Practical Workbook

Production Engineering II
T.E. (Mechanical)
Prepared By

Syed Haider Raza

Associate Professor

Name of Student: Qazi Muhammed Fayyaz Zahid

Class: 3rd Year Section: A Batch: 2018

Discipline: Mechanical Engineering

Class Roll No.: ME-18005 Seat No: ME-18005

This is certified that this Practical Workbook contains Pages.

Chairman

Department of Mechanical Engineering

NED University of Engineering & Technology
Karachi 75270, Pakistan.
 Practical No.1

OBJECT

Study of safety rules for working in a machine shop.

SAFETY RULES

DO’s

1. Immediately report any accident even if it is small.

2. Wear your overalls buttoned up to protect your clothes and prevent loose and ties
becoming caught in the moving part of the machine.
3. Either roll up your overall sleeves or button up the cuffs.
4. Keep your hair short or wear a cap, net or hair band.
5. Keep machine and all equipment clean and in good condition.
6. Before starting machine ensure that you know how to stop it.
7. Switch off the machine immediately if any thing goes wrong.
8. Keep the machine and surrounding area tidy.
9. Check oil level before first starting machine.
10. Switch off machine at the main, at the end of each day.
11. Check that chucks or clutches rotate in the correct directions before commencing
cutting operations.
12. Use the correct tool or cutter for the job.
13. Replace tools that are worn or damaged.
14. Keep tools and cutters in boxes or racks when not in use.
15. Report immediately to your instructor any mechanical or electrical fault.
16. Ensure that all machine parts are in position before starting.
17. Check that work area is clean before stating the machine.
18. Ensure that every thing is properly secure before starting the machine.
19. Ensure that feed mechanisms are not engaged before starting the machine.
DON’Ts

1. Don’t wear rings or watches while operating a machine.

2. Don’t keep sharp tools in your overall.
3. Don’t remove swarf with your bare hand, use a brush.
4. Don’t manually lift heavy equipment.
5. Don’t lean on the machine.
6. Don’t attempt to operate a machine until know how to correctly use it.
7. Don’t tamper with the machine unnecessarily.
8. Don’t remove any stop in an effort to obtain a greater cutting range or the machine
severely damaged.
9. Don’t try to reverse the direction of the motion of the machine during motion.
10. Don’t try to change the spindle speed while in motion.
11. Don’t throw things.
12. Don’t walk away and leave your machine running.
13. Don’t direct compressed air at your self or workmates, it can kill.
 Practical No.2

OBJECT
Study various parts and cutting tools used for a Centre Lathe Machine

LATHE MACHINE

Definition:

Lathe is the most versatile and commonly used among all machine tools. Te work piece
is held in a holding device (e.g. chuck) and rotated on the axis, while the cutting tool is advanced
along the line of the desired cut. Lathe size is determined by the “SWING” and “BED
LENGTH”. Swing indicated the largest diameter that can be turned. Bed length is the entire
length of the ways and should not be mistaken for the maximum length of the metal that can be
turned.

Operations performed on lathe:

A lathe machine is extremely versatile and with suitable attachments the lathe may be used for
performing a very large number of machining operations. Typical machining operations that are
performed on a lathe turning, facing, tapering, taper turning, drilling, boring, spinning, grinding,
threading, tapping and polishing operation.

Major Parts of Lathe Machine

Each of the lathe part fall into one of the three functional divisions:
1. Driving the lathe
2. Holding and rotating the work.
3. Holding and moving the cutting tool.
 MTo8 CONTROL

MOT0I1 CHD
Main parts of a centre lathe are:

1. The bed and ways.

2. The head Stock.
3. The quick change gear box.
4. The carriage assembly.
5. The tail stock.

1. Bed:

The bed is a heavy, rugged casting made to support the working parts of the lathe.
On its top section are machined ways that guide and provide for precise alignment
of the headstock and tail stock.

