Experiment#1

Perform Facing on Lathe machine to reduce Length of cylindrical workpeice.

Facing Operation:
Facing is the process of removing metal from the end of a workpiece to produce
a flat surface. Most often, the workpiece is cylindrical, but using a 4-jaw chuck
you can face rectangular or odd-shaped work to form cubes and other non-
cylindrical shapes.

Machine and Materials:

1) Lathe Machine
2) Single Point Cutting Tool
3) MS 1045
4) 590 RPM

Procedure:
1. Clamp the workpiece tightly in the 3-jaw chuck. To get the work properly centered, close
the jaws until they just touch the surface of the work, then rotate the workpiece by hand
in the jaws to seat it; then tighten the jaws. It's good practice to tighten the jaws from all 3
chuck key positions to ensure even gripping by the jaws.
2. Choose a cutting tool with a slightly rounded tip. A tool with a sharp pointed tip will cut
little grooves across the face of the work and prevent you from getting a nice smooth
surface.
3. Set the lathe to its lowest speed and turn it on.
4. Use the compound handwheel to advance the tip of the tool until it just touches the end of
the workpiece. Use the cross feed crank to back off the tool until it is beyond the diameter
of the workpiece. Turn the lathe on and adjust the speed to a few hundred RPM
5. Use the compound crank to advance the tool towards the chuck
6. Depending on how rough the end of the workpiece was to begin with and how large the
diameter is, you may need to make 3 or more passes to get a nice smooth finish across the
face. These initial passes are called roughing passes and remove a relatively large amount
of metal.
7. Facing operations leave a rather sharp edge on the end of the workpiece. It's a good idea
to smooth this edge down with a file to give it a nice champfer and to avoid cutting yourself
on it.

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Quality Check:
This picture shows the finished surface and beveled edge. This is what a good facing cut should look like:
smooth even surface with no raised bump in the center. Lay an accurate straight edge across the surface
of the face and you should not be able to see any light under the edge. If you detect a slight convex shape,
the carriage may be moving back away from the headstock during the cut.

Comments:
1) Always stop the lathe before making adjustments.
2) Remove chuck keys and wrenches before operating
3) Only a small amount of material should be removed - each pass of the cross slide.
4) When using a lathe it is always advisable to work patiently and safely. Do not attempt to
removed too much material in one go. At best this will cause damage to the steel being
worked on and to the expensive cutting tool being used. At worse an accident will occur.

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Experiment #3
Perform Taper Turing on Lathe Machine.

Taper Turning
Taper turning as a machining operation is the gradual reduction in diameter from one part of a cylindrical
workpiece to another part Tapers can be either external or internal. If a workpiece is tapered on the
outside, it has an external taper; if it is tapered on the inside, it has an internal taper.

Methods:
Tail Stock Offset for Taper Turning
Taper can be machined on a job that can be turned between centers by setting over the tailstock. The
method of setting over the tailstock. In this method the axis of the job rotates with an angle to machine
bed axis and the tool moves parallel to the machine bed. Under this method the tailstock is off set on the
basis the value of, which is in mm or inches instead of degrees. If the dead centre is set over in the opposite
direction it will turn a taper its larger diameter on the side of the tailstock.

Procedure:

1) Loosen the clamp nut of the tailstock.

2) Loosen one adjusting screw and tighten the other till the required set over is obtained.
3) Mount the tool in usual way as in parallel turning.
4) Take a rough cut.
5) Test the taper and readjust if needed.
6) When the required taper is obtained, finish the size.

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Non-uniform wear on the centre holes may be prevented by using ball centres instead of ordinary centres.
The ball centres may be used on both the ends.

Advantages of Tail Stock Method

1) Longer jobs can be tapered.

2) Good surface can be obtained by automatic feed.
3) External taper threads can be cut.

Disadvantages of Tail Stock Method

1) Steep taper cannot be cut.

2) Internal taper cannot be cut.
3) Since the centres are out of alignment the centre points do not seat exactly in the centre
holes on the work and therefore the danger of the work being thrown out is more under
severe machining condition.

