2018-Me-33 (MTM Lab Report)

DEPARTMENT OF MECHANICAL ENGINEERING
UNIVERSITY OF ENGINEERING AND TECHNOLOGY.
MACHINE TOOLS AND MACHINING LAB

REPORT
Submitted by Muhammad Humayun Arif

Submitted to Mr. Waqas Rafique
Registration Number 2018-ME-33
INTRODUCTION TO MACHINE TOOLS AND MACHINING LAB
The Machine Tools and Machining (MTM) laboratory is located at the ground floor of IME
(Industrial Manufacturing an Engineering) department of University of Engineering and
Technology. It is equipped with dozens of machines that are used to perform almost all kinds of
machining experiments. The lab extends to almost five different rooms. The machines include
Lathes, Shaper, Grinders, Millers, and Hacksaws etc. The different types of machines that can be
found in MTM lab are listed below.
Shaper Machine Cylindrical Grinder
Vertical Milling Machine NC Surface Grinder
Horizontal Milling Machine Simple Surface Grinder
Simple Lathe Machine Tool Cutter Grinder
Turret Lathe Machine Power Hacksaw
Universal Lathe Machine Spinning Machine
Tool Room Lathe Machine Manual Hydraulic Press
Universal Cylindrical Grinder Simple Drill Machine
Gear Hobbling Machine Plain Type Drill Machine
Various experiments that have been performed using these machines are explained in the lab
report below.
EXPERIMENT 1
TO PERFORM CENTERING OF THE CYLINDRICAL WORK PIECE

(CAST IRON) ON 3-JAW CHUCK LATHE AND PERFORM FACING,
TURNING, DRILLING, BORING, PARTING AND KNURLING
OPERATION USING SINGLE POINT CUTTING TOOL
1. INTRODUCTION
This experiment involves the centering of a cylindrical work piece made of cast iron in a three-
jaw chuck lathe machine. After the centering, multiple operations are to be performed on the
work piece using a single point cutting tool that include:
 Facing
 Turing
 Drilling
 Boring
 Parting
 Knurling
2. THEORY
2.1. Lathe Machine
Lathe Machine is a machining tool that rotates the provided work piece about a certain axis of
rotation to execute various machining operations, some of which include facing, turning, drilling,
boring, parting and knurling etc.
Types of Lathe Machines:
Depending upon the characteristics and functioning, lathe machines can be divided into the
following categories:
 Center Lathes
 Speed Lathes
 Turret Lathes
 Tool Room Lathes
 Bench Lathes
 CNC Lathes
 Special Lathes
 Automatic Lathes
A basic lathe machine is shown in the image below.
2.2. Centering of the Work Piece
The centering of the work piece is the fitting of work piece in the chuck of lathe machine and
aligning it as well as possible by naked human eye. The work piece is mounted in the tailstock
after the rod has been fitted into its end. The centering can be well understood with the help of
following image.
2.3. Facing Operation

Facing operation is the process of reduction of the length of work piece by feeding the tool
radially into the rotating work piece at one of its two ends. Most of the cylindrical work pieces,
similar to the one used in this experiment, are subjected to the facing operation.
The ideal way to perform this operation is to keep the end, which is to be faced as close as
possible to the chuck of lathe machine. Initially, the work piece is cut slightly longer than
required length and then a final cut is given which is equal to the desired length.
Types of Facing:
Facing operations are of two types:
 Lathe Facing
 Milling Facing
2.4. Turning Operation
Turning operation is the process of reduction of the outside diameter of rotating work piece. The
cutting tool is fed radially to the rotating work piece to produce a smooth finish on the surface of
work piece. Most of the cylindrical work pieces are subjected to turning.
2.5. Drilling Operation

Drilling operation is the process of the producing a cylindrical hole in a work piece. The side of
the rotating cutting tool called drill is fed to the work piece. The drill is held in the drill chuck.
Types of Drilling:
The various types of drilling operations are:
 Spot Drilling
 Centre Drilling
 Deep Hole Drilling
 Gun Drilling
2.6. Boring Operation
Lathe boring is the process of producing conical or cylindrical surfaces by enlarging the existing
opening in the work piece. This operation is done by using a single point cutting tool or boring
tool. For no tapered holes, the cutting tools moves parallel to the axis of rotation.
The difference between turning and boring is the fact that turning removes the material from
external surface of the work piece. Whereas, boring removes the material from internal surface
of the work piece.
2.7. Parting Operation
Parting operation is the process of cutting the work piece at a specific length. It uses a blade-like
cutting tool that is directly plunged into the work piece. This operation is normally used to
remove the finished end of a work piece from the bar stock that is clamped in the chuck. This
operation can be well understood with the help of image below.
Parting operation is used to divide the work piece into two or more parts.
2.8. Knurling Operation
The operation in which a pattern of straight, angled or crossed lines is rolled into the material is
called Knurling. It is normally done by a lathe machine.
Types of Knurling:
The knurling operation is of following two basic types:
 Cut Knurling
 Form Knurling
2.9. Single Point Cutting Tool
The cutting tool that uses only one edge for machining is called Single Point Cutting Tool. It is
used for various machining operations such as shaping, planning and turning. Important
characteristics that a cutting tool must possess are:
 It should be hard enough.
 It should be capable of bearing the heat produced during machining process.
3. PROCEDURE
i. With the help of a clean piece of cloth, clean the work piece carefully.
ii. After cleaning, mount the work piece on the chuck of lathe machine and tighten the
chuck.
iii. Align the work piece to the center of lathe machine.
Facing Operation
i. Mark the required length on work piece using a marker.
ii. Drag the tool post on one left side of compound rest in order to take the cutting tool to the
height of the center point of lathe.
iii. Select the cutting speed based on the diameter and nature of material.
iv. Start moving the cutting tool towards center of work piece after starting the lathe
machine.
v. Using the apron wheel, direct the carriage towards the left, until a small cut is given.
vi. Cut from the center outward by using cross-field handle.
vii. Repeat the procedure until the required length is obtained.
Turning Operation
i. After starting the lathe, position the cutting tool at a distance from the end.
ii. To remove any backlash, rotate the compound rest handle one-quarter clockwise.
iii. Rotate the cross-field handle clockwise and field the tool into the work until a ring shape
appears on the periphery of the cylinder.
iv. Rotate the carriage hand wheel until the tool carries the end of the work by about 1.5mm.
v. Along the work, take a trial cut.
vi. After disengaging the automatic feed, stop the lathe.
vii. After taking measurements, take another trial cut.
Drilling Operation
i. For the type of material to be drilled, set proper cutting speed.
ii. Make sure that the tailstock is in line.
iii. Using center drill, spot the hole.
iv. On the tailstock spindle, mount the drill.
v. While applying cutting fluid, start the lathe and drill to the desired depth.
vi. Measure the depth of the gauge.
vii. For removing the chip, the drill should be removed continuously and depth should be
measured simultaneously.
Boring Operation
i. Select a boring bar and extend it beyond the holder.
ii. Mount the boring bar older on the left of compound rest in the tool post.
iii. Center the boring cutting tool.
iv. Set the cutting speed and feed.
v. Start the lathe and move the boring tool to the inside diameter.
vi. Take a small trial cut.
vii. Stop the lathe and measure the diameter.
viii. Start the boring for half the amount of material removed.
ix. Keep on operating the procedure until the required diameter is obtained.
Parting Operation
i. Mark the required length of work piece using marker.
ii. Set the cutting speed and feed.
iii. Start the lathe and move the parting tool to the required length.
iv. Take a small trial cut.
v. Gradually keep on feeding the tool.
vi. Stop boring when the tool reaches the center.
vii. Keep on operating the procedure until the required length is obtained.
4. TOOLING USED (NOMENCLATURE)
A single point cutting tool has been used in this experiment to perform all the operations. Its
nomenclature is explained below.
4.1. Shank: The part of tool that is held by the tool holder is called shank.
4.2. Nose Radius: The radius of the nose of the cutting tool is called Nose Radius. It is
selected according to the type of required finish.
4.3. Back Rake: It is provided to give a uniform chip flow and better surface finish.
4.4. Side Rake: It is provided to direct the chip flow away and to give a sharp cutting
edge.
4.5. End Relief Angle: It is provided to avoid rubbing of tool with the work piece.
4.6. Side Relief Angle: It serves the cutting tool to feed into the work piece.
4.7. Side Cutting Edge Angle: It influences the thickness of cut and aids in directing
away the chips.
5. OBSERVATIONS
Facing and Turning
 RPM = 590
 Cutting Tool = Carbide tip of high hardness
 Workpiece Material = Mild Steel
 It can be done manually or automatically
Drilling
 RPM = 375
 Cutting Tool = High Speed Steel
 Diameter = 13mm
Knurling
 RPM = 38
 No cutting, only pressure is applied
Parting
 RPM = 230
6. RESULTS AND CONCLUSIONS
The length of the work piece is removed using several cuts in order to obtain the desired length.
The following factors influence the surface finish at the end face of work piece:
 Grip of the chuck
 Cutting speed
 Sharpness of the cutting tool
To improve the surface finish at the end face, following measures can be followed:
 Using a sharp cutting tool
 Mounting the work piece firmly on the chuck
 Selecting appropriate cutting speed
7. DRAWBACKS AND IMPROVEMENTS
The drawbacks as well as improvements that can be made regarding this experiment are
discussed in this section.
7.1. Solid Wastes
The discarded raw materials contain cutting fluid, which makes their cleaning vital and necessary
before recycling. Chips and Swarf are also produced during machining that can cause harmful
and serious injuries to the operator. Chips also increase the downtime of the machine. Swarf
contains cutting fluid that makes it dangerous for the environment as well as health. These issues
can be dealt with by following:
 Proper recycling and cleaning prior to the recycling of the discarded raw materials
 Proper discarding of Chips and Swarf
7.2. Liquid Wastes
The long exposure to cutting fluid can cause skin disorders, respiratory ailments and Cancer in
the operator. In addition, the inhaling of cutting fluid can lead to Asthma, Bronchitis and
irritation of eyes. These problems can be improved by:
 Proper protection against long exposures to cutting fluid
 Making an appropriate substitute for cutting fluid
7.3. Gaseous Wastes
The most dangerous gaseous waste produced in this operation is aerosol. These particles rest in
the work environment for large amount of time. Inhaling these particles can be dangerous as it
can cause pulmonary problems. These wastes can be dealt with by:
 Taking proper precautions against exposure to aerosol
8. SAFETY PRECAUTIONS
The following safety precautions must be strictly observed while working with Lathe machine:
i. Safety Goggles: Use safety goggles for protection of eyes against flying chips.
ii. Clothing: Use clothing with short sleeves in order to avoid any piece of clothing being
stuck in the machine.
iii. Ornaments: Use of ornaments such as rings and bracelets should be avoided.
iv. Safety Guards: Never use the machine in case there are no safety guards.
v. Measurement: Always make sure to turn off the machine while taking any
measurements.
vi. Stopping Machine: Do not stop machine with bare hands.
vii. Proper Mounting: Before starting, make sure that cutting tool is properly mounted.
viii. Chuck Wrench: Always remove the chuck wrench before starting the lathe
ix. Spindle and Carriage: Before starting, drag the carriage to the farthest position of the cut
and rotate the spindle once.
x. Removal of Chips: Use a brush instead of hands for removing chips.
xi. Removal of Cutting Tool: While polishing, cleaning, or any other amendments on the
machine, make sure that the cutting tool has been removed.
EXPERIMENT 2
TO PERFORM THREADING OPERATION ON LATHE MACHINE

