"School of Mechanical Engineering" Laboratory Manual MEC 332 Machine Tools and Machining Laboratory

“SCHOOL OF MECHANICAL ENGINEERING”
LABORATORY MANUAL
MEC 332
MACHINE TOOLS AND MACHINING LABORATORY
Name of the student

Registration number/Roll no./Group
School name
1|Page
INSTRUCTIONS TO STUDENTS
1. Students must ensure that they are wearing their ID cards with prescribe uniform.
2. Students must make sure that the components, instruments and machinery are in
working condition before setting up the experiment.
3. Mobile phone should be switched off and kept in bag during lab hours.
4. Students may contact the lab incharge immediately for any unexpected incidents and
emergency.
5. The apparatus used for the experiments must be cleaned and returned to the technicians,
safely without any damage.
6. Make sure, while leaving the lab after the stipulated time, that all the power
connections are switched off.
7. The student should take the permission of the Lab Staff / Tutor before handling any
machine.
8. The student should not lean on the machine when it is in running condition.
9. All students should go through the lab manual for the experiment to be carried out for
that day and come fully prepared to complete the experiment within the prescribed
periods. Student should also complete the lab record work within the prescribed
periods.
Dress code
• Lab apron, shoes, and safety glasses are mandatory while working in the lab.
Compulsory things to be carried by students in Lab

• Lab Manual
• lab coat and,
• Proper shoes.
2|Page
LIST OF EXPERIMENTS
S .NO. TITLE OF EXPERIMENT PAGE

NO.
1 To make a Gear profile on milling machine and prepare slots as key 6

ways using slotter machine tool.
2 To prepare a V block on shaper machine and improvement in 10
quality using surface grinder.
3 To prepare a multi operational job on turret lathe machine. 13
4 To prepare a multi operational job on capstan machine tool. 16
5 To prepare a multi operational job on lathe machine 19
6 To measure the dimension of a given specimen using Vernier 22
caliper, Micrometer, Height Gauge and to find the run-out error
using Dial Indicator.
7 To Measure angle of given specimen using Bevel Protractor, Sine 26

bar and to measure surface roughness of the given specimen
8 To carry out measurement of Screw thread and spur gear using 31
Profile Projector.
9 To determine bore diameter is a given hollow specimen. 33
3|Page
GENERAL TOLERANCES FOR LINEAR MEASURES ACCORDING TO ISO 2768-1
TABLE 1 PERMISSIBLE DEVIATION FOR LINEAR DIMENSIONS
TABLE 2-PERMISSIBLE DEVIATION FOR BROKEN EDGES (EXTERNAL RADIUS AND CHAMFER HEIGHTS)
4|Page
TABLE 3- PERMISSIBLE DEVIATION FOR ANGULAR DIMENSIONS
5|Page
EXPERIMENT NO.1
To make a Gear profile on Milling machine and Prepare slots as key ways using slotter machine tool.
Job specification:
MACHINE/EQUIPMENTS/TOOLS TO BE USED
Milling Machine with dividing head & Vernier caliper
Spanner set, Depth gauge
THEORY: Indexing is an operation of dividing a periphery of a cylindrical workpiece into equal number
of divisions by the help of index crank and index plate. A manual indexing head includes a hand
crank. Rotating the hand crank in turn rotates the spindle and therefore the workpiece. The
6|Page
hand crank uses a worm gear drive to provide precise control of the rotation of the work. The work
may be rotated and then locked into place before the cutter is applied, or it may be rotated during
cutting depending on the type of machining being done. Most dividing heads operate at a 40:1 ratio;
that is 40 turns of the hand crank generates 1 revolution of the spindle or workpiece.
SIMPLE INDEXING: It is also named as plain indexing. It over comes the major limitation of
direct indexing that is possibility of dividing circumference of workpiece into some fixed
number of divisions. In this case worm and worm gear is first engaged. So one Milling complete turn of
indexing crank revolves the workpiece by 1/40th revolution. Three indexing plates are used. These
plates have concentric circles of holes with their different numbers as described below
Plate No. 1 15 16 17 18 19 20
Plate No. 2 21 23 27 29 31 33
Plate No. 3 37 39 41 43 47 49
(f) The numerator of the process fraction stands for the number of holes to be moved by the
indexing crank in the selected hole circle in addition to complete turns of indexing crank equal to
whole number part of 40/N .
PRECAUTIONS: -
Do not carry tool in your pockets.
Follow the operative instructions given strictly.
Always remove chips by brush, do not remove by hand.
During working, never wear loose clothes. Always wear fitting clothes.
Always use correct speed & feed
7|Page
PROCESS FLOW CHART:
8|Page
PROCESS SHEET
S.No Job specification Operations Tool used Machine tool Remarks
In drawing In actual
LEARNING OUTCOME IN DETAIL:
TO BE FILLED IN BY THE FACULTY
Sr. Parameter (Scale from 1–10) 1 Marks obtained Max. Marks