Taper Turning by Swiveling the Compound Slide

This method is used to produce short or steep tapers. Compound slide is fixed on the top of cross slide
and it can be rotated on its central pins in both ways. Its base is graduated with 0 to 45° and degrees are
marked on both the sides of zero. Taper turning can be done outside the job or in the bore.

Disadvantages:
1) Production efficiency is low and finishing is not good because of hand feed.
2) Only short tapers can be turned because the length of the taper is limited by compound
slide travel.
3) Some important hints may be kept in mind while taper turning by compound slide and
these are the following:

Comments:
1) Avoid the over hang of the tool.
2) The height of the tool point must be in the centre. It should neither be low nor high.
3) The hand feed should be uniform as much as possible.

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4) Use coolant sparingly.

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Experiment #5
Perform boring to enlarging a hole that has already been drilled on Lathe.
Boring
In machining, boring is the process of enlarging a hole that has already been drilled (or cast), by means of
a single-point cutting tool (or of a boring head containing several such tools)

Mounting Workpiece for Boring

The workpiece may be supported in a chuck or fastened to a faceplate for boring operations depending
upon of the material to be machined. When boring is to be performed on the ends of long stock, the
workpiece is mounted in a chuck and a steady rest is used to support the right end near the cutter bit.
Some boring operations require the use of special chuck-mounted mandrels to hold workplaces that
cannot be successfully mounted otherwise.

Purpose for Boring

Boring is necessary in many cases to produce accurate holes. Drilled holes are seldom straight due to
imperfections in the material which cause drills to move out of alignment. Therefore, where accuracy is
important, drilled holes are usually made undersize and then bored or reamed to the proper dimensions.

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Boring is also useful in truing large holes in flat material. In this case, the hole is cut undersize using a
bandsaw or trepanning tool and is trued to proper dimensions by boring.

Tools:

Procedure:
1) Insert the workpiece in the 3-jaw chuck and tighten down the jaws until they just start to
grip the workpiece. Rotate the workpiece to ensure that it is seated evenly and to dislodge
any chips or grit on the surface that might keep it from seating evenly. You want the
workpiece to be as parallel as possible with the center line of the lathe
2) Insert the boring bar into spindle attachment with tail stock.
3) Set the rpm of chuck and start lathe machine.
4) Depth of cut is given by cross slide hand wheel
5) Move the carriage with handwheel to bore the hole.

Comments:
1) Always stop the lathe before making adjustments.
2) Remove chuck keys and wrenches before operating
3) Only a small amount of material should be removed - each pass of the cross slide.
4) When using a lathe it is always advisable to work patiently and safely. Do not attempt to
removed too much material in one go. At best this will cause damage to the steel being
worked on and to the expensive cutting tool being used. At worse an accident will occur.

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Experiment #6
Perform Knurling on Lathe Machine

Knurling:
Knurling is a process of impressing a diamond shaped or straight
line pattern into the surface of a workpiece by using specially
shaped hardened metal wheels to improve its appearance and to
provide a better gripping surface. Straight knurling is often used to
increase the workpiece diameter when a press fit is required
between two parts.

Knurling Tool:
The knurling tool can be designed differently, but all accomplish the same operation. Two common types
of knurling tools are the knuckle joint and revolving head type of knurling tools. The knuckle joint type is
equipped with a single pair of rollers that revolve with the work as it is being knurled. The revolving head
type of tool is fitted with three pairs of rollers so that the pitch can be changed to a different knurl without
having to change the setup. There are two knurl patterns, diamond and straight.

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 There are three pitches of rollers, coarse, medium, and fine. The diamond is the most common pattern
and the medium pitch is used most often. The coarse pitch is used for large-diameter work; the fine pitch
is used for small-diameter work.

Machine and Materials:

1) Lathe Machine
2) Knurling Tool
3) MS 1045
4) 60 RPM

Procedure:
1) The knurling operation is started by determining the location and length of the knurl, and
then setting the machine for knurling.
2) A slow speed is needed with a medium feed. Commonly, the speed is set to 60 to 80 RPM
3) The knurling tool must be set in the tool post with the axis of the knurling head at center
height and the face of the knurls parallel with the work surface.
4) Check that the rollers move freely and are in good cutting condition; then oil the knurling
tool cutting wheels where they contact the workpiece. Bring the cutting wheels (rollers) up
to the surface of the work with approximately 1/2 of the face of the roller in contact with
the work.If the face of the roller is placed in this manner, the initial pressure that is
required to start the knurl will be lessened and the knurl may cut smoother.
5) Apply oil generously over the area to be knurled.

