MT Lab Manual (Final) PDF

MACHINE TOOLS & METROLOGY LABORATORY
MACHINE TOOLS
&
METROLOGY
LABORATORY MANUAL
2019-20
DEPARTMENT OF MECHANICAL ENGINEERING

MVGR COLLEGE OF ENGINEERING (A)
VIJAYA RAM NAGAR CAMPUS
VIZIANAGARAM-535005
Reaccredited by NBA, Grade “A” by NAAC of UGC, Approved by AICTE, New

Delhi, and Permanently Affiliated to JNTUK, Kakinada Listed U/S 2(f) & 12 (B)
of the UGC Act 1956.
1
PREFACE
Machine Tools are versatile processes of major importance for component manufacturing.
The importance of machine tools in modern automated manufacturing systems has in fact
increased due to the significant increases in the production times and the need to offset the
high capital investment in these modern systems. The need for improving the technological
performance of machine tools as assessed by the forces, power, tool life and surface finish
has long been recognized to increase the economic performance of the machining operations.
As such, continual improvements in the technological performance of machine tools have
been sought through research and development including new and more wear resistant tool
materials as well as new geometrical tool designs.
Many researchers focusing on modeling of machine tools process to solve several

complicated problems arising in the development of new technologies. One of state of art
efforts in manufacturing engineering is to simulation machining process to predict cutting
forces, effective stress, and effective strain and chip formation using different methods. These
computational models would have great values in reducing or even eliminating the number
or trial and error experiments, which traditionally are used for machine tools design, process
selection, machinability evaluation and chip breaking investigation. The difficulty of
reaching a better theoretical understanding of machine tools impelled researchers in the field
to apply different model in metal cutting process. More attention to the finite element method
has been paid in the past decade in respect to its capability of numerical modeling different
types of machine tools problems.
Machine tools are heavy, power-driven machinery and equipment that perform specific
actions on materials like metal and plastic. The most common jobs these machines are used
for include material removal (turning, milling, drilling, grinding, water-jet or laser cutting);
material forming (stamping,
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bending, joining); and “work holding” (chucks, fixtures, clamps, blocks). The majority of this
equipment is technical in nature; with computer numerical control (CNC) or programmable
logic control (PLC) built in.
The tooling and machining industry is critical to our country’s economic health as it makes
possible the existence of virtually every other manufacturing industry. Tooling is, basically,
the means of production. “Special” tooling, such as dies and molds, is custom designed and
made to manufacture specific products, generally in quantity, and to desired levels of
uniformity, accuracy, interchangeability, and quality. Machining involves the use of a wide
variety of machine tools to cut or form material, usually metal, to precise shapes and
dimensions.
Advances in technology are creating major changes in the INDIAN machine tool industry.
The computerization of the industry is leading to rapid improvements in existing machine tool
product lines and the development of new products. The shortage of skilled labor and the
relatively high costs of labor are driving the demand for machine tools with greater flexibility
that is programmable to replace or reduce the need for more sophisticated operators.
The increased competitiveness of major consuming industries such as the automotive

and job shop sectors is driving the demand for more sophisticated machines. End users are
investing in machine tools that offer increased performance, flexibility and productivity.
Lab In-charge:
Mr. G Pramod kumar
Dr. Umamaheswara Raju. R. S.

Mr. B. Srinivas
Mr. P. Sreenu
Mr. N. Jagadeesh
Mr. Adithya Rathod
3
ACKNOWLEDGEMENT
The authors would like to thank Dr. K. V. L. Raju, Principal, MVGR College of
Engineering for his encouragement and suggestions in preparing this manual. Seeing
the lack of practical understanding and industry-institutes gap amongst the student
community, his idea of serving the students in their learning process is the basis for the
development of this manual. The authors are grateful to him for his thought-provoking
ideas and suggestions.
The authors would also like to thank Prof. S. Adinarayana, Head, Department of
Mechanical Engineering, for his encouragement and support in preparing this
manual. Several photographs of lab equipment were necessary to present a practical
viewpoint of the subject matter. Without his support this would not have been possible.
Authors thank Dr. R. Ramesh, Dean R & D, and Professor Department of Mechanical
Engineering. Dr. I. Sudhakar, Associate Professor, Department of Mechanical
Engineering for their efforts in development of the machine tools laboratory manual.
The authors thank all the lab technicians and department personnel who assisted in the
preparation of the manual by preparing the necessary equipment for photography.
We would like to express our sincere gratitude to our parents and friends for their
continuous support
Dr. Umamaheswara Raju. R. S.
Mr. B. Srinivas
Mr. P. Sreenu
Mr. N. Jagadeesh
Mr. Adithya Rathod
Lab In-charge:
Mr. G Pramod kumar

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COURSE OBJECTIVES
1. Enable the student to understand various kinds of cutting tool material, cutting tool and
nomenclature associated with them.
2. To understand the importance of specification of machine tool.
3. To enable the students to bring out the difference between accessories and attachment
pertaining to a specific machine tool and their effect on process capability.
4. Understand the association between measurement and machining while performing a
specific task.
5. To enable the student to know the importance of calibration & working principles of
precision measuring instruments
6. To enable the student to understand the importance of alignment tests of different kinds
of machine tools.
7. To demonstrate different instruments used for measuring the dimensional accuracy of
components like gears & tool nomenclature.
COURSE OUTCOMES:
i. Enable the student to understand various kinds of cutting tool material, cutting tool and
nomenclature associated with them.
ii. To understand the importance of specification of machine tool.
iii. To enable the students to bring out the difference between accessories and attachment
pertaining to a specific machine tool and their effect on process capability.
iv. Understand the association between measurement and machining while performing a
specific task.
v. To enable the student to know the importance of calibration & working principles of
precision measuring instruments
vi. To enable the student to understand the importance of alignment tests of different kinds of
machine tools.
vii. To demonstrate different instruments used for measuring the dimensional accuracy of
components like gears & tool nomenclature.
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LABORATORY EXERCISE:
3
Experiments
Internal lab examination

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Backlogs/revision
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TEXT BOOKS:
1. Production Technology By R. k. Jain and S. C. Gupta

2. Workshop Technology—B. S. Raghu vamsi
REFERENCES:
Production Technology by H. M. T
Machine Tools – c. Elanchezhian and M. Vijayan / Anuradha agencies
publishers. Tribology by I.M.Hutching, Wolward Arnold, Advision of Hodder
and Stoughton. Surface Engineering for wear resistance by Kenneth G.
Budinski, Prentice Hall Metal Cutting and Machine Tools / P.N. Rao
Manufacturing Technology / Adithan and
Gupta Theory of Metal Cutting /
Bhattacharya
Metal Cutting and Manufacturing Technology / Booth
Ryod Workshop Technology / Hajra Chowdary
Workshop Technology / Raghuvamsi
Metal Cutting and Machine Tools / Juneja
BOOKS AVAILABLE IN LIBRARY:

Production Engineering / P.C.
Sharma Production Technology /
R.K. Jain
Metal Cutting and Machine Tools / P.N. Rao
Manufacturing technology / Adithan and
Gupta Theory of Metal Cutting /
Bhattacharya Workshop Technology / Hajra
Chowdary Workshop Technology /
Raghuvamsi
Metal Cutting and Machine Tools / Juneja
JOURNALS:
ASME Journal of Manufacturing Science and Engineering.
International Journal of Manufacturing and Technology.
DIGITAL LEARNING MATERIALS:

Manufacturing Technology – IEEE Transactions on
IIT Kharagpur – CD’s on Metal Cutting and Machine Tools
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GENERAL INSTRUCTION
1. Every student should obtain a set of instruction sheets entitled manufacturing processes
Laboratory.
2. For reasons of safety, every student must come to the laboratory in shoes. It is unsafe for
the students to come to the laboratory wearing garments with parts that that hang about
loosely. Students should preferably Use half-sleeve shirts. The Students should also ensure
that floor around the machine is clear and dry (not oily) to avoid slipping.
3. An apron will be issued to each student. Students not wearing an apron will not be
permitted to the work in the laboratory.
4. Instruments and tools will be issued from the tool room. Every student must produce his
identity card for the purpose. Tools, etc. must be returned to the tool room on the same day.
5. The student should take the permission of the Lab Staff / Tutor before handling any
machine.
6. The student should not lean on the machine when it is working.
7. Power to the machines will be put off 10 minutes before the end of laboratory session to
allow the students to return the tools.
8. Students are required to clear off the chips from the machine and lubricate the guides etc.
at the end of the session.
9. Laboratory reports should be submitted on time.
10. Reports will be returned to the students at the end of each session. Students may see the
grades and revise reports for better grades.
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PROBABLE ACCIDENTS
1. Before switching on any machine tool, work piece, tool or tool holder or any supporting
assembly like tailstock in lathe to be clamped properly.
2. The chief hazard associated is accidental contact with moving cutter
3. Hazard of sharp edge contact with chips while machining.
4. Selection of no. of teeth or blade size on primer hacksaw machine.
5. Ramming of chips when machine in motion viz. shaping or slotting.
6. Locking of tables and ensure the feed.
7. Switch on the connection selection of lever (rapid/feed).
8. Approach the tool to the work piece while machining at slow pace to avoid cutting tool
damage.
9. Magnetic clamping refines starting the surface grinding.
10. Selection of proper depth cut or feeds or any machine.
11. Chip disposal system to the accident free.
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LIST OF EXPERIMENTS:
1. Introduction to General Purpose Machine Tools (Types, specifications, drive mechanism,
feed mechanism, operations performed and tools used).
2. Knurling, thread cutting and measure the pitch of the thread using thread gauge
3. Step turning, Taper turning and Cylindrical grinding
4. Drilling and boring on a flange and checking the bore diameter using dial bore indicator
5. Calibration of instruments like vernier caliper, micrometer and vernier height gauge
6. Machine tool alignment test on lathe
7. Machining a V-Block using Shaper
8. Grinding a single point cutting tool and measuring tool angles using tool makers
microscope
9. Drilling, Tapping and surface grinding
10. Gear Cutting on milling machine and find the profile of gear using vernier gear tooth
calliper
11. Measuring angles using sine-bar and bevel protractor
ADDITIONAL EXPERIMENTS:
12. CNC Turning part program for given component

13. CNC Milling part program for given component
10
KNURLING, THREAD CUTTING AND MEASURING THE PITCH OF THE

THREAD USING THREAD GAUGE
11
EXPERIMENT: 2
AIM: To select suitable cutting parameters to perform knurling operation on given M.S. Rod.
Cutting a BSW thread profile and comparing the profile of it with a standard thread gauge.
To find the material removal rate, Tangential cutting force and Torque requirements.
OBJECTIVES:
To study and understand the function of a lathe, its parts and specifications
To study and understand different drive and feed mechanisms involved in a lathe.
To study and understand different operations that can be performed on lathe.
To learn about different attachments that can be installed for performing other operations
To know the purpose of Knurling and Thread Cutting
THREAD CUTTING:
Thread cutting is one of the most important operations performed on lathe machine. The
thread is a helical groove on a cylindrical or conical surface by feeding the tool longitudinally
when the job is revolved in between centre’s of a chuck. The longitudinal feed should be
equal to the pitch of the thread to be cut per revolution of workpiece.
KNURLING:
Knurling is a process of embossing the diamond shaped pattern on the surface of work piece.
The purpose of the knurling is to provide an effective gripping surface on a workpiece to
prevent it from slipping when operated by hand. In some press fit work knurling is done to
increase the diameter of the shaft. The operation is performed by a special set of hardened
steel rollers in a holder with the teeth cut on their surface in a definite pattern.
12
Figure1. Schematic diagram of lathe machine
Figure2. Schematic diagram of thread cutting and knurled workpice
13
CUTTING PARAMETERS SELECTION FOR LATHE MACHINE
CMTI Machining hand book data.
Cutting Speed M/min
Work Tool Depth, mm
Material Material 5-10 2-5 0.5-2 0.1-0.5
Feed mm/rev
0.4-0.6 0.25-0.5 0.2-0.3 0.05-0.2
Free-machining steels HSS 20-40 40-70 40-110 50-120
Carbide 90-150 120-180 150-250 200-500
Mild Steel HSS 25-35 30-50 30-60 40-80
Carbide 60-120 80-150 120-200 150-450
Medium Carbon Steel HSS 15-25 25-45 25-50 30-70
Carbide 50-110 60-120 90-150 120-300
Alloy Steels HSS 10-15 15-25 15-35 20-45
Carbide 30-65 40-80 60-100 80-180
Tool steels HSS 15-20 20-25 20-30 30-60
Carbide 50-110 60-120 90-150 120-300
Stainless Steel HSS 15-20 15-25 15-30 20-50
Carbide 40-60 40-70 50-80 50-90
Cast iron, Grey, HSS 20-25 25-30 35-45 40-60
Ductile, Malleable. Carbide 60-90 70-100 80-110 80-120
Aluminium alloys HSS 40-70 70-100 90-120 100-200
Carbide 60-150 80-180 90-450 150-600

Copper alloys HSS 40-60 60-100 90-120 100-200
Carbide 50-110 60-150 90-180 120-310
Magnesium alloys HSS 40-70 70-100 90-120 100-200
Carbide 60-150 80-180 90-450 150-600
Titanium alloys HSS 10-15 15-30 30-50 50-90
Carbide 15-30 30-50 50-90 60-120
POWER AND FORCE REQUIREMENTS IN TURNING:
t
D
15
Diameter of the workpiece D Mm