USING A SINGLE POINT CUTTING TOOL
1. INTRODUCTION
In this experiment, threading operation is to be performed in the work piece using a single point
cutting tool.
2. THEORY
2.1. Lathe Machine
Lathe Machine is a machining tool that rotates the provided work piece about a certain axis of
rotation to execute various machining operations, some of which include facing, turning, drilling,
boring, parting and knurling etc.
Types of Lathe Machines:
Depending upon the characteristics and functioning, lathe machines can be divided into the
following categories:
 Center Lathes
 Speed Lathes
 Turret Lathes
 Tool Room Lathes
 CNC Lathes
A basic lathe machine is shown in the image below.
2.2. Threading Operation
Threading is a machining operation, which is used to produce screw threads. The most common
machine used to perform this operation is Lathe machine.
Types of Threading:
There are many methods of generating threads such as:
 Subtractive Method
 Transformative Method
 Additive Method
2.3. External and Internal Threads
A screw thread on the outside of a cylinder or cone is called and external thread. The workpiece
is either mounted on a chuck or held between two centers in external threading. The external
threads refer to those found in bolts, studs or screws. A screw thread on the inside of a cylinder
or cone is called and internal thread. In internal thread cutting, piece is held in the chuck.
Internal threads refer to those on nuts and tapped holes.
2.5. Thread Nomenclature
Important thread nomenclature will be discussed in this section.
 Pitch: Distance between a point at the start of one thread to adjacent point on second
thread.
 Lead: Axial distance covered in completion of one revolution.
 Major Diameter: Largest diameter of thread is called major diameter.
 Minor Diameter: Smallest diameter is called minor diameter.
 Thread per Inch: Number of threads contained in one inch.
 Depth: Perpendicular distance between crest and root.
2.6. Uses of Screw Threads
Screw threads have a wide range of applications. Some of them are explained below.
 Fastener: Used to hold parts together (bolts, nuts, screws)
 Movement: Transmit twisting power to straight line motion (lathe lead screw)
 Mechanical Advantage: Increase force to hold items (vise and clamp screws)
 Adjustments: Allows parts to be moved
3. PROCEDURE
i. To start with, machine the stir piece up to the significant breadth of the string, which
must be cut utilizing the turning.
ii. The work piece is set up in the toss for stringing between the focuses. The throw is
associated with the shaft, which is being outfitted with the lead screw. To have legitimate
speed proportion between the shaft and lead screw a fast change gearbox is utilized.
iii. Along these lines, set the fast change gearbox as indicated by the necessary pitch of the
string.
iv. Set the instrument bit at the correct point with work piece utilizing string check.
v. Moving the stringing device bit towards the work piece-utilizing compound and cross
feed.
vi. Micrometer of the two feeds ought to be set up as nothing.
vii. The carriage is being moved to a foreordained distance for every upset of the work
because of the pivot of the lead screw. This done by situating the carriage's half nut to be
locked in with the lead screw.
viii. The half nut or split nut should be locked in at a definite foreordained time for
appropriate cutting of progressive cuts. This is finished by the utilization of string
pursuing dial or graduated dial. This dial is being connected to the carriage and is being
driven by worm gear joined to lead screw. This progression is known as following of
string apparatus.
ix. The essence of the graduated dial is isolated into a much number of full and half
divisions.
x. On the off chance that the split nut isn't locked in and the lead screw is pivoted, at that
point the string dial is likewise turned.
xi. On the off chance that the quantity of the string must be cut is even in numbers at that
point split nut ought to have drawn in, when any line on string dial agrees with zero line
and when an odd number of strings must be cut at that point any numbered line ought to
correspond with the zero line.
xii. Take a scratch cut at the segment without ointment. Withdraw the half nut very nearly the
cut, stop the machine and back out the apparatus by the use of the cross feed. Return the
carriage to the starting point
xiii. Presently check the string pitch utilizing screw pitch measure. In the event that it is right,
continue to subsequent stage.
xiv. Feed the compound in 0.20 to 0.50 mm for the essential detour with the utilization of
cutting oil. As you draw near to the last pass, decrease the profundity of slice to .025 to .
075 mm.
xv. The cycle is proceeded or progressive cuts are proceeded until the string comes nearer to
the ideal profundity or inside .025 mm of definite profundity.
xvi. At that point last pass of cut is given at the profundity of cut .025-.075 mm.

