4me4 23 Production Practice Lab

JAIPUR ENGINEERING COLLEGE AND RESEARCH CENTRE
JECRC Campus, Shri Ram Ki Nangal, Via-Vatika, Jaipur
LAB MANUAL
LabName : Production Practice Lab
LabCode : 4ME4-23
Branch : Mechanical Engineering
Year : 2rd Year
Jaipur Engineering College and Research Center, Jaipur
Department of Mechanical Engineering
(Rajasthan Technical University,KOTA)

INDEX
S.NO CONTENTS PAGE

NO.
1 VISION/MISION III
2. PROGRAM EDUCATIONAL OBJECTIVES (PEOs) IV
3. PROGRAM OUTCOMES (POs) V
4. COURSE OUTCOMES (COs) VI
5. VII
MAPPING OF COs with Pos
6. SYLLABUS VIII
7. BOOKS X
8. INSTRUCTIONAL METHODS XI
9. LEARNING MATERIALS XII
10. ASSESSMENT OF OUTCOMES XIII
List of Experiments (RTU Syllabus)
Turning Shop
Exp:- 1 To study lathe machine construction and various parts including

attachments, lathe tools cutting speed, feed and depth of cut.
Exp:- 2 To perform step turning, knurling and chamfering on lathe machine
as per drawing.
Exp:-3 To cut multi-start Square/Metric threads on lathe machine.
Exp:-4 Boring using a boring bar in a centre lathe and cut BSW/Metric
internal threads on lathe machine.
i
Exp:-5 To perform taper turning using compound rest.
Machine shop
Exp:-1 To study the milling machine, milling cutters, indexing heads and
indexing methods and to prepare a gear on milling machine.
Exp:-2 To machine a hexagonal /octagonal nut using indexing head on

milling machine.
Exp:-3 To study of single point cutting tool geometry and to grind the tool
as per given tool geometry.
Exp:-4 To study shaper machine, its mechanism and calculate quick return
ratio. To prepare a job on shaper from given mild steel rod.
Exp:-5 Cylindrical grinding using grinding attachment in a centre lathe

Demonstration and study
Exp:-1 Demonstration for job by eccentric turning on lathe machine.
Exp:-2 Study of capstan lathe and its tooling and prepare a tool layout &
job as per given drawing.
Exp:-3 Demonstration on milling machine for generation of plane surfaces

and use of end milling cutters.
Exp:-4 Grinding of milling cutters and drills.
Foundry Shop
Exp:-1 To prepare mould of a given pattern requiring core and to cast it in

aluminum.
ii
Exp:-2 To perform moisture test and clay content test.
Exp:-3 To perform permeability test
Exp:-4 A.F.S. Sieve analysis test.
Exp:-5 Strength Test (compressive, Tensile, Shear Transverse etc. in green

and dry conditions) and Hardness Test (Mould and Core).
Welding Shop
Exp:-1 Hands-on practice on spot welding.
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Jaipur Engineering College & Research Centre Production Practice Lab
1. VISION & MISSION
VISION:
➢ The Mechanical Engineering Department strives to be recognized globally for excellent technical
knowledge and to produce quality human resource of high standard, who can manage the advance
technologies and contribute to society through innovation, entrepreneurship and leadership.
MISSION:
➢ To imparting highest quality technical knowledge to the learners to make them globally competitive
mechanical engineers.
➢ To provide the learners ethical guidelines along with excellent academic environment for a long
productive career.
➢ To promote industry-institute linkage.
iv
2. PROGRAM EDUCATIONAL OBJECTIVES (PEOS)

PEO1. To provide students with the fundamentals of Engineering Sciences with more
emphasis in Mechanical Engineering by way of analyzing and exploiting engineering
challenges.
PEO2. To train students with good scientific and engineering knowledge so as to
comprehend, analyze, design, and create novel products and solutions for the real life
problems in Mechanical Engineering.
PEO3. To inculcate professional and ethical attitude, effective communication skills,
teamwork skills, multidisciplinary approach, entrepreneurial thinking and an ability to relate
Mechanical Engineering issues with social issues.
PEO4. To provide students with an academic environment aware of excellence, leadership,
written ethical codes and guidelines, and the self-motivated life-long learning needed for a
successful professional career in Mechanical Engineering.
PEO5. To prepare students to excel in Industry and Higher education by Educating Students
along with High moral values and Knowledge in Mechanical Engineering.
v
3. PROGRAM OUTCOMES
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems in Mechanical Engineering.
2. Problem analysis: Identify, formulate, research literature, and analyze complex Mechanical
Engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex Mechanical Engineering
problems and design system components or processes that meet the specified needs with
appropriate consideration for the public health and safety, and the cultural, societal, and
environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of
the information to provide valid conclusions in Mechanical Engineering.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modeling to complex Mechanical Engineering
activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to
the professional Mechanical Engineering practice.
7. Environment and sustainability: Understand the impact of the professional Mechanical
Engineering solutions in societal and environmental contexts, and demonstrate the knowledge
of, and need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the Mechanical Engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader
in diverse teams, and in multidisciplinary settings in Mechanical Engineering.
10.Communication: Communicate effectively on complex Mechanical Engineering activities
with the engineering community and with society at large, such as, being able to comprehend
and write effective reports and design documentation, make effective presentations, and give
and receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the
Mechanical Engineering and management principles and apply these to one’s own work, as a
member and leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage
in independent and life-long learning in the broadest context of technological change in
Mechanical Engineering.
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4. COURSE OUTCOMES
4ME4-23 Production Practice Lab II
Class: IVSem.B.Tech. Branch:Mechanical Engineering Schedule per Week

PracticalHrs.:3 Examination Time = Three (3) Hours Maximum Marks =
75[Sessional (45) & End-term(30)]
On successful completion of this course the students will be able to:
Co 1: Students will able to recognized about various machining processes and

effect of machining parameters on quality of work piece.
Co2: Students will able to understand instruction efficiently given by industry

personnel by developing a manufacturing-centric knowledge.
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I
II
COURSE
OUTCOME
Engineering
3
3
1
Knowledge
2
0
2
Problem analysis
Design/Development
2
1
3
of Solution
Conduct Investigation
1
0
4
of complex Problems
0
0
5
viii
Modern Tool Usage
The engineer and
1
1
6
society
Environment and
1
1
7
Sustainability
5. MAPPING OF CO &PO
0
0
8 Ethics
Individual and Team
2
2
9
PO PO PO PO PO PO PO PO PO
Work
0
0
10
PO
Communication
Project Management
1
1
11
PO
and Finance
2
2
12
PO
Life-long Learning
6. SYLLABUS
4ME4-23: PRODUCTION
PRACTICE LAB
Credit: 1.5 Max. Marks: 75

(IA:45, ETE:30)
Turning Shop
1 To study lathe machine construction and various parts including attachments,
lathe tools cutting speed, feed and depth of cut.
2 To perform step turning, knurling and chamfering on lathe machine as per
drawing.
3 To cut multi-start Square/Metric threads on lathe machine.
4 Boring using a boring bar in a centre lathe and cut BSW/Metric internal
threads on lathe machine.
5 To perform taper turning using compound rest.
Machine shop
1 To study the milling machine, milling cutters, indexing heads and indexing
methods and to prepare a gear on milling machine.
2 To machine a hexagonal /octagonal nut using indexing head on milling
machine.
3 To study of single point cutting tool geometry and to grind the tool as per
given tool geometry.
4 To study shaper machine, its mechanism and calculate quick return ratio. To
prepare a job on shaper from given mild steel rod.
5 Cylindrical grinding using grinding attachments in a centre lathe
1 Demonstration for job by eccentric turning on lathe machine.
2 Study of capstan lathe and its tooling and prepare a tool layout & job as per
given drawing.
3 Demonstration on milling machine for generation of plane surfaces and use of
end milling cutters.
4 Grinding of milling cutters and drills.
Foundry Shop
1 To prepare mould of a given pattern requiring core and to cast it in aluminium.
2 To perform moisture test and clay content test.
3 To perform permeability test
4 A.F.S. Sieve analysis test.
5 Strength Test (compressive, Tensile, Shear Transverse etc. in green and dry
conditions) and Hardness Test (Mould and Core).
Welding Shop
1 Hands-on practice on spot welding.
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7. BOOKS
7.1 Text books:-

Manufacturing Process by R. K. Rajput
Reference Books:-
1.) Production Technology by P. C. Sharma , S. Chand Publication

2.) Production Technology by O.P. Kahnna ,DhanpatRai Publication
8. INSTRUCTIONAL METHODS
8.1. Direct Instructions:

I. Black board presentation.
II. Power point presentation.
8.2. Interactive Instruction:

I. Practical on respective equipment.
II. Practical Examples.
8.3. Indirect Instructions:

I. Problem solving
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9. LEARNING MATERIALS
9.1. Lab Manual
9.2. Reference Books
10. ASSESSMENT OF OUTCOMES

10.1 End term Practical exam (Conducted by RTU, KOTA)
10.2 Quiz
10.3 Daily Lab interaction.
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11. INSTRUCTIONS SHEET

We need your full support and cooperation for smooth functioning of the lab.
DO’s
1. Please switch off the Mobile/Cell phone before entering lab.
2. Enter the lab with complete source code and data.
3. Intimate the lab incharge whenever you are incompatible in using the system or
in case machine get infected.
4. Arrange all the peripheral and seats before leaving the lab.
5. Properly shutdown the experimental set up before leaving the lab.
6. Keep the bag outside in the racks.
7. Enter the lab on time and leave at proper time.
8. Maintain the decorum of the lab.
9. Utilize lab hours in the corresponding experiment..
DON’TS
1. Don’t mishandle the system.
2. Don’t leave the system on standing for long
3. Don’t bring any external material in the lab.
4. Don’t make noise in the lab.
5. Don’t bring the mobile in the lab. If extremely necessary then keep ringers off.
6. Don’t enter in the lab without permission of lab Incharge.
7. Don’t litter in the lab.
8. Don’t delete or make any modification in system files.
9. Don’t carry any lab equipments outside the lab.
BEFORE ENTERING IN THE LAB
1. All the students are supposed to prepare the theory regarding the next experiment
2. Students are supposed to bring the practical file and the lab copy.
3. Previous practical should be written in the practical file.
4. Any student not following these instructions will be denied entry in the lab.
WHILE WORKING IN THE LAB
1. Adhere to experimental schedule as instructed by the lab incharge.
2. Get the previously executed program signed by the instructor.
3. Get the output of the current program checked by the instructor in the lab copy.
4. Each student should work on his/her assigned computer at each turn of the lab.
5. Take responsibility of valuable accessories.
6. Concentrate on the assigned practical and do not play games.
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7. If anyone caught red handed carrying any equipment of the lab, then he will have to
face serious consequences.
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EXPERIMENT No.-1
Object: - Study of Lathe Machine, Lathe tolls and cutting speed and depth of cut.
Introduction:-
Machining is the process of converting the given work piece into the required shape and size with
the help of machine tool. The most widely used machine tools is lathe. in simple words machining
is the process of removing certain material from the work piece.
Lathe :-Lathe is the machine tool which is used to perform several operation so the work piece.
Lathe is useful in making several parts which is further assembled to make new machine. Hence
lathe is known as “mother of machines”.
Fig.: Center Lathe
Basic working principle of lathe machine