Revolutions for minute N Rpm
Cutting Speed V m/min V=πDn/1000
Feed Per Revolutoin S mm/rev
Feed per Minute Sm mm/min Sm=s×n
Depth of cut T Mm
Metal removal rate Q Cm3/min Q=s×t×v
Approach angle X Deg
Average Chip Thickness As Mm as=s.sinX
Unit Power U Kw/ cm3/min
Correction factor for flank wear Kh
Side rake angle Γ
Correction factor for rake wear Kγ
Power at the spindle N Kw N=U.Kh. K γ.Q
Power at Motor Nel kW Nel=N/E(Efficiency)
Tangential cutting force Pz Kgf Pz=6120N/v
Torque at spindle Ts Kgf.m Ts=975N/n
PROCEDURE: PRECAUTIONS: APPLICATIONS:
RESULT :
Thread cutting and knurling are performed on M.S.Rod using lathe by selecting proper
cutting tools and cutting parameters like speed rpm, feed m/min and at a depth
of cut mm. The material removal rate is Cm3/min, The tangential cutting
force is Kgf and Torque requirement for the motor is Kgf.m.
CONCLUSION:
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17
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STEP TURNING, TAPER TURNING AND CYLINDRICAL GRINDING
19
Experiment: 3
AIM: To select suitable cutting parameters to perform taper and step turning operation on
given M.S. Rod. To perform grinding operation on the turned surfaces to achieve better
surface finish. To find the material removal rate, Tangential cutting force and Torque
requirements for Turning and Grinding.
OBJECTIVES:
To study and understand the functioning of a lathe, cylindrical grinder and their parts.
Understand the specifications of lathe and cylindrical Grinding machines
To study and understand different drive and feed mechanisms of lathe and cylindrical
grinding machines.
To study and understand different operations that can be performed on lathe and
cylindrical grinding machines.
To know the purpose of doing taper turning, step turning and cylindrical grinding.
TAPER TURNING:
A taper may be defined as a uniform increase or decrease in diameter of a workpiece along its
length. In a lathe, taper turning means to produce a conical surface by gradual reduction in
diameter from a cylindrical workpiece. This tapering of a part has wide application in the
construction of machines. Almost all the spindles have taper holes which receive taper shank
of various tools and work holding devices.
STEP TURNING:
When a single workpiece is turned to different diameters than such turning, the surface
forming the step from one diameter to the othher is called step turning.
CYLINDRICAL GRINDING:
The cylindrical grinder is used to shape the outside (OD) of an object. The cylindrical grinder
can work on a variety of shapes, however the object must have a central axis of rotation. This
includes but is not limited to such shapes as a cylinder, an ellipse, a cam, or a crankshaft.
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Figure 1. schematic diagram of lathe machine.
Figure 2. schematic diagram of fixing the job in Cylindrical Grinding Machine.
Figure2. Schematic diagram of step turning, taper turning and grinding of workpiece
21
CUTTING PARAMETERS SELECTION FOR LATHE MACHINE
CMTI Machining hand book data.
Cutting Speed M/min
Work Tool Depth, mm
Material Material 5-10 2-5 0.5-2 0.1-0.5
Feed mm/rev
0.4-0.6 0.25-0.5 0.2-0.3 0.05-0.2
Free-machining steels HSS 20-40 40-70 40-110 50-120
Carbide 90-150 120-180 150-250 200-500
Mild Steel HSS 25-35 30-50 30-60 40-80
Carbide 60-120 80-150 120-200 150-450
Medium Carbon Steel HSS 15-25 25-45 25-50 30-70
Carbide 50-110 60-120 90-150 120-300
Alloy Steels HSS 10-15 15-25 15-35 20-45
Carbide 30-65 40-80 60-100 80-180
Tool steels HSS 15-20 20-25 20-30 30-60
Carbide 50-110 60-120 90-150 120-300
Stainless Steel HSS 15-20 15-25 15-30 20-50
Carbide 40-60 40-70 50-80 50-90
Cast iron, Grey, HSS 20-25 25-30 35-45 40-60
Ductile, Malleable. Carbide 60-90 70-100 80-110 80-120
Aluminium alloys HSS 40-70 70-100 90-120 100-200
Carbide 60-150 80-180 90-450 150-600
Copper alloys HSS 40-60 60-100 90-120 100-200
Carbide 50-110 60-150 90-180 120-310

Magnesium alloys HSS 40-70 70-100 90-120 100-200
Carbide 60-150 80-180 90-450 150-600
Titanium alloys HSS 10-15 15-30 30-50 50-90
Carbide 15-30 30-50 50-90 60-120
23
POWER AND FORCE REQUIREMENTS FOR LATHE MACHINE:
t
D
Diameter of the workpiece D Mm

Revolutions for minute N Rpm
Feed Per Revolutoin S mm/rev
Feed per Minute Sm mm/min Sm=s×n
Depth of cut T Mm
Metal removal rate Q Cm3/min Q=s×t×v
Approach angle X Deg
Average Chip Thickness as Mm as=s.sinX
Correction factor for flank wear Kh
Side rake angle Γ
Correction factor for rake wear Kγ
Ne
Power at Motor l kW Nel=N/E(Efficiency)
24
CUTTING CONDITIONS FOR CYLINDRICAL GRINDING
CMTI HANDBOOK DATA.
Work material Hardness Wheel Work In feed Transverse per Wheel

work
speed speed mm/pass revolution
m/sec m/min
Machining steels, (0.5 ) 0.16
MS, Upto 27-32 20-30 Rough(0.05) A60KV
Medium carbon
steels 48 HRC Finish(0.012)
48-65 27-32 20-30 Rough(0.05) 0.25 A60KV
HRC Finish(0.012) 0.125
Alloy steels Upto 27-32 20-30 Rough(0.05) 0.5 A60KV
48 HRC Finish(0.012) 0.16
Tool steels 100-250 27-32 18-30 Rough(0.05) 0.5 A60KV
HRC Finish(0.012) 0.16
25
56-65 27-32 18-30 Rough(0.05) 0.25 A60KV

HRC Finish(0.012) 0.125
Stainless Steel 135-275 27-32 15-30 Rough(0.05) 0.5 A60KV
HRC Finish(0.012) 0.16
Cast iron, grey, Upto 27-32 20-30 Rough(0.05) 0.5 A60KV
ductile, malleable 45 HRC Finish(0.025) 0.16
Alluminium alloys 30-150 27-25 15-45 Rough(0.05) 0.5 C46KV
HB Finish(0.012) 0.16
Copper alloys 10-100 27-32 20-30 Rough(0.05) 0.3 C60KV
HRB Finish(0.012) 0.16
Magnesium Alloys 40-90 HB 27-25 20-40 Rough(0.05) 0.3 C46JV
Finish(0.012) 0.16
Titanium Alloys 300-380 7.5-30 15-30 Rough(0.025) 0.2 C60JV
HB Finish(0.012) 0.1
POWER AND FORCE REQUIREMENTS IN CYLINDRICAL GRINDING
b
Ft T
Dw
Diameter of the wheel D Mm

Wheel RPM N Rpm
Peripheral wheel speed V m/sec V=(пDn)/1000x60
Diameter of work piece Dw Mm
Workpiece RPM Nw Rpm
Peripheral work speed Vw m/min V=(пDw n w)/1000
Depth of grind transverse grinding T mm/pass
Table Transverse feed rate Ft mm/min
Width of cut plunge grinding B Mm
Plunge infeed rate per work S Mm/rev
MRR Q cm3/min Q= пDw t.ft /1000
Power at the spindle N Kw N = U.Q
Power of motor Nel Kw Nel = N/E
Tangential cutting force Pz Kgf Pz =102N/V
Torque at spindle Ts Kgf.m Ts =975 N/n.
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RESULT:
Taper turning and step turning are performed on M.S.Rod using lathe by selecting proper cutting
tools and cutting parameters like speed rpm, feed m/min and at a depth of cut
3
mm. The material removal rate is Cm /min, The tangential cutting force is Kgf
and Torque requirement for the motor is Kgf.m. Performed Cylindrical grinding by
selecting a type grinding wheel with a speed rpm, feed _ m/min and at a depth
of cut mm. The material removal rate is Cm3/min, The tangential cutting force
is Kgf and Torque requirement for the motor is Kgf.m.
CONCLUSION:
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28
29
DRILLING & BORING A FLANGE AND CHECKING THE BORE

DIAMETER USING INSIDE MICROMETER & DIAL BORE INDICATOR
30
Experiment: 4
AIM: To select suitable cutting parameters to perform drilling and boring operation on lathe. To
measure the bore diameter using inside micrometer and dial bore indicator
OBJECTIVES:
To study and understand the functioning of a lathe and its parts.

