f LAB MANUAL METAL CUTTING AND TOOL DESIGN LAB SUBJECT CODE: ETAT-351 PUC ECCT bed r' Name of Program: B.Tech. Us Semester-5" (MAE) woe = 6 Department of Mechanical and ‘ Maharaja Agrasen Insti (ISO 9001:2008 Centified and AICTE approved) PSP Area, Rohini. ector 22, Delhi-110086 AMiliated to l ‘raifer x wars: Guru Gobind Singh Indraprastha University, New Delhi Automation Engineering itute of Technology,MAHARAJA AGRASEN INSTITUTE OF TECHNOLOGY VISION ‘To nurture young minds ina learning environment of high academic value and im spiritual ‘and ethical values with technological and management competence, MISSION ‘The Institute shall endeavour to incorporate the following basic missions in the teaching methodology: Engineering Hardware — Software Symbiosis: Practical exercises in all Engineering and Management disciplines shall be carried out by Hardware equipment as well as the related software enabling deeper understanding of basic concepts and encouraging inquisitive nature. Life - Long Learning: The Institute strives to match technologi ‘encourage students to keep updating their knowledge for enhancing the their habit of continuous learning, I advancements and skills and inculeating Liberalization and Globalization: ‘The Institute endeavors to enhance technical and management skills of students so that they are intellectually capable and competent professionals with Industrial Aptitude to face the challenges of globalization, Diversification: The Engineering, Technology and Management disciplines have diverse fields of studies with different attributes. The aim is to create a synergy of the above attributes by ‘encouraging analytical thinking, Digitizati of Learning Processes: The Institute provides seamless opportunities for e learning in all Engineering and Management disciplines through digitization of learning processes using analysis, synthesis, simulati create platform for multi-disciplinary approach. n, graphics, tutorials and related tools to Entrepreneurship: The Institute strives to develop enhancing their skills and research ea ‘and responsible citizens, P poiential Engineers and Managers by pabilities so that they emerge as suecessful entrepreneurs PRUPVVVUVVIVIGUVGIT 00 C0000 ove CV ee ~Coe CO Attainment Sheet Rub: Rubrics for : Laboratory (General) Tacsr | Experiment Taya, Grading Rubrics Acs | Component nooner | sae Tans vane ae Completeness of praca exhibits [Incomplete practi unformatted user] 9228 | 2. [poten nun teen pes |i conmens beonseatero brings otcency ciput contains few nga ror Gane cara acter Ona te races ‘Output and taines ynstrat excellent Pre oreo vaca | ougutand | |obuines denensats mcelertoonensats parlundestndngo retenading of the concepts the concepts relevant to the german Ree +_ One mark or aerdace vaca | ‘ansine, | [2 Tree mars for raverng moetnan 73% uesons ce 3, Two marks for answering more then 50% questions. a One ark fr answering less then 50% questions Tine ace |suomustnot| 2 [ontimesubmisin ate subrison RPDS DPT SD VTC CCC CC OO OS‘Year 2018-2019 Course Code: ETAT 351 Course Title: Metal Cutting and Tool Design Lab On completion of this course the student will be able to: Cor co2 Apply the conceptual knowledge to generate angles of a single point cutting tool €O3 entify and categorize various types of chips for different materials. C4 Analyse and deduce the cutting forces during turning operations. Examine and discuss the flank wear at different machining parameters. Cos Design the set up for cutting zone temperature measurement. cos Perceive and predict the accuracy machine, Course Outcomes $ S 9 & 2 y and performance of the workpiece on the lathe of Experiments Exp -xperiment Ne co Experiment Expt | COi | To study and design a single point cutting tool using bench grinder To study different type of chips formed at different speed, feed and Exp? | CO? | depth of cut for diferent materials. ‘To measure and analyze the cutting forees in orthogonal taming for Exp | C03 _| different materials at different speeds. “To measure and analyze the cutting forces in orthogonal turning for Exp | C03 | different materials at different feeds and depth of cuts To study the flank-weartime characteristics for single point cutting Bxp§ | CO4 | soo! fordifferent materials at different speeds, To study the flank wear-time characteristics for single point euling Fx 6 | C04 | too! for different materials at diferent feeds and depth of ute To study the tool-work thermocouple technique and to study the Exp7 | COS _ | effect of change in depth of cut on EMF produced for various cutting speeds on a center lathe. 