The lathe is a machine tool which holds the w/p b/w two rigid & strong supports called centres or
in a chuck or in face plate which revolves. The cutting tool is held and fed against the revolving
work.cutting tool fed either parallel or at right angles to the axis of w/p. Or may also at an angle
14
Types of Lathe Machine
Classification of Lathe Machine
1. Speed Lathe
(i) Wood working (ii) polishing (iii) Centering (iv) spinning
2. Engine or Centre Lathe
(i) Light Work (a) Bench Lathe
(ii) Medium and heavy duty Lathe
(a) Belt Drive (b) Individual motor drive
3. Production type lathe
(i) semi automatic (a) Capstan (b) Turret
(ii) special purpose (a) Duplicating (b) Gap bed (c) Wheel
(d) screw cutting (e) Axle
(iii) Automatic
Parts of Lathe Machine
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1. Bed :- It is the foundation of lathe .On the top of bed there are two sets of guide ways –
outer ways is for the carriage and inner ways for the tailstock .The bed is made of CI
to absorb the shocks and vibration , during machining
2. Head stock :-The headstock spindle , a hollow cylindrical shaft supported by bearings ,
provides a drive from the motor to the work holding device. A live centre and sleeve , a
face plate , or a chuck can be fitted to the spindle nose to hold and drive the work
.
3.Carriage
The carriage controls and supports the cutting tool . By the help of this tool moves away or
towards the headstock . It has five parts.
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(i) Saddle : - On the top it supports the cross slide . It is H shaped casting mounted on the
top of the lathe ways so it slides the way between the headstock and tailstock.
(ii) Cross slide :- It is mounted on the saddle. The cross slide dovetail provides the cross
movement (towards or away the operator) to the cutting tool. It supports the compound rest.
(iii) Compound rest: It is mounted on the top of the cross slide and is used to support the
cutting tool . It can be swiveled to any angle for taper turning operations
(iv) Tool post:- It is mounted above the compound rest. A T – slot is machined in the
compound rest to accommodated the tool post . It clamps the cutting tool or
cutting tool holder in a desired position.
(v) Apron:- It is fastened to the saddle and contains the feeding mechanism . The automatic
feed lever is used toe engage power feeds to the carriage and the cross slide.
4. Feed Rod and Lead Screw : Feed rod is powered by a set of gears from the headstock
5. Tailstock : It is located at the right end of the lathe bed and it cn be positioned anywhere in
the bed. It is used for supporting lengthy jobs and also carries tool to carry out operationssuch as
tapping, drilling, reaming.
6. Lead Screw: - It is a long with ACME threads . it is used for transmitting power
for automatic feed or feed for thread cutting operations
17
WORK HOLDING DEVICES

1. Lathe centers :- They are used to support work. It has two categories of centers. Live center is
one which is fitted in the headstock spindle. Dead is another one which is
fitted in the tail stock.
2.Chuck:- It is a device used to hold a job. It is easily fitted on the thread cut on the end of
headstock spindle. Various types of chuck are
(a) Two jaw chuck b) three jaw chuck c) four jaw chuck d) collet chuck e) Magnetic chuck
3. Centres: These are used to support work . type of centers are gven follow.
Live centre
Dead
centre
Tipped
centre
Ball
centre
Knurling: - It is process of making serration on the workpiece with the help of knurling tool.
Workpiece is rotated at lower speed amount of feed is given .
CUTTING SPEED
It is the peripheral speed of the workpiece to the cutting tool
It is speed at which metal is remove by the tool from the workpiece.
It is expressed in meter/min.
Cutting speed V=ΠDN/1000

18
Where D= diameter of w/p in mm

N= r.p.m.
Feed:-
It is defined as the rate of tool travel across a surface cutting it .
It is the distance of the tool advances for each revolution of the work piece.
It is expressed in mm/rev.
DEPTH OF CUT
It is the perpendicular distance measured from the machined surface to the uncut surface of work .
It is expressed in mm.
Depth of cut t= (D-d)/2,
Where:
D=diameter of w/p before machining
d=diameter of w/p after machining
SPECIFICATION OF LATHE
The size of a lathe is specified by the following points
1. The length of the bed
2. Maximum distance between live and dead centres.
3. The height of centres from the bed

4. The swing diameter the swing diameter over bed - It refers to the largest diameter of the work
that will be rotated without touching the bed the swing diameter over carriage - It is the largest
diameter of the work that will revolve over the saddle.
5. The bore diameter of the spindle
6. The width of the bed
7. The type of the bed
8. Pitch value of the lead screw
9. Horse power of the motor
10. Number and range of spindle speeds
11. Number of feeds
12. Spindle nose diameter
13. Floor space required

19
Safety Precautions
1. Job should be tightly held in the chuck.
2. If the job is held in between the centers, then apply grease on the nose of Dead
center, otherwise it will burnt out due to excess heat
3. Do not measure the job while it is rotating.
4. Do not leave the chuck key in the chuck.
5. Do not try to stop the lathe chuck or job with hands
6. Do not handle metal chips by hand.
7. Do not give more depth of cut while the job is rotating at high speed.
8. Tighten the tool I n the tool post.
9. Do not stand close to the rotating job or bring your face to it
10. Do not reduce or increase the speed during the lathe operations
Result :- Study the about the lathe machine parts and operations.
VIVA VOCE
1. What is a lathe?
2. What are the various operations can be performed on a lathe?
3. State the various parts mounted on the carriage?
4. What are principle parts of the lathe?
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Experiment No. -02
AIM: - To perform step turning, knurling and chamfering on lathe machine as per drawing.
Material Required: - Mild Steel polished round rod Φ 25X65 mm
Tool Required:-
1. Lathe Machine
2. Cutting Tool
3. Outside Rule
4. Steel Rule
5. Vernier Caliper
6. HSS single point cutting tool
Given Work piece Drawing:
Procedure:-
1. First loosen the jaw in the chuck key to position the work piece, and then
tighten the jaws.
2. Fix the cutting tool in the tool post.
3. Switch on the lathe and move the carriage near to the work piece. Give it a small
cross feed, and then move carriage longitudinally to the required length slowly.
4. Bring the carriage to the original position, give a small cross feed and move
carriage longitudinally. Repeat this step until required diameter is obtained.
5. To get smooth surface give a very small feed when the diameter is nearing the
required value.
6. To face the end surface of the work piece, move the carriage to make the tool touch
the end surface of the work piece.
7. Give a small feed in longitudinal direction, and then move the tool towards the axis of
the work piece using the cross slide to complete the work piece.
21
8. The turning operation is done with cutting tool to reduce the diameter up to the
required dimension for the two steps of various diameters.
9. The work piece is removed from the chuck and the dimensions of work piece are
checked for the requirements.
Result:-
The work piece is prepared as per the given drawing and facing, turning, chamfering and
knurling operations are done on the given work piece.
VIVA VOCE
1. What is the purpose of knurling?
2. Define taper turning.
3. What are the benefits of chamfering?
22
EXPERIMENT No. 3
Object: - To cut multi-start Square/Metric threads on lathe machine.

Basic Concept:-Thread Helical ridge of uniform section formed on inside or outside
of cylinder or cone
Screw thread:-Helical ridge of uniform section formed on inside or outside of cylinder
or cone
External thread:-Cut on external surface or cone
Internal thread:-Produced on inside of cylinder or cone
Thread Terminology
Pitch diameter: - Diameter of imaginary cylinder that passes through thread at point
where groove and thread widths are equal.
Lead:-The distance a screw thread advances in one revolution.
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Root:-Bottom surface joining sides of two adjacent threads.

Flank:-Thread surface that connects crest with root.
Depth of thread:-Distance between crest and root measured perpendicular to axis.
Angle of thread:-Included angle between sides of thread measured in axial plane.
Helix angle:-Angle that thread makes with plane perpendicular to thread axis.
ISO Metric Thread:-Metric threads can be identified by the letter M preceding the
major thread diameter, and the pitch.
Fig:- cutting tool multi-start square
Multi-start threads have a greater lead than single-start threads of equal pitch length,
but are there any other differences in function? Is there any difference in strength
between a single-start The advantage of multi-start threads is simply a faster lead in a
shallower form depth. This could certainly improve the stiffness, and consequently
critical speed of a lead screw used for motion control. Luer components, I imagine,
use the thread form because of its shallow radial depth requirements and quick
connect/disconnect abilities.
Equipments and Tools required:-
1. Marking tool i.ecentretool
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2. Cuttingtool
a. Longitudinal turningtool
b. Groovingtool
c. Square thread tool 3.175mmwide.
3. Measuringtool
a. Steelrule
b. Vernier caliper
4. Work piece:- mild steel of 25 dia and 125mmlong
Apparatus: - Right hand tool holder with bit, turning tool, parting tool, outside spring
caliper , vernier caliper , threads caliper and steel scale etc.
Procedure:-
1. Check that the machine is clean and oiled properly before starting it.
2. Hold the job in three-jaw chuck (self –centre chuck).
3. Centering the tool.
4. Facing the on side of rod.
5. Chamfer the side of job.
6. Make the cut external metric threads on lathe m/c.
7. meet it with the nut.
Outcome:-
Hence, we prepared the multi start square thread as per drawing over the length of
41mm on mild steel rod.
Viva Voce
1. Why the knurling operations are necessary for the given models in m/c shop
2. How the change gears calculations can be done during thread cutting operation for British
and Metric pitches?
3. What are the differences between 3-jaw chuck and 4-jaw chuck?
25
EXPERIMENT No. - 05
Aim :- To perform taper turning by

(b) Compound rest method as per drawing
Materials required:
Mild steel polished round rod diameter …… mm
Tools
required:
1. Lathe machine 2. Cutting tool 3. Outside Caliper

4.Steel Rule 5.Vernier Caliper 6.Spanner
Theory:
The compound rest is swiveled to the angle calculated as above and clamped. Feed
is given to the compound slide to generate the required taper
Calculation:
The taper angle is calculated using the following formula:
Taper angle
Where:
D = large diameter of taper in mm
d = small diameter of taper in mm
l = length of tapered part in mm
= angle of taper
Procedure:
1. The given work piece is held firmly in a lathe chuck.
2. The cutting tool is set in a tool post such that the point of the Cutting tool coincides with
the lathe axis.
3. The machine is switched on to revolve the work piece at the selected speed.
4. By giving Cross feed and longitudinal feed to the cutting tool, the facing and
turning operations are done respectively.
5. The compound rest is swiveled for the calculated taper angle.
6. By giving angular feed to the cutting tool through the compound slide the taper
turning operation is done.
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7. The machine is switched off.