edge.
away the chips.
5. OBSERVATIONS
 Industry level work is done on μm scale.
 In labs, we use mm scale.
 Material of workpiece = Mild Steel
 Diameter of workpiece = 19mm
 Turning and Facing = Carbide HP
 Threading and Parting = HSS (low RPM)
 Cutting speed
The drawbacks as well as improvements are discussed in this section.
7.1. Solid Wastes
7.2. Liquid Wastes
7.3. Gaseous Wastes
iv. Understanding: Do not attempt to operate the machine without having proper
understanding of the respective machine.
v. Safety Guards: Never use the machine in case there are no safety guards.
vi. Measurement: Always make sure to turn off the machine while taking any
measurements.
vii. Rag: Do not use rag for cleaning workpiece or machine.
viii. Stopping Machine: Do not stop machine with bare hands.
ix. Proper Mounting: Before starting, make sure that cutting tool is properly mounted.
x. Ground: Keep the floor/ground in the close vicinity of machine free of tools, oil or
grease.
xi. Horseplay: While the machine is working, strictly shun horseplay.
xii. Removal of Chips: Use a brush instead of hands for removing chips.
xiii. Removal of Cutting Tool: While polishing, cleaning, or any other amendments on the
EXPERIMENT 3
TO PERFORM GRINDING OPERATION ON BENCH GRINDER AND

NC SURFACE GRINDER
1. INTRODUCTION
This experiment deals with performing the grinding operation on both the bench grinder and NC
surface grinder.
2. THEORY
2.1. Grinding Operation
Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool. The
workpiece is brought into contact with the revolving grinding wheel that acts as a cutting tool.
Every periphery on the wheel acts as an individual cutting tool. Due to the heat and pressure
developed between the workpiece and the grinding wheel, dull particles of material are removed.
General Rules for Grinding:

The general rules for grinding that must be followed are:
 Use Silicon Carbide wheel for materials with low tensile strength.
 Use Aluminum Oxide wheel for materials with high tensile strength.
 If grinding wheel is soft, decrease the speed of workpiece and increase the speed of
wheel.
 If grinding wheel is hard, decrease the speed of wheel and increase the speed of
workpiece.
 Use soft wheel for hard work and hard wheel for soft work.
Types of Grinding
Several types of grinding operations help in the machining processes. Some types of grinding are
listed below:
 Surface Grinding
 Internal Grinding
 Cylindrical Grinding
 Centerless Grinding
 Thread Grinding
 Contour Grinding
2.2. Grinding Machine
A grinding machine, frequently abbreviated to grinder, is a machine device utilized for
granulating; it is a sort of machining utilizing a rough wheel as the cutting device. Each grain of
rough on the wheel's surface cuts a little chip from the work piece through shear twisting.
2.3. Grinding Wheel

Grinding wheel is made of abrasive grain particles that are held together by a bond. Several types
of bonds are used for holding the abrasive grains together. The degree of strength with which the
bond holds together the grains is called Grade. Grinding wheels are given a smooth circular
profile by turning. It is used as the cutting tool in the grinding machine. In case of centerless
type grinding, two grinding wheels are used. One is called Grinding wheel and the other is called
Regulating wheel.
Reasons for Wheel Grazing Reason for Rapid Wear of Wheel
Wheel speed too fast. Wheel speed too slow.
Work speed too slow. Work speed too fast.
Grain too small. Wheel too soft as compared to workpiece.
Wheel too hard as compared to work. Feed rate too great.
Structure too dense.
2.4. Abrasives
Abrasive is a small, hard and non-metallic particle with sharp edges and irregular shapes. It can
remove small amount of material, producing tiny chips. Abrasive processes such as grinding can
produce fine surface finishes and accurate dimensional tolerances.
Characteristic of Abrasives:
The general characteristics that abrasives must have are:
 Abrasives should be harder than the material being ground.
 They should be strong enough to bear the grinding pressure.
 Abrasives should be heat resistant and friable.
Types of Abrasives:
Abrasives are generally classified as either Natural (sandstones, flint etc.) or Manufactured
(Aluminum Oxide, Silicon Carbide, Boron Carbide etc.). The two most commonly used
manufactured abrasives are:
 Aluminum Oxide ( A l 2 O3 ) : It is used for materials with high tensile strength.
 Silicon Carbide (SiC): It is used for materials with low tensile strength and ranges from
green to black color.
2.5. Bench Grinder
It is a benchtop kind of granulating machine
used to drive grating wheels. ... Contingent
upon the bond and grade of the crushing
wheel, it very well might be utilized for honing
cutting apparatuses, for example, instrument
bits, boring tools, etches, and gouges. On the
other hand, it very well might be utilized to
shape metal preceding welding or fitting.
2.6. NC Surface Grinder
NC pounding machines are machine devices, which
utilize a pivoting crushing wheel to accomplish
material expulsion on a metallic workpiece
through cutting. NC means "Numerical Control".
This empowers part machining to be done completely
consequently.
3. PROCEDURE
i. Perform secure affixing of seat processors on a strong surface.
ii. Change instrument rests to inside 3 mm (1/8 in.) of wheels.
iii. Keep 6 mm (1/4 in.) wheel openness with a tongue monitor or a portable watchman.
iv. Guarantee that wheels have blotting surfaces on each side.
v. Check the wheel fits appropriately to the axle when mounting.
vi. Fix the nuts before you turn the processor on.
vii. Before you plug in the processor, physically turn the wheel to ensure it is turning openly.
viii. Tables should be in acceptable condition.
ix. Remain aside of the processor until the wheel arrives at working velocity.
x. Carry work into contact with the granulating wheel gradually and easily, without
knocking.
xi. Apply progressive strain to uniformly heat up the crushing wheel.
xii. Move work to and fro to forestall the arrangement of scores
.4. TOOLING USED (NOMENCLATURE)
The grinding machine is made of several individual components as shown in the schematic
diagram above. These parts are explained below.
4.1. Bed: It is made of cast iron and rests on the floor. It supports all other parts, which are
mounted on it.
4.2. Headstock: It is mounted over the bed and supports the workpiece by dead center.
4.3. Tailstock: It can be adjusted according to the length of the workpiece.
4.4. Table: There are two types of tables; upper and lower.
4.5. Wheel Head: It is mounted on the rear of the base and performs perpendicular
movement.

 Cutting speed
Use of cutting fluid while grinding is also encourages as it reduces heat, provides lubrication and
removes the chips. Centerless grinding requires the workpiece to be held on a worktable.
Whereas, center type grinding requires a chuck to hold the workpiece.
The drawbacks and advantages of grinding operation are discussed in this section.
6.1. Advantages of Grinding Operation
 It gives a high surface finish.
 It can machine hard materials.
 It can obtain highly accurate dimensions.
 It can work at high temperature.
6.2. Disadvantages of Grinding Operations
 Tool and process are costly.
 It can only remove little amount of material.
 The process is very time consuming.
 Imperfect contact can lead to serious damages.
6.3. Solid Wastes
6.4. Liquid Wastes
6.5. Gaseous Wastes
i. Dead Man Switch: Grinders shall be equipped with the ‘dead man switch’.
ii. Safety Goggles: Use safety goggles for protection of eyes against flying chips.
iii. Clothing: Use clothing with short sleeves in order to avoid any piece of clothing being
iv. Ornaments: Use of ornaments such as rings and bracelets should be avoided.
v. Understanding: Do not attempt to operate the machine without having proper
vi. Safety Guards: Never use the machine in case there are no safety guards.
vii. Measurement: Always make sure to turn off the machine while taking any
measurements.
viii. Rag: Do not use rag for cleaning workpiece or machine.
ix. Stopping Machine: Do not stop machine with bare hands.
x. Proper Mounting: Before starting, make sure that cutting tool is properly mounted.
xi. Ground: Keep the floor/ground in the close vicinity of machine free of tools, oil or
grease.
machine, make sure that the cutting tool has been removed..
xiv. Worn Out Wheels: Worn out wheels should be replaced.
EXPERIMENT 4
TO PERFORM INTERNAL/EXTERNAL GRINDING OPERATION ON