Understand the specifications of lathe
To study and understand different drive and feed mechanisms involved in a lathe.
To study and understand different operations that can be performed on lathe.
To know the purpose of Knurling and Thread Cutting.
To know the working principle of inside
micrometer To know the working principle of dial
bore gauge To know about different types of
gauges
DRILLING AND BORING ON LATHE:

Boring is the enlarging and truing of a hole by removing material from internal surfaces with
a single-point cutter bit. On the lathe, boring is accomplished in either of these two methods:
Mounting the holder and boring tool bar with cutter bit on the tool post and revolving
the workpiece.
Mounting the workpiece in a fixed position to the carriage and revolving the boring
tool bar and cutter bit in a chuck attached to the headstock spindle. (This is a special
process and not used in most machine shops).
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MEASURING BORE DIAMETER USING INSIDE MICROMETER CALIPERS

The inside micrometer is intended for internal measurement to an accuracy of
0.01mm. In principle, it is similar to an external micrometer and is used for measuring holes
in the range of 5-30mm.
Fig 1. Inside Micrometer Calipers

The instrument shown in fig. 1 comprises measuring tips constituted by jaws. One of
the jaws is held stationary and the second one moves by the movement of thimble. A lock nut
is provided for locking of spindle. It is also provided with a ratchet stop for applying constant
force.
MEASUIRNG BORE DIAMETER USING DIAL BORE GAUGE

The instrument basically consists of a hollow tube into which is contained a lever
pivoted about its intermediate support. One end of the lever is linked to the movable contact
point of the instrument and the other end of the lever actuates the dial indicator.
Interchangeable rods and washers can be used in order to broaden the range of measurement.
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Fig 2. Dial bore gauge
Fig 3. Set of Interchangeable rods
PROCEDURE:
INSIDE MICROMETER CALIPERS
1. First the diameter of the bore is measured approximately by a scale.
2. The micrometer is then adjusted at a dimension slightly smaller than the diameter of
the bore.
3. One tip is held against the bore and the other is adjusted by moving the thimble till the
correct feel is sensed.
4. The micrometer is then removed and reading is taken.
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S.No M.S.R(a) THIMBLE TOTAL READING

READING(b) a + (LC * b)
Average reading
DIAL BORE GAUGE

1. For the required measuring dimension select the appropriate interchangeable rod
and/or washers and set them on the main unit.
2. Diameter is obtained automatically from the guide. To adjust the instrument to
measure diameter , search for a position where the bore gauge reading is maximized by tilting
the bore gauge back and forth .
3. The indicator reading is recorded to get the required diameter.
S.No BORE GAUGE READING
Average Bore Diameter =
PRECAUT IONS:
RESULT:
1. Bore diameter measured by using inside micrometer =
2. Bore diameter indicated by dial bore indicator =
CONCLUSION:
34
35
CALIBRATION OF PRECISION MEASURING INSTRUMENTS
36
Experiment: 5
AIM:
To calibrate Vernier calipers, vernier height gauge & Micrometer and to measure
lengths, heights and diameters by these instruments
OBJECTIVES:
1. To know about calibration, precision & accuracy
2. To know about least count of any precise instrument.
3. To know the difference between line standard and end standard
THEORY:
CALIBRATION:
It is the process of determining true values by comparison with an accurate standard.

It is the process of framing the scale of the instrument by applying some standards.
Calibration is a pre measurement process, generally carried out by manufacturers. During the
course of use, due to friction and lack of proper maintenance, errors enter into the instruments
and these should be properly accounted for when taking measurements. If the accuracy is to
be maintained, periodical calibration is essential.
1) VERNIER CALIPER:
PRINCIPLE
The Vernier caliper has one ‘L’ shaped frame with a fixed jaw on which Vernier
scale is attached. The principle of Vernier is that when two scales or divisions slightly
different in size are used, the difference between them can be utilized to enhance the
accuracy of measurement.
LEAST COUNT
Least Count is the smallest length that can be measured accurately and is equal to the
difference between a main scale division and a Vernier scale division.
LEAST COUNT = 1 MSD – 1 VSD (OR) = 1MSD/no of vernier scale divisons
37
Fig 1. Vernier Callipers
1. Outside jaws: used to measure external diameter or width of an object

2. Inside jaws: used to measure internal diameter of an object
3. Depth probe: used to measure depths of an object or a hole
4. Main scale: gives measurements of up to one decimal place (in cm).
5. Main scale: gives measurements in fraction(in inch)
6. Vernier gives measurements up to two decimal places(in cm)
7. Vernier gives measurements in fraction(in inch)
USES:
It is used to measure the external diameter, the internal diameter and the length of the
given specimen.
2) MICROMETER:
PRINCIPLE
Micrometer works on the principle of screw and nut. A screw moves when it is
rotated through a nut. The relation between number of rotations and the distance moved is
used for measuring the dimensions.
LEAST COUNT
The micrometer essentially consists of U shaped frame. The component to be

measured is held between fixed anvil and movable spindle. The spindle can be moved with
the help of thimble. There are two scales on micrometer, a main scale and a circular scale.
38
The barrel is graduated in unit of 0.5 mm whereas thimble has got 50 divisions around its
periphery. One revolution of thimble moves 0.5 mm which is the lead of the screw and also
the pitch.
Least Count = Pitch of the spindle screw ÷ Number of divisions on the thimble
Fig 2. Micrometer Screw Gauge

USES:
1. Outside micrometer is used to measure the diameter of solid cylinder.
2. Inside micrometer is used to measure the internal diameters of hollow cylinders and
spheres.
3) VERNIER HEIGHT GAUGE
Vernier height gauge is similar to vernier caliper but in this instrument the
graduated bar is held in a vertical position and it is used in conjunction with a surface
plate.
The vernier height gauge is designed for accurate measurements and marking
of vertical heights above a surface plate datum. It can also be used to measure
differences in heights by taking the vernier scale readings at each height and
determining the difference by subtraction. The vernier height gauge is read in the
same way as vernier calipers.
39
Fig 3. Vernier Height Gauge
4) SLIP GAUGES:
They are rectangular blocks hardened and carefully stabilized. The surfaces are highly
polished to enhance wringing. It is used as a reference standard for transferring the
dimensions of unit of length from primary standard. It is generally made up of high carbon,
high chromium hardened steel.
USES:
These are accurate and used as comparator.
5) SURFACE PLATE:
The foundation of all geometric accuracy and indeed of all dimensional measurement
in workshop is surface plate. It is a flat smooth surface sometimes with leveling screws at the
bottom.
USES: It is used as a base in all measurements
40
PROCEDURE FOR CALIBRATION:
1.) The range of the instruments is noted down.
2.) Within that range, slip gauges are selected in steps of 2mm .
3.) The measuring instrument is placed on the surface plate and set for zero and the slip gauges
are placed one by one between the measuring points (jaws of the instruments.)
4.) The slip gauge (actual) readings and the corresponding (observed) readings in the measuring
instruments are noted down and tabulated.
CALIBRATION OF VERNIER CALLIPERS
S.No Slip M.S.R V.S.R LC Measured Error