8. The work piece is removed from the chuck and all the dimensions are measured and checked.
Result: - The given work piece is prepared as per given drawing and taper turning is done by
the compound rest method
Safety Precautions
2. If the job is held in between the centers, then apply grease on the nose of dead
center, otherwise it will burnt out due to excess heat
9. Do not stand close to the rotating job or bring your face to it
10. Do not reduce or increase the speed during the lathe operations
VIVA VOCE
1. What are the tools required in taper turning.
2. How compound rest method is different from other methods.
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EXPERIMENT No. 1
AIM:- To study the milling machine, milling cutters, indexing heads and indexing
methods and to cut teeth of spur gears on milling machine.
Milling machine Theory:-
Introduction:- The milling machine removes metal with a revolving cutting tool
called a milling cutter. With various attachments, milling machines can be used for
boring, slotting, circular milling dividing, and drilling. This machine can also be
used for cutting keyways, racks and gears and for fluting taps and reamers.
Types:-Milling machines are basically classified as being horizontal or vertical to

indicate the axis of the milling machine spindle.
Fig 1 - Colomn and knee type horizontal milling machine

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Knee-type Milling Machines:-Knee-type milling machines are characterized by a

vertical adjustable worktable resting on a saddle supported by a knee. The knee is a
massive casting that rides vertically on the milling machine column and can be
clamped rigidly to the column in a position where the milling head and the milling
machine spindle are properly adjusted vertically for operation.
(a) Universal Horizontal Milling Machine.
1 The universal horizontal milling machine has a worktable that can swivel on the
saddle with respect to the axis of the milling machine spindle, permitting work
pieces to be adjusted in relation to the milling cutter.
2 The universal horizontal milling machine also differs from the plain horizontal
milling machine in that it is of the ram type; i.e., the milling machine spindle is in a
swivel cutter head mounted on a ram at the top of the column.
Major Components:-
(1) Column.
(2) Knee.
(3) Saddle and Swivel Table.
(4) Power Feed Mechanism.
(5) Table.
(6) Spindle.
(7) Over arm.
(8) Arbor Support.
Milling cutters:-
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Types of Milling Cutters:-
Plain Milling Cutter:-It is a metal cylinder having teeth cut on its periphery for
producing a flat horizontal surface.
Metal Slitting Saw Milling Cutter:-The metal slitting saw milling cutter is a very
thin, plain milling cutter. It is used for metal sawing and for cutting narrow slots in
metal.
30
Side Milling Cutters:-Side milling cutters are plain milling cutters with the
addition of teeth on one or both sides. When teeth are added to one side only, the
cutter is called a half-side milling cutter and is identified as being either a right-
hand or left-hand cutter. Side milling cutters are generally used for slotting and
straddle milling.
End Milling Cutters:-End milling cutters have teeth on the end as well as the
periphery. End milling cutters are employed in the production of slots, keyways,
recesses, and tangs. They are also used for milling angles, shoulders, and the edges
of work pieces.
31
Face Milling Cutter:-Face milling cutters are cutters of large diameter having no
shanks. They are fastened directly to the milling machine spindle with adapters.
Face milling machine cutters are generally made with inserted teeth of high-speed
steel or tungsten carbide in a soft steel hub.
T-Slot Milling Cutter:-The T-slot milling cutter is used to machine T-slot grooves
in worktables, fixtures, and other holding devices. The cutter has a plain or side
milling cutter mounted to the end of a narrow shank.
Angle Milling Cutters:-The angle milling cutter has peripheral teeth which are
neither parallel nor perpendicular to the cutter axis. The angle of the right or left
cutter edge is usually 30, 45, or 60. Double-angle cutters have included the angles
of 45, 60, and 90.
32
Concave and Convex Milling Cutters:-Concave and convex milling cutters are
formed tooth cutters shaped to produce concave and convex contours of one-half
circle or less.
Corner-rounding Milling Cutter:-The corner-rounding milling cutter is a formed

tooth cutter used for milling rounded corners on work pieces up to and including
one-quarter of a circle.
Gear Hob:-The gear hob is a formed-tooth milling cutter with helical teeth
arranged like the thread on a screw. These teeth are fluted to produce the required
33
cutting edges. Hobs are generally used for such work as finishing spur gears, spiral
gears, and worm wheels.
Indexing Fixture:-
The index fixture consists of an index head, also called a dividing head, and a
footstock, similar to the tailstock of a lathe. An index plate containing graduations
is used to control the rotation of the index head spindle.
The plate is fixed to the index head, and an index crank, connected to the index
head spindle by a worm gear and shaft, is moved about the index plate.
The sector indicates the next hole in which the pin is to be inserted and makes it
unnecessary to count the holes when moving the index crank after each cut.
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Index Head:-The bead of the indexing fixture contains an indexing mechanism,

used to control the rotation of the index head spindle in order to space or divide a
work piece accurately. A simple indexing mechanism consists of a 40-tooth worm
wheel fastened to the index head spindle, a single-cut worm, a crank for turning the
worm shaft, and an index plate and sector. Since there are 40 teeth in the worm
wheel, one turn of the index crank causes the worm wheel, and consequently the
index head spindle to, make one-fortieth of a turn; so 40 turns of the index crank
revolves the spindle one full turn.
Indexing methods:-
Fig - simple indexing
Direct Indexing:-The construction of some index heads permits the worm to be

disengaged from the worm wheel, making possible a quicker method of indexing,
called direct indexing. Direct indexing is accomplished by an additional index plate
fastened to the index head spindle.
Direct index plates usually have 24 holes and offer a quick means of milling
squares, hexagons, taps, etc. Any number of divisions which is a factor of 24 can be
35
indexed quickly and conveniently by the direct indexing method.
Differential Indexing:-Sometimes a number of divisions are required which

cannot be obtained by simple indexing with the index plates regularly supplied. To
obtain these divisions aAngular Indexing. one turn of the index crank will revolve
the circumference of the work 1differential index head is used. The index crank is
connected to the worm shaft by a train of gears instead of by a direct coupling and
with simple indexing.
/40 of 360°, or 9°. To determine the number of turns, and parts of a turn of the
index crank for a desired number of degrees, divide the number of degrees by 9.
The quotient will represent the number of complete turns and fractions of a turn to
rotate the index crank.
Apparatus:-Milling machine and milling setup.
Outcome:- Study of milling machine, milling cutters, indexing heads and indexing
methods is done.
Viva Voce
1. What are the different types of lathes?

2.What are the functions of lead screw and feed rod?
3. What are the different methods of taper turning?
36
EXPERIMENT No. 2
AIM:-To machine a hexagonal / octagonal nut using indexing head on milling machine.
Theory:-
Basic Concept:-
Indexing:-Indexing is the process of evenly dividing the circumference of a circular
work piece into equally spaced divisions, such as in cutting gear teeth, cutting splines,
milling grooves in reamers and taps, and spacing holes on a circle. The index head of the
indexing fixture is used for this purpose.
Index Head:-The index head of the indexing fixture contains an indexing mechanism
which is used to control the rotation of the index head spindle to space or divide a work
piece accurately. A simple indexing mechanism consists of a 40-tooth worm wheel
fastened to the index head spindle, a single-cut worm, a crank for turning the worm shaft,
and an index plate and sector. Since there are 40 teeth in the worm wheel, one turn of the
index crank causes the worm, and consequently, the index head spindle to make 1/40 of a
turn; so 40 turns of the index crank revolve the spindle one full turn.
Screw thread:-Helical ridge of uniform section formed on inside or outside of cylinder

or cone
External thread:-Cut on external surface or cone
Internal thread:-Produced on inside of cylinder or cone
Thread Terminology:-
37
Pitch diameter :- Diameter of imaginary cylinder that passes through thread at point
where groove and thread widths are equal.
Lead:-The distance a screw thread advances in one revolution.
38
Root:-Bottom surface joining sides of two adjacent threads.

Flank:-Thread surface that connects crest with root.
Depth of thread:- Distance between crest and root measured perpendicular to axis.
Angle of thread:- Included angle between sides of thread measured in axial plane.
Helix angle:- Angle that thread makes with plane perpendicular to thread axis.
ISO Metric Thread :-Metric threads can be identified by the letter M preceding the
major thread diameter, and the pitch.
British Standard Whitworth (BSW) Thread:-
39
Internal Threads:-Cutting threads in a hole.

Operation performed on work held in chuck or collet or mounted on faceplate.
Threading tool similar to boring tool bit except shape ground to form of thread to be cut.
Apparatus:-Right hand tool holder with bit, turning tool, parting tool, out side spring
caliper , vernier caliper , threads caliper and steel scale etc.
Procedure:-
1. Check that the machine is clean and oiled properly before starting it.
2. Hold the job in three-jaw chuck (self –centre chuck).
3. Centering the tool.
4. Facing the on side of rod.
5. Prepare a hexagonal on milling m/c.
6. Chamfer the side of job.
7. Make the internal threads on lathe.
8. Meet it with the nut.
Outcome:- Prepared a hexagonal nut on milling machine.
Viva Voce
1. What is meant by eccentric turning?

2. What is the difference between L.H. thread cutting R.H. thread cutting?
3. Why the knurling operations are necessary for the given models in m/c shop?
40
EXPERIMENT No. 3
AIM:- To study of single point cutting tool geometry and to grind the tool as per given tool
geometry.
Tool required:- Grinder.