CYLINDRICAL GRINDER
1. INTRODUCTION
Internal and external grinding are to be performed on cylindrical grinder in this experiment.
Cylindrical Grinding is a type of grinding operation, which is used to shape the outside of the
workpiece. If axis of rotation is required, internal grinding can also be performed by an external
attachment.
2. THEORY
2.1. Grinding Operation
Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool. The
workpiece is brought into contact with the revolving grinding wheel that acts as a cutting tool.
Every periphery on the wheel acts as an individual cutting tool. Due to the heat and pressure
developed between the workpiece and the grinding wheel, dull particles of material are removed.
General Rules for Grinding:

The general rules for grinding that must be followed are:
 Use Silicon Carbide wheel for materials with low tensile strength.
 Use Aluminum Oxide wheel for materials with high tensile strength.
 If grinding wheel is soft, decrease the speed of workpiece and increase the speed of
wheel.
 If grinding wheel is hard, decrease the speed of wheel and increase the speed of
workpiece.
 Use soft wheel for hard work and hard wheel for soft work.
Types of Grinding
Several types of grinding operations help in the machining processes. Some types of grinding are
listed below:
 Surface Grinding
 Cylindrical Grinding
 Thread Grinding
 Contour Grinding
2.2. Grinding Machine
A grinding machine, frequently abbreviated to grinder, is a machine device utilized for
granulating; it is a sort of machining utilizing a rough wheel as the cutting device. Each grain of
rough on the wheel's surface cuts a little chip from the work piece through shear twisting.
2.3. Grinding Wheel

Grinding wheel is made of abrasive grain particles that are held together by a bond. Several types
of bonds are used for holding the abrasive grains together. The degree of strength with which the
bond holds together the grains is called Grade. Grinding wheels are given a smooth circular
profile by turning. It is used as the cutting tool in the grinding machine. In case of centerless
type grinding, two grinding wheels are used. One is called Grinding wheel and the other is called
Regulating wheel.
Reasons for Wheel Grazing Reason for Rapid Wear of Wheel
Wheel speed too fast. Wheel speed too slow.
Work speed too slow. Work speed too fast.
Grain too small. Wheel too soft as compared to workpiece.
Wheel too hard as compared to work. Feed rate too great.
Structure too dense.
2.4. Abrasives
Abrasive is a small, hard and non-metallic particle with sharp edges and irregular shapes. It can
remove small amount of material, producing tiny chips. Abrasive processes such as grinding can
produce fine surface finishes and accurate dimensional tolerances.
Characteristic of Abrasives:
The general characteristics that abrasives must have are:
 Abrasives should be harder than the material being ground.
 They should be strong enough to bear the grinding pressure.
 Abrasives should be heat resistant and friable.
Types of Abrasives:
Abrasives are generally classified as either Natural (sandstones, flint etc.) or Manufactured
(Aluminum Oxide, Silicon Carbide, Boron Carbide etc.). The two most commonly used
manufactured abrasives are:
 Aluminum Oxide ( A l 2 O3 ) : It is used for materials with high tensile strength.
 Silicon Carbide (SiC): It is used for materials with low tensile strength and ranges from
green to black color.
2.5. Cylindrical Grinding
Cylindrical Grinding utilizes either a round and hollow pounding machine or an all-inclusive
crushing machine. Both the tube shaped workpiece and the wheel are turned and the external
fringe of the workpiece is machined. Round and hollow Grinding is a sort of granulating activity,
which is utilized to shape the outside of the workpiece. In the event that hub of pivot is required,
inside pounding can likewise be performed by an outer connection.
2.6. Cylindrical Grinding Machine
The cylindrical grinder is a sort of machine used to shape the outside of an article. The round and
hollow processor can chip away at an assortment of shapes; nevertheless, the item should have a
focal hub of turn. This incorporates yet is not restricted to such shapes as a chamber, a circle, a
cam, or a driving rod. It can perform different kinds of pounding tasks, for example, External
Grinding
 Plunge Grinding
 Creep Feed Grinding
A cylindrical grinding machine is shown below:
2.7. External Grinding
It is the grinding happening on outer surface of an item between the focuses. The focuses are end
units with a point that permit the item to be pivoted. The pounding wheel is likewise being
pivoted a similar way when it experiences the item. This successfully implies the two surfaces
will be moving inverse headings when contact is made which takes into account a smoother
activity and less possibility of a jam up.
2.8. Internal Grinding

It is grinding happening within an article. The pounding wheel is consistently more modest than
the width of the opening being ground. The item is held set up by a collet, which additionally
pivots the article set up. Similarly likewise with OD granulating, the pounding haggle object
turned in inverse ways provide switched guidance contact of the two surfaces where the crushing
happens.
3. PROCEDURE
i. Perform secure affixing of seat processors on a strong surface.
ii. Change instrument rests to inside 3 mm (1/8 in.) of wheels.
iii. Keep 6 mm (1/4 in.) wheel openness with a tongue monitor or a portable watchman.
iv. Guarantee that wheels have blotting surfaces on each side.
v. Check the wheel fits appropriately to the axle when mounting.
vi. Fix the nuts before you turn the processor on.
vii. Before you plug in the processor, physically turn the wheel to ensure it is turning openly.
viii. Tables should be in acceptable condition.
ix. Remain aside of the processor until the wheel arrives at working velocity.
x. Carry work into contact with the granulating wheel gradually and easily, without
knocking.
xi. Apply progressive strain to uniformly heat up the crushing wheel.
xii. Move work to and fro to forestall the arrangement of scores
The grinding machine is made of several individual components as shown in the schematic
diagram above. These parts are explained below.
4.1. Bed: It is made of cast iron and rests on the floor. It supports all other parts, which are
mounted on it.
4.2. Headstock: It is mounted over the bed and supports the workpiece by dead center.
4.3. Tailstock: It can be adjusted according to the length of the workpiece.
4.4. Table: There are two types of tables; upper and lower.
4.5. Wheel Head: It is mounted on the rear of the base and performs perpendicular
movement.
5. OBSERVATIONS
 Both the cutting tool and workpiece are rotating.
 The minimum depth of cut that can be given to the workpiece is called maximum
precision. For cylindrical grinding machine, the maximum precision is 10 μm.
 High RPM and Low MRR were observed in this experiment.
 Workpiece shaft was rotated with the help of Dog.
 The center-to-center distance is maintained.
 RPM of grinding wheel = 2100 RPM
 RPM of workpiece = 51 RPM
 Carriage movement is hydraulic (auto) and cannot be changed due to the model being
old.
 Cutting speed
removes the chips. Centerless grinding requires the workpiece to be held on a worktable.
Whereas, center type grinding requires a chuck to hold the workpiece.
The drawbacks and advantages of grinding operation are discussed in this section.
7.1. Advantages of Grinding Operation
 It gives a high surface finish.
 It can machine hard materials.
 It can obtain highly accurate dimensions.
 It can work at high temperature.
7.2. Disadvantages of Grinding Operations
 Tool and process are costly.
 It can only remove little amount of material.
 The process is very time consuming.
 Imperfect contact can lead to serious damages.
7.3. Solid Wastes
7.4. Liquid Wastes
7.5. Gaseous Wastes
i. Dead Man Switch: Grinders shall be equipped with the ‘dead man switch’.
ii. Safety Goggles: Use safety goggles for protection of eyes against flying chips.
iii. Clothing: Use clothing with short sleeves in order to avoid any piece of clothing being
iv. Ornaments: Use of ornaments such as rings and bracelets should be avoided.
v. Understanding: Do not attempt to operate the machine without having proper
vi. Safety Guards: Never use the machine in case there are no safety guards.
vii. Measurement: Always make sure to turn off the machine while taking any
measurements.
viii. Rag: Do not use rag for cleaning workpiece or machine.
ix. Stopping Machine: Do not stop machine with bare hands.
x. Proper Mounting: Before starting, make sure that cutting tool is properly mounted.
xi. Ground: Keep the floor/ground in the close vicinity of machine free of tools, oil or
grease.
machine, make sure that the cutting tool has been removed..
xiv. Worn Out Wheels: Worn out wheels should be replaced.
EXPERIMENT 5
TO DRILL HOLE OF SPECIFIC DIAMETER ON VERTICAL DRILLING