2 To perform accuracy analysis of finished cylindrical workpiece Fan | C06 | produced on lathe machine tool : Exp9 | _ coe _| Testing main spindte and late machine Yoo Tor axl movement and true running. Exp 10] COG |"To study indexing mechanism on a milling machine tool iPREM eeeeesereres av IAB S™*AW®ON OG HT & ee Course Title: Metal Cutting and Tool Design Lab Course Code: ETAT 351 List of Experiments Exp No. | C° Experiment Expt | cot To study and design a single point cutting tool using bench grinder To study different type of chips formed at different speed, feed and depth Exp2 | coz Of cut for different materials. Exp3 | cog | T° measure and analyze the culting forces in orthogonal tuming for different materials at different speeds. ‘To measure and analyze the culling forces in orthogonal turing for Exp4 | co3 different materials at different feeds and depth of cuts. Exps | co4 To study the flank-wear-time characteristics for single point cutting tool for 7 different materials at different speeds. 7, | To study the Tank wear-imme characterises for single point culing Tool for Exp 6 | CO4 | siterent materials at different feeds and depth of cuts. To study the fool-vork thermocouple technique and to study the effect of Exp7 | COs | change in depth of cut on EMF produced for various cutting speeds on a center lathe. "To perform accuracy analysis of finished cylindrical workpiece produced on Exp 8 | CO6 | the machine tool in spindle and lathe machine tool for axial movement and true Expo | coe | Testing main spi running, Exp 10 | C06 | To study indexing mechanism on a milling machine tool.MCTD LAB (ETAT ~ 351) EXPERIMENT 4 AIM: To study and design a single point cutting tool using bench grinder. MACHINE TOOLITOOLS USED: Bench grinder WORK PIECE USE! mild steel cylindrical rod COOLANT USED: Oil based water emulsion or Plain water. THEORY: Different angles of a single point cutting tool: Back Rake angle Side Rake angle End Clearance angle Side Clearance angle End cutting edge angle Side cutting edge angle 7. Nose Radius ECUT Cee oees se © ~~ apenas Y (Define the angles along with their significance) (Draw single point cutting tool showing various angles) PROCEDURE: & € 4. Switch on the bench grinder and hold the workpiece blank against the surface of o 2 the grinder wheel to make the flank face. 2. After that, grind the other face of workpiece blank to generate the side faces, Cad 3. Now, turn workpiece sideways and again grind It to make the other side faces. e ‘4, Atlast, provide the nose radius on the tool by touching the front side of workpiece blank against the grinder wheel. 7 5. Check and compare newly formed tool with a standard HSS tool for all angles. ad PRECAUTIONS: e 4. Do not operate grinder with wet hands. eo 2. Workpiece blank should be held firmly in both the hands while grinding, = 3. Do not touch grinder wheel with finger while running. ; 3 4, Gap between the work rest and grinding wheels, should be suitably adjusted 2 > e eo? 1 eo © ey : €\i. aahG- MCTD LAB (ETAT ~ 351) ‘SOURCES OF ERROR: 1. Loose handling of workpiece blank may give wrong angles. 