Material required:- Mild steel work piece, permanent marker
Theory: - Single point cutting tool has an effective cutting edge and remove excess material from
the work piece along the cutting edge.
The metal cutting tool separates chips from the workpiece in order to cut the part to the
desired shape and size. There is a large variety of metal cutting tools available, each of
which is designed to perform a particular job or a group of metal cutting operations in an
efficient manner. The shape and the position of the tool, relative to the workpiece, have an
important effect on metal cutting. The most important geometric elements, relative to chip
formation, are the location of the cutting edge and the orientation of the tool face with
respect to the workpiece and the direction of the cut. Other shape considerations are
concerned primarily with relief or clearance, that is, taper applied to tool surfaces to prevent
41
rubbing or dragging against the workpiece.
Figure. (a) Three views of a typical HSS (High Speed Steel tool) showing the various angles and
their values with abbreviations. (b) Designations and symbols for the right-hand cutting tool with
the tool signature
The terminology used to designate the surfaces, angles and radii of single-point tools is
shown below. The tool shown in Figure (a) and (b) is a single-point cutting tool, but the
same definitions apply to indexable tools as well.
It is of the following types:-

1. Solid tool
2. Brazedtool
3. Inserted bittool
Schematic table for various angles:-
42
S. No. Angle name Description
1. Back rake angle It is the angle between the face of the tool and a line that
is parallel to the side cutting edge and perpendicular to
thebase.
2. Side rake angle It is defined as the angle between the tool face and plane
parallel to the toolbase
3. End relief angle It is the angle between the end flank and line
perpendicular to the base of the tool.
4. Side relief angle It is an angle between the side flank of the tool and a
line drawn perpendicular to the base.
5. End cutting edge It is an angle between straight cutting edge on the side of
angle the tool and the side of tool shank.
6. Side cutting edge It is an angle between straight cutting edge on a side of
angle the tool and the side of tool shank.
7. Nose radius The nose radius connects the side end and cutting edges
and should blend smoothly into each side to facilitate
grinding
Basic tool angle in single point cutting tool: -
1. Back rake angle
2. Side rakeangle
3. End reliefangle
4. Side reliefangle
5. End cutting edgeangle
6. Side cutting edgeangle
7. Nose radius
43
Procedure:-
1. Job is fixed in hand for proper alignment.

2. Start the grinding machine and grind the job as per given specification.
3. A rough cut is used to grind the outer periphery.
4. Final grinding operation is completed in sequence.
5. The compound slide is set at the angle as per calculation and grinding operation is completed
Precautions:-
• Work piece should be firmly gripped in the hand.
• Coolant is to be used.
• Hand gloves and apron must be used while working.
• Proper rpm should be selected before the operation
44
Outcome: - The study of single point cutting tool is done.
Viva-voce
1. What is machine?
2. What is machine tool?
3. Define the term turning?
45
EXPERIMENT NO: - 04
Aim :- To study shaper machine, its mechanism and calculate quick return ratio. To prepare a
job on shaper from given mild steel rod.
Materials required:
Mild steel polished rectangular bar …… mm
Tools
required:
1. Shaper machine 2. Cutting tool 3. HSS Tool

Working principle of Shaper Machine:-
The shaper also called shaping machine, is a reciprocating type of machine tool in which the ram
moves the cutting tool backward and forward in a straight line to generate the flat surface. The flat
surface may be horizontal, inclined or vertical.
Theory:-
In a shaper, a single point cutting tool reciprocates over the stationary work piece. The work piece
is rigidly held in a vice or clamped directly on the table. The tool is held in the tool head mounted
on the ram of the machine. When the ram moves forward, cutting of material takes place. So, it is
called cutting stroke. When the ram moves backward, no cutting of material takes place so called
idle stroke. The time taken during the return stroke is less as compared to forward stroke and this is
obtained by quick return mechanism. The depth of cut is adjusted by moving the tool downward
towards the work piece
Principal Parts of Shaper Machine
46
Parts of lathe Machine:-

Base
It is rigid and heavy cast iron body to resist vibration and takes up high compressive load. It
supports all other parts of the machine, which are mounted over it. The base may be rigidly
bolted to the floor of the shop or on the bench according to the size of the machine.
Column
The column is a box shaped casting mounted upon the base. It houses the ram-driving
mechanism. Two accurately machined guide ways are provided on the top of the column on
which the ram reciprocates.
Cross rail
Cross rail of shaper has two parallel guide ways on its top in the vertical plane that is perpendicular
to the rai1 axis. It is mounted on the front vertical guide ways of the column. It consists mechanism
for raising and lowering the table to accommodate different sizes of jobs by rotating an elevating
screw which causes the cross rail to slide up and down on the vertical face of the column. A
horizontal cross feed screw is fitted within the cross rail and parallel to the top guide ways of the
cross rail. This screw actuates the table to move in a crosswise direction
Saddle
The saddle is located on the cross rail and holds the table on its top. Crosswise movement of
the saddle by rotation the cross feed screw by hand or power causes the table to move
sideways.
Table
The table is a box like casting having T -slots both on the top and sides for clamping the
work. It is bolted to the saddle and receives crosswise and vertical movements from the
saddle and cross rail.
Ram
It is the reciprocating part of the shaper, which reciprocates on the guideways provided above the
column. Ram is connected to the reciprocating mechanism contained within the column.
Tool head
The tool head of a shaper performs the following functions-
(1) It holds the tool rigidly,
(2) It provides vertical and angular feed movement of the tool, and
(3) It allows the tool to have an automatic relief during its return stroke.
The various parts of tool head of shaper are apron clamping bolt, clapper box, tool post, down
feed, screw micrometer dial, down feed screw, vertical slide, apron washer, apron swivel pin, and
47
swivel base. By rotating the down feed screw handle, the vertical slide carrying the tool gives
down feed or angular feed movement while machining vertical or angular surface.
The amount of feed or depth of cut may be adjusted by a micrometer dial on the top of the down
feed screw. Apron consisting of clapper box, clapper block and tool post is clamped upon the
vertical slide by a screw. The two vertical walls on the apron called clapper box houses the clapper
block, which is connected to it by means of a hinge pin.
The tool post is mounted upon the clapper block. On the forward cutting stroke the clapper block
fits securely to the clapper box to make a rigid tool support. On the return stroke a slight frictional
drag of the tool on the work lifts the block out of the clapper box a sufficient amount preventing the
tool cutting edge from dragging and consequent wear. The work surface is also prevented from any
damage due to dragging.
Principle of Quick return motion:

In a shaper, rotary movement of the drive is converted into reciprocating movement by the
mechanism within the column of the machine. The ram holding the tool gets the reciprocating
movement. In a standard shaper metal is removed in the forward cutting stroke, while the return
stroke goes idle and no metal is removed during this period. To reduce the total machining time it
is necessary to reduce the time taken by the return stroke. The shaper mechanism should be
designed that it can allow the ram holding the tool to move at a comparatively slower speed during
the forward cutting stroke. During the return stroke it can allow the ram to move at a faster rate to
reduce the idle return time. This mechanism is known as quick return mechanism. The
reciprocating movements of the ram and the quick return mechanism of the machine are usually
obtained by anyone of the following methods.
1. Crank and slotted link mechanism

2. Whitworth quick return mechanism
3. Hydraulic shaper mechanism.
Principle of Quick Return Mechanism
When the link is in the position PM, the ram will be at the
extreme backward position of its stroke, and when it is at PN,
the extreme forward position of the ram will have been reached.
PM and PN are drawn target to the crank pin circle. The
forward cutting stroke, therefore, takes place when the crank
rotates through the angle C1KC2 and the return stroke takes
place when the crank rotates through the angle C2LC1. It is
evident that the angle C1KC2 made by
the forward or cutting stroke is greater than the angle C2LC1 described by the return stroke. The
angular velocity of the crank pin being constant the return stroke as therefore, completed within
a shorter time for which it is known as quick return motion.
48
Time of cutting stroke / Time of cutting

stroke = β/α = α / (3600 - β) or (3600 - α) / α
Travel of tool or length of stroke = R1R2 = L1L2 = 2AI X CB/AC
It can easily be seen that the angle β is more than α. Since the crank rotates with uniform
angular speed, therefore from equation (1), it can be concluded that the return stroke is
completed with in shorter time. Thus, it is a quick return motion mechanism.
Drawing of the workpiece:
Sequence of operations:
1. Measuring of specimen.
2. Fixing of specimen in the machine vice of the
shaping machine
3. Giving the correct depth and automatic feed for
the slot is to be made.
4. Check the slot with the Vernier calipers & precision measurement by slip gauges at the end.
Result:-
Study of Quick return mechanism of shaper machine and prepared the job as per
given drawing
Precautions:
1. The shaping machine must be stopped before setting up or removing the work piece
2. All the chips should be removed from the cutter
VIVA VOCE
1. Why shaper machine is needed.
2. Define Quick return mechanism.
3. What are the tools required in Shaper machine.
49
EXPERIMENT No. 5
Object: -Cylindrical grinding using grinding attachment in a centre lathe.
Introduction:-Grinding attachment is a special attachment which is purposely made for the lathe
to perform a grinding operation on the lathe. For small-sized cylindrical work pieces, it is neither
economic nor preferable to use a special type of grinding machine for grinding operations. While in
turning or facing process one can obtain surface finish of grade N8 with tool marks. But with this
attachment, one can get a surface finish of grade N5 without tool marks and scoring marks.
This ‘Grinding attachment’ is simplest one. A self-contained grinding attachment employs a rigid
housing having an electric motor for a grinding wheel. The shaft on which grinding wheel is
mounted is connected to the housing by flexible and resilient connections thereby to isolate the
grinding wheel from vibrations originating in motor lathe itself. For cylindrical grinding, one need
to have a cylindrical grinding machine which is big in size and costly too. Also one has to perform
turning on lathe machine and then need to take work-piece to the grinding machine which
consumes time. So it would be better and convenient to have a grinding attachment which can be
easily mounted on a center lathe machine.
So the objectives of the project are to:
• Design all components of grinding attachment
• Virtually validate the most critically stressed part.
• Fabrication of grinding attachment on lathe
• Testing of attachment
• Find the surface finish grade required
List Of Components:-
a. Grinding wheel:
The grinding wheel used in this application is a straight wheel type grinding wheel. The signature
of the wheel is as follows:
24-A-150-M-7-V
b. Shaft:
The shaft in this application is made of EN-9 alloy steel. The grinding wheel is mounted on the
shaft on the right-hand side and is mounted with help of washer. It is secured with fastener
50
hexagonal nut. The shaft is supported by two bearings. The shaft pulley is mounted with the help of
a washer on the left extreme of the shaft. Fig.1 shows the CAD model of the shaft.
Fig. Shaft
c. Shaft housing:
The shaft housing houses the bearings, the shaft and other auxiliaries. It is a hollow cylinder in
construction. It is made up of M.S.
d. Bearing:
The bearings used in this application are single groove deep ball bearings. These have been
selected from SKF manual. The bearings selected are:
SKF 6023
OD=42mm
D=17mm
WIDTH=12mm.
e. Belt and Pulley:
In this application we have used two pulleys viz. one on the shaft side i.e. shaft-side pulley and
other mounted on lay shaft of the motor. A belt is a loop of flexible material used to mechanically
link two or more rotating shafts, most often parallel.
f. Motor mounting plate:
A Motor mounting plate is a plate on which the motor is secured with help of bolts. The motor
mounting plate is made up of CAST IRON. This plate is further secured to the bottom housing with
help of bolts. Fig.2 shows motor mounting plate.
51
Fig. Motor mounting plate