No. for very poor and 10 for
excellent
1 Understanding of the student about 20

the procedure/apparatus (Process
sheet).
2 Dimensional Accuracy, Finishing 20
and Learning Outcome.
3 Completion of experiment/job, 10
Discipline and Cleanliness
Signature of the Faculty Total marks
obtained
9|Page
EXPERIMENT NO 2
To prepare a V block on shaper machine and improvement in quality using surface grinder.
Shaper machine tool and surface grinder
Vernier caliper
V-Shaped tool
Depth gauge
Try square, Vernier Caliper, Dot punch, Hammer
Also tool/machine/equipment requirement as per the requirement.
JOB SPECIFICATION
MATERIAL USED: Cast iron.
THEORY: A shaper is a type of machine tool that uses linear relative motion between the workpiece and a
single-point cutting tool to machine a linear toolpath. A shaper is analogous to a planer, but smaller,
and with the cutter riding a ram that moves above a stationary workpiece, rather than the entire
workpiece moving beneath the cutter. The ram is moved back and forth typically by a crank inside
the column; hydraulically actuated shapers also exist.
10 | P a g e
Surface grinding is the most common of the grinding operations. It is a finishing process that uses a rotating
abrasive wheel to smooth the flat surface of metallic or nonmetallic materials to give them a more refined
look or to attain a desired surface for a functional purpose.
The surface grinder is composed of an abrasive wheel, a work holding device known as a chuck, and a
reciprocating table. The chuck holds the material in place while it is being worked on. It can do this one of
two ways: ferromagnetic pieces are held in place by a magnetic chuck, while non-ferromagnetic and
nonmetallic pieces are held in place by vacuum or mechanical means.
PRECAUTIONS: -
Always remove chips by brush, do not remove by hand.
PROCESS FLOW CHART:
11 | P a g e
PROCESS SHEET

excellent
sheet).
obtained
12 | P a g e
EXPERIMENT NO 3
To prepare a multi operational job on turret machine tool.
Job specification
Scriber, Vernier Caliper, Power hacksaw,Turret Lathe Machines, Cutting Tool, Marking gauge.
Material used: Mild steel bar
THEORY: The turret lathe is a form of metalworking lathe that is used for repetitive production of duplicate
parts, which by the nature of their cutting process are usually interchangeable. It evolved from earlier
lathes with the addition of the turret, which is an indexable toolholder that allows multiple cutting
operations to be performed, each with a different cutting tool, in easy, rapid succession, with no need for
the operator to perform setup tasks in between, such as installing or uninstalling tools, nor to control
the toolpath.
PRECAUTIONS:-
Always remove chips by brush, Do not remove by hand.
13 | P a g e
PROCESS FLOW CHART:
14 | P a g e
PROCESS SHEET

excellent

sheet).
obtained
15 | P a g e
EXPERIMENT NO 4.
To prepare a multi operational job on capstan machine tool.
Job specification
Marking block, single point cutting tool.
Capstan Lathe Machines Steel rule, Vernier calipers, knurling tool, thread tool etc.
MATERIAL USED: Mild steel bar.
THEORY: The term "capstan lathe" overlaps in sense with the term "turret lathe" to a large extent. In many times
and places, it has been understood to be synonymous with "turret lathe". In other times and places it has been
held in technical contradistinction to "turret lathe", with the difference being in whether the turret's slide is fixed
to the bed (ram-type turret) or slides on the bed's ways (saddle-type turret)
PRECAUTIONS:-
16 | P a g e
PROCESS FLOW CHART:
17 | P a g e
PROCESS SHEET
S.No Job specification Operations Tool used Machine Remarks