2. Over heating of tool leads to blue color. VIVA-VOCE ‘What are single point cutting tools? Give example. ‘Why coolant is needed during machining operations? Explain different tool materials commonly used. ‘Why we don't require lubricant during machining certain materials? Name those materials. aeNeMECC CTOCCCICCCCESE MCTD LAB (ETAT ~ 351) EXPERIMENT 2 AIM: To study different type of chips formed at different speed, feed and depth of cut for different materials, MACHINE TOOLITOOL USED: Lathe machine tool, bench type fool grinder and keys like tool post key and chuck key, single point cutting tool WORK PIECE USED: Cylindrical rods of mild steel, aluminum and brass. COOLANT USED: Oil based water emulsion or Piain water. THEORY: Different type of chips and the reason for their formation are: “4. Continuous chip 2. Discontinuous chip =3. Continuous with builtup edge — (Explain the different types of chips with diagram) PROCEDURE: 4. Hold the workpiece firmly in the jaws of the chuck in lathe machine tool and tightened properly. Center the workpiece blank property in the chuck ‘Adjust the cutting speed to the minimum value. ‘Start the turning operation at predefined (or constant) depth of cut and feed rate. Collect the chips formed and interpret their characteristics. Gradually increase the cutting speed keeping the depth of cut and feed rate same and repeat the step 4 and step 5. 7. Now keeping cutting speed and feed rate constant, vary depth of cut and collect and interpret the chips so formed. 8. Further, Keeping cutting speed and depth of cut constant, vary feed rate and collect and interpret the chips so formedwilP } i { 40-92% iz EEE aoe } , Poot feed — Pe Leg ae LE = Sing i. Dotw — , pP= opp . 7! Z 5 Ms— Fiche s ay 3 Gre S PF Sok “SF AL 9 Ve by —1# v = aa) oop = ete Lith, Leety ¥ =o gobs 44 7 Ob YZ LeowMCTD LAB (ETAT — 351) TABLE OF OBSERVATIONS: Work Materi juminium: Constant Parameters Feed Rate: Depth of Cut os Varying Parameter Cutting Speed Types of Ct : Characteristics 2. m7 3. 4 Constant Parameters Cutting Speed: Feed Rater oS (= Varying Parameter Depth of Cut Types of Chips with Characteristics 7 os z 3. Constant Parameters Depth of Cut! OS Varying Parameter Feed Rate Types of Chips with Characteristics t B 2. ee 3. < Work Material: Mild Steel Constant Parameters | Feed Rate: Depth of Cut: Varying Parameter Cutting Speed Types of Chips with Characteristics 4. 2. 3. Constant Parameters | Cutting Speed: Feed Rate: i meter Depth of Cut Types of Chi eee mt Characteristics 4. 2 3. Constant Parameters | Cutting Speed: Depth of Cut: i Feed Rate ‘Types of Chips with nie Paes Characteristics 7. 2. 3.HSVVVSSCSCII CS COCCCCEE MCTD LAB (ETAT ~ 351) Constant Parameters Depth of Cut: Varying Parameter Cutting Speed Types of Chips with Characteristics 1 2. 3. Constant Parameters | Cutting Speed: Feed Rate: Varying Parameter Depth of Cut Types of Chips with Characteristics T. 2. 3. Constant Parameters | Cutting Speed: Depth of Cut: Varying Parameter Feed Rate ‘Types of Chips with Characteristics 7 2. 3. PRECAUTIONS: 1. 2. 3 Proper centering of job should be done. ‘The tool should be held rigidly while performing turning process. Depth of cut should be increased gradually so that changes can be recorded properly. SOURCES OF ERROR: 1 2. 3. Job should be centered properly to avoid damage to tooltip. Depth of cut should be increased in small steps. Collect chips carefully using gloves, sharp edges may cut hands. vivAvoce: 1 2 3, 4 5. 6 ‘What are the different reasons of forming discontinuous chips? What is the basic mechanism of chip forming? Wie the difference between feed and depth of cut during turing operation? ‘Write the composition of HSS tool material? Describe various types of chips with diagrams? What is the role of chip breaker?VUVVVGOTICCC RCL ECCeeeCeeeE MCTD LAB (ETAT ~ 361) EXPERIMENT 3 AIM: To measure and analyze the cutting forces in orthogonal turning for different ‘materials at different speeds. MACHINE TOOL/TOOLS USED: Lathe machine tool, single point cutting tool, tool post key, chuck key, cylindrical rod (Aluminium and Mild Stee!). THEORY: Different forces acting in the cutting zone are: oorene Cutting Force Thrust Force Shear Force Normal to shear force Friction Force Normal to friction force (Draw Merchant circle diagram indicating all the forces and associated angles) PROCEDURE: 1 