MACHINE USING TWIST DRILL
1. INTRODUCTION
This experiment deals with drilling a hole of a specific diameter using twist drill on vertical
drilling machine. The twist drill in this experiment is being used as a cutting tool.
2. THEORY
2.1. Drilling Operation
Drilling operation is the process of the producing a cylindrical hole in a work piece. The side of
the rotating cutting tool called drill is fed to the work piece. The drill is held in the drill chuck.
Types of Drilling:
The various types of drilling operations are:
 Spot Drilling
 Centre Drilling
 Deep Hole Drilling
 Gun Drilling
2.2. Drilling Machine
A drilling machine is used to form a hole of different sizes on a job, drilling is a metal removing
process, by a drilling machine you can do drilling operation, reaming operation and boring
operation.
Types of Drilling Machines:
Some common types of drilling machines are:
 Sensitive Drilling Machine
 Vertical or Pillar
 Radial Arm
 Gang Type
 Multi-Spindle
 Numerically control
 Special Purpose Drilling Machine
2.3. Applications of Drilling Machine
Drilling machine can be used to perform various operations that include Reaming, Tapping,
Counter-Boring, Countersinking, Counter drilling and Spot Facing.

 Tapping: Tapping in a drill press may be performed either by hand or under power with
the use of a tapping attachment. The advantage of using a drill press for tapping a hole is
that the tap can be started squarely and maintained that way through the entire length of
the hole.
 Countersinking: It is the process of enlarging the top end of a hole to the shape of a cone
to accommodate the conical shaped heads of fasteners so that the head will be flush with
or below the surface of the part. These cutting tools, called countersinks are available
with various included angles, such as 60°, 82°, 90°, 100°, 110°, and 120°.
 Counterboring: It is the process of enlarging the end of a hole that has been drilled
previously. A hole is generally counter bored to a depth slightly greater than the head of
the bolt, cap screw, or pin it is to accommodate.
 Reaming: The process of smoothening the holes that have been drilled is called reaming.
It is done by use of tools that are called reamers.
3. PROCEDURE
i. Select the proper size of center drill to suit the diameter of the work.
ii. Fasten the center drill in the drill chuck, having it extend beyond the chuck only about
0.500 in. (13 mm).
iii. Place the work to be center drilled in the drill vise.
iv. Set the drill press at the proper speed and start the machine.
v. Locate the center-punch mark in the work directly below the center drill point.
vi. Carefully feed the center drill into the center-punch mark in the work for about .060 in.
(1.5 mm).
vii. Raise the center drill, apply a few drops of cutting fluid, and continue drilling.
viii. Frequently remove the drill from the hole to apply cutting fluid, remove the chips, and
measure the diameter of the top of the center hole.
ix. Continue drilling until the top of the hole is the proper size
The tool used for this experiment is twist drill. Main parts of twist drill are shown and explained
below.
4.1. Back Taper: A slight decrease in diameter from front to back in the body of the drill.
4.2. Body: The portion of the drill extending from the shank or next to the outer corners of
the cutting lips.
4.3. Body Diameter Clearance: That portion of the land that has been cut away so it will not
rub against the wall of the hole.
4.4. Chisel Edge: The edge at the end of the web that connects the cutting lips.
4.5. Chisel Edge Angle: The angle included between the chisel angle and the cutting lips as
viewed from the end of the drill.
4.6. Clearance Diameter: The diameter over the cutaway portion of the drill lands.
4.7. Drill Diameter: The diameter over the margins of the drill measured at the point.
4.8. Flutes: Helical or Street grooves cut or formed in the body of the drill to provide cutting
lips, to permit removal of chips and to allow cutting Fluids to reach the cutting lips.
4.9. Flute Length: The length from the outer corners of the cutting lips to the extreme back
and of the flutes; it includes the sweep of the tool used to generate the flutes and, therefore
does not indicate the usable length of the flutes.
4.10. Helix Angle: The angle made by the leading edge of the land with a plane containing
the axis of the drill.
5. OBSERVATIONS
 RPM of the vertical drilling machine = 375 RPM
 Cutting Tool = Twist Drill
 Diameter = 13mm
 Cutting speed
The drawbacks and improvements regarding this experiment are discussed in this section.
7.1. Solid Wastes
7.2. Liquid Wastes
7.3. Gaseous Wastes
iv. Safety Guards: Never use the machine in case there are no safety guards.
v. Measurement: Always make sure to turn off the machine while taking any
measurements.
vi. Stopping Machine: Do not stop machine with bare hands.
vii. Proper Mounting: Before starting, make sure that cutting tool is properly mounted.
viii. Chuck Wrench: Always remove the chuck wrench before starting the lathe
ix. Spindle and Carriage: Before starting, drag the carriage to the farthest position of the cut
x. Removal of Chips: Use a brush instead of hands for removing chips.
xi. Removal of Cutting Tool: While polishing, cleaning, or any other amendments on the
machine, make sure that the cutting tool has been removed
EXPERIMENT 6
TO PRODUCE FLAT SURFACE ON SINGLE SPINDLE MILLING

MACHINE USING CYLINDRICAL MILLER CUTTER AND TO
PRODUCE SLOTS ON CAST IRON PLATE BY MILLING MACHINE
USING END MILL CUTTER
1. INTODUCTION
This experiment combines two separate experiments both related to milling operation. The first
one is to produce a flat surface on single spindle milling machine using a cylindrical miller
cutter. The second is to produce slots on cast iron plate by milling machine using end mill cutter.
Milling operation is widely used for the flattening of surfaces.
2. THEORY
2.1. Milling Operation
Milling is another essential machining measure by which surface is produced dynamically by the
expulsion of chips from a work piece as it is taken care of against a pivoting shaper. Processing
activities can be grouped into two general classifications:
1. Peripheral Milling
2. Face Milling
2.2. Peripheral Milling

Peripheral Milling Operation performed by milling cutter to create a machined surface
corresponding to pivot of revolution of shaper. Cutting power isn't uniform all through the length
of the cut by every tooth. Nature of surface created and state of the chip framed relies on the
revolution of shaper comparative with course of feed development.
Peripheral Milling can either be:
i. Up Milling
ii. Down Milling
2.3. Face Milling