tool
Sr. Parameter (Scale from 1–10) 1 for Marks obtained Max. Marks
No. very poor and 10 for excellent

sheet).
obtained
18 | P a g e
EXPERIMENT 5
To prepare a multi operational job on lathe machine.
Job:
Marking block, single point cutting tool.
Capstan Lathe Machines Steel rule, Vernier calipers, knurling tool, thread tool etc.
MATERIAL USED: Mild steel bar.
THEORY: A lathe is a machine tool which rotates the workpiece on its axis to perform various operations such
as Turning, facing, knurling with tools that are applied to the workpiece to create an object which has
symmetry about an axis of rotation. In order to get an efficient process and good surface at the lathe
machining, it is important to adjust a rotating speed, a cutting depth and Feed.
PRECAUTIONS:-
During working, never wear loose clothes. Always wear fitting clothes
19 | P a g e
PROCESS FLOW CHART:
20 | P a g e
PROCESS SHEET

excellent

sheet).
obtained
21 | P a g e
EXPERIMENT 6
To measure the dimension of a given specimen using Vernier caliper, Micrometer, Height
Gauge and to find the run-out error using Dial Indicator.
Job:
MACHINE/EQUIPMENTS/TOOLS TO BE USED:
Vernier caliper, Micrometer, Height Gauge.
THEORY: A Vernier scale is a device that lets the user measure more precisely
than could be done unaided when reading a uniformly-divided straight or circular
measurement scale. It is a scale that indicates where the measurement lies in between
two of the marks on the main scale.
The micrometer is a precision measuring instrument, used by engineers. Each revolution of

the rachet moves the spindle face 0.5mm towards the anvil face. The object to be measured
is placed between the anvil face and the spindle face.
A height gauge is a measuring device used either for determining the height of objects, or
for marking of items to be worked on.
RUN-OUT is an inaccuracy of rotating mechanical systems, specifically that the tool or

shaft does not rotate exactly in line with the main axis.
22 | P a g e
GEOMETRIC DIMENSIONING AND TOLERANCES ARE SHOWN BELOW:
PROCEDURE:
1. Clean the component and instruments to be used.
2. Calculate the least count of instrument to be used.
2. Check the instrument for zero error; if any error is present note it down.
3. Hold the component properly in the measuring jaws or anvils.
4. Note down the readings on main scale and Vernier scale / thimble scale.
5. Take the readings to at least five samples of each component separately by Vernier caliper,
micrometer and using height gauge.
6. Record the readings in the observation table.
7. Clean the instrument after the reading.
23 | P a g e
PROCESS FLOW CHART:
24 | P a g e
PROCESS SHEET
S.No Instrument details Reading Remarks
Instrument used Least count

