DEPARTMENT OF MECHANICAL ENGINEERING

Course Title: Manufacturing Processes

Course Code: ME - 313
Credit Hours: (2, 1)

LAB MANUAL

Course Instructor: Umer Azeem Khan

Lab Instructor: Engr. Hasan Kazmi
Lab Supervisor: M. Asif Zia

Prepared By: . Checked By: .

(Fall 2019)
Department of Mechanical Engineering
Swedish College of Engineering & Tehnology Wah Cantt
 GENERAL AND SAFETY RULES

 Be prepared. Read and fully comprehend the lab procedure as set forth in the lab manual before
you begin any experiment.
 Think safety. Work deliberately and carefully.
 All laboratory students must be supervised. Never work alone
 Know the hazards of any materials or machinery. The laboratory manual and/or instructor will
review specific safety issues on individual experiments before you perform any tests.
 All students must wear appropriate safety equipment. Safety goggles must be worn anytime
any laboratory experiment is being performed.
 All students must wear appropriate laboratory attire. No open toed shoes; no loose fitting
clothing; jewelry should be removed.
 No food or beverage in the laboratory.
 Know emergency procedures. Make note of fire escape routes and emergency phone locations.
 Report any perceived safety hazards. Immediately report any spills, equipment malfunctions,
injuries or other perceived safety hazards to your instructor / ta / or staff member.
 Failure to conform to any of the above rules may result in not being allowed to participate in
the laboratory experiment.

IN CASE OF EMERGENCY:
Contact Person: _________________

Cell No: __________________

Contents
1. Layout of Laboratory (Machine Shop) ....................................................................................................... 5
Objectives: ..................................................................................................................................................... 5
Apparatus: ...................................................................................................................................................... 5
Theory: ........................................................................................................................................................... 5
Conclusion: .................................................................................................................................................... 7
2. Power Hacksaw .......................................................................................................................................... 8
Objective: ....................................................................................................................................................... 8
Apparatus: ...................................................................................................................................................... 8
Theory: ........................................................................................................................................................... 8
Procedure: .................................................................................................................................................... 10
Precautions: .................................................................................................................................................. 10
3. Lathe Machine Terminologies .................................................................................................................. 11
Objective: ..................................................................................................................................................... 11
Apparatus: .................................................................................................................................................... 11
Theory: ......................................................................................................................................................... 11
4. Lathe Machine Operations........................................................................................................................ 14
Objective: ..................................................................................................................................................... 14
Equipment: ................................................................................................................................................... 14
Theory: ......................................................................................................................................................... 14
Procedure: .................................................................................................................................................... 15
Precautions: .................................................................................................................................................. 16
Results:......................................................................................................................................................... 16
5. Lathe Machine Operations........................................................................................................................ 17
Objective: ..................................................................................................................................................... 17
Equipment: ................................................................................................................................................... 17
Theory: ......................................................................................................................................................... 17
Procedure: .................................................................................................................................................... 18
Precautions: .................................................................................................................................................. 18
Results:......................................................................................................................................................... 18
6. Tool Grinder ............................................................................................................................................. 19
Objective: ..................................................................................................................................................... 19
Apparatus: .................................................................................................................................................... 19
Theory: ......................................................................................................................................................... 19
Procedure: .................................................................................................................................................... 21
Precaution: ................................................................................................................................................... 22
7. Horizontal Milling Machine ..................................................................................................................... 23
 Objective: ..................................................................................................................................................... 23
Equipment: ................................................................................................................................................... 23
Theory: ......................................................................................................................................................... 23
Procedure: .................................................................................................................................................... 28
Precautions: .................................................................................................................................................. 28
8. Vertical Milling Machine ......................................................................................................................... 30
Objective: ..................................................................................................................................................... 30
Equipment: ................................................................................................................................................... 30
Theory: ......................................................................................................................................................... 30
Procedure: .................................................................................................................................................... 32
Precautions: .................................................................................................................................................. 32
9. Surface finishing on Shaper Machine ....................................................................................................... 33
Objective: ..................................................................................................................................................... 33
Equipment: ................................................................................................................................................... 33
Theory: ......................................................................................................................................................... 33
Procedure: .................................................................................................................................................... 34
Precautions: .................................................................................................................................................. 34
10. Sand Casting ......................................................................................................................................... 35
Objective: ..................................................................................................................................................... 35
Equipment/ Apparatus and Materials: ......................................................................................................... 35
Theory: ......................................................................................................................................................... 35
Procedure: .................................................................................................................................................... 36
Precautions: .................................................................................................................................................. 36
11. 3D Printer .............................................................................................................................................. 38
Objective: ..................................................................................................................................................... 38
Equipment: ................................................................................................................................................... 38
Theory: ......................................................................................................................................................... 38
Installing 3D Printer:.................................................................................................................................... 39
Safety Warnings: .......................................................................................................................................... 39
Procedure: .................................................................................................................................................... 40
12. Open Ended Lab ................................................................................................................................... 41
 1. Layout of Laboratory (Machine Shop)
Objectives:
 To study about the layout, its types and importance.
 To draw the layout of laboratory.
 To get brief introduction of equipment and machines in the laboratory.

Apparatus:
 Blank White Paper
 Pencil
 Rubber
 Scale

Theory:
Layout:

An arrangement or plan especially the schematic arrangement of parts and area.

Types of Layout:

Product Layout: Multiple workstations arranged in sequence, and the parts or assemblies are moved through
the sequence to complete the product. The collection of stations is designed specifically for the product to
maximize efficiency.

Process Layout: In which the equipment is arranged according to function or type. The lathes are in one
department, milling machines are in another department and so on.

Fixed Position Layout: Workers and processing equipment are brought to the product, rather than moving
the product to the equipment.

Cellular/Matrix Layout: Each cell is designed to produce a limited variety of part configurations; that is the
cell specializes in the production of a given set of similar parts or products, according to the principles of
Group Technology.