The produced surface is at right points to the shaper pivot it is the consolidated aftereffect of
activities of the parts of the teeth situated on both outskirts and the substance of the shaper Most
of the cutting is finished by the fringe bits of the teeth, with the face divides gives the surface
completion.
2.4. Milling Machines
Milling machines are machine instruments used to deliver at least one machined surfaces
precisely on a piece of material, the workpiece; this is finished by at least one revolving
processing cutters having single or various bleeding edges. The workpiece is held safely on the
worktable of the machine or in a holding gadget clasped to the table. It is then carried into
contact with a rotating shaper.
Types of Milling Machines:
The Milling machines are classified into two types
 Vertical Milling Machine
 Horizontal Milling Machine
2.5. Vertical Milling Machine
The vertical milling machine, perhaps the most well-known and adaptable machine apparatuses,
utilizes end-processing type cutters to machine flat, vertical, and rakish surfaces, depressions,
openings, and keyways in addition to a wide assortment of other machining activities. It is not
difficult to set up and work; furnished with the appropriate adornments, it can machine
roundabout structures and perform dance-exhausting activities. Numerous activities for the most
part performed on a level processing machine can be delivered quicker and simpler on a vertical
processing machine. The vertical processing machine, created during the 1860s, consolidates the
vertical shaft of a drill press with the longitudinal and navigate (cross-feed) developments of a
processing machine. It is utilized to precisely machine level, rakish, adjusted, and multi formed
surfaces, which can be in one, two, or three planes (X, Y, Z-tomahawks). The processing
interaction might be vertical, even, precise, or helical. Since the axle is normally in a vertical
position, the vertical milling machine can be utilized milling, drilling, boring, and reaming
operations.
Types of Vertical Milling Machines:
The vertical milling machines are of following types:
 Ram Type Vertical Milling Machine
 The 2-Axis Control Vertical Milling Machine
 Heavy Duty Industrial Vertical Milling Machine
2.6. Horizontal Milling Machine
In horizontal, arbor supports the cutter and an over arm supports arbor. The vertical column
houses the electrical, main drive, spindles etc. mounted on a heavy base
Types of Horizontal Milling Machine:
Following are the types of horizontal milling machines:
 Manufacturing Type
 Special Type
 Knee-and-Column Type
2.7. Milling Cutters
They are the cutting tools that are mostly used in milling machines to perform machining
operations.
Types of Milling Cutters:
Milling cutters are of following types:
 Plain Milling Cutters
 Standard Shank-Type
 Helical Milling Cutters
 Side Milling Cutters
 Face Milling Cutters
 Angular Cutters
 Formed Cutters
2.8. Milling Cutter Materials
 High-Speed Steel: Consisting of iron with various amounts of carbon, tungsten,
chromium, molybdenum, and vanadium, is used for most solid milling cutters, since it
possesses all the qualities required for a milling cutter.
 Cemented-Carbide Cutters: Although more expensive, may be operated from 3 to 10
times faster than high-speed steel cutters. Either cemented-carbide tips may be brazed to
a steel body or inserts may be held in place by means of locking or clamping devices
3. PROCEDURE
i. When face milling a large surface, use an inserted- tooth cutter and mount it into the
spindle of the machine.
ii. When milling smaller surfaces, the face-milling cutter should be about 1 in. (25 mm)
larger than the width of the workpiece.
iii. Set the speeds and feeds for the type of cutter and the material being cut.
iv. Set up the work (3 discs) on the milling machine, making sure that the work-holding
clamps do not interfere with the cutting action.
v. Use cutting fluid if the cutter material or work will allow.
vi. Take as large a roughing cut as possible to bring the surface close to within .030 to .060
in. (0.8 to 1.5 mm) of the finish size.
vii. Set the depth of the finish cut and machine the surface to size.
viii. Rotate the work by 60 degrees and perform the operations.
ix. After completing the operation, clean and store the cutter and clamping equipment in
their proper places
The cutting tool used for this experiment is Miller Cutter. Its main parts are shown and explained
below.
4.1. Body of Cutter: The teeth rest on the body.
4.2. Periphery: It is defined as the locus of cutting edges of tooth of cutter.
4.3. Cutting Edge: The part that makes contact with workpiece.
4.4. Fillet: It is the part where one teeth joins the face with another.
4.5. Face of Teeth: It is the surface upon the chip is formed while cutting.
4.6. Back of Tooth: It is the created by fillet and the secondary clearance angle.
4.7. Land: The narrow surface on the back of cutting edge.
4.8. Bottom Land: The blank space between the consecutive teeth.
5. OBSERVATIONS
 End mill cutter is needed for making keyways, cavities, slots and facing.
 Spring collet is used to hold end mill cutter.
 End mill cutter is made of High Speed Steel (HSS).
 Diameter of end mill cutter is 8mm.
 The workpiece is made of aluminum.
 Direction of rotation of tool should be along the edges.
6. RESULTS AND CONCULSIONS
 Cutting speed
removes the chips.
7.1. Miller Cutter Failures
One of the major drawbacks of using miller cutters is the failure due to multiple reasons.
 Failure Due to Excessive Heat:
Heat, which is present in all milling operations, is caused by cutting edges rubbing on the
workpiece and by chips sliding along the faces of teeth when they are separated from the part
being milled. When this heat becomes excessive, the hardness of the cutting edges is affected,
resulting in less resistance to wear and subsequent rapid dulling
 Failure Due to Abrasion:
Abrasion is a wearing-away action caused by the metallurgy of the workpiece. It dulls cutting
edges and causes “wear lands” to develop around the periphery of a cutter. The rapid rise in
friction, heat, and rotational forces resulting from the abrasive nature of workpiece material can
reach a point where the cutter ceases to function effectively or is destroyed.
 Failure Due to Chipping:
Chipping takes place when the forces that are produced during cutting process exert a large
amount of pressure on the cutting edge. The cutting edge cannot bear this force and small cracks
called chips appear of its surface. The material that is left uncut by these chipped-out portions
imposes a still greater cutting load on the following cutter tooth, aggravating the problem.
 Failure Due to Cratering:
Cratering is caused by chips sliding on the tooth face adjacent to the cutting edge. This is the
area of high heat and extreme abrasion due to high chip pressures. The sliding and curling of the
chips erode a narrow hollow or a groove into the tooth face. Once this cratering starts, it can get
progressively worse until it results in total tool failure.
measurements.
x. Chuck Wrench: Always remove the chuck wrench before starting the lathe
xi. Spindle and Carriage: Before starting, drag the carriage to the farthest position of the cut
EXPERIMENT 7
TO PERFORM CUTTING OPERATION ON CAST IRON PLATE BY

ELECTRICAL DISCHARGE MACHINING (EDM)
1. INTRODUCTION
In this experiment, we deal with electric discharge machining which is a non-conventional
method of removing material. It is also called wire cutting. The experiment involves cutting of a
cast iron plate through EDM.
2. THEORY
2.1. Electric Discharge Machining
It is a non-conventional method of machining in which a test subject is cut into desired shape or
size by the means of electric sparks or electric discharges.
Electric discharge machining (EDM s perhaps the most generally utilized nontraditional cycles.
The state of the completed work surface is delivered by a shaped terminal device. The flashes
happen across a little hole among device and work surface. The EDM operation is necessary to
be performed by using a dielectric fluid which facilitates in the transfer of electrons.
2.3. Discharge Current and Surface Finish
The electric current frequency is directly related to the surface finish of the workpiece. At high
frequency of the discharge current, the metal finish we receive is smoot. However, at low
frequency current, the surface finish obtained is rough. Therefore, it is recommended to conduct
EDM at high current frequency to obtain the best results.
2.4. Discharge Current and Overcut
The distance by which cavity exceeds the size of the cutting tool is called as overcut. It occurs
due to the discharges taking place in side as well as front of the tool. The overcut depends upon
the frequency and amount of current used in the process. The relation between these parameters
is shown below in the graph.
2.5. Electric Discharge Wire Cutting
Electric release wire cutting (EDWC), usually called wire EDM, is an uncommon type of electric
release machining that utilizes a little breadth wire as the anode to cut a thin kerf in the work.
The cutting activity in wire EDM is accomplished by nuclear power from electric releases
between the terminal wire and the workpiece. The workpiece is taken care of past the wire to
accomplish the ideal cutting way, fairly in the way of a bandsaw activity. Mathematical control
is utilized to control the work part movements during cutting. As it cuts, the wire is gradually
progressed between a stock spool and a take-up spool to introduce a new cathode of steady
measurement to the work. This assists with keeping a steady kerf width during cutting. As in
EDM, wire EDM should be completed within the sight of a dielectric. This is applied by spouts
aimed at the apparatus work interface as in our figure, or the work part is lowered in a dielectric
shower
3. PROCEDURE
i. Turn on the electric diesinker.