excellent

sheet).
obtained
25 | P a g e
EXPERIMENT 7.
To Measure angle of given specimen using Bevel Protractor, Sine bar and to measure surface roughness
of the given specimen.
Job Description:
Sine bar, Slip gauges, Surface Plate, Height gauge, Bevel Protractor.
THEORY:
SINE BAR is based upon laws of trigonometry. To set a given angle one roller of the bar is placed on the
surface plate and the combination of slip gauges is inserted under the second roller as shown in the
figure.
If h is the height of the combination of the slip gauges, l is the distance between roller centers,
Then, θ = sin-1 (h/L).
The the angle can be measured as a function of sine. Thus, it is called sine bar.
26 | P a g e
BEVEL PROTRACTOR: It is also called universal bevel protractor. It is one of the simplest instruments
for angular measurement. It is a direct type of angular measuring instrument. The range of this
instrument is 0 to 360 degrees i.e. it can measure angles upto 360 degrees which any other
angular metrological instrument cannot measure. It has two arms (Fixed blade and Adjustable Blade),
which can be set along the faces and a circular scale to indicate the angle between them. Workpiece is
set in between these two arms (two blades, fixed blade and adjustable blade), and the difference of
two scale (main scale and vernier scale) readings gives accurate measurement.
SURFACE ROUGHNESS: Surface Roughness is like a fingerprint left behind by the manufacturing
process.
1. The surface irregularities of small wavelength are called primary texture or roughness these are
caused by direct action of the cutting elements on the material i.e., cutting tool shape, feed rate or by
some other disturbances such as friction, wear or corrosion.
2. The surface considerable wavelength of a periodic character are called secondary texture or
waviness. These irregularities result due to inaccuracies of slides, wear of guides, misalignment of
centers, non-linear feed motion, vibrations of any kind etc.
ARITHMETIC MEAN DEVIATION OF THE PROFILE, Ra
Ra is arithmetic mean of the absolute values of the profile deviation (Yi) from the mean line.
ROOT- MEAN – SQUARE DEVIATION OF THE PROFILE, Rq
Rq is the square root of the arithmetic mean of the squares of profile deviations (Yi) from the mean
line.
27 | P a g e
PROCEDURE FOR SINE BAR:
1. Take a given sample to measure the corresponding angle.
2. Select the suitable combination of slip gauges from standard set available.
3. Calculate the height (h) of slip gauges required using relation h = L * Sin θ
4. Place the work on sine bar & hold it properly.
5. Check parallelism of upper surface of work piece using dial indicator and height gauge.
6.Adjust the slip gauges so that deviation of dial indicator is zero.
7. Note the angle of component.
8. Confirm with bevel protractor.
PROCEDURE FOR BEVEL PROTRACTOR: For Checking V- Block
1. Study the bevel protractor and identify its main parts.
2. Introduce the adjustable blade in the slot of body and clamp it with the help of knob in the
convenient position.
3. Place the working edge of the stock on one surface of the job and rotate the turret holding the
blade so that the working edge of the blade coincides with another surface of the job. Fix the turret
and read the angle.
4. Measure the angles of the sample pieces with the bevel protractor and record the reading.
28 | P a g e
PROCESS FLOW CHART:
29 | P a g e
PROCESS SHEET

excellent

sheet).
obtained
30 | P a g e
EXPERIMENT 8
To carry out measurement of Screw thread and spur gear using Profile Projector. Job Description:
Screw thread, Spur Gear, Profile Projector.
THEORY: A profile projector is also referred to as an optical comparator, or even known as a

shadowgraph, a profile projector is an optical instrument utilized for measuring. The projector magnifies
the profile of the specimen, and shows this on the built- in projection screen. From this screen there is
usually a grid that could be rotated 360 degrees therefore the X-Y axis of the screen could be
aligned correctly using a straight edge of the machined part to analyze or measure. This projection
screen shows the profile of the sample and is zoomed for better ease of computing linear dimensions. An
edge of the sample to analyze could be aligned using the grid on the screen. After that, basic
measurements could be obtained for distances along with other points. When the specimen is solid, then
the light won‘t go through it, but can form a profile of the sample. Measuring of the sample can be
achieved on the projection screen.
31 | P a g e
PROCESS SHEET
Sr. No Job Specification/ Dimension Instrument used Remarks

Element Actual Dimension
1 Major Diameter
2 Minor Diameter
3 Angle of thread
4 Depth of thread
5 Pitch of screw
6 No. of teeth on the
gear
7 Outside diameter of
gear
8 Module (Given) 2.5
9 Pressure angle 20 Degrees
10 Pitch circle diameter
LEARNING OUTCOME:

excellent

sheet).
obtained
32 | P a g e
EXPERIMENT 9
To determine bore diameter is a given hollow specimen.
Job Description:
MACHINE/EQUIPMENTS/TOOLS TO BE USED:
Dial bore gauge
THEORY:-
Bore gauge, is generally used to determine the bore diameter of components. Bore gauge consists of
following parts.
1. Dial gauge
2. Vertical column
3. Arrangement of anvil and washer
4. Movable spindle
B) DIAL BORE INDICATIORTHEORY AND DESCRIPTION:
Dial bore indicator consists of measuring head and guide is attached with extension rod
&collars for specific dimension chosen from the table in the instrument box, holder is assembled to
the measuring head and dial indicator is fixed inside the holder during tightening. The condition is
initially 1 kgf is applied to the dial indicator for getting exact reading.
33 | P a g e
PRINCIPLE: Dial bore indicator iss works on comparator principle
PROCEDURE:-
1. Once approximate bore is finding out by using inside micro meter.
2. Chose the same little more size extension rod & collar if necessary select and fit.
3. Keep the dial bore indicator into the specimen bore.
4. Repeat same procedure to get the bore diameter at different positions of specimen.
SAMPLE CALCULATIONS:- Least count (LC) =0.01mm Anvil ssize = 45mm
Washer size = 45mm
Total indicator Reading = 14 X 0.01= 0.145mm
Total Reading= (Anvil size + Washer size)