2. The Head Stock:

The head stock is clamped on the left hand side of the bed. Hollow spindle
supported by the bearings, provides a drive through the gears from the motors to
the work holding devices. The spindle noses, or with a threaded spindle nose. 3-
jaw or 4-jaw chucks can be fitted on to the spindle in order to hold and drive the
work piece that would allow the cutting tool to perform various operations.
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3. Feed Mechanism:
The feed mechanism transmits power through a gear train to the quick
change gear box which in turn regulates the distance of tool travel per
revolution of the spindle. The LEAD SCREW transmits the power
to the carriage through a gearing and clutch arrangement in the apron.
Feed change levers on the apron control the operation of power feed
and when placed in neurtral, permits the half nuts to be engaged for
threading operations.

4. Carriage Assembly:
The Carriage Assembly consists of three main parts.
a. The saddle
b. Apron
c. Cross Slide

a. The Saddle
It is used to move the cutting tool along the lathe bed. The saddle is
an H-Shaped, casting mounted on the top of the lathe ways, provides
a mean of mounting the cross slide and the apron.

b. Apron
It is the part of carriage assembly on the side of the operator. It
contains levers for engaging and dis-engaging the feed rod and lead
screw via a half nut. Apron fastened to the saddle houses the gears
and mechanism required to move the carriage or cross side
automatically. The apron hand wheel can be turned manually to move
the carriage along the lathe bed. This hand wheel connected to a gear
that meshes on a rack fastener to the lathe bed.
c.
 c The cross slide:

The cross slide mounted on top of the saddle, provides a manual or

automatic cross movements for the cross movement of cutting tools.
The compound rest, fitted on the top of the cross slide is used to
support the cutting tool.

Tail Stock:
It consists of the upper and lower castings. It can be adjusted along
the lathe ways to accommodate works of different lengths. The tail
stock can be locked in any position along the bed of the laths by the
tail stock clamp. The tail stock spindle has an internal taper to
receive the dead centre, which provides support for the right hand end
of the work. Other standard tapered shank tool such as reamer and
drill can be held in the tail stock spindle. A spindle clamp is used to
hold the tail stock spindle in or out of the tail stock casting. It can be
used to provide a hand feed for drilling and reaming operations.

Lathe Tools:

The tools used for common machining operations on a lathe are single
point cutting tools i.e. they have only one cutting edge that must be re-
sharpened when becomes dull or worn out after a certain period of
machining. The most commonly used tool material is High Speed
Steel, although carbides and ceramics tool inserts are gaining
increased usage due to their many superior characteristics over HSS
tools. Refer to fig.2. for various configurations of lathe tools.
 Practical No.3

OBJECT
Study various operations that can be performed on a conventional lathe machine

OPERATIONS THAT CAN BE PERFORMED ON LATHE

1. Turning:
Turning constitutes the majority of the lathe work. It is an operation to
produce straight curved or grooved work piece such as shafts and
spindles. The cutting forces resulting from feeding the tool right to left
should be directed towards the head stock to force the work piece against
the work holder and thus provides better work support.

2. Boring:
Boring always involves the enlarging of the existing hole, which have
been made by a drill or may be a result of a core in a casting. An equally
important and concurrent purpose of boring may be to make the hole
concentric with the axis of rotation of the work piece.

3. Facing:
It is the operation to produce a flat surface as the result of the tool being
fed across the end of the rotating work piece. In facing the length of the
work piece is reduced in contrast to turning, where the diameter is
reduced. Facing can also be used to produce grooves in a work. piece.
4. Drilling:
Drilling on lathe machine is done, with the drill mounted in the tail stock
quill of the centre lathe and fed by hand against a rotating work piece.
Drills can also be mounted on the turrets of modern bed lathes and fed
automatically along the rotational axis of the work piece. It is also
possible to drill on a lathe with the drill bit mounted and rotated in the
spindle, while the work piece remains stationary supported on the tail
stock or the carriage of the lathe.

5. Knurling:
It produces a regular shaped surface on a work piece. Although knurling
can be applied on flat surfaces, in most cases it is done on external
cylindrical surfaces using lathes. Knurling is a chip less, cold forming
process. The two hardened tools are pressed against the rotating work
piece with sufficient forces to cause a slight lateral displacement of the
metal so as to form the knurl e.g. a raised diamond pattern. Because it
involves less pressure, therefore knurling does not band the work piece.
This method is often preferred for work piece of small diameter and for
use in automatic or semi automatic machines.