ii. Make sure that the wire supply spool is in good condition.
iii. Dielectric fluid flow in necessary in order to cut through the case iron plate.
iv. Place the cast iron plate inside the diesinker.
v. Direct the electrically charged wire from wire spool through the cut path.
vi. Make sure that wire is collected in wire take-up spool.
vii. Turn off the diesinker when you see bubbles pouring out.
The tooling used for this experiment was electric diesinker.
1. Pulse Generator (DC): It is responsible for providing discharge current that is used to
generate the spark used for wire cutting.
2. Workpiece: The workpiece in case of this experiment is a metal plate made of cast iron.
It is placed inside the diesinker and dielectric fluid.
3. Fixture: The fixture is used to house the workpiece inside the dielectric fluid of
diesinker.
4. Dielectric Fluid: The purpose of dielectric fluid is to transfer electrons from anode to
cathode and vice versa. The flow of current between electrodes is made possible by
dielectric fluid.
5. Pump: The pump is used to transfer dielectric fluid from bottom of the container to the
top again. This keeps the electrons flowing.
6. Filter: The filter performs a basic job of filtering out any impurities such as small
particles or dust inside the dielectric fluid or container.
7. Tool Holder: The tool holder is used to hold the cutting tool.
8. Spark: The wire is cut with the help of electric spark that is generated by pulse generator.
9. Tool: The cutting tool cuts through the metal plate.
The wire cutting or electric discharge machining is the most common and widely used non-
conventional method of machining. It is the most effective way of cutting through a metal plate
in a desired cutting path. The EDM diesinker uses dielectric fluid that makes the process so
much simpler. The purpose of dielectric fluid is to facilitate the transfer and flow of electrons
between both electrodes.
The drawbacks and improvements of EDM will be discussed in this section.
6.1. Hazards
Research has shown that in addition to being harmful for environment and health, EDM may
pose a threat to the safety of operator. In addition to the emission of aerosol and other harmful
gases, self-ignition of dielectric fluid and electric shock are most common dangers.
6.2. Solid Wastes

6.3. Liquid Wastes
6.4. Gaseous Wastes
measurements.
EXPERIMENT 8
TO REMOVE THE MATERIAL BY WATER JET CUTTING
1. INTRODUCTION
Water Jet Cutting has become one of the most widely used machining operation in the world
today due to its efficiency and effectiveness. This experiment deals with the cutting of workpiece
using Water Jet Cutting Method.
2. THEORY
2.1. Water Jet Cutting
Water jet cutting (WJC) utilizes a fine, high-pressure, high-speed stream of water guided at the
work surface to cause cutting of the work. This has become one of the most widely used non-
conventional cutting method all around the world.
2.2. Cutting Fluids in WJC

Cutting liquids in WJC are polymer arrangements, favored in light of their inclination to deliver
a sound stream. We have talked about cutting liquids before with regards to ordinary machining,
however never has the term been more fittingly applied than in WJC.
2.3. Water Jet Cutter
The apparats used for water jet cutting is called water jet cutter. It is available all around the
world with different specifications. It houses an intensifier pump that is required to build up the
pressure necessary for performing the cutting operation on respective workpiece. It is used for
cutting, reaming, aviation and mining.
2.4. Operation of Water Jet Cutter
All waterjets follow a similar standard of utilizing high-pressure water centered into a shaft by a
spout. Most machines achieve this by initial running the water through a high-pressure siphon.
There are two kinds of siphons used to make this high pressing factor; an intensifier siphon and
an immediate drive or driving rod siphon. An immediate drive siphon works similar as a motor,
constraining water through high-pressure tubing utilizing unclogs appended to a driving rod.
2.5. Intensifier Pump
These gadgets depend on a differential cylinder rule, where a bigger measurement cylinder
pushes a more modest distance across cylinder, in this way expanding the strain to a factor
equivalent to the proportion: Larger breadth region separated by more modest width zone. The
power source pressure will consistently be relative to the provided pressure. The development of
the intensifier cylinders is constrained by inner valves, and the cylinder speed can be just about
as high as 20 Hz while expanding the pressing factor. Now, the intensifier ceaselessly conveys
stream to the high-pressure side. At the point when the end pressure is reached, the cylinder
development stops. If there should be an occurrence of a pressing factor drop on the high-
pressure side, the intensifier will consequently begin attempting to keep up the pressure.
2.6. Abrasive Water Jet Cutting
Abrasive water jet cutting is the process of adding rough particles in the water stream to
encourage cutting metals. Mostly abrasives are added in water to cut through metals. These
particles are diamond, ruby, garnet etc.
3. PROCEDURE
i. Set the desired amount of pressure for cutting operation on intensifier pump.
ii. Add any abrasive particles in case of cutting metals.
iii. Clean the workpiece and place it above the catcher.
iv. Turn on the water supply and let pump provide it required pressure.
v. Use the nozzle and direct it along the cutting path at get desired shape.
The tool used in this experiment is Water Jet Cutter. Its main parts and explained and shown
below.
4.1. Water Treatment Plant: The incoming water that is to be used for cutting is purified.
Any impurities present in the water are removed in the water treatment plant.
4.2. Pump: It works on differential piston principle and provides necessary pressure for
cutting workpiece.
4.3. Nozzle: The nozzle is the opening from where high speed stream of water ejects and
performs the cutting operation. Diameter of nozzle opening affects the water jet speed.
4.4. Catcher: The catcher collects water splashes after water jet stream has made contact
with the workpiece. It also collects any excessive or cut workpiece parts.
4.5. Abrasive Supply Hopper: It contains abrasives in case any metallic parts need to be
cut and supplies abrasive to be mixed with the water.
The water jet cutting process is widely used and gradually becoming more and more popular
because of its high accuracy and time saving factors. It is the easiest process to operate and it can
cut through almost any shape and type of material. It can further be utilized by adding diamond
or ruby nozzles.
The benefits and detriments as well as hazards of water jet cutting will be discussed here.
6.1. Benefits of Water Jet Cutting
The most crucial benefits provided by water jet cutting are the flexibility, thickness range and
edge quality. As visible from the graphical comparison below, WJC beats other machining
methods such as CNC, Laser and Plasma cutting in all these 3 factors. That is the main reason
due to which many companies now prefer water jet cutting to other methods.
6.2. Detriments of Water Jet Cutting
 Cutting Time
 Orifice Failure.
 Greater Thickness, Less Accuracy
 Starting Costs
measurements.
EXPERIMENT 9
TO PRODUCE FLAT SURFACE ON SHAPER MACHINE USING