Mount the work piece on the chuck rigidly and secure the cutting tool firmly in the toolpost, Set the machine tool at the lowest speed with automatic feed enabled. Collect the chips formed during the turning operation and measure the length and width of chip. Using the following equation te te 1 Calculate the chip thickness ratio (F) Further, calculate the shear angle and hence, the cutting force and thrust force (taking values of shear strength and coefficient of friction according to the material ‘of workpiece). Now, increase the cutting speed and repeat from step 3 to step 5. Plot the graph between the cutting force and cutting speed and thrust force and cutting speed. Repeat the experiment with the second workpiece materialo-6t (Biased we (up shod = DOT ee WAS = (4k a 6 250 nietae Yoo nan Sess oo bb ceceneed ig eJ MCTD LAB (ETAT ~ 351) TABLE OF OBSERVATIONS: Skowl" Work Piece Material: Aluminium 0-6) ee Feed: | Doc: }K a: 6] Ts: A Chip | Chip &s Cutting | Length | Length | chip | width | Shear | Cutting | Thrust es Speed | before | after | Thickness | of Chip| Angle | Force | Force & ™) Tening senna Ratio (r) | (b) () (Fe) (F) | yas Work Piece Material: Mild Steel AS SUS Feed: | Doc:}/f a:< Te a x Chip | Chip Cutting | Length | Length | Chip Speed | before | after ” (le), Width | Shear Thickness | of Chip | Angle (V) | Turning | Turning | Ratio() | (b) (®) (Fe) Cutting | Thrust Force | Force (Fy) 4. Explain the effect of cuting speed, food rate and depth of cut on cutting forces, PRECAUTIONS: 4. The workpiece and tool should be fixed rigidly. 2. Proper centering of job should be done. SOURCES OF ERROR: 1, Job should be centered properly to avoid damage to tooltip. 2. Collect chips carefully using gloves, sharp edges may cut hands. \VIVAVOCE: 4. What are the different types of cutting process? Briefly describe with diagram, 2. Differentiate between orthogonal and oblique cutting process. 3. What components of cutting forces are measured in orthogonal cutting?MCTD LAB (ETAT - 351) EXPERIMENT 4 ‘AIM: To measure and analyze the cutting forces in orthogonal turning for different materials at different feeds and depth of cuts. MACHINE TOOLITOOLS USED: Lathe machine tool, single point cutting tool, tool post key, chuck key, cylindrical rod (Aluminium and Mild Steel). ‘THEORY: Different forces acting in the cutting zone are: 1. Cutting Force 2, Thrust Force 3. Shear Force 4. Normal to shear force 5. Friction Force 6. Normal to friction force (Draw Merchant circle diagram indicating all the forces and associated angles) PROCEDURE: Mount the work piece on the chuck rigidly and secure the cutting tool firmly in the toolpost Set the machine tool at the maximum speed with automatic feed enabled at the lowest value. Collect the chips formed during the turning operation and measure the length and width of chip. 4, Using the following equation t_ic tc 1 Calculate the chip thickness ratio (1) Further, calculate the shear angle and hence, the cutting force and thrust force (taking values of shear strength and coefficient of friction according to the material of workpiece). Now, increase the feed rate and repeat from step 3 to step 5. . Now, plot the graph between the cutting force and feed rate and thrust force and feed rate. Repeat the experiment with the second workpiece material. Further, repeat the above experiment by varying depth of cut at constant speed and feed for the two different workpiece materialMCTD LAB (ETAT — 351) ‘TABLE OF OBSERVATIONS: v Work Piece Material: Aluminium or Cutting 7 - - 7 Speed: | POC! | a ic ne x i) Chip_| Chip Feed | Length | Length | chip | width | Shear | Cutting | Thrust oe () | before | after | Thickness | of Chip | Angle | Force | Force ore Turning | Turning | Ratio() | (b) | (®) | (Fe) | (Fd yy (le) as Work Piece Material as Cutting : i : Snore | Doc: | a a " X aed Chip | Chip aa ee Length | Length | Chip idth | Shear | Cutting | Thrust [ Feed | ‘before | after | Thickness | of Chip | Angle | Force | Force es | turning | Turning | Ratio) | (6) | @) | | (Fy ) (le) i ‘Work Piece Material: Aluminium Cutting 7 7 = Sheed | Feed: | a: Te © Chip | Chip poc | Lensth | Length | chip | width | Shear | Cutting | Thrust a) | Before | after | Thickness | of Chip | Angle | Force | Force Turning | Turning | Ratio(e) | (b) | (@) | (Fe | (FD 0) (le) oe e o ° o e ¢MCTD LAB (ETAT ~ 351 Work Piece Material: Mild Steel Cutti gutting | Fea: | a: Chip Chip poc | Length | Length | Chip | width | Shear | Cutting | Thrust (a) | Defore | after | Thickness | of Chip| Angle | Force | Force Turning | Turning | Ratio(r) | (b) | (0) | (Fe) | (Fd wy) (le) PRECAUTIONS: 1. The workpiece and tool should be fixed rigidly. 2. Proper centering of job should be done. @ SOURCES OF ERROR: 1. Job should be centered properly to avoid damage to tool tip. 2. Collect chips carefully using gloves, sharp edges may cut hands. VIVA-VOCE: 1. What are the different types of cutting process? Briefly describe them with diagram, 2. What is reduction coefficient? 3. Briefly discuss the Lee and Shaffer theory of metal cutting with assumptions? 4, What are plowing forces? 0eo MCTD LAB (ETAT — 351) EXPERIMENT 5 ‘AIM: To study the flank-wear-time characteristics for single point cutting tool for different materials at different speeds. MACHINE TOOL/TOOLS USED: Lathe mac e tool, tool marker’s microscope, single Point cutting tool, tool post key, chuck key, cylin Steel) I rods (Aluminium and Mild THEORY: The two types of wear occurring in cutting tool are: 4. Flank wear 2. Crater wear (Discuss the types of wear with diagram) PROCEDURE: 4. Check the tip and other angles of the tool given, regrind the tool properly ifrrequired. 2. Set the tool firmly in the tool post for turning operation. 3. Set the job on the automatic feed at maximum value with the help of the lever provided on the L.H.S. of the machine and perform the turning operation for predefined time i.e.1 minute, 3 minutes and 5 minutes. Now, place the tip of the tool on the cross wire of the tool maker microscope and take readings (Ri). 5. Similarly take reading at the end of hatching value Re, 6. Calculate the value of wear as (Re - Ri). 7. Repeat the steps by increasing the speed value and calculate the flank wear. ‘TABLE OF OBSERVATIONS: 4. Work Material: Aluminium Constant ; : Parameters | Feed Rate: Depth of Cut: Varying Width of Flank Wear Land Parameter Time (min) Cutting Speed: (vB) 1. 7 2. 3 3. 5 Constant | rocq Rate: Parameters: Se Depth of Cut: Cutting Speed: "MCTD LAB (ETAT — 351) Narying ‘i Width of Flank Wear Land Parameter Time (min) (vB) 1 1 2. 3 3. 5 Constant z 7 : in Paraaters | Feed Rat Depth of Cut: Cutting Spee Varying ‘i ir Width of Flank Wear Land Parameter Time (min) (ve) 1. 4 2. 3 3. 5 ‘Work Material: Mild Stee! Constant | reeg Rate: '- | Depth of Cut: [0%] Cutting Speed: lo-> Parameters Varyi a Width of Flank Wear Land Parameter fee ve) 1. 4 2. 3 3. 5 Constant. 5 Depth of Cut: Med. | Cutting Speed: Hed, eeonstant | Feed Rate: z > z 2 ® > 2 > 3MCTD LAB (ETAT —~ 351) —_______—— EXPERIMENT 6 AIM: To study the flank wear-time characteristics for single point cutting tool for different materials at different feeds and depth of cuts. MACHINE TOOL/TOOLS USED: Lathe machine tool, tool marker's microscope, single Point cutting tool, tool post key, chuck key, cylindrical rods (Aluminium and Mild Stee!) ‘THEORY: he two types of wear occurring in cutting tool are: 1. Flank wear 2. Crater wear (Discuss the types of wear with diagram) PROCEDURE: 1. Check the tip and other angles of the tool given, regrind tool properly if required. 2. Set the tool firmly in the tool post for turning operation. 3. Set the job on the automatic feed at minimum value with the help of the lever provided on LH.S. of machine and cutting speed at maximum value to perform ‘uming operation for predefined time ie.1 minute, 3 minutes and § minutes. 4, Now, place the tip ofthe tool on the cross wire of the tool maker microscope and take readings (Ri). 5. Similarly take reading at the end of hatching value Ro. 6. Calculate the value of wear as (Re - Ri). 