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 6) Start the lathe while forcing the knurls into the work about 0.010 inch. As the impression
starts to form, engage the carriage feed lever.
7) Observe the knurl for a few revolutions and shut off the machine. The knurl is complete
when the diamond shape ( or straight knurl) is fully developed.

Comments:
1. Never stop the carriage while the tool is in contact with the work and the work is still
revolving as this will cause wear rings on the work surface

2. Keep the work and knurling tool well oiled during the operation.
3. Excessive knurling after the knurl has formed will wear off the full knurl and ruin the work
diameter.

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Experiment #7
Perform Parting on Lathe machine to cut a cylindrical workpeice into two pieces.

Parting:
Parting uses a blade-like cutting tool plunged directly into the workpiece to cut off the workpiece at a
specific length. It is normally used to remove the finished end of a workpiece from the bar stock that is
clamped in the chuck.

Machine and Materials:

1) Lathe Machine
2) Parting Tool
3) MS 1045
4) 200 RPM

Parting Tool:

Procedure:
1. Parting is always done close to the chuck jaws - no more than 1/2 out.
2. For a parting cut the top of the tool should be exactly on the center line of the lathe
3. With the tip of the tool just beyond the surface of the workpiece, turn on the lathe. Slowly
advance the cross-slide crank until the tool starts cutting into the metal. Keep advancing
the tool until you get a steady chip curling off the workpiece and then try to maintain this
cutting speed
4. Keep advancing the tool until it reaches the center of the workpiece. As you get close, the
workpiece is suspendend by a thin stalk of metal.

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 5. The end of the workpiece that you cut off will generally have a pretty rough finish and a
little stalk of metal protruding from the end.
6. The final step it to mount this piece in the chuck and make a facing cut to clean up the end.

Comments:
1. Chatter: Parting often causes 'chatter'. It is a pulsing, whining vibration that can shake
the whole lathe and even cause it to move around on the workbench if is not bolted down.
You can stop chatter quickly by backing off the pressure on the tool. The trick is to find the
right speed at which to advance the tool with minimal chatter.

Here are some tips to minimize chatter:

 Tool tip should be quite sharp

 Top of tool should be right on the lathe centerline
 Tool should be perpendicular to the workpiece
 Saddle should be snug to the ways
 Use cutting fluid
 Maintain steady advance of cross-slide

2. Parting cuts impose great tangential force on the workpiece that could cause the workpiece
to be forced out of the chuck if you cut too far from the chuck jaws.
3. The tip of the tool should be exactly perpendicular to the workpiece.

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 4. if the workpiece extends from the chuck more than a few times its diameter, the end of the
workpiece can start to swing in a dangerous arc. As you get near the center, you may need
to slow down the chuck speed to keep things safe. If you notice the workpiece starting to
wobble, stop the lathe and move the workpiece back and forth by hand to break it free.
5. One limitation of parting tools is the diameter of the work that can be parted.
6. Parting cuts should be made at low speed; say 200-300 RPM or even slower.

Experiment #8
Producing a Flat Surface Using Shaper Machine.

Shaper Machine:
Shaper is commonly used to produce flat surfaces can be horizontal, vertical or inclined by machining with
the help of a reciprocating tool. Due to its limited length of its ram stroke, shaper is conveniently adapted
to smaller jobs. However it’s a slow machine and is only considered suitable only for unit or batch
production rather than mass production. It is even preferred to other quick metal cutting machines with
even multiple teeth cutters because it can give all kinds of surface finish on this single machine along with
ease of machining varieties of surfaces with minimum change over time since the set up time for a shaper
is much less for most of the jobs

Working Principle:
1) On a shaper machine, job is fixed on the work table and the tool cuts while reciprocating
over the job.
2) The tool is mounted on a reciprocating ram and the table which supports the job is fed
normal to the tool motion at each stroke of the ram.