Gauge reading ( Measured
Reading MSR+(VSRXL.C) reading- Actual)
(Actual)
mm
MEASUREMENT OF LENGTH BY VERNIER CALLIPERS
S.No M.S.R V.S.R LC Measured Error Final

Reading Reading
MSR+(VSRXL.C)
Average reading
CALIBRATION OF MICROMETER
S.No Slip M.S.R H.S.R LC Measured reading Error

Gauge MSR+(HSRXL.C) ( Measured
Reading reading- Actual)
(Actual)
41
MEASUREMENT OF DIAMETER BY MICROMETER
S.No M.S.R HSR LC Measured Error Final Reading

Reading
MSR+(HSRXL.C)
Average reading
CALIBRATION OF VERNIER HEIGHT GAUGE
S.No Slip M.S.R V.S.R LC Measured Error

Gauge reading ( Measured
Reading MSR+(VSRXL.C) reading- Actual)
(Actual)
mm
42
MEASUREMENT OF HEIGHT BY VERNIER HEIGHT GAUGE
S.No M.S.R V.S.R LC Measured Error Final Reading

Reading
MSR+(VSRXL.C)
GRAPHS:
Calibration graphs are then drawn for all measuring instruments between
1.) Actual value and Observed value.

2.) Actual value and Absolute error.
RESULT:
CONCLUSION:
43
44
MACHINE TOOL ALIGNMENT TESTS ON LATHE
45
EXPERIMENT: 6
AIM:
To conduct alignment tests on lathe machine.
OBJECTIVES:
1. To know about the different alignment tests of lathe

2. To know the use of spirit level & dial gauge in alignment tests
APPARATUS:
A lathe in good working condition with all standard accessories, i.e. live and dead centers,
sleeve etc, Dial indicator, Dial stand 'with magnetic base, Flexible dial stand, Parallel blocks,
Straight edge, Straight bar, Standard mandrel, Straight spirit level, Box type spirit level,
Alignment microscope, Taut wire, Set of spanners, Mandrel and centre draw bar.
PURPOSE OF ALIGNMENT TEST:
1. The alignment test is carried out to check the grade of manufacturing accuracy of the
machine tool. It consists of checking the relationship between various machine elements
(such as bed, table, spindle etc) when the machine tool is idle and unloaded.
2. The various tests applied to any machine tool could be grouped as below :
(a) Tests for the level of installation of machine in horizontal and vertical planes,
(b) Tests for flatness of machine bed and for straightness and parallelism of bed ways or
bearing surfaces,
(c) Tests for perpendicularity of guide ways to other guide ways or bearing surfaces,
(d) Tests for true running of the main spindle and its axial movements,
(e) Tests for parallelism of spindle axis to guideways or bearing surfaces.
(f) Tests for the line of movement of various members, e.g., saddle and table cross slides etc.
along their ways,
(g) Performance tests in which some test pieces are machined and their accuracy and finish is
checked.
PROCEDURE:
1. Clean all surfaces perfectly on which alignment tests are to be performed,

2. Follow the following test chart for performing different alignment tests.
46
ALIGNMENT TABLE:
S. OBJECT MEASURING PERMISSIBLE ERROR ACTUAL

No INSTRUMENT ERROR
1 Test for level of Spirit level, Front guide ways
installation Gauge block to 0.02mm/metre convex only.
a) In longitudinal suite the guide Rear guide ways 0.01 to
direction ways of the lathe 0.02mm/metre convexity.
b) In transverse Bed Bed level in crosswise
direction direction ± 0.02mm/metres.
Tailstock guide ways
parallel with the movement
of carriage 0.02mm/m.
2 Straightness of saddle Cylindrical test 0.02mm over 600mm

in horizontal plane mandril(600mm length of mandrel.
long), Dial
Gauge
3 Alignment of both the Cylindrical test 0.02mm over 600mm
centres in vertical plane mandril(600mm length of mandrel.
long), Dial
Gauge
4 True running of taper Test mandrel Position A, 0.01mm,

socket in main spindle with taper shank position B 0.02mm.
& 300mm long
Cylindrical
measuring part,
Dial gauge
5 Parallelism of main Test mandrel a) 0.02/300 mm
spindle to saddle with taper shank mandrel rising
movement & 300mm long towards free end
a) In vertical plane Cylindrical only.
b) In horizontal measuring part, b) 0.02/300 mm
plane Dial gauge mandrel inclined at
free end towards
tool pressure only.
6 Movement of upper Test mandrel 0.02 mm over total
slide parallel with main with taper shank movement of the slide
spindle in vertical plane & 300mm long
Cylindrical
measuring part,
Dial gauge
7 True running of Dial gauge 0.01mm/revolution of the
loacating cylinder of spindle.
main spindle
8 True running of head Dial gauge 0.01mm/revolution of the
stock centre spindle.
47
9 Parallelism of tail stock Dial gauge a) 0.01/100 mm( tail

sleeve to saddle stock sleeve inclined
movement towards tool
a) In vertical plane pressure only)
b) In horizontal b) 0.01/100mm
plane (Tailstock sleeve
rising towards free
end only)
10 Parallelism of tail stock Test mandrel a) 0.03/300 mm,
sleeve taper socket to with taper shank mandrel rising
saddle movement & 300mm long towards free end
a) In vertical plane Cylindrical only.
b) In horizontal measuring part, b) 0.03/300 mm,
plane Dial gauge mandrel inclined at
free end towards
tool pressure only.
PRECAUTIONS:
1. Care should be taken while fixing the dial indicator

2. Travel of distance of atleast 100 microns need to be given for the dial indicator
for finding the negative errors.
3. Care should be taken while using the slip gauges
4. Proper wringing procedure need to followed during slip gauge wringing.
RESULT:
CONCLUSION:
48
49
MACHINING A V- BLOCK USING A SHAPER MACHINE
50
EXPERIMENT: 7
AIM:
To machine a V- Block of given dimension using a horizontal shaper machine.
OBJECTIVES:
To understand the functioning of a shaping machine

To know how a quick return mechanism works
To understand different drive and feed mechanisms in shaping machine
To understand the different operations that can be performed on shaper Machine.
To understand different types of tools used in shaping machine
To know how to adjust the stroke length of the shaper
To know how to position the shaper exactly on the work
SHAPER:
Shaper is a versatile machine which is primarily intended for producing flat surfaces on
metallic blocks. These surfaces may be horizontal, vertical or inclined. This machine involves
the use of a single point tool held in a properly designed tool box mounted on a reciprocating
ram.
Figure 1. Schematic diagram of shaper machine
51
Figure 2. Schematic diagram of V-Block to be machined.