g. Bottom housing:
This is the base of the attachment. It supports the whole structure. The bottom housing is split type
in construction. It is a casted component made up of CAST IRON. Fig.3 and fig.4 show bottom
housing
Fig.Bottom housing (B)

h. Motor mounting clamp:
The motor mounting plate is secured on the on the bottom housing with the help of motor mounting
clamp. It is used so that the pressure due to fastening is equally and uniformly distributed. It is a
casted component made up of cast iron.
i. Belt guard and belt guard mounting:
The belt and pulley arrangement are partially covered with the help of belt guard. This guard keeps
the belt-pulley arrangement isolated from the surrounding. It is made up of M.S. The belt guard is
52
mounted on the base with the help of belt guard mounting. The belt guard is bolted to the belt guard
mounting & the belt guard mounting is bolted to the bottom housing. It is made up of M.S.
Construction of Attachment:-Our designed ‘Grinding attachment' is the simplest in construction.
A grinding wheel is mounted on a shaft with the help of washer and nut. A shaft is fixed in a
bearing. The bearings are mounted in the shaft housing. Bearings are fixed with the help of bearing
caps. The total shaft assembly is mounted on the casted housing with the help of Allen bolts. At
another end of the casted housing motor is mounted on the motor mounting plate. The Motor
mounting plate is adjustable for belt tensioning. The drive is belt transmission from the motor to
shaft pulley. The motor pulley and shaft pulley are fixed with keys on the motor shaft and shaft
respectively. For protection belt drive and grinding wheel is covered with sheet metal guards.
Working:-When the motor is switched ON, power will be transmitted from the motor to lay shaft.
Through the belt drive power will be transmitted to the main shaft with a reduction in speed and
amplification in torque. This tool attachment is mounted over the compound slide of lathe (tool
post is totally removed). The job may be held between centers or in the chuck. The wheel is fed
against the job. In grinding operation both job and grinding wheel rotate. Due to this conduct
surface will get high degree finish. Here the feed is given by moving the carriage and depth of cut
is given by cross slide. The automatic feed can also be given by back gear mechanism.
The objective of this project was to design and fabricate a compact, robust and economic grinding
attachment for a center lathe for small scale industries, small workshops, machine shops etc. which
provides a surface finish of grade N5. All the components were designed as per the deterministic
method of design. After the design procedure was completed, we performed FEA on the
component which experienced worst loading conditions i.e. the shaft. The results showed that the
shaft was safe under the various applied loads. Then we manufactured some components and some
were selected from manufacturers’ catalog (standard parts) and finally all parts were assembled.
Then we tested our attachment on a lathe and measured the surface roughness value achieved. The
surface roughness value was found to be 0.63 microns i.e. N5 grade surface finish, which was the
required one. Hence, we have successfully fulfilled all the objectives stated:
• Design all components of the grinding attachment.
• Virtually validate the most critically stressed part i.e. .shaft.
Experimental Design Matrix:-Rotational speed of work piece, axial movement of grinding wheel
also called transverse feed rate and the plunge distance or the depth of cut are the parameters
53
chosen in the present investigation. The high and low levels of these parameters are identified by
reviewing the literature and also by making trial runs are given in (Table 1). A two level full
factorial design matrix is employed for the experimentation and the surface roughness (Ra) of the
components is evaluated at the input parameters for the wet and dry data are listed is shown in
(Table 2). The regression equation for the data considered is in the form y = b0 + b1 X1 + b2 X2 + b3
X3 + b4 X1 X2 + b5 X2 X3 + b6 X3 X1
Advantages:-
Low cost: This attachment is simple in construction and uses simple belt drive transmission.
Minimum maintenance: Due to lesser no of components and same being simple ones, the
maintenance is low. Also, use of standard parts makes replacement of damaged or worn out part
easy.
Lightweight: Due to its compact nature it is light weight. It is a handy tool and can be carried
easily where ever and whenever wanted. The place for storage required is also less compared to a
special grinding machine.
Minimum operating cost: It works on a 0.5HP motor. Hence the power consumption is also very
less. This lowers the operation cost.
Limitations:-
54
Setup time: It takes considerable time for mounting this attachment on a lathe.
Accuracy: The accuracy and surface finish is less compared to a special grinding machine.
Limited operation: Only cylindrical grinding operation can be performed using this attachment.
Productivity: The speed of operation is lower than the special grinding machine. It takes more
time to grind the same work piece as compared to a special grinding machine
Outcome:-
Viva Voce
1. What is the spindle speed during thread cutting operation?
2. What is difference between orthogonal cutting and oblique cutting?
3. What are the measuring (limit) gauges used while doing/machining components on lathe?
55
EXPERIMENT No. 1
Aim :- To prepare the job by eccentric turning on the lathe machine.
Materials required:
Mild steel polished round rod diameter …… mm
Tools
required:
1. Lathe machine 2. Cutting tool 3. Outside Caliper

7. HSS tool 8 Chuck key
If a cylindrical workpiece has two separate axes of rotating, one being out of centre to the other, the
workpiece is termed as eccentric and turning of different surfaces of the workpiece is known as
eccentric turning. Eccentric turning is shown in Fig. The distance between the axes is known as
offset. Eccentric turning may also be done on some special machines. If the offset distance is more,
the work is held by means of special centres. If the offset between the centres is small, two sets of
centres are marked on the faces of the work. The work is held and rotated between each set of
centres to machine the eccentric surfaces.
Given workpiece Drawing
Procedure:
1. The given work piece is held firmly in a lathe chuck.
56
2. Next a piece of packing material was made to give the required offset for the
eccentric in the 3 jaw chuck
3. The calculations for this are given below
Packing = offset x 1.5
P = 5 x 1.5 = 7.5mm
The following formula gives a slightly more accurate result
Packing = 1.5 x offset x (1 - (1/8 x (Offset / Bar Diameter))).
Packing = 1.5 x 5 x (1 - (1/8 x (5 / 22))) = 7.29mm
This means that a piece of packing of 7.29mm against one jaw of the 3 jaw chuck should give
the required offset of 5mm.
4. The off-cut was placed between one of the 3 jaw chuck jaws
5. In this setting the hole for the axle was centre drilled, drilled and reamed to size
6. To finish the part was reversed in the chuck and the working surface was finished to
final thickness.
Result :-
Prepared the workpiece as per given drawing on which the eccentric operation is done
Safety Precautiions
2. If the job is held in between the centers, then apply grease on the nose of eadcenter,
otherwise it will burnt out due to excess heat
VIVA VOCE
1. What do you mean by eccentric?
2. What are the tools used in eccentric turning.
3. What are the applications of eccentric turning method.
57
EXPERIMENT No. 2
Object:-Study of capstan lathe and its tooling and prepare a tool layout & job as per given
drawing.
Theory: - Capstan lathe is a light or medium duty turret lathe, which is quick and easy to
handle. The hexagonal turret is mounted on a ram or a short slide can move
forwarding and backward in ways machined on the saddle. The saddle can be moved
longitudinally and positioned close to the work. It is best suited for bar work and for
chucking hobs which permit the overhand of the ram to be minimum.
S no. Aspects Capstan lathe
1. Feeding of tools The saddle is fixed at a convenient distance

from the work and the tools are fed by moving
the slide
2. Rigidity Because of over hung of the slide or ram, the
tool support unit is subjected to bending and
deflection resulting in vibrations.
3. Position of turret Turret is mounted on an auxiliary slide, which
moves on the fuide ways provided on the
saddle
4. Capability of handle jobs Since this type of lathe cannot with stand
heavy cutting loads, therefore its use is
confined to relatively lighter and smaller jobs
and precision work.
5. Tool travel Limited tool travel since the tool feeding is
done by the transverse of the slide
6. Maximum bar size Upto 60mm diameter
7. Type of carriage Usually equipped with the reach over type

only sin ce it is employed for relatively
smaller jobs and therefore doesn’t require a
large swing over bed, moreover this types of
58
carriage provides betterrigidity.
8. Rate of tool feeding The tool transverse is further and offers less
fatigue to the operator’s hands.
9. Other provisions These lathers do not have such provisions.
59
Fig.Schematic configuration of capstan lathe.
In contrast to centre lathes, capstan and turret lathes

• are semiautomatic
• possess an axially movable indexable turret (mostly hexagonal) in place of tailstock
• holds large number of cutting tools; upto four in indexable tool post on the front slide, one in
the rear slide and upto six in the turret (if hexagonal) as indicated in the schematic
diagrams.
• are more productive for quick engagement and overlapped functioning of the tools in addition
to faster mounting and feeding of the job and rapid speed change.
• enable repetitive production of same job requiring less involvement, effort and attention of the
operator for pre-setting of work–speed and feed rate and length of travel of the cutting
tools
• are relatively costlier
• are suitable and economically viable for batch production or small lot production.
There are some differences in between capstan and turret lathes such as,
• Turret lathes are relatively more robust and heavy duty machines
60
• Capstan lathes generally deal with short or long rod type blanks held in collet, whereas turret
lathes mostly work on chucking type jobs held in the quick acting chucks
• In capstan lathe, the turret travels with limited stroke length within a saddle type guide block,
called auxiliary bed, which is clamped on the main bed as indicated in Fig. 8.1
whereas in turret lathe, the
Heavy turret being mounted on the saddle which directly slides with larger stroke length on the
main bed as indicated in
• One additional guide rod or pilot bar is provided on the headstock of the turret lathes, to
ensure rigid axial travel of the turret head
• External screw threads are cut in capstan lathe, if required, using a self opening die being
mounted in one face of the turret, whereas in turret lathes external threads are
generally cut, if required, by a single point or multipoint chasing tool being mounted
on the front slide and moved by a short leads crew and a swing type half nut.
Tool layout:-
61
Fig:-Basic configuration of multispindle automatic vertical lathe
Principle parts of a capstan lathe :
1 Bed 2 Headstock 3 TurretSaddle

