4th – Sem Lab Manual

(1)SPUR GEAR MILLING:

AIM :
         
To machine a spur gear to the given module and number of teeth in the given
workpiece.

TOOLS AND EQUIPMENTS REQUIRED :

         
Milling machine, Vernier caliper, Mandrel.

PROCEDURE :

1.    Calculate the gear tooth proportions.

Blank diameter      = ( Z + 2 ) m
Tooth depth           = 2.25 m
Tooth width           = 1.5708 m
 where,  
Z = Number of teeth required
              m = module

2.    Indexing calculation
Index crank movement = 40 / Z

3.    The dividing head and the tail stock are bolted on the machine table. Their
axis must be set parallel to the machine table.

4.    The gear blank is held between the dividing head and tailstock using a
mandrel. The mandrel is connected with the spindle of dividing head by a
carrier and catch plate.
5.    The cutter is mounted on the arbor. The cutter is centred accurately with the
gear blank.

6.    Set the speed and feed for machining.

7.    For giving depth of cut, the table is raised till the periphery of the gear blank
just touches the cutter.

8.    The micrometer dial of vertical feed screw is set to zero in this position.

9.     Then the table is raised further to give the required depth of cut.
10. The machine is started and feed is given to the table to cut the first groove of
the blank.

11. After the cut, the table is brought back to the starting position.

12. Then the gear blank is indexed for the next tooth space.

13. This is continued till all the gear teeth are cut.

CALCULATION :

Z = No. of teeth     = 23

m = module           = 2 mm

Blank Diameter      = (Z + 2) m
                             = (23 + 2) 2
                             = 50 mm

Tooth Depth          = 2.25 m

                             = 2.25 * 2
                             = 4.5 mm

Indexing Calculation        = 40 / Z
                                      = 40 / 23
                                      = 1  17/23

RESULT :

Thus the required gear is machined using the milling machine to the required
number of teeth.

(2) CAPSTAN LATHE:

AIM :
         
To machine the workpiece to the given dimensions using capstan lathe.
  

TOOLS AND EQUIPMENTS REQUIRED :

Capstan Lathe, Stopper, drill chuck, counter sink bit, drill bit, turning tool,
parting off tool, Vernier Caliper.

PROCEDURE :

1.    Prepare the tooling layout for the given workpiece.

2.    Set the tools in their respective positions of the tool stations.

3.    The workpiece is chucked and checked for the rotation.

4.    The adjustment to the length of feed for each tool is adjusted by rotating the
adjustment screws.

5.    Feed the tools in the required sequence to machine the given workpiece.

RESULT :

Thus the given workpiece is machined to the given dimensions using capstan
lathe.

(3)ASSEMBLY OF FLANGE COUPLING:

AIM :

To machine and assemble the Flange Coupling as shown in the figure using
required machines.
 TOOLS AND EQUIPMENTS REQUIRED :

Drilling machine, Drill set, Tap set, Bolts & Nuts, Vernier Caliper.

PROCEDURE :

1.    The given workpieces are checked for its initial dimensions.

2.    The center of the workpieces are marked and the Pitch Circle Diameter is
marked in both the workpieces.

3.    The first workpiece is drilled and tapped to the dimensions as shown in the
figure.

4.    The second workpiece is drilled to the dimensions as shown in the figure.

5.    Both the workpieces are mated together by using bolts and nuts.

6.    Thus a Flange Coupling assembly is made using required machines.

RESULT :

Thus, a Flange Coupling is machined as per the given dimensions and

assembled using the required machines.

(4) FACING, PLAIN TURNING AND STEP TURNING:

Aim: To perform turning, facing and chamfering on a cylindrical work
piece.

Material used : Mild steel rod.

Tools required : • Lathe

•Three-jaw chuck
• Chuck key
• Vernier caliper
 • Single-point cutting tool

Procedure :
1. First loosen the jaw in the chuck key to position the work piece,
and then tighten the jaws.
2. Fix the cutting tool in the toolpost.
3. Switch on the lathe and move the carriage near to the workpiece.
Give it a small cross feed, and then move carriage longitudinally to
the required length slowly.
4. Bring the carriage to the original position, give a small cross feed
and move carriage longitudinally. Repeat this step until required
diameter is obtained.
5. To get smooth surface give a very small feed when the diameter is
nearing the required value.
6. To face the end surface of the workpiece, move the carriage to
make the tool touch the end surface of the work piece.
7. Give a small feed in longitudinal direction, and then move the tool
towards the axis of the workpiece using the cross slide to complete
the workpiece.
8. The turning operation is done with cutting tool to reduce the
diameter upto the required dimension for the two steps of various
diameters.
9. The workpiece is removed from the chuck and the dimensions of
workpiece are checked for the requirements.
 Result :
Thus the required shape and size is obtained by Facing, plain turning
and step turning.

(5) TAPER TURNING USING COMPOUND REST:

Aim

To get a required shape and size from a given workpiece by taper turning operations in the lathe.