Advantages:
 Machines are better utilized and fewer machines are required
 Flexibility of equipment & personnel is possible
 Higher utilization of production facility
 Reduced material handling activities.
 Simplification of the production planning and control systems.
 Tasks simplification.
Description:

1. Conventional Lathe Machines

2. Milling Machines
3. Shaper Machine
4. Power Hacksaw M\C
5. Entry Door
6. Windows
7. White board
8. Seating arrangement
9. Teacher table
10. Cup board for cutting tools
11. Tool Grinder
12. Cupboard (lab reports & note books)
13. Raw material
14. Teacher Chair
Equipment’s/Apparatus in Laboratory:
Shaper Machine: A shaper is a type of machine tool that uses linear relative motion between the work piece
and a single-point cutting tool to machine a linear tool path. Its cut is analogous to that of a lathe, except that
it is linear instead of helical. The most common use is to machine straight, flat surfaces, but with ingenuity
and some accessories a wide range of work can be done.

Universal Milling Machine: a milling machine having a table fitted with all motions and a dividing head
with change gears so that it can perform any type of milling operation. Milling is the machining process of
using rotary cutters to remove material from a workpiece by advancing (or feeding) in a direction at an angle
with the axis of the tool.

Turret Lathe: 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.

Bench Lathe Machine: A bench lathe is a material reduction machine built into a bench or worktable. A lathe
takes a solid block of a material and reduces it to create a symmetrical item. Using a bench lathe, you can cut,
knurl, drill, or sand material down to create a new object. The lathe is designed to hold the block at two points
and spin it while allow the user to reduce the material to the new shape.

Center Lathe: The Centre Lathe is used to manufacture cylindrical shapes from a range of materials
including; steels and plastics. Many of the components that go together to make an engine work have been
manufactured using lathes.

Power Hacksaw: Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting
diameters of more than 10/15mm is very hard work with a normal hand held hacksaw. Therefore power
hacksaws have been developed to carry out the difficult and time consuming work.

Tool Grinder: Removing of metal by a rotating abrasive wheel. (Very high speed, Shallow cuts) the wheel
action similar to a milling cutter with very large number of cutting points. Grinding was first used for making
tools and arms. To grind different type of cutting tools we use tool grinder.

Conclusion:
The layout of any laboratory or workshop is very important. By optimizing the layout of the room one
can have many advantages including cost minimization, more production and more utilization of space and
machinery.
 2. Power Hacksaw
Objective:
To study and perform experiment on Power Hacksaw machine.

Apparatus:
 Power Hacksaw
 Scale
 Coolant
 Stock Material (Mild Steel)

Theory:
Introduction:

Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting diameters of
more than 10/15mm is very hard work with a normal hand held hacksaw. Therefore power hacksaws have
been developed to carry out the difficult and time consuming work.

The heavy ‘arm’ moves backwards and forwards, cutting on the backwards stroke. . Power hacksaws
have electric motors that power the blade through a pulley system. Some have ratchet systems. The rotary
power is transferred from the motor and changed to reciprocating motion by means of mechanical systems,
allow the blade to cut through the material.

Cutting Blade:
 Blades of power hacksaws are graded according to the material they are made from and the number of
teeth per inch. Top quality blades are manufactured from High Speed Steel. Although there are cheaper
alternatives such as carbon steel blades. In general the number of teeth per inch (TPI) range from 14 to 24.
The more teeth per inch - the smoother the cut

Cutting Speed:

Since the cutting speed of hacksawing machines is measured in strokes per minute, the length of the
stroke is an important consideration. A longer stroke at a given speed will cut faster than a shorter stroke at
the same speed. Thus. To obtain a proper cutting speed the length of the stroke must be specified.

The length of the stroke of most power hacksaws is between 4 and 10 inches depending upon the size
of the machine. On machines with an adjustable stroke, the wider the stock being cut, the shorter the stroke to
prevent the blade holders from hitting the stock.

With most power hacksaws, the stroke length is adjustable within 2 or 3 inches and on some machines
more than one speed can be selected. On single-speed hacksawing machines, the speed must be regulated by
changing the stroke.

Feed:

The feed of machines having gravity feed is regulated by the weight of the saw frame and any
additional weights or springs that might be connected or attached to the frame to increase or decrease the
downward force of the hacksaw blade. Maximum and minimum blade pressures obtainable are determined by
the manufacturer of the hacksawing machine, and are specified as relatively light or heavy. Power hacksaw
machines having a mechanical feed can usually be regulated to feed the saw downward from 0.001 to 0.025
inch per stroke, depending upon the type and size of the material to be cut. On these machines, a device to
stop the feed when hard spots are encountered is usually incorporated.
Procedure:
 The metal to be cut is held in a machine vice which is an integral part of the base. Turning the handle
tightens or loosens the vice. The vice is very powerful and locks the metal in position.
 When the metal is placed and fixed in the vice, the blade is lowered onto its top surface.
 Now turn on the machine by Power switch.
 The arm with cutting blade will move forward & backward on the surface of work piece due to witch
cutting takes place.
 Gravity feed is occurs due to heavy arm.
 When the cut is completed loose the vice and take the material out.

Precautions:
Sawing machines have some special safety precautions that must be observed. These are in addition
to those safety precautions described in manual. Here are some safety precautions that must be followed:

 Keep hands away from the saw blade of the hacksawing machine when in operation.
 When removing and installing band saw blades, handle the blades carefully. A large heavy blade can
be dangerous if the operator does not exercise caution.
 Ensure the power supply is disconnected prior to removal or installation of saw blades or Material.
 3. Lathe Machine Terminologies
Objective:
To study & demonstrate the experimental terminologies of lathe machine.

Apparatus:
 Lathe Machine
 Single Point Cutting Tools

Theory:
A lathe is a machine tool which is used to rotate a work piece to perform various operations such as
turning, facing, knurling, grooving, drilling, boring etc., with the help of tools that are applied to the work
piece.

A lathe (shown in fig.) basically consists of a bed to provide support, a head stock, a cross slide to
traverse the tool, a tool post mounted on the cross slide. The spindle is driven by a motor through a gear box
to obtain a range of speeds. The carriage moves over the bed guide ways parallel to the work piece and the
cross slide provides the transverse motion.