4 Carriage 5 Legs
Capstan Lathe Operations:
1 Turning 2 Facing 3 Boring
4 Drilling 5 Knurling 6 Threading
Outcome:-Thus, we studied a capstan lathe and its tooling in detail.
Viva Voce
1. What are the differences between lathe accessories and lathe attachments? Give
examples.
2. What is meant by single point cutting tool
3. What is meant by multi point cutting tool? Give examples
62
EXPERIMENT No. 3
Object: - Demonstration on milling machine for generation of plane surfaces and use of end
milling cutters.
Introduction
Recently, the demands for precision die and mold manufacturing technology are increasing. The
quality of die and mold is determined by their surface roughness and form accuracy. In this regard,
high speed machining is widely used for high productivity and high precision. In high speed
machining, feed per tooth and pick feed are very small compared to those in general machining. As
a result, it is necessary to study surface texture characteristics precisely in microscopic view. End
milling is an important machining process used extensively in the manufacturing industry to make
flat surfaces of precision dies and molds. To date, considerable effort has been made to explain the
surface generation mechanism of end milled surfaces. Recently, Sutherland (1) presented a two
dimensional worst case analysis of the plane surface generated by the end cutting edges.
Melkote(2) improved the surface texture model including the effects of radial rake and primary
relief angles. In this study, an effective surface prediction model in plane end milling is developed.
Considered in this study are back cutting by the trailing cutting edge, tool run-out, tool setting
error, and tool deflection caused by cutting forces. For understanding the surface texture more
Efficiently, three dimensional surface topography parameters such as RMS deviation, skewness
and kurtosis are used in expressing the surface texture characteristics. From a series of cutting tests,
it is verified that the presented model predicts the surface texture accurately.
Surface Generation
Plane surface is generated by the end cutting edges of an end mill. The end cutting edge angle is
necessary for avoidance of rubbing between the tool and the machined surface. The rotation of the
bottom edge makes the machined surface shape as a part of a conical surface. Plane surface texture
is constructed by the superposition of a series of surface generation process in feed direction. The
machined surface is cut once again by the trailing cutting edge. The shape of back cutting is
determined by the phase difference and tool deflection. The magnitude of phase difference is
decided by the combinations of tool diameter and feed per tooth. Tool deflection reduces back
cutting.
63
Surface texture and roughness are affected by tool run-out and tool setting error. Tool run-out
consists of radial run out and axial run-out (Fig. 1). Radial run-out has a serious effect on chip load
variation of each flute. Axial run-out has an important role in surface texture generation. Tool
setting error also influences surface texture characteristics.
Tool setting error can be decomposed as eccentricity and tilting between tool axis and spindle axis
(Fig. 2).
The factors determining surface texture are shown in Fig. 3. Two coordinates are established to
describe the surface generation vectors more efficiently. X axis is in the feed direction and X¢ axis
is set in accordance with tool tilting direction. The position vectors, P, Fi, and Vi represent the
peak point of bottom edge, cutting edge end point,and side cutting edge, respectively. The
subscription i means the flute number. The vector origin, O, is the point of contact between the axis
of spindle rotation center and the bottom surface of tool arbor. Surface texture is constructed
through the superposition of surface generation process with cutting edge vectors expressed by a
series of vector transformations considering tool run-out and tool setting-error.
64
Tool deflection caused by cutting forces affects the surface texture and surface flatness. As shown
in Fig. 4, the magnitude of back cutting is influenced by tool deflection. In this work, tool
deflection angle is calculated using a cantilever beam theory under the assumption of quasi-static
tool motion. The area moment of inertia of flute part is assumed to be equivalent to that of a
cylinder with 0.8 times tool diameter.
In end milled surfaces, the Ra and Rmax values are quite different according to
measurement position and direction. Hence three dimensional surface topography parameters are
used for assessing the surface texture characteristics more precisely. In this paper, RMS deviation,
skewness and kurtosis are used. The RMS surface roughness is a widely used parameter. Skewness
indicates the asymmetry of surface deviations about mean plane and kurtosis represents the
peakness or sharpness of the surface height distribution. These three parameters are used to analyze
surface characteristics.
Results and Discussion
A set of cutting experiments were carried out to verify the surface generation model. The work
material, SUS420J2 stainless mold steel, was milled by two-fluted WC end mill with 30° helix
angle. Tool run-out was measured using a vision system by mounting the tool on a V-block. Tool
setting error was measured by capacitance type proximity sensors in air cutting condition.
The end cutting edge angle was measured indirectly by a coordinate measuring machine from a cast
NYLONMC901 workpiece machined by the tool without feed motion. Surface texture was
measured using Rank Taylor Hobson Form Taly surf.
Outcome
65
In this research, surface generation mechanism in plane machining with a flat end mill is studied.
The cutting edges are expressed by the position vectors. Surface is generated through a series of
vector transformations considering tool run-out and tool setting error. Developed model considers
back cutting frequently observed in finishing process. Tool deflection is also included under the
assumption of quasi-static tool motion using a cantilever beam theory. Surface topography
parameters are introduced and used in expressing the surface texture characteristics. For a range of
cutting conditions, it is confirmed that the presented model predicts the surface profile precisely.
The following conclusions can be made based on the simulated and experimental work.Surface
roughness in the middle area is worse than that in the side area by about 2mm in Rmax and 0.5mm
in Ra under the test condition. Surface roughness is better at low feed rate with large pick feed than
that at the high federate with small pick feed. The Ra and Rmax values are not sufficient for
representing the whole surface characteristics because these values are quite different according to
measurement position and direction. So it is necessary to use three dimensional surface topography
parameters. As tool run-out increases, the RMS deviation increases and skewness and kurtosis
decrease. Tool tilting increases RMS deviation but decreases skewness and kurtosis. The results
show that tool run-out and tool tilting reduce the peaks of surface texture. But surface topography
parameters considered here are insensitive to eccentricity. This study contributes to effective cutter
design, optimal cutting condition selection and tool path generation for the reduction of machining
and manual finishing time especially in precision die and mold industry.
Viva Voce
a. How are knee-type milling machines characterized?
b. What is the basic difference between a universal horizontal and aplain horizontal milling
machine?
c. Which component holds and drives the various cutting tools on the knee-type milling machine?
d. Which component on the ram-type milling machine aligns the outer end of the arbor with the
spindle?
e. How are milling machines classified or identified?
f. What is the most common means of fastening the arbor in the milling machine spindle?
g. What is another name for the indexing head?
h. When clamping workpieces to the table, what is used to protect the surfaces of the workpiece?
i. Workpieces mounted between centers are prevented from backlash by what type device?
66
j. What is the ratio on a standard indexing head?

k. Direct indexing plates usually have how many holes?
l. Face milling operations require the flat surface to be machined atwhat angles to the axis to the
cutter?.
m. What determines the cutting speed for a milling operation?
n. What is angular milling?
o. Which teeth do most of the cutting during a face milling operation?
p. What is the required time allocated for proper gib adjustment on a new milling machine?
q. When making knee gib adjustments with a dial indicator, the deflection should not be more than
how many thousandths of an inch?
r. When the gibs are adjusted too tightly, what is the end result?
s. Which type milling cutter requires less power to operate and producesa smoother finish?
t. How do milling cutters receive their names?
u. Pitch on a milling cutter refers to the__________.
v. What is the most common type of milling cutter?
67
EXPERIMENT No. 4
Object: -Grinding of milling cutters and drills.
Milling Cutters:-The milling cutters are revolving tools having one or several cutting edges of
identical form equally spaced on the circumference of the cutter. The cutting elements arc called
teeth which intermittently engage the work piece and remove material by relative movements of the
workpiece and cutter. Milling cutters may be classified as:
1. According to the constructional feature of the cutter

(a) Solid cutter
(b) Tipped solid cutter
(c) Inserted teeth cutter
2. According to the relief characteristics of the cutter teeth

(a) Profile relieved cutter
(b) Form relieved cutter
3. According to the methods of mounting the cutter

(a) Arbor type cutter
(b) Shank type cutter
(c) acing type cutter
4. According to the direction of rotation of the cutter.

(a) Right hand rotational cutter
(b) Left hand rotational cutter
5. According to the direction of helix of the cutter teeth

(a) Parallel or straight teeth cutter
(b) Right hand helical cutter
(c) Left hand helical cutter
(d) Alternate helical teeth cutter.
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6. According to purpose or use of the cutter

(a) Standard milling cutter
(b) Special milling cutter
Standard Milling Cutter

There are many different types of standard milling cutters. They are classified below
1. Plain milling cutter
2. Side milling cutter
3. Metal slitting saw
5. End mill
6. T slot milling cutter
7. Wood ruff key slot milling cutter
8. Fly cutter
9. Formed cutter
10. Tap and reamer cutter.
Elements Of A Plain Milling Cutter