RESULT :
A V- Block is machined using shaping machine at strokes per minute and a Depth of cut
of mm is given. Different types of tools, mechanisms, operations different parts has been
observed while performing the job work.
CONCLUSION:
52
GRINDING OF SINGLE POINT CUTTING TOOL AND MEASURING TOOL

ANGLES USING A TOOL MAKERS MICROSCOPE
53
EXPERIMENT: 8
AIM:
To grind single point tool angles using Tool & cutter grinding machine and measure tool
angles using a tool maker’s microscope.
Objectives:
To understand tool signature.
To understand the importance of different tool angles.
To understand the effect of tool angles on machining.
To understand the working principal of tool makers microscope.
To learn linear and angular measurement using tool makers microscope
Schematic diagram:
Figure 1. Schematic diagram of single point cutting tool
54
PROCEDURE: PRECAUTIONS: RESULT: CONCLUSION:
55
56
DRILLING, TAPPING AND SURFACE GRINDING
57
EXPERIEMENT: 09
AIM: To select suitable operating parameters to make holes for a given pattern using Radial
arm drilling machine. To make internal threading in a drilled hole using hand taps. To ground
MS flat using Surface grinding machine.
OBJECTIVES:
To understand different types and specifications of drilling and grinding machines

To understand parts of Drilling and Grinding machines
To understand different mechanisms of drilling and grinding machines
To understand different operations performed
To understand different types of tools used in drilling and grinding machines
DRILLING:
Drilling is an operation through which holes are produced in a solid metal by means of a
revolving tool called ‘Drill”. Since it is not possible to produce a perfectly true hole by
drilling,it is considered as a roughing operation.
TAPPING:
Tapping is the operation done for forming internal threads by means of the tool called
“Tap”.To perform this operation,the machine should be equipped with a reversible motor or
some other reversing mechanism.
Surface Grinding:
Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used
abrasive machining process in which a spinning wheel covered in rough particles (grinding
wheel) cuts chips of metallic or nonmetallic substance from a workpiece, making a face of it
flat or smooth.
58
Figure 1. Schematic diagram of drilling machine
Figure 1. Schematic diagram of Surface Grinding machine
Figure 2. Schematic diagram of holes made in chain, zig-zag pattern and after tapped
59
Cutting conditions for Drilling, Reaming and Tapping

CMTI Machining Hand Book Data
Cutting Seed, m/min Hole Dia Feed mm/rev.

Work Material
Drilling Reaming Tapping (mm) Drilling Reaming
Free-machining steels 20-30 11-15 9-12 1.5-2.5 0.04-0.06 0.08-0.13
Mild Steel 20-23 11-14 11-12 3-4 0.05-0.1 0.1-0.2
Medium Carbon Steel 14-20 9-14 8-11 4.5-5.5 0.05-0.13 0.15-0.3
Alloy Steels 18-22 10-14 10-12 6-8.5 0.1-0.18 0.2-0.4
Tool steels 5-8 3-5 3-5 9-11.5 0.12-0.2 0.3-0.51
Stainless Steel 12-15 9-25 8-9 12-14.5 0.15-0.25 0.41-0.61
Cast iron, grey, 20-23 12-17 9-12 15-18 0.18-0.28 0.46-0.66
Ductile, Malleable. 18.5-20.5 0.2-0.3 0.5-0.71
Aluminium alloys 35-55 25-30 14-18 21-24 0.23-0.33 0.56-0.76
Copper alloys 30-45 20-40 9-12 25-29 0.25-0.36 0.61-0.81
Magnesium alloys 60-105 30-40 15-25 30-38 0.28-0.41 0.71-0.91
Titanium alloys 12-15 9-25 8-9 Over 38 0.3-0.41 0.81-1.00
POWER AND FORCE REQUIREMENTS IN DRILLING
Diameter of the cutter D Mm

Revolutions per minute n Rpm
Cutting Speed v m/min V=πDn/1000
Feed Per Revolution Sz mm/rev
Power at the spindle N Kw N=1.25D2Kn(0.056+1.5S)/105
Power at Motor Nel kW Nel=N/E(Efficiency)
Thrust Th Kgf Th=1.16kD(100S)0.85
60
Cutting conditions for surface grinding

CMTI Machining Hand Book Data
Work material Hardness Wheel Table Down feed Cross feed Wheel
speed Speed mm/pass mm/pass
m/sec m/min
Machining steels, Upto 28-32 15-30 Rough(0.075) 1.25-12.5 A46JV
MS, Medium 48 HRC Finish(0.025) (1/4 W)
carbon steels 48-65 28-32 15-30 Rough(0.05) 0.65-12.5 A46IV
HRC Finish(0.012) (1/10 W)
Alloy steels Upto 28-32 15-30 Rough(0.075) 1.25-12.5 A46IV
48 HRC Finish(0.012) (1/4 W)
Tool steels 100-250 28-32 15-30 Rough(0.05) 0.625-12.5 A46IV
HRC Finish(0.012) (1/10 W)
56-65 28-32 15-30 Rough(0.05) 0.625-12.5 A46IV
HRC Finish(0.012) (1/10 W)
Stainless Steel 135-275 28-32 15-30 Rough(0.05) 1.25-12.5 A46JV
HRC Finish(0.012) (1/4 W)
Cast iron, grey, Upto 28-32 15-30 Rough(0.05) 1.25-12.5 A46IV
ductile, malleable 45 HRC Finish(0.012) (1/5 W)
Alluminium alloys 30-150 20-25 15-30 Rough(0.075) 1.25-12.5 C46KV
HB Finish(0.025) (1/3 W)
Copper alloys 10-100 28-32 15-30 Rough(0.075) 1.25-12.5 C46KV
HRB Finish(0.012) (1/3 W)
Magnesium Alloys 40-90 HB 20-25 15-30 Rough(0.075) 1.25-12.5 C46KV
Finish(0.025) (1/3 W)
Titanium Alloys 300-380 7.5-30 12 Rough(0.025) 1.25-12.5 C46KV
HB Finish(0.012) (1/3 W)
POWER AND FORCE REQUIREMENTS IN SURFACE GRINDING
ft
bc b
61
Diameter of the wheel D mm
Wheel RPM N Rpm
Peripheral wheel speed V m/sec V=(пDn)/1000x60
Depth of grind T mm/pass
Cross feed transverse grinding bc mm/pass
Width of cut plunge grinding B mm
Table Transverse feed rate ft mm/min
MRR Q cm3/min Q= (bc or b).t.ft /1000
Power at the spindle N kw N = U.Q
Power of motor Nel kw Nel = N/E
Tangential cutting force Pz kgf Pz =102N/V
Torque at spindle Ts Kgf.m Ts =975 N/n.
62
PROCEDURE : PRECAUTIONS: APPLICATIONS:
RESULT :
Drilling and Hand tapping operations are performed on M.S. Flat Plate using lathe by
selecting proper cutting tools and cutting parameters like speed rpm, feed
m/min and at a depth of cut mm. The material removal rate is Cm3/min, The
tangential cutting force is Kgf and Torque requirement for the motor is
Kgf.m. Performed Surface grinding operation by selecting a type grinding wheel at a
speed rpm, feed _ m/min and at a depth of cut mm. The material removal
rate is Cm3/min, The tangential cutting force is Kgf and Torque
requirement for the motor is Kgf.m.
CONCLUSION:
63
MILLING A SPUR GEAR & MEASURING PROFILE OF THE GEAR BY

