4. The tag weld is done on the both the ends of joining plates to avoid the
movement of work pieces during welding.
5. The welding is carried throughout the length of the work pieces on both sides
by maintaining 3mm gap between plates and the welding rod.
6. The welded plates are allowed for air cooling after the slags are removed.
7. The weld joint portions are cleaned by wire brush.
RESULT:
Thus the required Lap joint is made by gas metal arc welding / arc welding.
43
SQUARE BUTT JOINT
44
EX.NO: 10 DATE:
SQUARE BUTT JOINT
AIM:
To join the given two work pieces as a “square butt joint” by gas metal
arc welding / arc welding.
TOOLS REQUIRED:


PROCEDURE:
3. The work pieces are positioned on the table form a “square butt joint”.
5. The welding is carried throughout the length of the work pieces on both
sides by maintaining 3mm gap between plates and the welding rod.
6. The welded plates are allowed for air cooling after the slags are removed.
RESULT:
Thus the required square butt joint is made by gas metal arc welding / arc
welding.
45
TEE FILLET JOINT
46
EX.NO: 11 DATE:
TEE FILLET JOINT
AIM:
To join the given two work pieces as a “Tee fillet joint” by gas metal
arc welding / arc welding.
TOOLS REQUIRED:


PROCEDURE:
3. The work pieces are positioned on the table to form a “Tee fillet joint”.
5. The welding is carried throughout the length of the work pieces on both sides
by maintaining 3mm gap between plates and the welding rod.
6. The welded joint portions are allowed for air cooling after the slag is removed.
RESULT:
Thus the required Tee fillet joint is made by gas metal arc welding / arc welding.
47
PIPE JOINT
48
EX.NO: 12 DATE:
PIPE JOINT
AIM:
To join the given pipe with a work piece as required type of joint by using gas
welding.
TOOLS REQUIRED:
1. Oxygen and acetylene gas cylinder with the equipments (pressure
gauge & regulators)
2. Gas welding torch
3. Filler rod
4. Safety goggles, gloves
5. Chipping hammer
6. Wire brush
PROCEDURE:
1. The given work piece are thoroughly cleaned, i.e., rust, scales are removed.
2. The joining work pieces are positioned properly.
3. Acetylene and Oxygen cylinder valves are opened then the Acetylene torch
valve is opened.
4. Light tip of torch using lighter.
5. Oxygen and Acetylene torch valves are adjusted and the required flame is
obtained.
6. The welding torch and the filler rod are moved along the line of weld and
welding is done by maintaining 3mm gap between plate and inner cone of
flame.
RESULT:
Thus the required pipe welding is obtained by gas welding process.
49
SHEET METAL TRAY
50
EX.NO: 13 DATE:
SHEET METAL TRAY
AIM:
To make a rectangular tray from the given sheet metal.
TOOLS REQUIRED:
1. Steel rule
2. Mallet
3. Scriber
4. Divider
5. Protractor
6. Snips
7. Stakes
8. Ball peen hammer
PROCEDURE:
1. The size of the given sheet is checked for its dimension using steel rule.
2. Then the sheet is leveled on the leveling plate using a mallet.
3. The development procedure is followed the same as the square taper tray.
4. The dimensions are marked as shown in figure.
5. The sheet is cut as per the marked dimensions by straight snips.
6. Then a single hemming is made on the four sides of the tray as shown in
figure.
7. The four sides of the tray bent to 90_ using the stakes anvil.
8. Finally all the corners of the tray are joined by riveting.
RESULT:
Thus desired rectangular tray is made from the given sheet metal.
51
CONE FUNNEL
52
EX.NO: 14 DATE:
CONE FUNNEL
AIM:
To make a funnel from the given sheet metal.
TOOLS REQUIRED:
1. Steel rule
2. Mallet
3. Scriber
4. Divider
5. Protractor
6. Snips
7. Stakes
8. Ball peen hammer
9. Solder
PROCEDURE:
1. The size of the given sheet is checked for its dimension using steel rule.
2. The required development of surface is being made on the white paper which
is overlapped on the sheet metal.
3. The marking is done on the sheet metal as per the development being done
on the paper.
4. Now using straight snips, unwanted material are removed.
5. Now fold and bend the workpiece to make the funnel shape and joint is
made on the workpieces.
6. Then using a groove, a locked grooved joint is made for about 5mm. also;
hemming is done in the bottom of the funnel.
7. In between top face and bottom face, a butt joint is made using a solder.
8. Finally, trimming and finishing operations are carried out.
RESULT:
Thus desired cone funnel is made from the given sheet metal.
53
MOULDING OF STEPPED CONE PULLEY
54
EX.NO: 15 DATE:
MOULDING OF STEPPED CONE PULLEY
AIM:
To make the green sand mould for the given stepped cone pulley.
TOOLS REQUIRED:
1. Moulding board 8. Riser pin
2. Moulding box 9. Sprue pin
3. Green sand 10. Rammer
4. Trowel 11. Lifter
5. Riddle 12. Draw spike
6. Gate cutter 13. Bellow
7. Vent rod
PROCEDURE:
1. Place the moulding board on a horizontal surface.
2. A suitable core is prepared with the help of core box.
3. The drag box is placed above the moulding board. Now the pattern is kept at
center of drag.
4. Now parting sand in sprinkled before we keep pattern.
5. Facing sand is sprinkled over the pattern to a depth of 5mm. then green sand
is filled over it.
6. Proper ramming is done on the green sand to get a air tight packing.
7. Excess sand is removed by strike off bar.
8. The drag box is inverted upside down.
9. The cope box is placed over the drag box and locked.
10. The riser pin sprue pin placed at right position and green sand is filled over
the pattern.
11. Proper ramming is done on the green sand to get air tight packing with strike
off bar leaving is done.
12. Now riser pin and sprue pin get removed from the green sand mould. The
pattern is removed by draw spike tool.
13. Gate is prepared using gate cutter and core is placed vertically inside the
cavity.
14. The vent holes are made with vent rod and cope.
RESULT:
Thus the green sand mould is made for given stepped cone pulley.
55
MOULDING OF SPLIT PATTERN
56
EX.NO: 16 DATE:
MOULDING OF SPLIT PATTERN
AIM:
To make the green sand mould for the given split pattern.
TOOLS REQUIRED:
1. Moulding board 8. Riser pin
2. Moulding box 9. Sprue pin
3. Green sand 10. Rammer
4. Trowel 11. Lifter
5. Riddle 12. Draw spike
6. Gate cutter 13. Bellow
7. Vent rod
PROCEDURE:
1. Place the moulding board on a horizontal surface.
2. The drag box is placed above the moulding board. Now one piece of pattern is
kept at center of the drag as shown in figure.
3. The parting sand is spread before we keep the pattern.
4. Facing sand is sprinkled over the pattern to a depth of 2mm. then greensand
is filled over it.
5. Proper ramming is done on the green sand to get a air free packing.
6. Excess sand is remove with strike off bar.
7. The drag is inverted upside down.
8. The cope box is place over the drag box.
9. Now the parting sand is sprinkled over the parting surface.
10. The other piece of pattern is placed over the drag pattern.
11. Facing sand is riddled over the pattern to a depth of 5mm. then riser is place
over the pattern and another sprue pin above parting surface.
12. Now green sand is filled over it.
13. Ramming operation is done to get an air tight packing with strike off bar
leaving it.
14. Riser pin and sprue pin gets removed from the green sand.
15. Pattern is removed gently now.
16. Gate is cut using gate cutter.
17. The vent holes are made with vent rod on the cope side.
RESULT:
Thus the green sand mould is made for given split pattern.
57
METAL SPINNING CONE
58
EX.NO: 17 DATE:
METAL SPINNING CONE
AIM:
To make a cone by metal spinning operation by using a lathe machine for
the given G.I sheet.
TOOLS REQUIRED:
1. Lathe machine
2. Roller Forming tool
3. Cutting tool
4. outside Caliper
5. Steel Rule
6. Vernier Caliper
PROCEDURE:
1. The given G.I sheet is sheared for the required area for cone.
2. Then the sheared G.I sheet is held firmly in a lathe chuck.
3. The roller forming tool is set in a tool post such that the point of the roller tool
4. The machine is switched on to revolve the G.I sheet at the selected speed.
5. By giving Cross feed and longitudinal feed to the roller forming tool, the cone
shape is achieved form the given G.I sheet.
7. The cone is removed from the chuck and all the dimensions are measured and
checked.
RESULT:
Thus the sheet metal cone was made by metal spinning operation in lathe
machine.
59