6. Grinding:

The TOOL POST GRINDER permits both internal and external grinding
on a lathe. With a few simple attachments, the lathe can be utilized to
sharpen the milling cutters and reamers is addition to grinding shafts and
trueing the lathe centers.
 Practical No.4

OBJECT:
To study drill machine, tools and operations.

INTRODUCTION:
Drilling holes is one of the most basic of machining operations, and
probably is the one which produces maximum chip volume. Drilling often is not
the ultimate operation in hole production. Because the finishing is not very good,
and there may be tapering of hole diameter with depth, therefore, drilling is most
often followed by finishing operations like reaming, boring and honing. Various
other hole modification operations are also performed subsequent to drilling that
include counter-boring, counter-sinking and spot-facing.

DRILL PRESS:
The commonly used drill press are (1) Upright or Center drill press (2)
Radial Drill Press. The major parts of these machines are illustrated in the attached
figures.
In an UPRIGHT DRILLING MACHINE the major parts include:
a. Motor
b. Driving system that contains belts/pulleys or gear train for speed change.
c. Head
d. Column
e. Table
f. Base that supports the whole structure.

The RADIAL ARM DRILL PRESS is the most versatile drilling machine. Its size
is determined by the diameter of the column and length of the arm measured from
centre of spindle to the outer edge of the column. It is useful for the operation on
large and heavy parts and casings that are too heavy to be re-positioned by
’’ Table lock
the operator for drilling every hole. The radial arm drill press is used for drilling
very small to very large holes and for boring, reaming, counter-boring and counter-
sinking. It like upright drill press has a power feed mechanism and a hand feed
lever.
DRILLING TOOLS:
The drilling tool or the DRILL is an end cutting rotary type tool having one or
more cutting lips and one or more flutes for the removal of chips and passage of
coolant. TWIST DRILL is by far the most common type of drill used today.
These are made with two or more flutes and cutting lips and available in varieties
of design. The twist drill has a straight or taper shank.

Apart from twist drill there are many other types of drills that are used for specific
applications. A list of these tools is as follows:
1. High and low helix drill
2. Core drills.
3. 3 or 4 fluted drills.
4. Center drills.
5. Step drills
6. Spade drills.
The students can refer to figures 3 & 4 for drill tools.
DRILLING RELATED OPERATIONS:
1. REAMING:
Reaming is done to precision finish an already drilled hole. In the heavy
construction industry, reaming may also be used to enlarge or align existing
holes. Reaming can be done machine or hand reamers.
2. BORING:
Boring is used to enlarge and already drilled hole. Boring has an additional
advantage that is straightens the Walls of a hole and improves its cylindricity.
Boring is done on lathe
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C. 6arbidé

D: T‘firee-fluted core fifill

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E. Subland driCl

fi.Oil hole drill

G. Spade drill

Several types of drills.

and specially designed boring machines. Boring tool is a single point cutting tool.

3. COUNTER BORING:

Counter boring is enlarging an already drilled hole to a certain depth. Counter

boring is done to provide a bearing surface for nuts, bold heads and pin heads
so that they do not protrude above the surface. Counter-bores are the tools used
for this operation, and are guided by a pilot to ensure the concentricity of the
two holes.

4. COUNTER SINKING

Counter sinking is done to produce a conical enlargement at the ends of holes.

The purpose of counter sinking is (a) chamfering or deburring the end of hole to
prepare of reaming or tapping (b) modifying a hole to receive a flat head screw
or rivet.

5. SPOT FACING

Spot facing is similar to counter boring except that its main purpose is to
provide a flat bearing surface for nut or bolt heads on rough castings and a
raised boss. The depth of enlarged hole is much less than in counter boring.
 QUESTIONS:

1. In what cases drilling becomes a challenging machining operation?

2. What are the deficiencies in a drill hole, and how can we rectify those?
3. With the help of a clean figure, illustrate the nomenclature of a twist drill.
4. How can we accurately drill very small holes of large depths?
5. On a drill press, explain the function and use of quill.