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 3) The tool cuts only in the forward stroke of the ram except for a draw-cut shaper in which
the tool cuts in the backward stroke of the ram. The other stroke in both the cases remains
idle.
4) The job may be indexed in horizontal or vertical direction.

Advantages:
1) Shaper tools are simple and cheap.
2) Intricate fixtures are replaced by simple holding devices.
3) In comparison to a planner, for shorter cuts, shaper cost less to buy, consumes less power,
occupies less floor space and is easier to operate.
4) Shaper is one third quicker in action than a planner.

Principal Parts:
1) Base: It’s a heavy cast iron structure supporting all the other parts and assembly and
bolted down to the shop floor through foundation bolts.
2) Column: A cast iron box structure housing the operating mechanism. It provides support
for other parts f the machine such as ram, cross rails, etc.
3) Cross rails: It is mounted on the front two vertical guide ways of the column.
4) Saddle: It moves on the cross rail block and carries the table on it such that it can be
moved sideways withers by power or by hand using a cross feed screw.
5) Table: It is firmly attached to the saddle. It gets its sideways motion from the saddle.
6) Ram: It is a reciprocating member with the tool head mounted on it.
7) Tool head: It is mounted on the front end of the ram and has the provision of being
swiveled in any direction for shaping angular surfaces. The vertical feed may be given with
tool feed handle.

Procedure:
1) Clamping of the workpiece
2) Clamp the workpieces according to their shape safely and firmly and secure them against
distortion and deformation.
3) Clamping of the tool
4) Clamp the tool short and firmly.
5) Check the tools for operational reliability (visual inspection).Setting of cutting values
6) Set the number of strokes per minute, stroke length, feed, cutting depth taking into
consideration the tables available and graphical symbols.
7) Switch only when machine is at rest!
8) Operation of the shaping machine (sequence of operations):
9) Approach the tool to the surface to be shaped until the latter is contacted.
10) Set the dial (tool slide) to "O".
11) Swing the machine table aside so that the tool is no longer above the workpiece.
12) Feed cutting depth according to dial.
13) Start machine (switch on stroke).
14) Move machine table by hand up to the tool.
15) Switch on feed of machine table and machine workpiece surface.

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 16) After having machined the surface, switch off feed and disengage machine (switch off
stroke). Ram should be in rear position.
17) Switch off machine.
18) Check for evenness, surface finish, accuracy to size.
19) Unclamp and deburr the workpiece.

Quality Check:
1) Comparison techniques use specimens of surface roughness produced by the same
process, material and machining parameters as the surface to be compared. Visual and
tactile senses are used to compare a specimen with a surface of known surface finish.
Because of the subjective judgment involved, this method is useful for surface roughness
>1.6 micron.
2) Machine vision: In this technique, a light source is used to illuminate the surface with a
digital system to viewing the surface and the data being sent to a computer to be analyzed.
The digitized data is then used with a correlation chart to get actual roughness values.

Comments:
1) Never stand in front of the machine, but always beside the machine on the side of the
control elements (splashing chips, danger of getting injured).
2) Make inspections of the workpiece or tool, on principle, only when the machine is at a
standstill.

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Experiment #11
Perform EDM wirecut.

EDM wirecut:
In wire electrical discharge machining (WEDM), also known as wire-cut EDM
and wire cutting, a thin single-strand metal wire, usually brass, is fed through
the work piece, submerged in a tank of dielectric fluid, typically deionized
water. Wire-cut EDM is typically used to cut plates as thick as 300mm and to
make punches, tools, and dies from hard metals that are difficult to machine
with other methods.

The wire, which is constantly fed from a spool, is held between upper and
lower diamond guides. The guides, usually CNC-controlled. The upper and
lower diamond guides are usually accurate to 0.004 mm, and can have a
cutting path or kerf as small as 0.021 mm using Ø 0.02 mm wire, though the
average cutting kerf that achieves the best economic cost and machining
time is 0.335 mm using Ø 0.25 brass wire.

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The wire-cut process uses water as its dielectric fluid, controlling its resistivity and other electrical
properties with filters and de-ionizer units. The water flushes the cut debris away from the cutting zone.
Flushing is an important factor in determining the maximum feed rate for a given material thickness.