size)-(Dial indicator for
Reading) = (45+4.5)-(0.145)
(0.145) =49.355mm
Calculation Total reading:-
Bore diameter = (Anvil size + Washer SSize) - (Dial indicator Reading)
34 | P a g e
INNDER DIA OF SPECIMEN 1
S.NO ANVIL SIZE WASHER SIZE DIAL INDICATOR READING TR=ANVIL SIZE+WASHER SIZE-
DIAL INDICATOR READING
(MM)
INNDER DIA OF SPECIMEN 2
S.NO ANVIL SIZE WASHER SIZE DIAL INDICATOR READING TR=ANVIL SIZE+WASHER SIZE-
DIAL INDICATOR READING
(MM)
OBSERVATION TABLE
35 | P a g e

excellent

sheet).
obtained
36 | P a g e
ROUGH WORK
37 | P a g e

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“SCHOOL OF MECHANICAL ENGINEERING”

Name of the student

Compulsory things to be carried by students in Lab

S .NO. TITLE OF EXPERIMENT PAGE

1 To make a Gear profile on milling machine and prepare slots as key 6

7 To Measure angle of given specimen using Bevel Protractor, Sine 26

TABLE 1 PERMISSIBLE DEVIATION FOR LINEAR DIMENSIONS

Milling Machine with dividing head & Vernier caliper

Spanner set, Depth gauge

Do not carry tool in your pockets.

Follow the operative instructions given strictly.

Always remove chips by brush, do not remove by hand.

Always use correct speed & feed

S.No Job specification Operations Tool used Machine tool Remarks

LEARNING OUTCOME IN DETAIL:

TO BE FILLED IN BY THE FACULTY

Sr. Parameter (Scale from 1–10) 1 Marks obtained Max. Marks

1 Understanding of the student about 20

Shaper machine tool and surface grinder

Try square, Vernier Caliper, Dot punch, Hammer

Also tool/machine/equipment requirement as per the requirement.

MATERIAL USED: Cast iron.

Do not carry tool in your pockets.

Follow the operative instructions given strictly.

Always remove chips by brush, do not remove by hand.

PROCESS FLOW CHART:

S.No Job specification Operations Tool used Machine tool Remarks

LEARNING OUTCOME IN DETAIL:

TO BE FILLED IN BY THE FACULTY

Sr. Parameter (Scale from 1–10) 1 Marks obtained Max. Marks

To prepare a multi operational job on turret machine tool.

Material used: Mild steel bar

Do not carry tool in your pockets.

Follow the operative instructions given strictly.

Always remove chips by brush, Do not remove by hand.

S.No Job specification Operations Tool used Machine tool Remarks

LEARNING OUTCOME IN DETAIL:

TO BE FILLED IN BY THE FACULTY

Sr. Parameter (Scale from 1–10) 1 Marks obtained Max. Marks

1 Understanding of the student about 20

To prepare a multi operational job on capstan machine tool.

Marking block, single point cutting tool.

MATERIAL USED: Mild steel bar.

Do not carry tool in your pockets.

Follow the operative instructions given strictly.

Always remove chips by brush, Do not remove by hand.

S.No Job specification Operations Tool used Machine Remarks

LEARNING OUTCOME IN DETAIL:

TO BE FILLED IN BY THE FACULTY

1 Understanding of the student about 20

To prepare a multi operational job on lathe machine.

Marking block, single point cutting tool.

MATERIAL USED: Mild steel bar.

Do not carry tool in your pockets.

Follow the operative instructions given strictly.

Always remove chips by brush, Do not remove by hand.

S.No Job specification Operations Tool used Machine tool Remarks

LEARNING OUTCOME IN DETAIL:

TO BE FILLED IN BY THE FACULTY

Sr. Parameter (Scale from 1–10) 1 Marks obtained Max. Marks

1 Understanding of the student about 20

Vernier caliper, Micrometer, Height Gauge.

The micrometer is a precision measuring instrument, used by engineers. Each revolution of