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Practicals of MT

( An Autonomous Institute Affiliated to SPPU) ACADEMIC YEAR SYBTECH

Alandi (D), Pune – 412105 SEM / TRI IV

SCHOOL OF MECHANICAL AND CIVIL CLASS &

ENGG. DIVISION / SYBTECH DIV – A
BLOCK

NAME OF THE
COURSE PARAS KAPOOR
MANUFACTURING TECH STUDENT.

COURSE
AMOL.M KOLHE DATE 22/04/2020
INSTRUCTOR

CONTENT
PRACTICAL NO 1 LATHE MACHINE JOB

PRACTICAL NO 3 WELDING

PRACTICAL NO 4 PRESS MACHINE AND ITS OPERTIONS

PRACTICAL NO 5 CLAMPING TECHNIQUES

PRACTICAL NO 6 JIGS AND FIXTURES

PRACTICAL NO 7 CNC PROGRAMMING

PRACTICAL NO 8 RIVETING JOINT

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Practical No 3
PRACTICAL: - Welding, Its Types, Causes, Defects, Advantages and Its Limitations
Theory: - Types Of Welding
1.) Fusion welding/ non pressure welding
The material at the joint is heated to a molten state and allowed to solidify

- Filler material used

Ex. Gas welding, Arc welding

2.) Plastic/Solid state/pressure welding

The piece of metal to be joined are heated to a plastic state and forced together by external pressure

-no filler material

Ex. Resistance, diffusion, ultrasonic welding

ARC WELDING

Arc welding is a welding process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the
melted metals when cool result in a binding of the metals. This electric arc can create temperatures upwards of 3500°C, which is
sufficiently high to melt high strength metals like carbon steel. This method also uses shielding gas in conjunction with arc welding.

This is because the atmospheric air can interact with the weld pool and cause oxidation.

MIG welding - Metal Inert Gas Welding

MIG or Metal Inert Gas Welding is another welding method that uses an electric arc to create welds. However, when compared with
arc welding, MIG requires a consumable electrode to join metals.

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A consumable electrode is a metal that supplies electricity to the weld joint. However, the electrode itself undergoes melting when
it is near the weld pool.

Hence it gets consumed during the welding process.

In MIG welding, the melted electrode facilitates the joining of the two metals. Hence, MIG is ideal for joining dissimilar metals.
Shielding gas is also supplied through the weld gun to ensure that the weld pool does not interact with the atmospheric air

TIG Welding - Tungsten Inert Gas Welding

Tungsten Inert Gas welding uses a tungsten electrode to create an arc between the metals. TIG welding is a non-consumable electrode
welding method, therefore the tungsten doesn’t get consumed with the process.

TIG welding also doesn’t use any form of flux or slag for shielding. Instead, an inert gas is used as a shielding agent in the entire
process. Argon is the most used inert gas in TIG welding.

TIG welding can work on both AC and DC power sources. One of the greatest strengths of TIG welding is that it can be used for
welding non-ferrous metals like aluminium, copper, magnesium, copper, nickel, titanium, etc.

Gas Welding – Oxyacetylene Welding

Gas welding uses the heat from a concentrated flame to melt metals and then join them. Gas welding is possible with or without
filler metal.

The flame is controlled using a welding torch. An oxygen gas canister and a fuel gas canister is connected to the welding torch. The
welder can control the flame by controlling the number of gases fed to the torch using a pressure regulator.

Most commonly, we see a gas combination of Oxygen and Acetylene which is capable of producing 3200°C. Other fuel gases that
are also seen in gas welding are Hydrogen, Butane, & Propane.

DEFECTS IN WELDING

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• Residual Stresses and Warpage

• Rapid heating and then uncontrolled cooling result in uneven expansion and contraction in the work piece and weldment.

• This causes development of residual stresses in the weldment. Distortion and warpage may also be there. Sometimes wrong selection of
filler metal and welding technique may also be the cause of residual stress and warpage.

Cracks

• This is a serious welding defect appears as fracture type interruptions in the weld. Crack works as a point of stress concentration so reduce
the strength of the joint

• Cavities or Porosity

• Porosity consists of small voids in weld metal formed by gases entrapped during solidification.