Advantages and Disadvantages of EDM-Wire Cut

EDM-Wire Cut also has its own particular advantages. The machine capability is cutting materials
regardless of its hardness. EDM-Wire Cut is much faster than EDM. It can cuts intricate shapes, narrow
slots, small products and others. Furthermore no burrs generated during the process. The wire electrodes
used are much cheaper than shaped electrodes in EDM. Nowadays, EDM-Wire Cut cables to cut tapered
shape products. Electrical Discharge Machining or EDM is a highly accurate method of part production.
Wire EDM technology is essential for higher tolerance parts and repeatable tooling. Achieving high
accuracy and tighter tolerances is essential for many industries such as aerospace, medical, injection
molding and tool and die.

Besides that, EDM-Wire Cut also has disadvantages. The EDM-Wire Cut Machine more expansive
than other machine. High skills are required to handle the machine. The work piece only conductors can
be machine. EDM-wire cut have slow material removal rate (MRR) and less flexible compared others
machine.

Comments:
1) Make sure there are no leaks in the tank dielectric liquid tank hose and pipe connections.
2) Make sure the materials are installed in areas where the right job.
3) Make sure the cutting wire is not touching things work.
4) Make sure each cable there is no leakage.
5) Clear oily liquid that is in place the working substance during the installation process.

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 6) Clean all dirt in the tank desk and storage tanks.
7) Wear appropriate clothing while using machines.

Experiment #12
Perform milling to reduce thickness of workpeice.

Milling Machine:
Milling is the machining process of using rotary cutters to remove material from a workpiece by advancing
(or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different
operations and machines, on scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes in industry and machine shops today for
machining parts to precise sizes and shapes.

Types of Milling Machines

There are several types of milling machines, but usually they are classified by the orientation of their
spindles, which are positioned either horizontal or vertical. Each type of mill has its own attributes
depending on what type of work one is doing,

Horizontal Mill
Horizontal milling machines have a spindle or cutters mounted on a horizontal arbor above an X-Y table.
Some horizontal mills have a table, known as universal table, that features a rotary function for machining
at different angles. Horizontal mills are optimal for machining heavier pieces because the cutters have
support from the arbor, as well as a bigger cross-section area than a vertical mill. The design of the

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horizontal milling machine allows for the rapid removal of material off of the piece one is machining.
These types of milling machines can range in size from something small enough to fit on a tabletop to
room-sized machines.

Vertical Mill
Vertical milling machines have a spindle that moves in a vertical orientation over the table, working on
the top and bottom sides of the object being machined. Vertical milling machines lend themselves to
standing machinists and detailed work. These machines tend to be taller than they are wide since their
operation is vertical, which works well when dealing with die sinking. Die sinking is when a cavity of a
particular size and shape is machined into a steel block. The opening can then be used for molding plastic
or for forging, coining, or die-casting. Below are the two types of vertical milling machines most commonly
used.

Types of Milling Operations:

Face milling
the cutting action occurs primarily at the end corners of the milling cutter. Face
milling is used to cut flat surfaces (faces) into the workpiece, or to cut flat-
bottomed cavities.

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Peripheral milling
the cutting action occurs primarily along the circumference of the cutter, so
that the cross section of the milled surface ends up receiving the shape of
the cutter. In this case the blades of the cutter can be seen as scooping out
material from the work piece. Peripheral milling is well suited to the cutting
of deep slots, threads, and gear teeth.

Comments:
1) Do not make contact with the revolving cutter.
2) Place a wooden pad or suitable cover over the table surface to protect it from possible
damage.
3) Use the buddy system when moving heavy attachments.
4) Do not attempt to tighten arbor nuts using machine power.
5) When installing or removing milling cutters, always hold them with a rag to prevent
cutting your hands.
6) While setting up work, install the cutter last to avoid being cut.
7) Never adjust the workpiece or work mounting devices when the machine is operating.
8) Chips should be removed from the workpiece with an appropriate rake and a brush.
9) Shut the machine off before making any adjustments or measurements.
10) When using cutting oil, prevent splashing by using appropriate splash guards. Cutting oil
on the floor can cause a slippery condition that could result in operator injury

Experiment #13
CNC machining

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CNC Machining:
Computer Numeric Control (CNC) is the automation of machine tools that are operated by precisely
programmed commands encoded on a storage medium (computer command module, usually located on
the device) as opposed to controlled manually by hand wheels or levers, or mechanically automated by
cams alone.