Lathe removes undesired material from a rotating work piece in the form of chips with the help of a
tool which is traversed across the work and can be fed deep in work. The tool material should be harder than
the work piece and the later help securely and rigidly on the machine. The tool may be given linear motion in
any direction. A lathe is used principally to produce cylindrical surfaces and plane surfaces, at right angles to
the axis of rotation. It can also produce tapers and bellows etc.

Cutting Conditions:

Important parameters for an operator working on lathe machine are known as cutting conditions. These
conditions are as follows:
Cutting Speed:

Cutting speed means the linear speed at which cutting takes place. The speed at which the work
material approaches the cutting edge of tool is the cutting speed. It is measured in meters per minute. The
optimum cutting speed depends upon the tool material, the material to be cut and whether a cutting fluid is
being used or not. The purpose of using cutting fluid is to remove heat from the cutting area and to lubricate
the tool face so that the friction between chip and tool surface reduces. Use of cutting fluid makes cutting
process more efficient. Similarly, cutting at recommended cutting speed results in improved tool life and
performance.

Recommended cutting speed for machining cast iron and mild steel with high speed tools is 35 meters
per minute. However, if tungsten carbide tools are used, cutting speeds of 65–70 meters per minute may be
used. For non-ferrous material, much higher cutting speeds are permissible.

Lathe Feed:

The feed of a lathe is the distance the cutting tool advances along the length of the work for every revolution
of the spindle. For example, if the lathe is set for a .020 inch feed, the cutting tool will travel the length of the
work .020 inch for every complete turn that work makes. The feed of a lathe is dependent upon the speed of
the lead screw or feed rod. The speed is controlled by the change gears in the quick change gearbox.

The recommended feeds for cutting various materials when using a high speed steel cutting tools for
general purpose machining a 0.005 – 0.020 inch feed for roughing and a 0.012 to 0.004 inch feed for finishing
is recommended.

Important Formulae:

 The rotational speed in turning is related to the desired cutting speed at the surface of the cylindrical
work piece
𝒗
𝑵=
𝝅𝑫

 The turning operation reduces the diameter of the work from its original diameter Do to a final diameter
Df, as determined by the depth of cut d;

Df= 𝑫𝐨 − 𝟐𝒅

 The feed in turning is generally expressed in mm/rev (in/rev). This feed can be converted to a linear
travel rate in mm/min (in/min)
𝐅𝐫 = 𝐍𝐟

Fr=feed rate, mm/min (in/min), f=feed, mm/rev (in/rev).

 The time to machine from one end of a cylindrical work part

𝐿
Tm= 𝑓𝑟

Tm=machining time, min; and L=length of the cylindrical work part mm (in)

 A more direct computation of the machining time

𝜋𝐷𝑜𝐿
Tm= 𝑓𝑣
Do work diameter, mm (in); L work part length, mm (in); f feed, mm/rev (in/rev); and v=cutting speed,
mm/min (in/min)

 The volumetric rate of material removal can be most conveniently determined by the following
equation;

RMR = vfd

Operations on Lathe Machine:

The most common operations which can be performed on lathe machine are

 Facing
 Plain turning
 Step turning
 Taper turning
 Eccentric Turning
 Drilling
 Reaming
 Boring
 Counter Boring
 Grooving
 Chamfering
 Under cutting
 Threading

Lathe Tools

Different types of operations can be performed on the lathe machine. For these operations different tools
can be used.
 4. Lathe Machine Operations
Objective:
To perform operations on Lathe Machine (Tapper Turning, Drilling, Boring, Counter Sinking &
Chamfering).

Equipment:
 Vernier calipers.
 Steel rule.
 Chuck spanner
 H.S.S. single point cutting tool.
 Spanner
Materials:

____________________________

Theory:
Tapper Turning:

Taper turning means production of a conical surface by gradual reduction in diameter as we proceed
along the length of the cylinder. A conical surface will be produced, if the cutting tool moves along a line
which is inclined to the longitudinal axis of the work piece instead of moving parallel to it. A taper is defined
by the half angle (a) of the cone as shown in Fig.

Following methods are used for taper turning on lathe:

 By swiveling the compound rest.

 By offsetting tailstock.
 By using a taper turning attachment.
 By using a form tool.

Drilling:

For initial drilling of a hole on the lathe machine, tailstock center is removed and in the tailstock spindle
a drill is inserted. The tailstock is brought closer to the work piece, which is held in the chuck and rotated.
Now using the hand wheel of the tailstock, the drill is advanced. The advancing drill comes in contact with
end face of the work piece and drills a hole through it. After the hole has been drilled to required depth, the
drill is withdrawn. This hole can then be enlarged in diameter by using a boring tool.

Boring:

Boring means enlarging an existing hole. The operation of boring is shown in Fig. It is a delicate
operation. The diameter of the boring tool or boring bar fitted with a tool bit has to be smaller than the hole in
the work piece. The boring operation is really an internal turning operation but not being able to see the actual
cutting, makes the operation tricky and delicate.

Counter Sinking:

Countersinking is a process that creates a V-shaped edge near the surface of a hole. It is often used to
debar a drilled or tapped hole, or to allow the head of a countersunk-head screw to sit flush or below a surface.

Chamfering:

Chamfering removes the burrs and sharp edges, and thus makes the handling safe. Chamfering can be
done by a form tool having angle equal to chamfer which is generally kept at 45°.

Procedure:
1. The work piece is fixed in a 3-jaw chuck with sufficient length extending from chuck so that it could
be worked on.
2. Check that job is centered, applying centering.
3. Adjust the machine to run the job to a required cutting speed.
4. Fix the cutting tool in the tool post
5. Adjust the feed rate and depth of cut.
6. Plain turning operation is performed until the diameter of the work piece reduces to desired thickness.
7. Dimensions are noted using the Vernier calipers.
8. Then chamfering is done on the given/mentioned diameter surface.
9. Reverse the work piece in the chuck and facing operation is performed to reduce the length of work
piece to the required dimensions.
10. Again Plain turning operation is performed until the diameter of the work piece reduced to desired
dimensions.
 11. Compound slide is swiveled to the required angle and taper turning operation is performed by rotating
the compound slide wheel (Angle is measured by using the formula).
12. By using drill spindle in to the tailstock, drill of certain diameter is done.
13. Then boring is done to gain required dimension of hole.
14. By using boring counter sinking is also done.
15. Finally, the dimensions of the job are measured using Vernier calipers.