• Shape of the voids may be spherical holes or elongated holes.

• Solid Inclusions

• This is the entrapped non-metallic solid material. It may be the inclusion of slag generated in a welding process.

• Incomplete Fusion

• It is also called lack of fusion. It is a weld bead in which fusion has not occurred throughout the entire cross-section of the joint. In other
word it is a lack of penetration. That is molten metal has not penetrated up to root of the joint.

REMEDIES

• Clean the materials before you begin welding.

• Use dry electrodes and materials.
• Use correct arc distance.
• Check the gas flow meter and make sure that it’s optimized as required with proper with pressure and flow settings.
• Reduce arc travel speed, which will allow the gases to escape.
• Use the right electrodes.
• Use a proper weld technique

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ADVANTAGES

• Money- certified welders normally get payed alot becayse of the danger of welding
• Cool factor- there are two kinds of people, welders and people who want to learn to weld
• Skills- you can literally build just about anything you want, especially with the aid of other trades (machining, carpentry.. ect.)
• Tolerance to pain- you get used to getting burned and heat in general

DISADVANTAGES:

• Metal gets extremely hot. Can burn you. Can set things on fire.
• Fumes can poison you.
• Looking at an electric arc can blind you instantly and permanently.
• Some welding gases are explosive.
• Compressed oxygen makes almost everything burn explosively, including metal.
• Improper welds can fail at just the wrong time.
• The metal around an improper weld can fail at just the wrong time

APPLICATIONS

• Automobile.
• Rail joints in railways
• Aerospace and nuclear. reactors.
• Heavy engineering, ship building.
• Joining of metals (stainless)

CONCLUSION

Welding is a vast field were new material joining techniques are consistently being developed. The reason for an active interest
in this field is because every machinery that we use to create complex and common items require some form of welding.

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Practical No 4

Practical: - Press Machine and Its Operations

Theory: -

Also known as a forming press, a machine press is a tool used in the manufacturing industry to deform a workpiece under high pressure.
There are different types of machines presses, including press brakes, punch presses, shop presses and more. The defining characteristic of
all machine presses, however, is that they press a workpiece using high pressure to change the shape of a workpiece.

While the exact mechanics vary depending on the type of machine press, most machine presses work by pressing a plate or die onto or
against a workpiece. They are controlled by one or more workers known as “tool setters” who position the workpiece and control the machine
press. Once the workpiece is positioned underneath the machine press’s plate or die, the tool setter activates the machine press. Using
hydraulic pressure, the machine press pushes the plate or die against the surface of the workpiece, which causes the workpiece’s shape to
deform.

• Classification based on the source of power

o Hand press or ball press or fly press
o Power Press
• Classification based on the design of the frame
o Gap
o Inclinable
o Adjustable
o Horn
o Straight side
o Pillar

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Operations

• Blanking – Cutting or shearing of outside contours or shapes from sheetor strip stock. The piece cut out is the useful part.
• Coining – A squeezing operation, usually performed in a closed die in which the metal is forced to flow and fill the shape and profile of
the die. There is a definite change in metal thickness.
• Crimping – An operation in which the open end of a can or shell is forced tight over or around a mating part. This type of work is limited
largely to assembly operations.
• Curling – The forming of an edge having a circular cross section along a sheet or around the end of a shell or tube. This operation is
sometimes called false wiring.
• Drawing- A process in which a shell of any shape, is produced from flat sheet metal. Holding pressure is applied to the blank edge to
prevent wrinkles in the flange as the punch forces the metal down into the die.
• Embossing – A process for producing raised or sunken designs in sheet metal by means of a male and female die.
• Extrusion – A process in which pressure is applied to a slug of metal causing the metal to flow either up around the punch (toothpaste
tubes) or down in the direction of pressure (cartridge cases – Hooker process).
• Ironing – A process in which the wall thickness of the shell is reduced without changing th O.D. of the shell (cartridge case work for
example).
• Lancing – Slitting and forming a pocket shaped opening in sheet metal, without removing metal.
• Necking – Reducing the diameter of a portion of the length of a cylindrical shell or tube.
• Piercing – Practically the same operation as blanking, except it is limited to holes or slots in sheet metal. The piece cut out is the scrap.
• Redrawing – The second operation following deep-drawing operations, in which cups are deepened and reduced in cross section.
• Staking – An operation in which two or more parts are assembled permanently by upsetting a small portion of metal over the mating part,
causing the compression on the assembled parts.
• Swaging – Forming a metal by the rapid striking of a large number of successive blows. In the case of aircraft cable fittings, the fitting is
rotated while the press blows are being struck.
• Trimming – A secondary operation on drawn or formed parts to remove excess metal on the flange or axial length.