Me6311-Mt - 1 - Lab Manual

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INDEX

S.No DATE NAME OF THE EXPERIMENT MARK SIGNATURE

Average Mark: Staff - in – charge

1.1 BASIC WORKING PRINCIPLE OF LATHE

There are different types of lathe machines, they are

1.3 DESCRIPTION OF LATHE

Lathe is a machine which has several parts in it. They are

1.4 WORK HOLDING DEVICES

Three Jaw Universal self- Four Jaw Independent

1.5 CUTTING TOOLS USED

7. THREAD CUTTING TOOL

Drawing slanting or square projecting lines on the surface of a job is known

1.7 NOMENCLATURE OF SINGLE POINT CUTTING TOOL

1.8 CUTTING TOOL ANGLES

 Top rake angle (back rake angle)

1.9 LATHE OPERATIONS

Where D – large Diameter

1.10 CUTTING SPEED

 It is the peripheral speed of the work past the cutting tool.

N – Spindle speed in rpm

 It is defined as the rate of tool travel across a surface cutting it.

1.12 DEPTH OF CUT

 It is the perpendicular distance measured from the machined surface to the

Thus the construction, working principle and sequence of operations of

FINISHED WORK PIECE (FIG: 2)

FACING, PLAIN TURNING AND STEP TURNING

FINISHED WORK PIECE (FIG: 2)

Length of the cut

FINISHED WORK PIECE (FIG: 2)

EXTERNAL THREAD CUTTING

2) Time taken for external threads:

Minor diameter = Major diameter – (2 x 0.613 x pitch)

1. Change Gear Calculation:

Driver teeth Pitch of the work in mm 5

FINISHED WORK PIECE (FIG: 2)

FINISHED WORK PIECE (FIG: 2)

INTERNAL THREAD CUTTING

To machine a work piece by internal thread cutting operation by using

1. Lathe machine 5.Outside Caliper

2) Time taken for external threads:

1. The given work piece is held firmly in a lathe chuck.

FINISHED WORK PIECE (FIG: 2)

To machine a work piece by Eccentric Turning operation by using a

1. Four jaw chuck lathe

Speed , N = 1000 x s/π x D

1. The given work piece is held firmly in a lathe chuck.

FINISHED WORK PIECE (FIG: 2)

SQUARE SHAPING MACHINE

FINISHED WORK PIECE (FIG: 2)

HEXAGONAL HEAD MILLING

Length of the job + added table travel

1. The selected speed and feed of the machine is set.

1. Welding power supply 6. Flat file

2. Welding rod 7. Chipping hammer

4. Gloves and apron 9. Earthing clamps

5. Shield and goggles

1. Welding power supply 6. Flat file

2. Welding rod 7. Chipping hammer

4. Gloves and apron 9. Earthing clamps

5. Shield and goggles

1. Welding power supply 6. Flat file

2. Welding rod 7. Chipping hammer

4. Gloves and apron 9. Earthing clamps