Precautions:
1. Follow the general instructions written in the manual.
2. The work piece should be held rigidly in the chuck before operating the machine.
3. Tool should be properly ground, fixed at correct height and properly secured, and work also be firmly
secured.
4. Before operating the machine see whether the job and tool is firmly secured in devices or not.
5. Optimum machining conditions should be maintained.
6. Chips should not be allowed to wound around a revolving job and cleared as often as possible.
7. Apply cutting fluids to the tool and work piece properly.

Results:
Thus the work piece for the required dimensions is obtained by performing above mentioned
operations in lathe.
 5. Lathe Machine Operations
Objective:
To perform operations on Lathe Machine (Threading & Knurling).

Equipment:
 Vernier calipers.
 Steel rule.
 Chuck spanner
 H.S.S. single point cutting tool.
 Spanner
 Thread Gauge
Materials:

Theory:
Threading:

Threading is an operation of cutting threads or helical grooves on the external cylindrical surface of
the job. In this process, the carriage is connected to the lead screw.

𝑟𝑝𝑚 𝑜𝑓 𝑙𝑒𝑎𝑑 𝑠𝑐𝑟𝑒𝑤

𝑃𝑖𝑡𝑐ℎ 𝑜𝑓 𝑇ℎ𝑟𝑒𝑎𝑑 𝑡𝑜 𝑏𝑒 𝑐𝑢𝑡 = 𝑋 𝑃𝑖𝑡𝑐ℎ 𝑜𝑓 𝐿𝑒𝑎𝑑 𝑆𝑐𝑟𝑒𝑤
𝑟𝑝𝑚 𝑜𝑓 𝑊𝑜𝑟𝑘 𝑝𝑖𝑒𝑐𝑒

Thus there should be an arrangement to change the ratio of r.p.m. of work piece and the r.p.m. of lead screw.
This is done by a system of gears, which give the required ratio. Threads have a standard profile. The cutting
tool profile should match with this profile. Now the threads can be cut in the usual manner by traversing the
tool by engaging the clutch between carriage and lead screw. Such screw cutting lathes are provided, with
reversible motors. The r.p.m. of spindle is kept very low for thread cutting.

Knurling:

For providing better grip, some work pieces are provided with a shallow diamond shaped pattern on
its circumference. Knurling rollers, which have a similar pattern cut on their surface are hardened. When a
work piece surface is required to be knurled, the work piece is held in a chuck and rotated and the knurling
roller is clamped in the tool post and by moving the cross slide, the roller is pressed into the surface of the
work piece. As the roller and work piece surface rotate together, the pattern is etched into the surface of the
work piece.

Procedure:
1. The work piece is fixed in a 3-jaw chuck with sufficient length extending from chuck so that it could
be worked on.
2. Check that job is centered, applying centering.
3. Adjust the machine to run the job to a required cutting speed.
4. Fix the Threading tool in the tool post.
5. Adjust the feed rate and Cutting Speed by using lead & feed screw adjustment levers.
6. Now provide appropriate depth to tool then by attaching carriage to auto feed we can start threading
operation of adjusted pitch.
7. Dimensions are noted using the Vernier calipers & Thread gauge.
8. Then knurling is done on the given/mentioned surface by using knurling tool.
9. Finally, the dimensions of the job are measured using Vernier calipers.

Precautions:
1. Follow the general instructions written in the manual.
2. Pay full attention while using auto feed to avoid collision of tool post & chuck.
3. The work piece should be held rigidly in the chuck before operating the machine.
4. Tool should be properly ground, fixed at correct height and properly secured, and work also be firmly
secured.
5. Before operating the machine see whether the job and tool is firmly secured in devices or not.
6. Optimum machining conditions should be maintained.
7. Chips should not be allowed to wound around a revolving job and cleared as often as possible.
8. Apply cutting fluids to the tool and work piece properly.

Results:
Thus the work piece for the required dimensions is obtained by performing above mentioned
operations in lathe.
 6. Tool Grinder
Objective:
 To study & demonstrate the Operational techniques and Parts of Tool Grinder.
 To grind a single point cutting tool.

Apparatus:
 Tool Grinder
 Blended Single point cutting tool
 Coolant

Theory:
Introduction:

A tool and cutter grinder is used to sharpen single point cutting tool, milling cutters and tool bits. It is
an extremely versatile machine used to perform a variety of grinding operations: surface, cylindrical, or
complex shapes. We are using a manually operated setup in our laboratory for learning purposes, however
highly automated Computer Numerical Control (CNC) machines are becoming increasingly common due to
the complexities involved in the process. The operation of this machine (in particular, the manually operated
variety) requires a high level of skill. The two main skills needed are understanding of the relationship between
the grinding wheel and the metal being cut and knowledge of tool geometry. The illustrated set-up is only one
of many combinations available. The huge variety in shapes and types of machining cutters requires flexibility
in usage. A variety of dedicated fixtures are included that allow cylindrical grinding operations or complex
angles to be ground.

Tool Geometry:

The word tool geometry is basically referred to some specific angles or slope of the salient faces and
edges of the tools at their cutting point. Rake angle and clearance angle are the most significant for all the
cutting tools.

Single Point Cutting Tool:

 Cutting edge: The edge on the tool which removes materials from the work piece is called cutting
edges. It lies on the face of the tool. The single point cutting tool has two edges and these are

 Side cutting edge: The top edge of the major flank is called side cutting edge.
 End cutting edge: The top edge of the minor flank is called end cutting edge.

Nose or cutting point: The intersection point of major cutting edge and minor cutting edge is called
nose.

Nose radius: It is the radius of the nose. Nose radius increases the life of the tool and provides better
surface finish.