Examples of CNC machines

1) Mills
2) Lathes
3) Plasma cutters
4) Electric discharge machining
5) Wire EDM
6) Sinker EDM
7) Water jet cutters

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CNC co-ordinates:
The X, Y and Z axis control the movement of the cutter on a 3D CNC
machine. This allows materials to be machined in three directions
(3D manufacture)

The plastic block shown below has been shaped on a CNC machine.
It started as a cube.The design (produced on CAD, Computer Aided
Design software) has been converted into coordinates. The cutter is
instructed to go from one coordinate to another. A simple plastic
block such as this may have a thousand coordinates.

For example, point ‘A’ on the plastic block has coordinates 18, 8, 23 (see diagram). The block is composed
of thousands of coordinates and the cutter goes from the first set of coordinates to the second set to the
third set and so on, until it has completed the thousand coordinates. As the cutter is spinning at high
speed, and travels through all the sets of coordinates, it cuts and shapes the block, as it goes along.

Advantages:
1) CNC machines can be used continuously 24 hours a day, 365 days a year and only need
to be switched off for occasional maintenance.
2) CNC machines are programmed with a design which can then be manufactured
hundreds or even thousands of times. Each manufactured product will be exactly the
same.
3) Less skilled/trained people can operate CNCs unlike manual lathes / milling machines
etc.which need skilled engineers.

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 4) CNC machines can be updated by improving the software used to drive the machines
5) Training in the use of CNCs is available through the use of ‘virtual software’. This is
software that allows the operator to practice using the CNC machine on the screen of
a computer. The software is similar to a computer game.
6) Modern design software allows the designer to simulate the manufacture of his/her
idea. There is no need to make a prototype or a model. This saves time and money.
7) One person can supervise many CNC machines as once they are programmed they can
usually be left to work by themselves. Sometimes only the cutting tools need replacing
occasionally.
8) A skilled engineer can make the same component many times. However, if each
component is carefully studied, each one will vary slightly. A CNC machine will
manufacture each component as an exact match.

Disadvantages:
1) CNC machines are more expensive than manually operated machines, although costs are
slowly coming down.
2) The CNC machine operator only needs basic training and skills, enough to supervise
several machines. In years gone by, engineers needed years of training to operate centre
lathes, milling machines and other manually operated machines. This means many of the
old skills are been lost.
3) Less workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.

Procedure:
1) As you decide on the correct work holding, many other aspects of machining such as what
processes to perform first, what type of tooling to consider, and in what order the
programming processes must be programmed will also come into play.
2) After you have decided on how you will hold the workpiece as you machine it to
completion, you can now determine step by step how you will machine each phase. As you
layout the machining process, you can decide on what tooling will be used in that
machining as well.
3) Once tooling is decided, cutting data such as speed & feed data can be gathered to suit the
chosen tooling, material and workholding.
4) Now that workholding and tooling have been determined, the programmer is ready to start
to create the program. the first step is to determine the PART ZERO or ABSOLUTE ZERO
location.
5) All information needed to create the program should now be at hand. The best way to
create the program is simply to sit down and write it, visualizing that you are at the
machine actually machining the part.

6) After the program has been entered into the machine, it is always a good idea to check
your programmed path again as you read thru the program as well as check for typing
errors even if the program was input through a word processor or by hand.

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 7) The set-up involves mounting all fixturing, tooling, recording the part zero, recording all
tool offsets and any other task required before machining.
8) Once you are satisfied with the tool path and cutting conditions, let it rip. Your first
program will usually not be the final product. Constant refinements are usually done to
improve tool life, cycle time or finish. The majority of the product is done but you should
always be looking for ways to improve the program or process.

Common machining problems

PROBLEM CAUSE SOLUTION
The material burns on outside Feed speed too slow. Increase feed speed.
edge.