ANSWERS:

Answer No.1:
Hole drilling is the most common option performed on a vertical machining center. When this operation
involves drilling deep holes it becomes challenging.

Answer No.2:
In drill hole, finishing is not very good therefore it is most often followed by foaming, boring and
broaching

Answer No.3:

Answer No.4:
Small holes cannot be accurately drill on ordinary drill press to achieve this non-traditional machining
operation is done for this electro discharge machining (EDM) or electrochemical machining operation is
adopted.

Answer No.4:
Small holes cannot be accurately drill on ordinary drill press to achieve this non-traditional machining
operation is done for this electro discharge machining (EDM) or electrochemical machining operation is
adopted.

Answer No.5:
A quill drive is a mechanism that allows drive shaft to shift its position (either axially, radially or both)
relative to its driving shaft. It uses on a drill press is to allow the check to move vertically being driven
rotationally
 Practical No.5

OBJECT:
To study a milling machine and the milling cutters.

INTRODUCTION:
Milling machine is probably the most versatile of all traditional machine
tools. It has been said that a milling machine is capable of reproducing itself. With
an extremely wide range of attachments and cutters, almost every machining
operation can be performed on a milling machine. But the main disadvantage is the
cost and skill requirement for operating a milling machine.
Milling machine is well known for gear manufacturing and production of
dies and moulds. Although the latter application has been snatched by non-
traditional machines like EDM and wire-EDM, nevertheless modern milling
machines with computer controls are an important part of today’s industry.

TYPES OF MILLING MACHINES:

Milling machines come in two main types:
1. Vertical milling machines.
2. Horizontal milling machines.
The vertical milling machine is a recent development and is closely related to drill
press. As the name suggests the spindle that accommodates the tools and cutters is
vertical. Mainly performed operations include milling (with multiple point cutters
like end-mill), drilling, boring and slotting. The student can refer to figure 1. for
parts of a vertical milling machine.
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In a horizontal milling machine the spindle lies in a horizontal axis. One type is
bed type milling machine, in which the position of milling spindle but not the
height of the table can be adjusted. Another popular version is a KNEE AND
COLUMN milling machine. The are also available as UNIVERSAL MILLING
MACHINES in which the machine table can swivel on its horizontal axis so that
the work so that the work can be presented to cutter at an angle. The swiveling
feature also helps in performing helical milling.

MILLING CUTTERS:
Although there is a huge variety of milling cutters, but here we shall discuss the
mostly use cutter i.e. END MILL

End Mill Cutter:

End mills are so named because their primary cutting action is done on their
ends. End mills may have 2, 3 or more flutes and may be right hand (counter clock
wise) or left hand cutting. The most common cutter is high speed steel end mill. It
may be single or double ended. Also available are carbide end mills that may have
a carbide tip or made from solid carbide. These are more expensive than HSS end
mills but are extremely efficient for difficult-to-machine materials and high speed
machining applications.

When large amounts of material are to be quickly removed (roughed) from the
work piece. ROUGHING END MILLS are also used. These hand mills have a
wavy tooth form cut on their periphery having many individual cutting edges.
During the cutting operation, a large number of cutting teeth are in contact with the
work, thus reducing the possibility of vibration or chatter during heavy cuts.

TAPERED END MILLS are used in mould making, die work and pattern making
where precise tapered surfaces need to be made. These have included tapers
ranging from 1 to 10 degrees. These are also called die-sinking mills.

BALL END MILLS are used to form an inside radius and fillet between adjacent
surfaces. Round bottom grooves can also be machined with them.
S l'ANlJAltD sir i.i.1Nc Cui” i rits
 Apart from these end mills are also available to machine dove tails, T-slots
and woodruff key seats. When large flat surfaces need to be machined, a shell end
mill can be used.