VERNIER GEAR TOOTH CALIPER
64
EXPERIMENT-10
AIM:
To select suitable operating parameters to machine a spur gear using universal milling
machine. To Index the workpiece to the required number of teeth using universal indexing
head. To measure and compare the actual tooth thickness measured using vernier gear tooth
caliper with the calculated thickness.
OBJECTIVES:
To know different parts of milling machine and working principle
To know the difference between MRR in lathe machine and milling machine
To understand the cutting tool geometry involved in multipoint cutting tool and single
point cutting tool.
To know the upward milling and down ward milling process
To know the selection of speed and depth of cut for given job in milling
To know the mechanism (indexing) involved for rotating work piece for a particular angel
To know the importance of truing and dressing
MILLING:
Milling machines are very versatile. They are usually used to machine flat surfaces, but can
also produce irregular surfaces. They can also be used to drill, bore, cut gears, and produce
slots. The type of milling machine most commonly found in student shops is a horizontal
machine with a swiveling head. A milling machine removes metal by rotating a multi-toothed
cutter that is fed into the moving workpiece.
CUTTING PARAMETERS FOR MILLING USING FORM CUTTERS
CMTI Machining Handbook Data

Feed,
Work Tool Speed mm/tooth
Material Material m/min Form
Cutters
Free-machining HSS 30-40
0.1
Steels Carbide 100-200
Mild Steel HSS 25-40
0.1
Carbide 90-130
Medium
CarbonSteel HSS 20-30
0.075
Carbide 60-9
Alloy Steels HSS 10-20
0.05
Carbide 40-55
Tool steels HSS 15-25
0.05
Carbide 60-80
Stainless Steel HSS 15-20
0.05
Carbide 30-60
Cast iron, grey, HSS 20-30
Ductile, 0.1
Malleable. Carbide 70-100
Aluminium alloys HSS 60-100
0.175
Carbide 60-180
Copper alloys HSS 40-75 0.15
Carbide 60-100
Magnesium alloys HSS 60-100
0.175
Carbide 60-180
Titanium alloys HSS 10-30
0.05
Carbide 30-50
65
POWER AND FORCE REQUIREMENTS FOR MILLING
Ψ
s
t
Diameter of the cutter D Mm

Revolutions per minute N Rpm
Feed Per tooth Sz mm/rev
Number of Teeth Z
Feed per Minute Sm mm/min Sm=Sz×Z×n
Depth of cut T Mm
Width of cut B Mm
Metal removal rate Q Cm3/min Q=b×Sm×t/1000
as=114.6 o
Average Chip Thickness as Mm ×Sz×t/D.Ψ s
Kw/
Unit Power U cm3/min
Correction factor for radial rake angle Kh
Nel=N/E(Efficienc
Power at Motor Nel kW y)
Figure 1. Schematic diagram of Milling machine
66
67
MEASURING THE THICKNESS OF TEETH USING VERNIER GEAR TOOTH

CALIPER
Figure Schematic diagram of Vernier gear tooth calipers
PROCEDURE:
Spur gear Tooth Thickness Measurement:
1. First find the Gear outer diameter (OD) by a vernier calliper and also count the number of
teeth (T) of the machined spur gear.
2. Next calculate pitch circle diameter D
D=(TxOD)/(T+2)
3. Find addendum, clearance, pitch, module and dedendum as per the formulae given below.
4. Set the chordal depth (addendum) on the vertical slide of the gear tooth vernier and then
insert the jaws of the instrument on the tooth to be measured.
5. Adjust the horizontal vernier slide by the fine adjusting screw so that the jaws just touch
the tooth.
6. Read the horizontal vernier slide and note the reading. It gives the chordal thickness of
tooth.
7. Repeat the observations for the different teeth.
8. Compare the values of different characteristics with the standard value and set the
percentage error.
68
OBSERVATION:
1. Least count of caliper = mm
2. Number of teeth (T) =
3. Outer Diameter (OD) =_
CHORDAL THICKNESS:
S.NO M.S.R V.S.R CHORDAL

THICKNESS
(M.S.R+V.S.R*L.C)
Average Chordal Thickness
CALCULATIONS:
1. Pitch circle diameter (D), D=(TxOD)/(T+2) =
2. Module (m), m=D/T mm =
3. Pitch (P)= m * π
4. Depth of teeth= 0.7P
5. Addendum= m = 0.4P
6. Dedendum= m+0.157m =
7. Theoretical Chordal Thickness = mT Sin(90/T)
COMPARISION BETWEEN THEORETICAL AND ACTUAL MEASURED

TOOTH THICKNESS
1. Theoretical Chordal Thickness =

2. Chordal thickness measured by gear tooth vernier calipers =
RESULT
A Spur Gear is machined with a _ module cutter and of teeth using a universal
milling machine. Cutting parameters used are speed rpm, feed m/min and at a
3
depth of cut mm. The material removal rate is Cm /min, The tangential
cutting force is Kgf and Torque requirement for the motor is Kgf.m. The
chordal thickness of the spur gear is mm, measured using a Vernier gear tooth
caliper. The theoretical calculated thickness of the spur gear is mm.
CONCLUSION:
69
ANGLE MEASUREMENT USING BEVEL PROTACTOR & SINE BAR
70
EXPERIEMNT-11
AIM:
To determine the angle of the given wedge using Since bar & Bevel Protractor
APPARATUS:
1. Sine bar 2. Dial Gauge 3. Slip gauges 4. Bevel Protractor. 5. Surface plate
OBJECTIVES:
1. To know the working principle of sine bar & bevel protractor
2. To know about the wringing of slip gauges
THEORY:
SINE BAR:
It is a simple instrument used for setting and measuring angles. It consists of a flat bar
and two rollers attached to the bar at each end. The axes of these rollers are parallel to each
other and also to the upper surface of the sine bar. The distance between the centres of the
rollers is fixed for a particular sine bar and the same is always written on the bar.
Fig 1. Sine Bar
The principle of the sine bar is shown in figure 2. The sine bar is always used in conjunction
with a true surface (surface plate). If ‘h’ is the height of the combination slip gauges and ‘l’
is the distance between the roller centres , then the angle of the setting is given as,
θ =Sin-1(h/l)
71
The angle to be measured is determined by an indirect method, as a function of sine. For this
reason, device is called as ‘sine bar’.
Fig2. Measurement of parallelism of the upper surface of the workpiece using dial gauge
PROCEDURE:
1. For measuring unknown angle it is necessary to first find the angle approximately with
the help of a bevel protractor.
2. The sine bar is then set up at that nominal(approximate) angle on a surface plate by
suitable combination of slip gauges.
3. The component to be checked is placed over the surface of the sine bar.(if necessary the
component may be clamped with the angle plate)
4. The dial gauge is then set at one end of the work and moved along the upper surface of
the component.
5. If there is any variation in parallelism of the upper surface of the component and
the surface plate, it is indicated by the dial gauge.
6. The combination of the slip gauges is so adjusted that the upper surface is truly parallel
with the surface plate.
7. Than note down the height of the combination of slip gauges.
8. Then angle of the component is Calculated by the relation , θ =Sin-1(h/l)
9. Repeat the procedure 3 or 4 times and take the average.
72
OBSERVATIONS:
S. No Height of Slip Gauge Length of The Sine Bar (l) Angle