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Advantages of Hydraulic Press

• Built-in overload protection

• It is safe compared to mechanical press
• It is compact
• Lower tool cost due to built-in overload protection
• It is quiet in operation
• Greater versatility compared to mechanical press
• Lower initial and operating cost
• It offers a full power stroke

Disadvantages of Hydraulic Press

• Handling of hydraulic oil can be messy

• Hydraulic lines could burst due to excess pressure
• Some hydraulic fluids can catch fire
• There are chances of hydraulic fluid leakage
• System gets heated because the hydraulic fluid is forced through the pumps
• It has low operational speed
• They have relatively high energy consumption

Applications of Hydraulic Press

• Aerospace industry
• Automotive parts
• Thermoplastic Industries

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• Carbon Fibre Moulding

• Glass Mat Transfer (GMT)
• Resin Transfer Moulding (RTM)
• Sheet Moulded Composites (SMC)
• Metal forming operations
• Deep drawing operations
• Punching operations
• Blanking operations
• Moulding operations
• Clinching operations
• Forging operations

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Practical No 5

Practical: - Clamping Techniques

Theory: - In jigs and fixtures the workpiece or blank has to be strongly and rigidly clamped against the supporting surfaces and also the locating
features so that the blank does not get displaced at all under the cutting forces during machining

Various methods of clamping

Clamping method and system are basically of two categories:

(a) General type without much consideration on speed of clamping operations

(b) Quick acting types

(a) General clamping methods of common use:

• Screw operated strap clamps as typically shown in Fig.

• The clamping end of the strap is pressed against a spring which enables quick unclamping

Common strap type clamping.

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Clamping from side for unobstructed through machining (like milling, plaining and broaching) of the top surface. Some commonly used such
clamping are shown in Fig

Clamping from side for free machining of the top surface

Clamping by swing plates

Such clamping, typically shown in Fig, are simple and relatively quick in operation but is suitable for jobs of relatively smaller size, simpler shape
and requiring lesser clamping forces.

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Other conventional clamping methods include:

• Vices like drilling and milling vices.

• Magnetic chucks
• Chucks and collets for lathe work

Quick clamping methods and systems

Use of quick acting nut :– a typical of such nut and its application is visualised schematically in Fig

Quick acting nut for rapid clamping.

Cam clamping

• Quick clamping by cam is very effective and very simple in operation.

• Some popular methods and systems of clamping by cam are shown in Fig
• The cam and screw type clamping system is used for clamping through some interior parts where other simple system will not have access.

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Quick clamping by cams

• Quick multiple clamping by pivoted clamps in series and parallel. This method shown in Fig. is capable to simultaneously clamp number of
rods even with slight diameter variation
• Quick clamping by hydraulic and pneumatic force for strong and light clamping respectively
• Light but quick clamping by bayonet type clamp as indicated in Fig.

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Advantages

• Bar clamps have adjustable arms that are easily widened or narrowed to fit the workpiece and, therefore, requires fewer turns
of the screw spindle, compared to a C-clamp, to hold the piece tightly.
• Work holder embraces all devices that hold, grip or chuck a work piece in a prescribed manner of firmness and location to
perform on it a manufacturing operation

Applications

They are used for many applications including carpentry, woodworking, furniture making, welding, construction and metal working.