The students are advised to study other milling cutters that are available in
the machine shop, especially SIDE MILLING CUTTERS that are used to machine
steps or grooves. Other important cutter is the SLITTING SAW designed for
slotting and cut-off operations.
 QUESTIONS:

1. How many degrees of freedom can be controlled in a horizontal milling

machine?
2. Briefly describe at least ten machining operations performed on a
milling machine.
3. in what aspects a CNC milling machine is superior to a conventional
milling machine? Do these superior aspects justify the huge difference in
cost?
4. What are the uses and advantages of a ball end mill cutter?
5. With a clean sketch illustrate the geometry of a milling cutter. Take
any type of your choice.

ANSWERS:

Answer No.1:
Commonly in a horizontal mining machine here are three degree of freedom can be controlled namely x,
y & z axis.

Answer No.2:
1. Plain Milling
2. Face Milling
3. Profile Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. End Milling
8. Saw Milling
9. Keyway Milling
10. Gear cutting Milling
11. Flute Milling

Answer No.3:
 CNC milling machines are programmed with a design that can reproduce exactly
 They produce part in short time
 They can easily be updated
 They can make both plastic and metal parts
Answer No.4:
Ball and Mill cutter is used to mill dies, cavities and fillets. Round bottom holes and slot can be milled
with this cutter with a round force geometry, ball and mill cutter can help in machining complex parts.
 Practical No. 6

OBJECT:
To study SHAPERS and PLANNERS.

INTRODUCTION:
Shapers and Planners are the machine tools where the relative motion
between tool and the work piece is a reciprocating one; neither tool not the work
piece rotates. The difference is that in shapers tool reciprocates while in planer
work piece along with the table undergoes reciprocating motion. Also planers are
much larger in size as compared to a shapers, In shapers, the work piece is
stationary during the cutting but it takes a sideward feed that is accomplished
automatically. This is done to ensure that the cutting tool covers the full surface or
work piece. In the same way the tool takes the cross feed in case of planers.

Shapers and Planers are mainly used for machining flat surfaces. The
typical applications include machining of slots, keyways, dovetails, splines and
other shapes. A specialized type shaper called GEAR SHAPER is used to cut gear
teeth in the blanks.
Shapers and planers require many strokes of tools or work piece to complete
a cutting operation; and large time during a cutting cycle is wasted during return
stoke. That’s why operation time is large and cutting process is slow with these
machines. Because milling machines can remove material at a much rapid rate,
therefore, in production work horizontal and vertical milling machines have
completely replaced shapers and planers. However, for a small shops and tool
rooms these machines are still in use.
Fig. 93
PARTS OF A SHAPER

Horizontal shapers are inexpensive to maintain, and they also use inexpensive
single point cutting tools like that of lathe. The size of shaper is designated by the
maximum length of 12” or 18”. Main parts of a shaper are:

1. Driving mechanism
2. Speed change mechanisms.
3. Work table.
4. Tool Head assembly

a. Tool slide
b. Swivel base
c. Apron
d. Clapper box
e. Clapper block
f. Tool Post

5. Table feed mechanism (Cam or Ratchet type).

 JOB ASSIGNMENT

OBJECT:
To manufacture a “SHORT ARBOR” as per drawing.
APPARATUS & EQUIPMENT:
Vernier Caliper, Steel rule, Outside caliper, Lathe machine, Drill press, Milling
Machine.

TOOLS USED:
Single point cutting tool, twist drill, threading tool, milling cutter, Diamond
knurling tool.

In this job assignment, students are required to perform the following tasks under the
supervision of laboratory instructor:

1. Prepare PROCESS PLANNING CHART that indicates the operation to be performed in

sequence, estimated time for each operation and machine tool used.
2. Perform the machining tasks that would involve the following processes:
a. Facing
b. Turning
c. Taper turning
d. Chamfering
e. Knurling
f. Threading
g. Drilling
h. Reaming
i. Tapping
j. Buffing/Polishing
3. After completing the part, inspect the dimensional values and check for tolerances.
4. Compare the actual working with their process plan that was initially prepared as a
tentative guideline.
 “HEXAGON Threods
16 tpi
Chomfer 2 x 4h” — 2 places

10 20

SESSION JOB ASSIGNk!ENT T.E. (MECHANICAL )