SINGLE POINT CUTTING TOOL
1. INTRODUCTION
In this experiment, a flat surface was produced using Shaper machine. The cutting tool used was
single point cutting tool.
2. THEORY
2.1. Machine Tool
A machine tool is a machine for shaping the metal part or any other kind of rigid material.
Examples:
 Drill Press
 Hobbing Machine
 Broaching Machine
 Wood Shaper
2.2. Shaper Machine
Shaper machine uses the relative motion between cutting tool and the workpiece to perform the
cutting. The cutting tool used by shaper is same as that of lathe machine with only difference
being that shaper gives a linear cut whereas lathe gives a helical cut.
2.3. Parts of Shaper Machine
The parts of shaper machine are shown in the following schematic diagram.
 Base: Made of cast iron and rests on the floor to support and house all other parts.
 Column: Made of cast iron and mounted on the base. It contains guideways to which the
ram reciprocates.
 Table: T Type bolts are used for clamping at the top and bottom.
 Ram: It performs the cutting action by reciprocating to the guideways of coloumn.
2.4. Working Principle
The Ram displays responding movement on the workpiece, which is held unbendingly or braced
in the table. In standard shaper machine, cutting happens in forward stroke and in reverse stroke
is viewed as inactive. This movement of the cutting device is accomplished by the "Brisk Return
Mechanism". The cutting profundity is accomplished through the development of the apparatus.
The apparatus moves a descending way towards the workpiece.
2.5. Single Point Cutting Tool
The cutting tool that uses only one edge for machining is called Single Point Cutting Tool. It is
used for various machining operations such as shaping, planning and turning. Important
characteristics that a cutting tool must possess are:
 It should be hard enough.
 It should be capable of bearing the heat produced during machining process.
3. PROCEDURE
i. The workpiece is mounted on the table.
ii. The table is unbending and enclose formed and put front of a machine or close to the
machine.
iii. The Ram displays responding movement on the workpiece.
iv. The tallness of the table is effectively customizable and it is acclimated to coordinate
with the workpiece.
edge.
away the chips.
5. OBSERVATIONS
 Diameter = 0.5mm
 Table Movement = 0.3mm/stroke
 Table Reciprocation Speed = 34.5 m/min
 Length of Workpiece = 8in
 Cutting speed
The drawbacks as well as improvements that can be made regarding this experiment are
discussed in this section.
7.1. Solid Wastes
7.2. Liquid Wastes
7.3. Gaseous Wastes
ii. Clothing: Use clothing with short sleeves in order to avoid any piece of clothing
being stuck in the machine.
measurements.
ix. Ground: Keep the floor/ground in the close vicinity of machine free of tools, oil or
grease.
x. Horseplay: While the machine is working, strictly shun horseplay.
xi. Removal of Chips: Use a brush instead of hands for removing chips.
xii. Removal of Cutting Tool: While polishing, cleaning, or any other amendments on the
EXPERIMENT 10
TO PERFORM DIFFERENT OPERATIONS AT CNC MACHINE
1. INTRODUCTION
In this experiment, multiple operations are performed on the CNC machine. CNC machining has
become very popular in recent years due to its ease of use and time saving factors. CNC
machines have stepped foot in almost all machining operations such as water jet cutting, drilling,
milling, grinding etc.
2. THEORY
2.1. Numerical Control (NC)
Numerical control (NC) is the automation of machine tools that are operated by precisely
programmed commands encoded on a storage medium, as opposed to controlled manually. Most
NC today is computer numerical control (CNC), in which computers play an integral part of the
control. In modern CNC systems, end-to-end component design is highly automated using
computer-aided design (CAD) and computer-aided manufacturing (CAM) programs.
2.2. Role of Computer in CNC
Computers find many uses in overall manufacturing process. They fill three major roles in CNC:
i. Almost all machine control units include or incorporate computer in operation.
ii. Most of part programming for CNC machine tools done with off-line computer
assistance.
iii. Increasing number of machine tools controlled or supervised by computers that may be in
separate control room (direct numerical control-DNC).
Types of Computers:
Two types of computers are used in CNC.
 Analog (Used primarily in scientific research and problem solving)
 Digital (Accept input of digital information in numerical form to process it and develop
output data)
2.3. Advantages of CNC
CNC has many advantages over conventional machining process. Some of these advantages are:
 Greater operator safety
 Greater operator efficiency
 Reduction of scrap
 Reduced lead time for production
 Fewer chances for human error
 Maximum part accuracy and interchange
2.4. Cartesian Coordinates & Three Dimensional Coordinate Planes
Cartesian coordinates allow any specific point on job to be described in mathematical terms in
relation to any other point along three perpendicular axes Machine tool construction based on
three axes of motion (X, Y, Z) plus axis of rotation
2.5. Programming Systems

Two types of programming systems are used in CNC machining. These are:
i. Incremental System: Program dimensions or positions given from current point
ii. Absolute System: All dimensions or positions given from one reference point on job or
machine
2.6. CNC Machine and its Elements
A basic CNC machine along with its different elements is shown below in the image.
A CNC machine consist of following 6 major elements:
 Input Device
 Machine Control Unit
 Machine Tool
 Driving System
 Feedback Devices
 Display Unit
3. PROCEDURE
Part Programming Example
Tool size = 0.25 inch,
Feed rate = 6 inch per minute,
Cutting speed = 300 rpm,
Tool start position: 2.0, 2.0
Programming in inches
Motion of tool:
P 0 → P 1→ P 2→ P3 → P 4 → P 5 → P 1 → P 0
Step 1: Set Up the Programming Parameters

N010 G70 G90 G94 G97 M04
 G70 – Programming in inches
 G90 – Absolute Programming System
 G94 – Fixed in ipm
 G97 – Spindle Speed in RPM
 M04 – Spindle CCW
Step 2: Set Up the Machining Coordinates

N020 G17 G75 F6.0 S300 T1001 M08
 G17 – Machine moves in XY- Plane
 G75 – Use full circle interpolation
 F6.0 – Feed rate
 S300 – Spindle speed
 T1001 – Tool number
 M08 – Flood coolant ON
Step 3: Move Tool from p0 to p1 in Straight Line
N030 G01 X3.875 Y3.698
 G01 – Linear Interpolation
 X3.875 Y3.698 – Target Coordinates
Step 4: Cut Profile from p1 to p2

N040 G01 X3.875 Y9.125
Step 5: Cut Profile from p2 to p3
N050 G01 X5.634 Y9.125
Step 6: Cut Along from p3 to p4

N060 G03 X7.366 Y9.125 I6.5 J9.0
 G03 – Circular Interpolation (CCW motion)
 I6.5 J9.0 – Coordinates of center of circle
Step 7: Cut from p4 to p5
N070 G01 X9.302
Step 8: Cut from p5 to p1
N080 G01 X3.875 Y3.698
Step 9: Return to Home Position, Stop Program
N090 G01 X2.0 Y2.0 M30
N100 M00

4.1. Advantages of 5 Axis CNC
 Machine complex shapes in a solitary arrangement
 Diminishes the mechanic arrangement time and expands creation rates
 By killing various set-ups, time and mistakes are decreased
 Since concurrent development is permitted along the X and Y pivot, more limited
and more unbending apparatuses might be utilized
 Higher shaft/cutting instrument velocities might be accomplished while
diminishing the heap on the cutting device
 More limited and thicker cutters additionally diminish vibration while machining
profound pockets or formed highlights with three-hub machines
. 4.2. Disadvantages of CNC
 More costly than physically worked machines
 The CNC machine administrator just requirements essential preparing and abilities,
enough to oversee a few machines. In years passed by, engineers required long stretches
of preparing to work focus machines, processing machines and other physically worked
machines. This implies a considerable lot of the old abilities are been lost.
 Interest in CNC machines can prompt joblessness
measurements.
x. Ground: Keep the floor/ground in the close vicinity of machine free of tools, oil or
grease.
xi. Horseplay: While the machine is working, strictly shun horseplay.

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DEPARTMENT OF MECHANICAL ENGINEERING

UNIVERSITY OF ENGINEERING AND TECHNOLOGY.

MACHINE TOOLS AND MACHINING LAB

Submitted by Muhammad Humayun Arif

TO PERFORM CENTERING OF THE CYLINDRICAL WORK PIECE

2.3. Facing Operation

2.5. Drilling Operation

TO PERFORM THREADING OPERATION ON LATHE MACHINE

4. TOOLING USED (NOMENCLATURE)

TO PERFORM GRINDING OPERATION ON BENCH GRINDER AND

General Rules for Grinding:

2.3. Grinding Wheel

5. RESULTS AND CONCLUSIONS

TO PERFORM INTERNAL/EXTERNAL GRINDING OPERATION ON

General Rules for Grinding:

2.3. Grinding Wheel

2.8. Internal Grinding

TO DRILL HOLE OF SPECIFIC DIAMETER ON VERTICAL DRILLING

2.3. Applications of Drilling Machine

TO PRODUCE FLAT SURFACE ON SINGLE SPINDLE MILLING

2.2. Peripheral Milling

2.3. Face Milling

TO PERFORM CUTTING OPERATION ON CAST IRON PLATE BY

2.3. Discharge Current and Surface Finish

2.5. Electric Discharge Wire Cutting

i. Turn on the electric diesinker.

4. TOOLING USED (NOMENCLATURE)

The tooling used for this experiment was electric diesinker.

5. RESULTS AND CONCLUSIONS

6. DRAWBACKS AND IMPROVEMENTS

The drawbacks and improvements of EDM will be discussed in this section.

6.2. Solid Wastes

TO REMOVE THE MATERIAL BY WATER JET CUTTING

2.2. Cutting Fluids in WJC

5. RESULTS AND CONCLUSIONS

TO PRODUCE FLAT SURFACE ON SHAPER MACHINE USING

2.2. Shaper Machine

TO PERFORM DIFFERENT OPERATIONS AT CNC MACHINE

2.5. Programming Systems

Step 1: Set Up the Programming Parameters

Step 2: Set Up the Machining Coordinates

Step 4: Cut Profile from p1 to p2

Step 6: Cut Along from p3 to p4

4. DRAWBACKS AND IMPROVEMENTS

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