Angles of Single Point Cutting Tool:

The various angles of the single point cutting tool have great importance. Each angle has its own
function and specialty.

End Cutting Edge Angle: The angle formed in between the end cutting edge and a line perpendicular
to the shank is called end cutting edge angle.

Side Cutting Edge Angle: The angle formed in between the side cutting edge and a line parallel to
the shank.

Back Rack Angle: The angle formed between the tool face and line parallel to the base is called back
rake angle.

End Relief Angle: The angle formed between the minor flank and a line normal to the base of the tool
is called end relief angle. It is also known as front clearance angle. It avoid the rubbing of the work piece
against tool.

Lip Angle/ Wedge Angle: It is defined as the angle between face and minor flank of the single point
cutting tool.
 Side Rake Angle: The angle formed between the tool face and a line perpendicular to the shank is
called side rake angle.

Side Relief Angle: The angle formed between the major flank surface and plane normal to the base of
the tool is called side relief angle. This angle avoids the rubbing between work piece and flank when the tool
is fed longitudinally.

Procedure:
1. At first, we need to select the metal. Then we need to choose the side of the metal.
2. With grinding machine, we start to cut the metal through one side. Metal must be formed in curved.
We have to make it perfectly curved at the middle of the side. They should not exist above 60ᵒ angle.
3. After finishing that, we need to clear the every surface of the metal with file.
4. Then we punch our id in the one surface of the metal.
5. After that, we have to put crater wear on the upper side of the curve with grinding machine.
6. Then we need to flat out the edge of the curve.
 7. Then we have to lapper the metal with grease and fold it with paper.

Precaution:
 After every grinding, we need to put the metal to the coolant for safety of the hand because of the
increasing temperature of the metal.
 We must use paper or cloth piece to hold the metal for heat.
 We must make a distance of our hand with the grinding machine for safety.
 We must wear apron and glasses for safety.
 7. Horizontal Milling Machine
Objective:
 To Study and demonstrate the experimental terminologies of Horizontal Milling Machine.
 To make the students enable to perform milling operations (slitting and side milling) on given job.

Equipment:
 Universal Milling Machine
 Vernier calipers.
 Slitting cutter/side milling cutter
 Steel rule.
 Level
 Spanner.
 Vise and clamping step blocks
Material:
 Mild Steel Block

Theory:
Introduction:

Milling is the process of machining flat, curved, or irregular surfaces by feeding the work piece against
a rotating cutter containing a number of cutting edges. The milling machine consists basically of a motor
driven spindle, which mounts and revolves the milling cutter, and a reciprocating adjustable worktable, which
mounts and feeds the work piece.

Types of Milling Machines:

Most of the milling machine are constructed of column and knee structure and they are classified into
two main types namely Horizontal Milling Machine and Vertical Milling Machine. The name Horizontal or
Vertical is given to the machine by virtue of its spindle axis. Horizontal machines can be further classified
into Plain Horizontal and Universal Milling Machine. The main difference between the two is that the table
of a Universal Milling Machine can be set at an angle for helical milling while the table of a Plain Horizontal
Milling Machine is not.

Horizontal Milling Machine:

Parts:

Column: The column houses the spindle, the bearings, the gear box, the clutches, the shafts, the pumps, and
the shifting mechanisms for transmitting power from the electric motor to the spindle at a selected speed.

Knee: The knee mounted in front of the column is for supporting the table and to provide an up or down
motion along the Z axis.

Saddle: The saddle consists of two slide ways, one on the top and one at the bottom located at 90º to each
other, for providing motions in the X or Y axes by means of lead screws.

Table: The table is mounted on top of the saddle and can be moved along the X axis. On top of the table are
some T-slots for the mounting of work piece or clamping fixtures.

Arbor: The arbor is an extension of the spindle for mounting cutters. Usually, the thread end of an arbor is of
left hand helix.

Base: The base of the milling machine, along with the column, are the major structural components. They
hold, align, and support the rest of the machine.

Spindle: The spindle holds the tool and provides the actual tool rotation.

Spindle Reverse Lever: The position of this lever determines the spindle direction. The three positions of the
handle (In, Middle, and out). The middle position is the neutral position. Never move the spindle reverse lever
when the spindle is turning.

Spindle Speed Selection Lever: The spindle speed selection lever is used to change the spindle R.P.M.
setting. This type of machine has a geared head so the spindle speed can only be changed when the spindle is
stopped.

Spindle Clutch Lever: The spindle clutch lever engages the spindle clutch to the motor. By manipulating the
spindle clutch lever the operator can start and stop the spindle.

Feed Rate Selection Lever: The feed rate selection lever is used to change the feed rate setting. The feed rate
settings are expressed in inches per minute.

Motor Start and Stop Buttons: The motor start and stop buttons control the power to the main motor for the
machine

Types of Horizontal Milling Cutters:

Helical Milling Cutters: The helical milling cutter is similar, to the plain milling cutter, but the teeth nave a
helix angle of 45° to 60°. The steep helix produces a shearing action that results in smooth, vibration-free cuts.
They are available for arbor mounting, or with an integral shank with or without a pilot. This type of helical
cutter is particularly useful for milling elongated slots and for light cuts on soft metal.

Metal Slitting Saw Milling Cutter: The metal slitting saw milling cutter is essentially a very thin plain
milling cutter. It is ground slightly thinner toward the center to provide side clearance. These cutters are used
for cutoff operations and for milling deep, narrow slots, and are made in widths from 1/32 to 3/16 inch.
Side Milling Cutters: Side milling cutters are essentially plain milling cutters with the addition of teeth on
one or both sides. A plain side milling cutter has teeth on both sides and on the periphery. When teeth are
added to one side only, the cutter is called a half-side milling cutter and is identified as being either a right-
hand or left-hand cutter. Side milling cutters are generally used for slotting and straddle milling. Interlocking
tooth side milling cutters and staggered tooth side milling cutters are used for cutting relatively wide slots with
accuracy Interlocking tooth side milling cutters can be repeatedly sharpened without changing the width of
the slot they will machine. After sharpening, a washer is placed between the two cutters to compensate for the
ground off metal. The staggered tooth cutter is the most washer is placed between the two cutters to
compensate for efficient type for milling slots where the depth exceeds the width.