Proper use of a bar clamp:

• Used for woodwork, especially for holding edges when gluing.

• Apply clamping pressure at right angles to the glue line otherwise slippage may result.

Proper use of a c-clamp:

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• Used for carpentry, welding, or cutting.

Proper use of a hand screw clamp:

• Can be made of metal or wood.

• Used to hold small pieces or in furniture repair.

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Practical No 6

Practical: - Jigs and Fixtures

Theory

Jigs along with fixtures are specifically designated machine parts, which can be manufactured by any of the following methods : (a)
Machining, (b) Forging, (c) Casting and (d) Complicated. Jigs are fabricated in different pieces and joined together by welding. Normally
jigs are made of hardened steel, which are wear resistant, corrosion resistant, and thermally in sensitive. Their dimensional accuracy directly
influences the accuracy of performance of the operations where these are used.

DIFFERENT TYPES OF JIGS

Different types of jigs used are described below

Drilling Jigs

Drilling jigs are used for large number of operations. Different types of drilling jigs are described below.

Template Jig

This is a simple plate of metal or wood which carries correct locations of holes to be made in the workpiece. Size of template jig should be
same as that of the workpiece. It is overlapped with the workpiece and drilling is done quickly. Use of this jig avoids the marking operation
completely.

Plate Type Jig

If the work is to be done on very large scale, an improvement can be made to template jig that is plate type jig. This uses a plate having drill
pushes and suitable means to hold and locate the works that it can be clamped to the plate and holds drilled directly through the bushes in
correct positions.

Open Type Jig

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In this jig the top is kept open and workpiece is placed on the base of the jig and the drill plate. Carrying the drill bushes is placed on the top
to guide the tool. After the operation is over, the drill plate is removed, and workpiece is replaced.

Swinging Leaf Type Jig

This type of jig carries a leaf or plate, arranged at the top or on one side, which is capable of swinging about a fulcrum. It is normally the
drill plate itself which is pivoted about a point at its one end. A swinging leaf type jig is shown in Figure 4.15. The work is loaded and
unloaded with the help of swinging bolt

Box Type Jig

Its construction is like a box and it is used for the components having irregular shape and to be operated at different places. This type of jig
provides rigid support, so machining on the various places of workpiece becomes comfortable.

Solid Type Jig

This is also used for drilling holes in articles of simple shapes and relatively smaller sizes. This is made of standard section of rolled steel.

Pot Type Jig

This jig is used for drilling holes in hallow cylindrical components having smaller size. Here the body of the jig is like a pot that is used to
accommodate the workpiece comfortably. Location on the inside surface of the component is provided by the clamp projecting from the
bush plate located over the top of the workpieces.

Index Jigs

This type of jig is equipped with the facility of indexing, which creates positional division of the workpiece suitably. This jig is used for
quick drilling of equidistant holes on the circular surface of the workpiece. By means of indexing device a hole is drilled then the workpiece
is moved (indexed) to next position under the drill bush for drilling automatically.

Multi-station Jigs

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These jigs are designed for multi-spindle machine where many operations can be performed simultaneously. Each spindle of the machine
carries a different tool to perform a different operation. Tools and spindles are arranged in the sequence in which operations are to be
performed.

Universal Jig

As indicated by the name universal jigs are meant to do large number of operations. These may have replaceable elements on them. Selection
and mounting of an element depend on the type of operation to be performed.

Fixtures are designed specifically for an operation and so these are named on the base of the operation to be carried out with their help.
Fixtures are used to hold the workpiece properly to carry out the operations

Different types of fixtures are listed below.

(a) Turning fixtures

(b) Milling fixtures

(c) Fixture for grinding

(d) Fixture for broaching

(e) Fixture for boring/drilling

(f) Tapping fixture

(g) Fixture for welding

(h) Assembling fixture

Out of these fixtures two fixtures are described below.

