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69427004 Manufacturing Technology Lab Manual

# 69427004 Manufacturing Technology Lab Manual

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05/20/2013

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Document Name: Manufacturing Technology Lab 1

www.VidyarthiPlus.in

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5. Repeat the same procedure for different depth of cuts.in EXERCISE NO.in) Page 2 . The Lathe Tool Dynamometer is initially set to zero reading.www. Calculate the resultant cutting force P = Sqrt (Px2 + Pz2) 4. RESULT : Thus the cutting forces are measured for different depth of cuts.Vidyarthiplus. TOOLS AND EQUIPMENTS REQUIRED : Lathe. © Copyright 2011 – 2015 (VidyarthiPlus. 2. Repeat the same procedure to get few more readings and calculate the mean cutting force. The known depth of cut is given and take the readings of Px and Pz force components from the Lathe Tool Dynamometer. Lathe Tool Dynamometer. 1 CUTTING FORCE MEASUREMENT Manufacturing Technology Lab I III Semester A & B AIM : To measure the cutting forces for the given cutting conditions. 3. PROCEDURE : 1.

50 1 2 3 4 0. acts in the direction of the tool traverse and it is at right angles to Pz. Px – the axial component.50 2 0.50 3 0.Vidyarthiplus. This component acts in the direction of the cutting speed.www. (mm) Px (kg) Pz (kg) (Kg) (Kg) 1 0.75 0. 2.75 NOTE : 1.50 4 0.in Px Py Px Py Pz Pz TABULATION : DEPTH HORIZONTAL VERTICAL RESULTANT AVERAGE SL. OF CUT COMPONENT COMPONENT P = Sqrt (Px2 + Pz2) NO. It contributes very little to the power consumption. the deflection of the tool and the required power. © Copyright 2011 – 2015 (VidyarthiPlus.75 0. determines the torque on main drive mechanism.in) Page 3 . Pz – the main or tangential component.75 0.

7. rc = t1 / t2 5. t2.rc sinα where. α . © Copyright 2011 – 2015 (VidyarthiPlus.in 3. Calculate the shear angle for the given rake angle of the tool. Micrometer. rc cosα tan φ = ----------1 . 2 SHEAR ANGLE MEASUREMENT AIM : To measure the shear angle to the given conditions. Find the mean chip thickness. 6. Repeat the same procedure to get few more readings and calculate the mean shear angle. TOOLS AND EQUIPMENTS REQUIRED : Lathe. It has no share in the power consumption.www.in) Page 4 .rake angle. EXERCISE NO. Single point turning tool. acts along the tool shank and perpendicular to the other two components. Repeat the experiment for different depth of cuts. 2. Py – the radial component. t1). Calculate the chip thickness ratio. The chip is taken for thickness inspection. The workpiece is held in the chuck. 4. 3. The known depth of cut is given (uncut chip thickness.Vidyarthiplus. PROCEDURE : 1.

in) Page 5 . tool geometry. If the Shear angle is small. Hence. the plane of shear will be shorter and the chip is thin. 2.www. © Copyright 2011 – 2015 (VidyarthiPlus. less force is required to remove the chip.in t2 t1 Tool Workpiece NOTE : 1. 3. the chip is thicker. tool material and work material. the plane of the shear is large. If the shear angle is large.Vidyarthiplus. more force is required to remove the chip. The value of Shear angle depends on the cutting conditions.

25 1 2 3 4 0.50 0.in CHIP THICKNESS : LC = Least Count DEPTH PITCH SCALE HEAD SCALE HEAD SCALE CHIP SL.25 4 0. THICKNESS RATIO SHEAR ANGLE 1 2 3 4 1 2 3 4 t1 (mm) 0.50 0. t1 (mm) (PSR) (HSC) HSR = HSC*LC t2 = PSR + HSR 1 0.50 SHEAR ANGLE : UNCUT CHIP CHIP SHEAR ANGLE CHIP THICKNESS THICKNESS AVERAGE SL.50 0.25 0.25 0. OF CUT READING COINCIDENCE READING THICKNESS NO.50 0.25 0.25 3 0.25 2 0.in) Page 6 .50 t2 (mm) rc = t1 / t2 RESULT : Thus the shear angle is found for different depth of cuts.www.50 0. © Copyright 2011 – 2015 (VidyarthiPlus.Vidyarthiplus.25 0. NO.50 0.

5. 50 70 10 70 9±0. 6. the finished workpiece is checked for the given dimensions. The reciprocating and cross feed is given to grind the required length and width of the workpiece respectively. RESULT : © Copyright 2011 – 2015 (VidyarthiPlus. 3 SURFACE GRINDING AIM : To grind the workpiece to the given tolerance using surface grinding machine. 2.www. PROCEDURE : 1. The permanent magnet worktable is cleaned thoroughly.Vidyarthiplus. Keep the workpiece over the worktable and push the lever to “ON” position to hold the workpiece. Finally. 3.in EXERCISE NO.01 TOOLS AND EQUIPMENTS REQUIRED : Surface Grinding machine. The given workpiece is checked for its initial dimensions. Micrometer. The required depth of cut is given by raising the table. 4.in) Page 7 50 .

© Copyright 2011 – 2015 (VidyarthiPlus.in Thus the given workpiece is ground to the given tolerance using surface grinding machine. 4 SPUR GEAR MILLING AIM : To machine gear to the given module and number of teeth in the given workpiece. Mandrel. Their axis must be set parallel to the machine table. Ø18 TOOLS AND EQUIPMENTS REQUIRED : Milling machine. PROCEDURE : 1.Vidyarthiplus. Calculate the gear tooth proportions.www. Vernier caliper.5708 m . Z = Number of teeth required m = module 2. Indexing calculation Index crank movement = 40 / Z 3.25 m = 1.in) Page 8 0 Ø5 =(Z+2)m = 2. EXERCISE NO. Blank diameter Tooth depth Tooth width where. The dividing head and the tail stock are bolted on the machine table.