Corner Rounding Milling Cutter: The corner-rounding milling cutter is a formed tooth cutter used for
milling rounded corners on workplaces up to and including one-quarter of a circle. The size of the cutter is
specified by the radius of the circular form the cutter produces, such as concave and convex cutters generally
used for such work as finishing spur gears, spiral gears, and worm wheels. They may also Defused to cut
ratchets and spline shafts.

Special Shaped-Formed Milling Cutter: Formed milling cutters have the advantage of being adaptable to
any specific shape for special operations. The cutter is made especially for each specific job. In the field, a fly
cutter is formed by grinding a single point lathe cutter bit for mounting in a bar, holder, or fly cutter arbor.
The cutter can be sharpened many times without destroying its shape.

Milling Processes:
 Milling is a metal removal process by means of using a rotating cutter having one or more cutting teeth
as illustrated in figure. Cutting action is carried out by feeding the work piece against the rotating cutter. Thus,
the spindle speed, the table feed, the depth of cut, and the rotating direction of the cutter become the main
parameters of the process. Good results can only be achieved with a well-balanced settings of these parameters.

There are two types of process for milling

Up milling: Cutters rotate against direction of feed. Also called conventional milling. Chip width is zero at
start and maximum at end. Tool life is short.

Down milling: Cutter rotate with direction of feed. Also called climb milling. Chip size is maximum at start
and minimum at end. Tool life is long.

Types of Horizontal Milling Operations:

Various types of milling operations are as fallow

 Plain milling
 Form milling
 Angular milling
 Helical milling
 Profile milling
 Keyway milling
 Gear milling

Plain or slab milling: Machining of a flat surface which is parallel to the axis of the rotating cutter.
Angular milling: Machining of a flat surface at an angle, other than a right angle, to the axis of revolving
cutter.

Straddle milling: Simultaneous machining of two parallel vertical faces of the work-pieces by a pair of side
milling cutters.

Form milling: Machining of surfaces which are of irregular shape. The teeth of the form milling cutter have
a shape which corresponds to the profile of the surface to be produced.

Gang milling: Simultaneous machining of a number of flat horizontal and vertical surfaces of a work piece
by using a combination of more than two cutters mounted on a common arbor.
Procedure:

Precautions:
 Wear appropriate safety glasses.
 Ensure that the milling machine has a start/stop button within easy reach of the operator.
 Ensure that the work piece and cutter are mounted securely before taking a cut.
 Mount work in a vise that is bolted or held magnetically to the table. Use proper hand tools to make
adjustments.
 Hold milling cutters with a cloth to avoid being cut when handling them.
 Move table as far as possible from cutter while setting up work to avoid injuring your hands.
 Mill the largest surface first.
 Keep hands, brushes and rags away from the revolving milling cutter.
 Use a vacuum, brush or rake to remove cuttings only after the cutters have stopped moving.
 Keep cutters sharpened correctly and in good condition.
 Keep working surface clear of scraps, tools and materials.
 Remove cutting tools from spindle when cleaning the machine.
 Keep floor around the milling machine free of oil and grease.
 Use lifting equipment when appropriate to move heavy work to or from milling machines.
 Make sure the power is off before changing cutters.
 Always stay at the machine when it is in operation.
 8. Vertical Milling Machine
Objective:
 To make the students enable to perform milling operations (end milling/face milling) on given job.

Equipment:
 Vernier calipers.
 End mill/Face mill cutter
 Steel rule.
 Level
 Spanner.
 Vise and clamping step blocks
Material
 Mild Steel Block
Theory:
Vertical Milling Machine:

Vertical milling machine which is of similar construction to a horizontal milling machine except that
the spindle is mounted in the vertical position.

Its additional features are:

Milling head: The milling head consisting the spindle, the motor, and the feed control unit is mounted on a
swivel base such that it can be set at any angle to the table.

Ram: The ram on which the milling head is attached can be positioned forward and backward along the
sideway on the top of the column.

Vertical Milling Cutters:

The end milling cutter, also called an end mill, has teeth on the end as well as the periphery. The
smaller end milling cutters have shanks for chuck mounting or direct spindle mounting. End milling cutters
may have straight or spiral flutes. Spiral flute end milling cutters are classified as left-hand or right-hand
cutters depending on the direction of rotation of the flutes. If they are small cutters, they may have either a
straight or tapered shank.
 The most common end milling cutter is the spiral flute cutter containing four flutes. Two-flute end
milling cutters, sometimes referred to as two-lip end mill cutters, are used for milling slots and key ways where
no drilled hole is provided for starting the cut. These cutters drill their own starting holes. Straight flute end
milling cutters are generally used for milling both soft and tough materials, while spiral flute cutters are used
mostly for cutting steel.

Large end milling cutters are called shell end mills and are recessed on the face to receive a screw or
nut for mounting on a separate shank or mounting on an arbor, like plain milling cutters. The teeth are usually
helical and the cutter is used particularly for face milling operations requiring the facing of two surfaces at
right angles to each other.

The T-slot milling cutter is used to machine T-slot grooves in worktables, fixtures, and other holding
devices. The cutter has a plain or side milling cutter mounted to the end of a narrow shank. The throat of the
T-slot is first milled with a side or end milling cutter and the head space is then milled with the T-slot milling
cutter.

The Woodruff key slot milling cutter is made in straight, tapered-shank, and arbor-mounted types. The
most common cutters of this type, under 1 1/2 inches in diameter, are provided with a shank. They have teeth
on the periphery and slightly concave sides to provide clearance’s cutters are used for milling semi cylindrical
key ways in shaft.

Face milling: Machining of a flat surface which is at right angles to the axis of the rotating cutter.