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Fixtures used to perform different types of milling operations are called milling fixtures. The fixture is probably located on the table of the
machine and secured in position by means of bolts and nuts. The workpiece located on the base of fixture and clamped. The fixture and
associated jigs holds the workpiece and direct the tool to right position by avoiding frequent measurement and marking. The experience of
varying forces by the workpiece are also overcome by the concerning fixtures and jigs. Proper locations of the fixture on the machine table
is usually achieved with the help of two tons provided under the fixture base. These tons enter a T-slot of the table to provide the required
location. The fixture base can then be secured to the table by means of T-bolts and nuts. The fixtures for milling operations are designed and
described on the basis of milling operations, milling techniques and clamping power techniques.

(a) On the basis of types of operations the milling fixture may be of different types are listed below : These are straddle milling fixture, face
milling, slot milling, plain milling, side milling, form milling and gang milling fixtures.

(b) On the basis on technique of milling machining, milling fixtures are named as single piece milling fixture, string milling, reciprocal
milling, index milling and abreast milling fixture.

(c) On the basis of clamping power and clamping method milling fixtures are named as fixture with mechanical clamping, hydraulic
clamping, pneumatic clamping, automatic clamping and vice jaw clamping fixture. Some examples of sturdy fixtures which are 1/4 steel
are illustrated in Figure 4.16. The holes are spaced to go between the „T‟ posts in the milling table. There is a 3/8 holes in each corner,
and that if for the cap head screws that may go into the „T‟ slots nuts of the table. In third case the positioning bar holds the table absolutely
parallel to the front of the table.

Welding Fixtures Welding fixtures are normally designed to hold and support the various components (workpieces) to be welded. It is
necessary to support them in a proper location which is capable of preventing distortions in workpieces during welding. For this the locating
elements need to be placed carefully, clamping has to be light but firm, placement of clamping elements has to be clear of the welding area
and the fixture has to be quite stable and rigid to withstand the welding stresses. There is no limit of designing a welding fixture. Its design
depends on and driven by the hard facts that are what you want, and how to overcome the problems appearing with the current fixture.
Keeping the defect free fast production rate as major target. The famous saying “Need is the mother of invention” hold perfectly true in case

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of welding fixture design. In many cases, most preferred practice is to first tack weld the structure by holding it in a welding jig and then
transfers it to a holding fixture for full welding. This helps in reducing the chances of distortion considerably and also the fixture is subjected
to lesser stresses. An example of a welding fixture is illustrated in Figure 4.17. The fixture is equipped with a rotatable clamp at variable
speeds. There is an adjustable torch holder which can be moved to the right position in the limited space. This fixture is recommended for
the welding on circular shaped objects.

Advantages and Disadvantages

1) It reduces or sometimes eliminates the efforts of marking, measuring and setting of workpiece on a machine and maintains the accuracy
of performance.

2) The workpiece and tool are relatively located at their exact positions before the operation automatically within negligible time. So it
reduces product cycle time.

3) Variability of dimension in mass production is very low so manufacturing processes supported by use of jigs and fixtures maintain a
consistent quality

(4) Due to low variability in dimension assembly operation becomes easy, low rejection due to les defective production is observed.

(5) It reduces the production cycle time so increases production capacity. Simultaneously working by more than one tool on the same
workpiece is possible.

(6) The operating conditions like speed, feed rate and depth of cut can be set to higher values due to rigidity of clamping of workpiece by
jigs and fixtures.

(7) Operators working becomes comfortable as his efforts in setting the workpiece can be eliminated.

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(8) Semi-skilled operators can be assigned the work so it saves the cost of manpower also.

(9) There is no need to examine the quality of product if quality of employed jigs and fixtures is ensured.

Applications of Jigs and Fixtures:

• Mass production of automobile parts.

• Inspection of parts in continuous production in manufacturing industries.

• Cutting the ingots in the steel plant.

• In the refrigeration industry.

• Pump assembling process.

• For drilling the flanges and drilling holes to any required angles

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Practical NO 7
PRACTICAL: - Write CNC programming on given turning and mining part program.
Write Part Pogram of following turning job, raw material MS rod Dia. (40x75)mm. Take absolute dimensioning and feed rate 0.25 mm/min.
Consider data for programming.