The tool is burnt. The tool is blunt. Replace with sharp tool.
Burnt edges of holes. The tool is blunt. Replace with sharp tool.
Rough edge, cutter marks Machine is travelling too fast Reduce the feed speed.
visible. (feed speed).
Component not the correct Tool data has been entered Edit tool data settings.
size. incorrectly.

Component not the correct Component sizes entered Edit component data.
size. incorrectly.

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Experiment # 15
Vertical Drilling Machine
A drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other materials
Drilling machines use a drilling tool that has cutting edges at its point. This cutting tool is held in the drill
press by a chuck or Morse taper and is rotated and fed into the work at variable speeds. Drilling machines
may be used to perform other operations. They can perform countersinking, boring, counterboring, spot
facing, reaming, and tapping.

Operations on Drilling Machine:

 Drilling may be defined as the operation of producing a hole by removing metal from a
solid mass using a cutting tool called a twist drill.
 Countersinking is the operation of producing a tapered or cone-shaped enlargement to
the end of a hole.
 Reaming is the operation of sizing and producing a smooth, round hole from a previously
drilled or bored hole with the use of a cutting tool having several cutting edges.
 Boring is the operation of truing and enlarging a hole by means of a single-point cutting
tool, which is usually held in a boring bar.

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  Spot-facing is the operation of smoothing and squaring the surface around a hole to
provide a seat for the head of a cap screw or a nut. A boring bar, with a pilot section on the
end to fit into the existing hole, is generally fitted with a double-edged cutting tool. The
pilot on the bar provides rigidity for the cutting tool and keeps it concentric with the hole.
For the spot-facing operation, the work being machined should be securely clamped and
the machine set to approximately one-quarter of the drilling speed.
 Tapping is the operation of cutting internal threads in a hole with a cutting tool called a
tap. Special machine or gun taps are used with a tapping attachment when this operation
is performed by power in a machine.
 Counterboring is the operation of enlarging the top of a previously drilled hole to a given
depth to provide a square shoulder for the head of a bolt or cap screw.

Twist Drills
Twist drills are the most common cutting tools used with drilling machines. Twist drills are designed to
make round holes quickly and accurately in all materials. They are called twist drills mainly because of the
helical flutes or grooves that wind around the body from the point to the neck of the drill and appear to
be twisted Twist drills are simply constructed but designed very tough to withstand the high torque of
turning, the downward pressure on the drill, and the high heat generated by friction.

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Procedure:
1) Set the Speed. The speed on most drill presses is adjusted by moving the drive belt from
one pulley to another. In general, the smaller the pulley on the chuck axis, the faster it
spins. A rule of thumb, as with any cutting operation, is that slower speeds are better for
drilling metal, faster speeds for wood. Again, consult your manual for the manufacturer’s
recommendations.
2) Fit the Bit. Open the chuck, slide in the bit, snug the chuck by hand around the bit’s shaft,
then tighten the chuck’s three jaws with the key. Make sure to remove the chuck. If you
don’t, it’ll become a dangerous projectile when you turn on the drill. When drilling large
holes, drill a smaller, pilot hole first.
3) Adjust the Table. Some models have a crank that adjusts the table height, others move
freely once the clamping lever has been released. Set the table to the desired height for the
operation you are to perform.
4) Gauging the Depth. If you are simply drilling a hole in a piece of stock, you may not
need to adjust the depth gauge, the threaded rod that controls the distance the spin-dle
travels. However, if you are concerned with a stopped hole of a fixed depth, lower the bit
to the desired height, and ad-just the pair of knurled nuts on the depth gauge to the proper
stopping point. One of them should stop the spindle; the other locks the first nut in place.
5) Secure the Workpiece. Before operating your drill press, be sure that the workpiece to
be drilled is fixed in place. The ro-tation of the drill bit may try to spin the wood or metal
workpiece, so it must be clamped to the worktable, braced against the supporting column
at the rear of the machine, or other-wise secured. Never operate the tool without firmly
anchoring the workpiece.
6) Drilling. Once the drill press setup has been completed, put-ting it to work is easy. Make
sure the drill is spinning at full speed, then present the bit to the workpiece, lowering the
bit by swinging the rotating lever. Once you’ve finished drilling the hole, release the
pressure on the lever and its spring-loaded return mechanism will return it to its original
position.