Material used
Mild steel rod.
Tools required
required value.
• Single point cutting tool
• Lathe
• Vernier caliper
• Try square
• Chuck key

Procedure
1. First loosen the jaw in the chuck key to position the work piece, and then tighten the
jaws.
2. Fix the cutting tool in the toolpost.
3. Switch on the lathe and move the carriage near to the workpiece. Give it a small cross
feed, and then move carriage longitudinally to the required length slowly.
4. Bring the ca iage to the original position, give a small cross feed and move carriage
longitudinally Repeat this step until required diameter is obtained.
5. To get smooth surface give very small feed when the diameter is nearing the
tool.
6. To face the end surface of the workpiece, move the carriage to make the tool touch
the end surface of the work piece.
7. Then the taper turning operation is done on the workpiece according to the taper

angle calculated. The compound rest base is swirled and set a calculated
taper angle, for this the tool is moved by 45 to the lathe axis.

The workpiece is removed from the chuck and the dimensions of workpiece are
checked for the requirements.

Result:

Thus the required shape and size is obtained by taper turning operation.

(6)Boring:
Aim

To perform boring on a cylindrical work piece.

Material used

Mild steel rod.

• Lathe
• Three-jaw chuck
• Chuck key
• Vernier caliper
• Cutting tools

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Procedure
1. First loosen the jaw in the chuck key to position the work piece, and then tighten the
jaws.
2. Fix the cutting tool in the toolpost.
 3. Switch on the lathe and move the carriage near to the workpiece. Give it a small cross
feed, and then move ca iage longitudinally to the required length slowly.
4. Bring the carriage to the original position, give small cross feed and move carriage
longitudinally.Repeat this step until required diameter is obtained.
5. To get smooth surface give a very small feed when the diameter is nearing
the required value.
6. The drill bit is fixed in the tail stock.
7. The hole is made by moving the tailstock through over the bed.
8. By rotating the hand wheel which is in the tailstock, the tailstock is move.
9. The drill bit is removed .Then the boring bar is fixed in the tailstock. The
boring operation is done in the drilled workpiece.
Finally the dimensions of workpiece are again checked .

Result

Thus the required size and shape of the given work piece is obtained.

(7)Shear Angle Measurement:

SHEAR ANGLE MEASUREMENT

AIM :

To measure the shear angle to the given conditions.

TOOLS AND EQUIPMENTS REQUIRED :

Lathe, Single point turning tool, Micrometer.

PROCEDURE :

1.    The workpiece is held in the chuck.

2.    The known depth of cut is given (uncut chip thickness, t1).

3.    The chip is taken for thickness inspection. Find the mean chip thickness, t2.

4.    Calculate the chip thickness ratio, rc = t1 / t2

5.    Calculate the shear angle for the given rake angle of the tool.
                                      
  rc cos
tan  =   -----------
             1 - rc sin       where,  - rake angle.

1.    Repeat the same procedure to get few more readings and calculate the mean
shear angle.

2.    Repeat the experiment for different depth of cuts.

NOTE :

1.    The value of Shear angle depends on the cutting conditions, tool geometry,
tool material and work material.

2.    If the Shear angle is small, the plane of the shear is large, the chip is thicker,
more force is required to remove the chip.

3.    If the shear angle is large, the plane of shear will be shorter and the chip is
thin. Hence, less force is required to remove the chip.

RESULT :

Thus the shear angle is found for different depth of cuts.

(8) Milling:
OBJECTIVE: To study the characteristic features of Shaper.

OUTLINE OF PROCEDURE :
i) Run the machine at low speed and observe the motions, which control the
shapes of the surfaces produced. Note particularly the features, which
control the geometrical form of the surface.
ii) Learn the names of the major units and the components of each machine.
Record these details . (Please ensure that the main isolator switch is off and
check that the machine cannot be inadvertently started. Do not remove
guards). Use the manufacture's handbook for details that cannot be
inspected.
iii) Record the obtainable speed and feed values .
iv) Note down the special features of the speed and feed control on each
machine.
v) Pay attention to the following: a. Size specification of various machine tools. b.
Machine tool structures and guide ways I slide ways. c. Drive mechanism for
primary (cutting) motion. d. Drive mechanism for secondary (feed) motion.
(8)Drilling:

AIM: To perform drilling operations on the given work piece according to the
given dimensions.

REQUIRED MATERIAL: M.S. Flat of 45 x 45 x 10 mm3 .

REQUIRED TOOLS: Vernier height gauge, v-block, Steel rule, dot punch, ball peen
hammer and drill bits of diameters 4.5 mm, 8.5 mm & 14 mm and taps of
diameter 5mm, 10mm and 16mm.

SEQUENCE OF OPERATIONS:  Checking the raw material  Marking and sawing 

Marking on the flat  Drilling  Tapping  Grinding the corners  Surface grinding
THEORY: Drilling machine is one of the simplest, moderate and accurate machine
tool used in production shop and tool room. It consist of a spindle which imparts
rotary motion to the drilling tool, a mechanism for feeding the tool into the work,
a table on which the work rests. It is considered as a single purpose machine tool
since its chief function is to make holes.