7. Repeat the steps by increasing the feed value and calculate the flank wear. 8. Further, repeat the experiment by varying the depth of cut while other parameters remaining at constant values for the two different materials. ‘TABLE OF OBSERVATIONS: Change of Feed rat Work Material: Aluminium Constant Parameters | Feed Rat Depth of Cut: Cutting Speed: Varying Width of Flank Wear Land Parameter Time (min) (vB) 1. 7 2. 3 L 3. 5 1“| MCTD LAB (ETAT ~ 351) Constant Parameters | Feed Rate: Depth of Cut: Cutting Speed: Varying in ‘Width of Flank Wear Land Parameter Time (min) (vB) 4. 4 2 3 3. 5 Constant | F ; cut ee Parameters | Feed Rate: Depth of Cut: utting Speed: Varying i of Flank Wear Land Parameter Time (min) VB) 1. 7 2. 3 3. 5 Work Material: Mild Stee! Constant : : i : Paretants | Feed Rate: Depth of Cut: Cutting Speed: Varying .e (mit ‘Width of Flank Wear Land Parameter Tae (ein) (vB) 7 1 2. 3 3. 5 Constant . : tt : Paemtars | Feed Rate: Dopth of Cut: Cutting Speed: Varying a ‘Width of Flank Wear Land Parameter Time (min) (ve) 1. 7 2. 3 3. 5 Pocabtors | Feed Rate: Depth of Cut: Cutting Speed: Varying : Width of Flank Wear Land Parameter Time (min) (vB) 1. 7 2. 3 3. 3 15MCTD LAB (ETAT ~ 351 Change of Depth of cut Work Material: Aluminium i poonstant | Feed Rate: Depth of Cut: Cutting Speed: Varying Width of Flank Wear Land Parameter Time (min) (vB) » 1 1 2. 3 3. 5 Constant ; : . Parcettars | Feed Rate: Depth of Cut: Cutting Speed: e Varying ir Width of Flank Wear Land Parameter Time (ein) i) - 1. 1 S 2. 3 _ 3. 5 a Constant : of Cuts i : Parmalat, | Feed Rate: Depth of Cut: Cutting Speeds & Varying i Width of Flank Wear Land Parameter etna) (vB) 1 1 2. 3 _ 3. 5 a Work Material: Mild Steel ‘Constant 3 poenstant, | Feed Rate: Depth of Cut: Cutting Speed: Varying ; Width of Flank Wear Land e Parameter Time (min) (ve) o 4. i oe 2 3 3. Constant parameters | Feed Rate: Depth of Cut: Cutting Speed: 16guoGossoEGeToeVeTTeseese MCTD LAB (ETAT - 351) Varying rt Width of Flank Wear Land Parameter Time (min) (vB) 1. 1 2 3 3. 5 Constant Parameters | Feed Rate: Depth of Cut: Cutting Speed: Varying ir Width of Flank Wear Land Parameter Time (min) (vB) 1 1 2. 3 3 5 RESULT: 4. The graph was plotted between flank wear of tool and time at diferent feed and depth of cut values. PRECAUTION: 4. The workpiece and tool should be fixed rigidly. 2. Proper centering of job should be done. 2. The reading of the flank wear land should be accurately noted. VIVA-VOCE: 4, Hows the flank wear land measured? 2. Where do flank and crater wear occur? 3, Whatis the ISO recommended value of VB & VEnax in case of flank wear? 44, What type of tool wear mechanism are mainly responsible for crater wear? 5, How can we determine crater wear on a single point cuting tool? 7MCTD LAB (ETAT — 351) EXPERIMENT 7 AIM: To study the tool-work thermocouple technique and to study the effect of change 5 in depth of cut on EMF produced for various cutting speeds on a center lathe. MACHINE TOOLITOOLS USED: Lathe machine tool, voltmeter, mercury cup, copper Wires, single point cutting tool (carbide tip), mild steel cylindrical rods, insulating material ‘THEORY: (Discuss and draw the diagram of tool-work thermocouple apparatus) PROCEDURE: 1. The workpiece and the cutting tool are insulated from the chuck and headstock using the plastic sheets and nylon as insulating material. 2. One end of the workpiece is connected to the slip ring in the mercury box through copper wires. 3 ‘The shank of the cutting tool is connected to the mercury cup through the voltmeter using the copper wires, 4. On completion of the circuit, the readings are noted at different depth of cut and cutting speed, ‘TABLE OF OBSERVATIONS: Constant Parameters S.No Induced EMF Depth of Cut 1 | 2 Constant Parameters S.No Induced EMF Cutting Speed 1 2 3 18MCTD LAB (ETAT — 351) RESULT: 1. The graph was plotted between the induced EMF and different depth of cut values and cutting speeds. PRECAUTION: 1. The workpiece and tool should be fixed rigidly and must be insulated well. 2. Proper centering of job should be done. 3. The reading of the generated EMF should be accurately noted. VIVANOCE: 4. Discuss various methods of measuring the chip-tool interface temperature? 