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Problems:
The main problems occur in differential gear box are the failure of the worm threading on the motor
shafts, worm wheels, bevel gears etc.

1) Bending of the shaft due to high impact of loads

2) Failure of the bearings due to heavy loads

Comments:
1) Do not support the workplaces by hand. Use a holding device to prevent the workpiece
from being tom from the operator’s hand.
2) Never make any adjustments while the machine is operating.
3) Never clean away chips with your hand. Use a brush.
4) Keep all loose clothing away from turning tools.
5) Make sure that the cutting tools are running straight before starting the operation.
6) Never place tools or equipment on the drilling tables.
7) Keep all guards in place while operating.
8) Ease up on the feed as the drill breaks through the work to avoid damaged tools or
workplaces.
1. Remove all chuck keys and wrenches before operating.
2. Always wear eye protection while operating any drilling machines.

Experiment # 17
The sinker EDM machining

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The sinker EDM machining:
The sinker EDM machining (Electrical Discharge Machining) process uses an electrically charged electrode
that is configured to a specific geometry to burn the geometry of the electrode into a metal component.
The sinker EDM process is commonly used in the production of dies and molds.

How Sinker EDM works

Two metal parts submerged in an insulating liquid are connected to a source of current which is switched
on and off automatically depending on the parameters set on the controller. When the current is switched
on, an electric tension is created between the two metal parts.

If the two parts are brought together to within a fraction of an inch, the electrical tension is discharged
and a spark jumps across. Where it strikes, the metal is heated up so much that it melts.

Innumerable such sparks spray, one after the other (never simultaneously) and gradually shape the
desired form in the piece of metal, according to the shape of the electrode. Several hundred thousand
sparks must fly per second before erosion takes place.

Die-sinking EDM Machining

In the case of die-sinking EDM, the required shape is formed negatively in the metal with a three-
dimensional electrode. By superimposed movements in the main axes x, y, c, z, the most varied shapes,
indentations and cavities are created, such as cannot in part be achieved by any other machining system.

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Experiment #18
Water Jet Cutting

Water Jet Cutting

Waterjet is a generic term used to describe equipment that uses a high pressure stream of
water for cutting or cleaning purposes. Abrasive jet is a subcategory of waterjet in which
abrasive is introduced to accelerate the process. Pure waterjet and water-only cutting are
phrases for specifically distinguishing waterjets that do not use abrasive.

How do waterjets work?

Take ordinary tap water and pressurize it to 60,000 psi (4,000 bar) and force it through a very
small hole. Mix the water with garnet abrasive and you have a very thin stream of water
traveling very fast that will rapidly erode most materials.

Some waterjets are "pure waterjets" and don't add the garnet abrasive. These are used to cut
softer materials, such as food, rubber, and foam.

What can waterjets cut? What can't they cut?

Waterjets can cut just about any material that can be made into a sheet and placed in
front of them.

The most popular materials are metals (especially aluminum, because it's relatively soft and cuts quickly),
because waterjets can cut intricate shapes to a high precision quickly and economically. Since metals are
the most common material cut by machining shops, waterjets tend to cut a lot of metal.

Waterjets also commonly cut stone and glass, because the waterjet can get intricate shapes not possible
using traditional machining methods. These materials are popular with artists who like to work with these
materials and waterjets because it lets them create almost anything they can envision.

Among the very few materials that waterjets cannot cut are diamonds and tempered glass. Diamonds are
too hard to cut (and there may be a few other very hard materials that can't be cut). Tempered glass will
shatter when it is cut with a waterjet (tempered glass is designed to shatter when it's disturbed and is
frequently used in windshields for this very reason).

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Advantages of waterjet machining
1) Cut virtually any material
2) Fast setup and programming
3) Little fixturing for most parts
4) No mechanical stresses
5) Machine thick material
6) Environmentally friendly
7) No start hole required
8) Narrow kerf removes only a small amount of material

Disadvantages of Waterjet Machining

1) Waterjet technology cuts slower than plasma cutting process, reducing material
processing productivity.
2) Waterjet technology has a higher entry cost than the plasma cutting machines.
3) The abrasive material used for cutting harder materials tends to be quite expensive.

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