N10 G90 G71 G94

N20 M06 M03 T010 S800
N30 G28 U0 W0
N40 G00 X-1 Z1
N50 G42 Z0 F0.25
N60 G01 X24 C2

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N70 G01 Z-28

N80 G01 X32 Z-50
N90 G01 Z-56
N100 G02 X40 Z-60 R4
N110 G01 X40 Z-75
N120 G40 G00 X50 Z10
N130 M02 M30

The following part program for a finishing pass shows the recommended method for start up and cancellation of cutter compensation. Consider data
per requirement.

N010 G17 G71 G40

N020 G95 G90 G81

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N030 G28 U0 W0
N040 G41 G00 X-15 Y-15
N050 G01 X0 Y40
N060 G01 X30 Y80
N070 G01 X60
N080 G02 X100 Y40 R40
N090 G01 Y30
N100 G03 X70 Y0
N110 G01 X0
N120 G00 X-15 Y-15
N130 G40 M09 M02 M30

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Practical No 1
Practical: - Lathe Machine Job
Theory: -

Lathe machine: - The lathe is a machine tool used principally for shaping articles of metal (and sometimes wood or other materials) by causing
the workpiece to be held and rotated by the lathe while a tool bit is advanced into the work causing the cutting action. The basic lathe that was
designed to cut cylindrical metal stock has been developed further to produce screw threads. tapered work. drilled holes. knurled surfaces, and
crankshafts. The typical lathe provides a variety of rotating speeds and a means to manually and automatically move the cutting tool into the
workpiece. Machinists and maintenance shop personnel must be thoroughly familiar with the lathe and its operations to accomplish the repair
and fabrication of needed parts.

The main feature of its construction are the ways which are formed on its upper surface and run the full length of the bed. Ways provide the
means for holding the tailstock and carriage, which slide along the ways, in alignment with the permanently attached headstock.

The headstock is located on the operator’s left end of the lathe bed. It contains the main spindle and oil reservoir and the gearing mechanism

The tailstock is located on the opposite end of the lathe from the headstock. It supports one end of the work when machining between centers,
supports long pieces held in the chuck, and holds various forms of cutting tools, such as drills, reamers, and taps.

The carriage includes the apron, saddle, compound rest, cross slide, tool post, and the cutting tool. It sits across the lathe ways and in front of
the lathe bed. The function of the carriage is to carry and move the cutting tool. It can be moved by hand or by power and can be clamped into
position with a locking nut. The saddle carries the cross slide and the compound rest. The cross slide is mounted on the dovetail ways on the
top of the saddle and is moved back and forth at 90° to the axis of the lathe by the cross-slide lead screw. The lead screw can be hand or power
activated. A feed reversing lever, located on the carriage or headstock, can be used to cause the carriage and the cross slide to reverse the
direction of travel. The compound rest is mounted on the cross slide and can be swivelled and clamped at any angle in a horizontal plane. The
compound rest is used extensively in cutting steep tapers and angles for lathe centres. The cutting tool and tool holder are secured in the tool
post which is mounted directly to the compound rest. The apron contains the gears and feed clutches which transmit motion from the feed rod
or lead screw to the carriage and cross slide.

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Job operations performed over lathe machines are explained above

• Straight & Taper turning: Operation is performed for producing a cylindrical surface by removing excess material from workpiece to

reduce diameter.

• FACING: Removing the material from the end surface or face of work piece. Produces a flat surface. Used for reducing the length of the

work piece.

• DRILLING: It is the process of producing cylindrical hole by means of cutting tool known as drill. During operation drill is fed by

rotating hand wheel of the tailstock in clockwise direction.

• KNURLING: It is the Process of embossing a diamond shaped pattern on the surface of work piece using a tool called knurling tool.

• THREAD CUTTING: Process of producing the helical ‘ V ‘ grooves on the surface with the help of lead screw

• CHAMFERING: Process of beveling the sharp ends of the work piece. Chamfering is provided: for avoiding the injuries to the persons

handling the finished products and for aesthetic look to the finished product.

• GROOVING: Process of providing a narrow groove on the cylindrical surface of the work piece

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