2. Whatis the working principle of tool-work thermocouple technique? 3. Why workpiece and cutting tool should be insulated from other machine parts? 4, Why mercury is used in tool-work thermocouple technique? 19MCTD LAB (ETAT ~ 351) EXPERIMENT 8 AIM: To perform accuracy analysis of finished cylindrical workpiece produced on lathe machine tool. MACHINE TOOLITOOLS USED: Lathe machine tool, chuck key, tool post key, Vernier caliper, mild steel cylindrical rod ‘THEORY: (Discuss about turning process and Vernier caliper) PROCEDURE: 41. Mount the workpiece and the cutting tool in the chuck and tool post respectively. 2. Set the pre-decided cutting conditions. 3. Perform the turning operation over a certain length of cylindrical workpiece. 4. After the operation, the diameter is measured at various points on the turned part with the help of Vernier caliper. 5. Readings are noted at various cutting parameters and error percentage is calculated. TABLE OF OBSERVATIONS: sno [Constant Parameters: Depth of Cut Reading of Diameter 1 so | Sonstant Parameters: Cutting Speed Reading of DiameterMCTD LAB (ETAT — 351) Constant Parameters: S.No Feed Rate Reading of Diameter 1 2 3 RESULT: 1. The accuracy analysis on the workpiece with various combinations of cutting parameters was carried out PRECAUTION: 1. The workpiece and tool should be fixed rigidly. 2. Proper centering of job should be done. 3. Least count of Veimier caliper should be noted carefully. wwe vIVA-VocE: 1. Discuss various operations performed on the lathe machine tool 2. What do you mean by least count of Vernier caliper? 3. Give the reasons of variations in diameter on the same tured part? 2MCTD LAB (ETAT ~ 351) EXPERIMENT 9 AIM: Testing main spindle and lathe machine tool for axial movement and true running. MACHINE TOOLITOOLS USED: Lathe machine tool, chuck key, tool post key, mild steel cylindrical rod, plunger gauge (L.C. — 0.02 mm) THEORY: (Discuss about turning process and Plunger gauge) PROCEDURE: 4. Mount the workpiece and the cutting too! in the chuck and tool post respectively. 2. Set the pre-decided cutting conditions. 3. Perform the turning operation over a certain length of cylindrical workpiece. 4. After the operation, the plunger gauge is magnetically set on the saddle. 8. For true running, mark a line on the workpiece and touch the needle of plunger ‘gauge to that line giving one full rotation to the workpiece. ‘The maximum defection in the plunger gauge define the value of error in true running. 7. For axial movement, mark two lines over a certain length. Now move plunger gauge axially from one end of line to the other end. 8. The maximum deflection in the plunger gauge gives the error in axial movement, 9. Readings are noted at various cutting parameters. ‘TABLE OF OBSERVATIONS: Constant Par: 2 Ho ameters: Cutting Speed True Running Axial Movement RESULT: +. The errors in true running and axial movement were calculated with various combinations of cutting parameters, PRECAUTION: 22MCTD LAB (ETAT — 351) 4. The workpiece and tool should be fixed rigidly. 2. Proper centering of job should be done. 3. Least count of Plunger gauge should be noted carefully. VIVA-VOCE: 4. What do you mean by true running and axial movement in lathe machine tool? 2. What do you mean by least count of plunger gauge? ‘3, What are the possible causes of error occurrence during true running and axial movement? 23£6-0000002200-0-20) MCTD LAB (ETAT - 351) EXPERIMENT 10 ‘AIM; To study indexing mechanism on a milling machine tool. MACHINE TOOLITOOLS USED: Milling machine too, indexing plate, dividing head THEORY: (Discuss about milling process, milling machine tool with line diagram, types of indexing with example) RESULT: Indexing mechanism on the miling machine tool was studied thoroughly. 24