Blocks (h)
Average Reading:
BEVEL PROTRACTOR:
The simple bevel protractor can be extended in its accuracy by the application of a
circular vernier scale and this instrument is known as vernier bevel protractor. It consists of a
base plate attached to the main body and an adjustable blade which is attached to the circular
plate containing vernier scale. The adjustable blade can be set at any angle with the base plate
and can be locked.
The main scale on the disc is graduated in degrees. The vernier scale has 12 divisons
on each side of the center zero. These are marked 0-60 minutes of arc, so that each divison
equals 1/12 of 60, that is 5 minutes of arc. These 12 divisons occupy the same space as 23°
on the main scale. Therefore each divison of the vernier is equal to 1/12 of 23° or 5 minutes
of arc. Thus the least count of the instrument is 5 minutes.
Fig 3. Bevel Protractor.
73
The graduations are read to the right and left on both the main scale and the vernier
scale. When the main scale is read to the right of the zero of the main scale, the vernier is also
read to the right of zero of the vernier scale.
Fig 4. Enlarged View of Vernier Scale of Bevel

Protractor The reading shown above gives
a) The largest whole degree on the main scale indicated by the vernier zero divison
ie 28°
b) The reading on the vernier scale in line with a main scale divison is 3*5ꞌ = 15ꞌ
c) Hence the vernier bevel protractor reads 28° + 15 ꞌ = 28°15 ꞌ
OBSERVATIONS:
Least count of Bevel Protractor =
S.No Main scale Vernier Coincidence(VC) Total Reading

reading(MSR) MSR + (VC*LC)
1
2
3
Average Reading:
PRECAUTIONS:
RESULT:
The angle of the given specimen measured with the sine bar is…………….
The angle of the given specimen measured with the Bevel Protractor is………….
74
CONCLUSION:
75
Machine Tools and Metrology Laboratory
Department of Mechanical Engineering
MVGR College of Engineering (A)
Design Projects 2019-20 AY
1. Design and manufacture a ball turning tool post for producing a

cylindrical gripper for holding a cylindrical solid of diameter 30mm.
2. Manufacturing of a hexagonal bolt and nut with multi start threads for a
vice.
3. Design and Manufacturing of a machinist hammer for metal working
application
4. Design and Manufacturing of a screw jack to lift automobile.
5. Manufacturing of a split muff coupling to transmit power from driving
shaft to driven shaft for a power transmission application.
6. Manufacturing of a flange coupling to transmit power from propeller
shaft to generator shaft which produces 3 KW.
7. Design and Manufacturing of external spline drag racing alloy axle for
automobile.
8. Design and Manufacturing of a rack and pinion mechanism for a lathe
machine.
9. Manufacturing of a double rack gear lever mechanism for a locomotive.
10. Design and Manufacturing of a shaft with external and internal splines
for thumbler gear.
Machine Tools and Metrology Laboratory
VI Semester
Department of Mechanical Engineering
MVGR College of Engineering (A)
2019-20 AY
Project Time line
No of Weeks Project Plan Remarks

Week I Orientation to Machine Tools and Metrology
Lab and Allocation of the Projects
Week II Literature Survey-Abstract, Introduction
Week III Literature Survey-Methodology
Week IV Submit the Abstract of the Project
Week V Project Plan to be submitted
Week VI Requirement of the material to be submitted
Week VII If any Design Calculations/designs to be done
with the help of Software to be submitted
Week VIII Status of the project – Review 1
Week IX Status of the project – Review 2
Week X Status of the project – Review 3
Week XI Final review before submission
Week XII Report Submission
Project Representative: Name: Reg. No:
Faculty Advisor: Name and Designation:

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MACHINE TOOLS & METROLOGY LABORATORY

DEPARTMENT OF MECHANICAL ENGINEERING

Reaccredited by NBA, Grade “A” by NAAC of UGC, Approved by AICTE, New

Many researchers focusing on modeling of machine tools process to solve several

The increased competitiveness of major consuming industries such as the automotive

Mr. G Pramod kumar

Dr. Umamaheswara Raju. R. S.

Mr. G Pramod kumar

Internal lab examination

1. Production Technology By R. k. Jain and S. C. Gupta

BOOKS AVAILABLE IN LIBRARY:

DIGITAL LEARNING MATERIALS:

2. The chief hazard associated is accidental contact with moving cutter

3. Hazard of sharp edge contact with chips while machining.

4. Selection of no. of teeth or blade size on primer hacksaw machine.

5. Ramming of chips when machine in motion viz. shaping or slotting.

6. Locking of tables and ensure the feed.

7. Switch on the connection selection of lever (rapid/feed).

9. Magnetic clamping refines starting the surface grinding.

10. Selection of proper depth cut or feeds or any machine.

11. Chip disposal system to the accident free.

3. Step turning, Taper turning and Cylindrical grinding

6. Machine tool alignment test on lathe

7. Machining a V-Block using Shaper

9. Drilling, Tapping and surface grinding

11. Measuring angles using sine-bar and bevel protractor

12. CNC Turning part program for given component

KNURLING, THREAD CUTTING AND MEASURING THE PITCH OF THE

Figure1. Schematic diagram of lathe machine

Figure2. Schematic diagram of thread cutting and knurled workpice

CUTTING PARAMETERS SELECTION FOR LATHE MACHINE

CMTI Machining hand book data.

Cutting Speed M/min

Work Tool Depth, mm

Material Material 5-10 2-5 0.5-2 0.1-0.5

0.4-0.6 0.25-0.5 0.2-0.3 0.05-0.2

Free-machining steels HSS 20-40 40-70 40-110 50-120

Carbide 90-150 120-180 150-250 200-500

Mild Steel HSS 25-35 30-50 30-60 40-80

Carbide 60-120 80-150 120-200 150-450

Medium Carbon Steel HSS 15-25 25-45 25-50 30-70

Carbide 50-110 60-120 90-150 120-300

Alloy Steels HSS 10-15 15-25 15-35 20-45

Carbide 30-65 40-80 60-100 80-180

Tool steels HSS 15-20 20-25 20-30 30-60

Carbide 50-110 60-120 90-150 120-300

Stainless Steel HSS 15-20 15-25 15-30 20-50

Carbide 40-60 40-70 50-80 50-90

Cast iron, Grey, HSS 20-25 25-30 35-45 40-60

Ductile, Malleable. Carbide 60-90 70-100 80-110 80-120

Aluminium alloys HSS 40-70 70-100 90-120 100-200

Carbide 60-150 80-180 90-450 150-600

Carbide 50-110 60-150 90-180 120-310

Magnesium alloys HSS 40-70 70-100 90-120 100-200

Carbide 60-150 80-180 90-450 150-600

Titanium alloys HSS 10-15 15-30 30-50 50-90

Carbide 15-30 30-50 50-90 60-120

POWER AND FORCE REQUIREMENTS IN TURNING:

Diameter of the workpiece D Mm

PROCEDURE: PRECAUTIONS: APPLICATIONS:

STEP TURNING, TAPER TURNING AND CYLINDRICAL GRINDING

Figure 1. schematic diagram of lathe machine.

Figure 2. schematic diagram of fixing the job in Cylindrical Grinding Machine.