Operations:
Procedure:

Precautions:
Safety rules during / or before operation:

 Use safety protective equipment such as safety shoes, goggles, clothes, etc.
 Work table near machine must be strong enough to prevent accidents.
 Tools and any unnecessary items are not allowed to be placed on the machine table, moving parts, or
similar locations.
 Before operating switches, always check if the switches are the right ones and never touch a switch
accidently or it may cause malfunctions or danger.
 Do not operate switches with gloves on. This could malfunctions and even danger.
 Do not touch switches with wet hands, an electric shock will occur
 Warm up the machine before use, especially the spindle and feeding axes by running them for 10 to
20 minutes. It is very important for maintaining machine accuracy.
 If job is to be done by two or more operators, the function of each must be well known, what action
will be done and what danger may occur, before the next step is taken.
 Tools should be conform to the machine’s specifications, such as dimensions, weight and types.
 Grip work pieces securely to minimize movement or vibration between work piece and cutting tool or
it may injure personnel, or damage the machine or work piece.
 Stop the machine before replacing a work piece and provide plenty of distance between work piece
and tool to avoid impact between work piece and tool during change over. In the event of power failure,
turn off the main circuit breaker immediately.
 After a power failure or an emergency stop, it is necessary to return to reference point of three axes.
Limit switches, proximity switches, interlock mechanisms including functional parts and other safety
devices should not be removed or modified.
 9. Surface finishing on Shaper Machine
Objective:
To understand the linear cutting/machining on shaper.

Equipment:
 Steel rule
 Dot punch
 Ball peen hammer
 Surface gauge and scriber
 Vernier height gauge
 V-block
 H.S.S. Single point cutting tool.
Material:

Theory:
The processes of shaping and planning are among the oldest single-point machining processes.
Shaping has largely been replaced by milling and broaching as a production process, while planning still has
applications in producing long flat cuts, like those in the ways of machine tools. From a consideration of the
relative motions between the tool and the work piece, shaping and planning both use a straight-line cutting
motion with a single-point cutting tool to generate a flat surface. In shaping, the work piece is fed at right
angles to the cutting motion between successive strokes of the tool, as shown in Figure a, where fc is the feed
per stroke is the cutting speed, and d is the depth of cut (DOC). For either shaping or planning, the tool is held
in a clapper box, which prevents the cutting edge from being damaged on the return stroke of the tool. In
addition to plain flat surfaces, the shapes most commonly produced on the shaper and planer are those
illustrated in Figure c. Relatively skilled workers are required to operate shapers and planers, and most of the
shapes that can be produced on them can also be made by much more productive processes, such as milling,
broaching, or grinding. Consequently, except for certain special types, planers that will do only planning have
become obsolete. Today, shapers are used mainly in tool and die work, in very low volume production, or in
the manufacture of gear teeth. In shaping, the cutting tool is held in the tool post located in the ram, which
reciprocates over the work with a forward stroke, cutting at velocity V and a quick return stroke at velocity
VR. The rpm of drive crank (Ns) drives the ram and determines the velocity of the operation (see Figure 27-
1d). The stroke ratio is
Procedure:
1. The two ends of the work piece are first smoothened by filing and apply chalk on its surface.
2. Place the work piece on the V-block and mark center on the end face using surface gauge, scriber and
Vernier height gauge.
3. Mark square on the end face according to the required dimensions.
4. By using dot punch made permanent indentation marks on the work piece.
5. The tool is fixed to the tool post such that the tool movement should be exactly perpendicular to the
table.
6. The work piece is then set in the vice such that the tool is just above the work piece.
7. Adjust the length of the stroke.
8. Make sure that line of action of stroke should be parallel to the surface of the work piece.
9. Give depth of cut by moving the tool and feed is given to the work piece during return stroke of the
ram.
10. Continue the process, until the required dimensions are to be obtained.
11. Repeat the process for all the four sides.
12. Finally make a key way on one side according to the given dimensions

Precautions:
1. Follow the general instructions written in the manual.
2. The work piece should be held rigidly in the chuck before operating the machine.
3. Tool should be properly ground, fixed at correct height and properly secured, and work also be
firmly secured.
4. Before operating the machine see whether the job and tool is firmly secured in devices or not.
5. Optimum machining conditions should be maintained.
6. Chips should not be allowed to wound around a revolving job and cleared as often as possible.
7. Apply cutting fluids to the tool and work piece properly
 10. Sand Casting
Objective:
 To prepare a sand mold.
 To manufacture a component through sand casting process.

Equipment/ Apparatus and Materials:

1. Molasses
2. Aluminum (Al scrap can also be used)
3. Bentonite
4. Water
5. Molding sand
6. Hammer
7. Flat swap
8. Pipe clamp
9. Trowel
10. Sprue pins
11. Mold box
12. Strike of bar
13. Molding box
14. Roller
15. Laboratory sand Muller
16. Molding boxes (flasks)
17. Core box
18. Melting crucible
19. Melting furnace

Theory:
Introduction:

A casting may be defined as, “A metal object obtained by allowing molten metal to solidify in a mold
cavity." The shape of the casting depends upon the shape of the mold cavity." The basic steps involved in sand
casting are:

 Pattern making (including core box)

 Core making
 Molding
 Melting and pouring
 Cleaning

Patterns are required to make a mold cavity. A mold is made by packing the molding sand around the
pattern so that when the pattern is withdrawn, its imprint remains as a cavity that is filled with the liquid metal
to be cast. To make a cavity or hole in a casting, cores are used which are usually made of sand. The metal is
poured in the cavity and allowed to solidify. Solidified casting is taken out of the mold, cleaned and if required
machining is done. Finally, different casting defects and their remedies are studied.

Parameters: Following are some parameters that affect sand casting:

 Silica grain size

 Type of binder
  Moister percentage
 Binder percentage
 Pouring rate
 Viscosity of molten metal
 Solidification time

Advantages:

 Low Cost
 No skilled operators needed
 Equipment are cheap and easy to deal with.
 Suitable for few small production rates
 Can produce large (very large) castings

Disadvantages:

 Bad surface finish, due to sand indentation and oxidizing medium.