Then the gear blank is indexed for the next tooth space.25 m = 2. After the cut. The cutter is centred accurately with the gear blank. The cutter is mounted on the arbor. 12. The gear blank is held between the dividing head and tailstock using a mandrel. The machine is started and feed is given to the table to cut the first groove of the blank. For giving depth of cut.in) Page 9 . 7. This is continued till all the gear teeth are cut. 6. the table is raised till the periphery of the gear blank just touches the cutter.www.Vidyarthiplus. 9.25 * 2 = 4. of teeth m = module Blank Diameter = 23 = 2 mm = (Z + 2) m = (23 + 2) 2 = 50 mm = 2. 8. CALCULATION : Z = No. Set the speed and feed for machining. 5. 13.in 4. The mandrel is connected with the spindle of dividing head by a carrier and catch plate. The micrometer dial of vertical feed screw is set to zero in this position. the table is brought back to the starting position. Then the table is raised further to give the required depth of cut.5 mm = 40 / Z = 40 / 23 = 1 17/23 Tooth Depth Indexing Calculation RESULT : © Copyright 2011 – 2015 (VidyarthiPlus. 10. 11.

turning tool. © Copyright 2011 – 2015 (VidyarthiPlus. The workpiece is chucked and checked for the rotation. 4. 20 12 18 TOOLS AND EQUIPMENTS REQUIRED : Capstan Lathe.Vidyarthiplus. EXERCISE NO. Vernier Caliper. Set the tools in their respective positions of the tool stations. Stopper. 2.in) Page 10 12 18 . counter sink bit. drill chuck. 5. drill bit. Prepare the tooling layout for the given workpiece. Feed the tools in the required sequence to machine the given workpiece. PROCEDURE : 1. The adjustment to the length of feed for each tool is adjusted by rotating the adjustment screws. parting off tool. 3.www.in Thus the required gear is machined using the milling machine to the required number of teeth. RESULT : Thus the given workpiece is machined to the given dimensions using capstan lathe. 5 CAPSTAN LATHE AIM : To machine the workpiece to the given dimensions using capstan lathe.

in) Page 11 . Threading tool.I AIM : To machine and assemble the given workpieces to the given dimensions using required machines. The given workpiece is checked for its initial dimensions. The internal thread is made on another workpiece. 2. 4. RESULT : Thus the given workpieces are machined as per the given dimensions and assembled using the required machines. Check for the mating of internal and external threads formed.www. 5. Turning tool. 3. Vernier caliper. © Copyright 2011 – 2015 (VidyarthiPlus.4 x 3.Vidyarthiplus. PROCEDURE : 1. The external thread is made on the workpiece. M 25.75 30 18 40 10 30 Chamfer 45° x 2 TOOLS AND EQUIPMENTS REQUIRED : Lathe.in EXERCISE NO. Parting tool. The workpiece is chucked and turned for the required dimensions. 6 ASSEMBLY .

The given workpieces are checked for its initial dimensions. 7 ASSEMBLY . PROCEDURE : 1.II AIM : To machine and assemble the given workpieces to the given dimensions using required machines. © Copyright 2011 – 2015 (VidyarthiPlus.in EXERCISE NO. 4.www. 3. The workpiece is chucked in lathe and machined to the projection dimensions as given in the figure. 2.Vidyarthiplus.in) Page 12 Ø50 . The other workpiece is machined for recess dimensions as given in the figure. Vernier caliper. Mate both the workpieces. Ø55 Ø50 Ø40 Ø40 Ø55 5 10 20 10 5 20 TOOLS AND EQUIPMENTS REQUIRED : Lathe.

www.Vidyarthiplus. © Copyright 2011 – 2015 (VidyarthiPlus.in) Page 13 .in RESULT : Thus the given workpiece is machined as per the given dimensions and assembled using the required machines.

Steel rule. The width across the flat is first determined ( Across flat = 1.5 S + 3 mm ) 3. Mandrel PROCEDURE : 1. TOOLS AND EQUIPMENTS REQUIRED : Milling Machine. 6. 4. The workpiece is mounted at the nose of the dividing head spindle by the help of a suitable chuck.www. The workpiece is rotated through one sixth of a revolution by using the indexing mechanism and then the second cut is taken. 5. It is to be repeated for six number of times to finish six faces of the workpiece. © Copyright 2011 – 2015 (VidyarthiPlus.in) Page 14 . 2. The given workpiece is checked for its dimensions. A universal dividing head is mounted on the table with its spindle swiveled to the horizontal position. The workpiece is centred below the cutter and the first cut is taken. Vernier caliper.in EXERCISE NO.Vidyarthiplus. RESULT : Thus the required hexagonal surface is machined using the milling machine to the given dimensions. 8 MILLING OF HEXAGONAL SURFACE AIM : To machine a given hexagonal surface in a given workpiece using milling machine.

Vidyarthiplus.www. 40 ---Z 40 ---6 26 6 ---39 Simple Indexing = = = © Copyright 2011 – 2015 (VidyarthiPlus. D = 2 x S Distance across the Flat S= 20 = (1. the number of faces. Z = 6.in CALCULATION : Diameter.5 x S) + 3mm Depth of cut = Diameter (D) – Distance across the Flat ----------------------------------------------------2 INDEXING CALCULATION : For Hexagonal surface.in) Page 15 .

in) 10 20 Page 16 .in EXERCISE NO.www. 9 CNC LATHE AIM : To create a workpiece with the help of CNC Lathe Machine.Vidyarthiplus. 30 20 20 20 © Copyright 2011 – 2015 (VidyarthiPlus.

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