 Many defects arise in the casting (no good control on the process , die casting is much better)
 Not suitable for mass production, often used to produce few number of products compared with other
casting processes which produce thousands and millions.
 Dangerous operation may cause harmful injuries.

Defects:

 Shrinkage defects can occur when standard feed metal is not available to compensate for shrinkage as
the thick metal solidifies.
 Gas porosity is the formation of bubbles within the casting after it has cooled. This occurs because
most liquid materials can hold a large amount of dissolved gas, but the solid form of the same material
cannot, so the gas forms bubbles within the material as it cools.
 Pouring metal defects include misruns, cold shuts, and inclusions. A misrun occurs when the liquid
metal does not completely fill the mold cavity, leaving an unfilled portion. Cold shuts occur when two
fronts of liquid metal do not fuse properly in the mold cavity, leaving a weak spot. Both are caused by
either a lack of fluidity in the molten metal or cross-sections that are too narrow.
 Hot tears, also known as hot cracking, are failures in the casting that occur as the casting cools.
 Hot spots are areas on the surface of casting that become very hard because they cooled more quickly
than the surrounding material. This type of defect can be avoided by proper cooling practices or by
changing the chemical composition of the metal.

Procedure:
There are six steps in this process:

1. Place a pattern in sand to create a mold.

2. Incorporate the pattern and sand in a gating system.
3. Remove the pattern.
4. Fill the mold cavity with molten metal.
5. Allow the metal to cool.
6. Break away the sand mold and remove the casting.

Precautions:
Followings are few safety tips that one should know if he/she is dealing with casting process or alloys:
 Wear eye protection, gloves, spats (covering top of feet), and thick clothing protecting all exposed skin
on arms and legs. NO polyester or synthetic clothing.
 Sand Floor in pouring area shall be clear of all objects not involved in pouring.
 Clamp or weight up molds that require it.
 Metal added to heat must be free of moisture and impurities.
 Metal added to heat during melt must be preheated.
 Skimmers and other melting tools must be preheated before use.
 Move slowly while removing crucible from furnace and moving to mold.
 Do not look into exhaust during operation.
 Inspect crucibles before use.
 Inspect propane lines.
 Use outdoors only.
 No alcohol or drug use.
 Wear respiratory protection while melting copper-base alloys (brass, bronze).
 11. 3D Printer
Objective:
To learn processing techniques associated with a 3D Printer.

Equipment:
3D Printer

Theory:
Introduction:

A 3D printer is a computer-aided manufacturing (CAM) device that creates three-dimensional objects.

Like a traditional printer, a 3D printer receives digital data from a computer as input. However, instead of
printing the output on paper, a 3D printer builds a three-dimensional model out of a custom material.

3D printers use a process called additive manufacturing to form (or "print") physical objects layer by
layer until the model is complete. This is different than subtractive manufacturing, in which a machine
reshapes or removes material from an existing mold. Since 3D printers create models from scratch, they are
more efficient and produce less waste than subtractive manufacturing devices.

The process of printing a 3D model varies depending on the material used to create the object. For
example, when building a plastic model, a 3D printer may heat and fuse the layers of plastic together using a
process called fused deposition modeling (FDM). When creating a metallic object, a 3D printer may use a
process called direct metal laser sintering (DMLS). This method forms thins layers of metal from metallic
powder using a high-powered laser.
Installing 3D Printer:
1. Before you begin, make sure your computer has a working internet connection and that it’s
connected to the mains or has enough charge left in its battery.
2. Next, log on to www.Xplorer3D.com and download the most recent version of XPLORER
ENGINE & XPLORER 3D DRIVERS for your particular operating system or find one in the SD-
card given.
3. After XPLORER ENGINE & Driver has finished downloading, go to the download folder and run
both the installation file one by one or install from SD-card.
4. Follow the installation instructions to the end, selecting the desired options.
5. Run XPLORER ENGINE as administrator by right clicking on the shortcut on your Desktop or
Applications menu and selecting “Run as Administrator”.
6. After installing XPLORER ENGINE, follow the steps in the bed leveling wizard to calibrate your
XPLORER 3D PROTO using the “SETUP & INSTALLATION GUIDE”.

Safety Warnings:
 Make sure you’ve removed all the printer’s packaging material and check to see if the main switch
is in the “OFF” position.
 Attach the power cable of adapter, connecting it first to the XPLORER 3D PROTO printer, and
next, to the socket.
 Connect the USB cable to XPLORER 3D PROTO and to the computer. Place one, and only one,
layer of Adhesive tape on the printer bed
 Glass/Acrylic, carefully to avoid any overlapping (Already done in some cases).
  Place the spool inside the spool mount. Take care to keep the filament wound tight, because any
looseness might cause kinks or knots to appear in the filament, which makes printing impossible.
 Place assembled items (spool + mounting) on the left side of your XPLORER 3D PROTO from
where the filament is entering the extruder motor.
 Click the main switch to the “ON” position.

Procedure:
 Make sure you have disabled your computer’s hibernation or suspend to disk function. If the computer
goes into hibernation or suspend to disk state while something is being printed, you will be unable to
resume this task and you will have to start again.
 Make sure the adhesive tape is in an acceptable state. If it’s damaged, it should be replaced as described
in point 4 of ‘Installing XPLORER 3D PROTO’.
 Check to see if no kind of object or filament debris is on the printer table.
 Import the 3D model you wish to print. You can find a range of 3D models in the SD-CARD, online
or you can create your own 3D model by using modeling software.
 Make sure you’ve followed the steps laid out in XPLORER ENGINE’s printer calibration/bed leveling
wizard.
 Click on the “Load” button in XPLORER ENGINE and select the file you imported.
 Click on the “Print” button and select the desired printing options.
 XPLORER ENGINE will prepare the selected file for printing (a process called “slicing”), which may
take a few minutes. Once it’s ready, the printing process will begin

After Printing:

After your print is over, you must remove the object from the table. Try to do it first gently by hand
without damaging it. If you are not able to do it, use something like spatula parallel to the table. If none of
these techniques work, remove the tape. Don’t forget to replace the tape before printing again.
12. Open Ended Lab