1. Body of cutter
The part of the cutter left after exclusion of the teeth and the portion to which the teeth are
attached.
2. Cutting edge
The edge formed by the inter section of the face and the circular land.
69
3. Face
The portion of the gash adjacent to the cutting edge on which the chip impinges as it is cut
from the work.
4. Fillet
The curved surface at the bottom of gash which joins the face of one teeth to the back of the
tooth immediately ahead.
5. Gash
The chip space between the back of one tooth and the face of the next tooth.
6. Land
The part of the back of tooth adjacent to the cutting edge.
7. Lead
The axial advance of the helix of the cutting edge in one complete revolution of the cutter.
8. Outside diameter
The diameter of the circle passing through the peripheral cutting edge
9. Root diameter
The diameter of the circle passing through the bottom of the fillet.
10. Relief angle
70
The angle in a plane perpendicular to the axis, which is the angle between the land of a tooth
and the tangent to the outside diameter of cutter at the cutting edge of that tooth.
11. Primary clearance angle
The angle formed by the back of the tooth with a line drawn tangent to the periphery of the
cutter at the cutting edge.
12. Secondary clearance angle
The angle formed by the secondary clearance surface of the tooth with a line drawn tangent to
the periphery of the cutter at the cutting edge.
13. Rake angle (Radial)
The angle measured in the diametric plane between the face of the tooth and a radial line
passing through the tooth cutting edge. The rake angles which may be positive, negative or
zero.
14. Lip angle
The included angle between the land and the face of the tooth, or alternatively the angle
between the tangent to the back at the cutting edge and the face of the tooth.
15. Helix angle
The cutting edge angle which a helical cutting edge makes with a plane containing the axis of a
cylindrical cutter.
Fundamentals Of The Milling Process
Upmilling:- The up milling, which is also called conventional milling, is the processes of removing
metal by a cutter which is rotated against the direction of travel of the work piece. The surface
milled by up milling appears to be slightly wavy as the cutter teeth do not begin their cut as soon as
they touch the work surface. The up milling process, being safer, is still commonly used inspite of
having so many disadvantages.
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1. Direction of work feed, 2. Chip, 3.Machined surface, 4. Direction of rotation,
5. Start of cut, 6. Work surface, 7. Depth of cut, 8. Feed per tooth
Down milling:- The down milling, which is also called climb milling, is the process of removing
metal by a cutter which is rotated in the same direction of travel of the work piece. Down milling
operation cannot be used on old machines due to backlash error that may be present between
the feed screw of the table and nut. Down milling should only be performed on rigid machines
provided with backlash eliminator.
Gear Cutting
Gear Cutting Methods:-The most common and accurate method of production of gears is by
machining. The different methods of production of gears by machining operations are described
below.
a) Formed cutter method
b) Template method in a gear cutting machine
c) Generating method
Gear Cutting By Formed Disc Cutter:- The method of gear cutting by a formed disc cutter
involves the mounting of a gear blank at the end of dividing head spindle fitted on the table of a
72
horizontal, column and knee type milling machine and then feeding the work past a rotating,
formed, peripheral, type of cutter mounted on the horizontal arbor of machine. The plane of
rotation of the cutter is radial with respect to the blank. After one tooth is formed, the next surface
of the gear blank is brought under the cutter by rotating the dividing head spindle by a
predetermined amount by indexing. The tooth profile of the formed cutter should correspond to the
tooth space of the gear that again depends upon the module of the gear.
Indexing And Dividing Heads:-The indexing is the operation of dividing the periphery of a piece
of work into any number of equal parts. In cutting spur gear, equal spacing of teeth on the gear
blank is performed by indexing. The indexing operations can also be adapted for producing
hexagonal and square headed bolts, cutting splines on shafts, fluting drills, taps and reamers and
many other jobs,all requiring the periphery of the work piece to be divided equally and accurately.
Indexing is accomplished by using a special attachment known as dividing head or index head. The
dividing heads are of three types.
a) Plain or simple dividing head
b) Universal dividing head
c) Optical dividing head.
Plain or simple dividing head:-The plain dividing head comprises of a cylindrical spindle housed
in a frame, and a base bolted to the machine table. The index clank is connected to the tail-end of
the spindle directly, and the crank and the spindle rotate as one unit. The index plate is mounted on
the spindle and rotates with it. The spindle may be rotated through the desired angle and then
clamped by inserting the clamping lever pin into any one of the equally spaced holes or slots cut on
the periphery of the index plate. The work is mounted at the nose end of the spindle by a chuck or
may be supported between the two centres. This type of dividing head is used for handling large
number of work pieces, which requires very small number of divisions on the
periphery.
Universal dividing head:-Universal dividing head shown in Figure below is the most common
type of indexing arrangement used in workshops. As the name implies, this type of index head can
be used to execute all forms of indexing.
73
The important parts of a universal dividing head are the worm and worm gear, index plate,
sector arm, change gears and the spindle. The working mechanism of a universal dividing
head is shown in Figure below. The main spindle 5 housed on two accurate bearings carries a
worm gear 4 is mounted on a shaft 10 at the other end of which a crank 13 is fitted. The
worm gear 4 has 40 teeth and the worm 6 is single threaded. Thus 40 turns of the crank 13
will rotate the spindle 5 through one complete revolution or one turn of the crank 13 will
cause the spindle 5 to be rotated by 1/40 of a revolution. In order to turn the crank 13 a
fraction of a revolution, an index plate 12 is used. An index plate is a circular disc having a
different number of equally spaced holes arranged in concentric circles. The index plate 12 is
screwed on a sleeve which is loosely mounted on the worm shaft 10. Normally, the index
plate12 remains stationary by a lock pin 11 connected with the frame. A spring loaded pin 14
fixed to the crank 13 fits into the holes in the index plate 12. If the pin 14 is moved from one
hole to the next hole in a 18 hole circle of the index plate, the spindle 5 will revolve 1/40 × 1/18 =
1/720 of a turn. The sector arms shown in figure is used to eliminate the necessity of counting holes
on the index plate each time the index crank is moved.
74
1, 2. Change gears, 3. Spindle stud, 4.Worm gear, 5.Spindle, 6.Worm, 7.Carrier, 8.Work,
9. Dead centre, 10. Worm shaft, 11.Lockpin, 12.Index plate, 13. Index crank,
14. Spring loaded pin, 15. Mitre gears, 16.Driven shaft.
Indexing Methods:-There are several methods of indexing. The choice of any method depends
upon the number of divisions required and the type of dividing head used. The following are the
different methods of indexing.
1. Direct or rapid indexing
2. Plain or simple indexing
3. Compound indexing
4. Differential indexing
5. Angular indexing
Simple Indexing:-The simple indexing, sometimes called plain indexing, is more accurate and
suitable for numbers beyond the range of rapid indexing. Here, the dividing head spindle is moved
by turning the index crank 13, shown in Fig. above (universal dividing head). As the shaft 10
carrying the crank has a single threaded worm 6 which meshes with the worm gear 4 having
40 teeth, 40 turns of the crank 13 are necessary to rotate the index head spindle 5 through one
revolution. In other words, one complete turn of the index crank 13 will cause the worm
75
wheel4 to make 1/40 of a revolution
To facilitate indexing to fractions of a turn, index plates are used to cover practically all
numbers. Index plates with circles of holes patented by the Brown and Sharp manufacturing
company are as follows:
Plate No. 1 - 15, 16, 17, 18, 19, 20
Plate No. 2 - 21, 23, 27, 29, 31, 33
Plate No. 3 - 37, 39, 41, 43, 47, 49
These plates have also been accepted as standard index plates by the Indian machine tool
manufacturers.
Rule for simple indexing: To find the index crank movement, divide 40 by the number of
divisions required on the work.
The formula for index casement is given
below: Index crank movement =
Where, N = number of divisions required
If the index crank movement deduced from the above formula is a whole number, the index
crank should be rotated through a complete number of turns equal to the derived whole
number. If the index crank movement deduced from the equation is a whole number and a
fraction, the numerator and the denominator of the fraction after simplifying are multiplied by a
suitable common number which will make the denominator of the fraction equal to the
number of holes in the index plate circle. The new numerator now stands for the number of
holes to be moved by the index crank in the hole circle derived from the denominator, in
addition to the complete turns of the index crank.
Thus for indexing, one complete turn and 7 holes in 21 hole circle of the index plate will have
to be moved by the index crank.
Outcome:-
76
Viva Voce
a. When making knee gib adjustments with a dial indicator, the deflection should not be more
than how many thousandths of an inch?
b. When the gibs are adjusted too tightly, what is the end result?
c. Which type milling cutter requires less power to operate and produces a smoother finish?
d. How do milling cutters receive their names
e. Pitch on a milling cutter refers to the__________.
f. What is the most common type of milling cutter
g. Which type cutters are used for cutting relatively wide slots with accuracy?
77
EXPERIMENT NO. – 02
AIM: To perform the moisture and clay present in base sand.
Materials used: Base sand, 5 % NaoH solution and water.
Apparatus used: electronics balance , oven , crucible , bottle, measuring jar, mechanical stirrer
and siphon tube.
Moisture content Test :

1. Take the 100 gm sample of sand
2. Mix the waste till it becomes in the paste form
3. Make it in the cylindrical shape
4. Weight it
5. Put the sample in the oven for 10 min. at 1200 C temp
6. Take the sample put out of the oven
7. Weight it again
8. The difference is the amount of moisture
Calculation :
Moisture present in the sand ( %) =( Initial weight – final weight ) X Initial weight
W1 Initial weight of the sand sample with wate in gm

W2 Final weight of the sand sample with wate in gm
78
Clay content Test:

1. Clay can be those particles having less than 20 microns size. Moulding sand contains 2
to 50 percent of clay. When mixed with water it imparts, binding strength and plasticity.
2. Clay consists of two ingredients a) Fine silt and b) True clay. Fine silt as no binding power
where as true clay imparts the necessary boundary strength to the moulding sand; thereby the
mould does not loose its shape after ramming.
3. Clay also can define as those particles which when mixed with water, agitated and then made
to settled, fails to settle down at the rate of 1”/mm.
4. The particles of clay are plate like from and have a very large surface area compared to
its thickness and therefore have a very high affinity to absorb moisture.
5. Clay is the main constituent in a moulding sand and mixture other than sand grains. Clay
imparts binding action to the sand and hence the strength.
6. Clay is of mineral origin available in plenty on earth. It is made of alumina silicate. The types of
clay are a) montmorillonite b) Kaolinite and c) illite the first type is generally referred to as
Bentonite. Clay is the main constituent in a moulding sand mixture other than sand grain.
Clay help impart binding action to the sand and hence strength to the sand.
Procedure:
1. Take 100g of base sand in a wash bottle and add 475ml of distilled water and 25ml
of NaOH solution to it.
2. using the mechanical stirrer, stir the mixture for about 5 minutes add distilled water to make
up the level to 6"height. Stir the mixture again for 2 minutes. Now allow the content of the
bottle to settle down.
3. Siphon out 5” level of unclean water using a standard siphon.
4. Add distilled water again up to 6" height and stir the content again. Allow the mixture to
settle down for 5minutes.
5. Siphon out 5” level of water from the bottom of the bottle Repeat the above procedure for
3-4 times till the water becomes clear in the wash bottle.
6. Transfer the wet sand from the bottle in to a tray and dry in it in an oven at 110 o C to
remove moisture. Note down the dry sand weight accurately.
Using the calculations find percentage of clay.
79
Calculations
Weight of sand W1= 100 gms

Weight of dried sand W2 = ----------- gms
% of clay= ( W1- W2) X
100 100
Results and discussion:

The % of clay is -----------------%
Discuss whether the % of Water is present is high or low and whether this % is enough to
act as binder in the sand.
Fig.: Clay Washer
80
EXPERIMENT NO.-03
AIM: To perform permeability test.
Materials used:
Base sand, clay and water. Apparatus used: Sand rammer, Permeability meter, Electronic
weighing scale, stripper, stop watch, measuring jar, specimen tube, specimen tube cup.
Theory:
1. Molten metals always contain certain amount of dissolved gases, which are evolved when
the metal starts freezing.
2. When molten metal comes in contact with moist sand, generates steam or water vapour.
3. Gases and water vapor are released in the mould cavity by the molten metal and sand. If they
do not find opportunity to escape completely through the mould, they will get entrapped and
form gas holes or pores in the casting. The sand must therefore be sufficiently porous to allow
the gases and water vapor to escape out. This property of sand is referred to as permeability.
4. Permeability is one of the most important properties affecting the characteristic of moulds
which depends upon the grain size, grain shape, grain distribution, binder content, moisture
level and degree of compactness.
5. Permeability is a physical property of the physical sand mixture, which allows gases to pass
through it easily.
6. The AFS (American Foundry Men Society) definition of permeability is “the number obtained
by passing 2000cc of air through a standard specimen under a pressure of 10 gm/cm2 for a
given time in minutes”.
7. The permeability number PN can be found out by the equation

PN =
Where
V = Volume of air passing through the specimen, 2000cc
H = Height of the specimen = 50.8 mm (standard value)
P = Pressure as read from the manometer in gm/cm2
A = Area of the specimen = d 2 /4
d = 50.8 mm (standard value)
T= time in minutes for 2000 cc of air passed through the sand specimen.
Experimental setup details:

Permeability meter has a cylindrical water tank in which an air tank is floating. By properly
opening the valve, air from the air tank can be made to flow through the sand specimen and a back
pressure is setup. The pressure of this air is obtained with the water manometer. The meter also
81
contains the chart, which directly gives the PN depending on pressure.
Procedure:
1. Conduct the experiment in two parts. In the first case vary water percent keeping clay
percent constant. In the second case vary clay percent and keep water percent constant.
2. Take weighed proportions of sand dry mix them together for 3 minutes. Then add required
proportions of water and wet mix for another 2 minutes, to get a homogeneous and mixture.
Take the total weight of the mixture between 150-200 grams. The correct weight has to be
determined by trail and error method.
3. Fill the sand mixture into the specimen tube and ram thrice using sand rammer. Use the
tolerance limit provided at the top end of the rammer for checking the specimen size. If the
top end of the rammer is within the tolerance limit, the correct specimen is obtained. If it lies
below the limit, increase the weight of sand mixture and prepare a new specimen. The
specimen conforming to within limits represent the standard specimen required.
4. Now the prepared standard specimen is having a dia.50.8mm and height 50.8mm.
5. Place the standard specimen along with the tube in the inverted position on the rubber seal or
on the mercury cup (specimen in the top position in the manometer reading).
6. Operate the valve and start the stop watch simultaneously. When the zero mark on the
inverted jar just touches the top of water tank, note down the manometer reading.
7. Note down the time required to pass 2000cc of air through the specimen. Calculate
the permeability number by using the formula given.
Direct scale reading:

The permeability can also be determined by making use of the graduated marker provided
near the manometer.
Procedure to be followed:
Coincide the graduations on the transparent scale with the meniscus of the manometer
liquid.
Note the reading of the scale.
This reading represents the permeability number of the sand.
TABULAR COLUMN
Varying the percentage of Clay and keeping percentage of Water constant.

Indicate percentage of Clay (No. of arms = 3)
Percentage of Pressure PN
SL. NO Time in min.
82
Clay gm/cm2 Indicated Calculated
Varying the percentage of water and keeping percentage of Clay constant. Indicate
percentage of Water (No. of arms = 3)
Percentage of Pressure PN
SL. NO Time in min.

Clay gm/cm2 Indicated Calculated
Draw graph:
Permeability number v/s % Clay

Permeability number v/s % water
Discuss the effect of water and clay on Permeability
PERMEABILITY METER
83
EXPERIMENT NO. -4
AIM: A.F.S Sieve Analysis Test.
Materials used: Base sand- Silica sand.

Apparatus used: Electronic weighing scale, stop watch, sieve shaker.
Theory:
1. The base sand is a mixture of grains having a variety of shapes such as
a) Round b) sub-angular c) angular
Base sand is relatively free from any binder or additives.
2. Depending on the average size of the grains, the sand can be grouped into:
a) Fine b) Medium and c) Coarse grains.
3. The shape and size of grains has a large influence on the permeability of sand mix as well
as on the bonding action.
4. The shape and size of grains determine the possibility of its application in various types of
foundry practice.
Ex: Fine grain sand results in good surface, on the casting but gases cannot escape out of the
mould made from it. Coarse grain sand allows gases to escape out easily but the casting surface
will be very rough. Hence grain size should select appropriately.
5. The given size of sand grains is designated by a number called grain fineness number that
indicates the average size of grains in the mixture.
6. The size is determined by passing the sand through sieves having specified
apparatus which are measured in microns.
7. The sieve number designates the pore size through which the sand grains, may
pass through it or retained in it.
8. Average grains fineness number can be found out by the equation GFN
= Q/P
Where
Q = sum of product of percentage sand retained in sieves and
Corresponding multiplier.
P = sum of percentage of sand retained in sieves.
Procedure:
1. Take 50 gm or100 gm of dry sand and place in the top sieve of a series and close the lid.
2. Place the whole assembly of sieves on the vibratory sieve shaker and clamp it.
3. Switch on the motor and allow the sieve assembly to vibrate for 5 minutes. Then switch off the
motor.
84
4. Collect the sand particles retained in each of the sieve separately and weigh in Electronic
weighing scale and enter into the tabular column. Calculate the percentage weight retained
by each of the sieves. Multiply this value with the multiplier for each sieve.
(Calculate the average GFN using the formula as shown below.)
Tabular Column:
Total weight of sand taken = 100g.
(b)
Weight in grams
(c) (d) (e)
(a)
SL. % Multiplying Product
Sieve NO Empty Sieve
NO Retained factor e=cxd
in icrons Sieve with
W1 sand
W2
1 1000 5
2 850 10
3 600 20
4 425 30
5 300 40
6 212 50
7 150 70
8 106 100
9 75 140
10 50 180
P= c Q= e
% Retained C = Weight of sand in each sieve x
100 Total weight of sand
Calculation: AFS grain number = Q (sum) / P (total)

Results:- The average grain fineness number is =
Graph: Percentage of sand retained v/s sieve number
85
VIVA VOCE
1. What are the applications of A.F.S Sieve test?

2. How much percent of material which passes through a specific sieve is contained in that
single-size aggregate?
3. Coarse aggregates are classified into how many groups?
86
EXPERIMENT NO. -05
AIM: Strength test & Hardness Test
Materials used: Base sand, clay, water,
Apparatus used: Sand Ramming machine (Rammer) with specimen tube with base, stripper,
universal sand testing machine with Compression shackles, weighing pan, measuring jar, steel
scale, Electronic weighing scale.
Theory:
1. Periodic tests are necessary to check the quality of foundry sand and compression strength test
is one among them.
2. The constituents of moulding sand are silica sand, clay, water and other special additives.
3. Clay imparts the necessary bonding strength to the moulding sand when it is mixed with water
etc.
bentonite.
4. Compression test determines the bonding or adhesiveness power of various bonding materials
in green sand.
5. The green compressive strength of foundry sand is the maximum compression strength a
mixture is capable of developing when it is in most condition.
Procedure:
1. Conduct the experiment in two parts:
a) Vary the clay content keeping the water content constant
b) Vary the water content keeping the clay content constant
2. Take weighed proportions of sand and clay and dry mix them together in a Muller for 3 minutes.
3. Adjust the weight of the sand to get standard specimen
4. Remove the standard specimen by the stripper and place it between shackles which are fixed
in the sand testing machine.
5. Rotate the handle of the testing machine to actuate the ram. Thus hydraulic pressure is
applied continuously till the specimen raptures.
6. Read the compression strength from the gauge and record the same.
7. Conduct the experiment for the above said two cases and tabulate the result.
Result and Discussion

Plot the graphs with compression strength on y-axis & percentage clay on x-axis and the other
with compression strength on y-axis v/s percentage water on x-axis.
Discuss the result with respect to the variation of percentage of clay on compression strength and
percentage of water on compression strength. TABULAR COLUMN
VARYING THE % OF CLAY
SL. NO Percentage Of Percentage of Percentage of compression
sand clay water strength gm/cm2
87
VARYING THE % OF
WATER
SL. NO Percentage Of Percentage of Percentage of compression

3
UNIVERSAL STRENGTH MACHINE
(Model-VUN)
SAND RAMMER
88
TENSILE STRENGTH TEST OF CORE SAND

AIM: To determine the tensile strength of sand using two types of binders Viz. core oil binder
and sodium silicate binder.
Materials used: Base sand, core oil, sodium silicate.
Apparatus used:
universal sand testing machine, Split core box, Sand rammer, oven, tension shackles.
Theory:
1. A core is compacted sand mass of a known shape.
2. When a hallow casting (to have a hole – through or bind) is required, a core is used in the mould
or when a complex contour is required a mould is created out of cores. This core has to be
properly seated in the mould on formed impressions in the sand. To form these impressions extra
projections called core points are added on the pattern surface at proper places.
3. Core boxes are used for making cores. They are either made single or in two parts. Their
classification is generally according to the shape of the core or the method of making the
core.
4. Split core box is very widely used and is made in two parts, which can be joined together by
means of dowels to form the complete cavity for making the core.
5. The purpose of adding binder to the moulding sand is to impart strength and cohesiveness to
the sand to enable it to retain its shape after the core has been rammed.
6. binders used can be a) organic: ex. Dextrin, core oil b) Inorganic: ex. Sodium silicate, Bentonite
7. Classification of binders:
a. Baking type: Binding action is realized in the sand after baking the sand mixture in an
oven.
b. Gassing type: Binding action is obtained in the sand after passing a known gas through
the sand mixture.
Ex. Co2 gas passed through a mixture of sand and sodium silicate.
8. Core oil is used as binder that hardens with the addition of heat. The sand and binder is mixed
and backed at a temperature of 250O – 300O C and binding action takes place within few
hours.
89
9. Sodium silicate is a self setting binder and no external heat is required for the binding action
which takes place at room temperature when Co2 gas is passed.
10. During casting the core is placed inside the mould and the molten metal is poured in to the
cavity. As the molten metal begins to cool, it begins to contract on the inner radius as well as the
outer radius. Due to the contraction of the inner radius the core sand will be pulled outwards
causing a tensile load around the core. Hence knowledge of tensile strength of core sand is
important.
Procedure:
1. Conduct the experiment in two parts.
a. Using core oil as binder and
b. Using sodium silicate as binder.
2. Take proper proportions of base sand and binder then mix them together thoroughly.
3. Assembly the core box and fill the mixture into it.
4. Place the core box under sand rammer and ram the sand thrice.
5. Using a wooden piece tap the core box gently from sides. Remove the core box leaving
the rammed core on a flat metal plate
6. Bake the specimen (which is on a plate) for about 30 minutes at a temperature of 150O –
200O C in an oven. (When the binder is core oil)
7. If the binder is sodium silicate, pass Co2 gas for 5 secs. The core hardens instantly and the
core can be directly used.
8. Fix the tension shackles on to the sand testing machine, and place the hardened specimen in
the shackles.
9. Apply the load gradually by turning the hand wheel of the testing machine. Note down the
readings when the specimen breaks.
10. Repeat the procedure for the different percentage of binder and tabulate the readings.
TABULAR COLUMN
SL. NO Percentage of Percentage of Tensile strength N/m

sand sodium Silicate
or core oil
90
Result and discussion:

Plot the graph of tensile strength on y-axis and binder on x-axis. Discuss the effect of
variation of binder content on tensile strength.
Figures to be drawn:
1) Split core box for tensile specimen (fig.1)
2) Tensile stress on core (fig.2)
3) Dimensions of standard tensile specimen (fig.3)
4) Tensile test shackles (fig.4)
TENSILE CORE BOX
91
Tensile strength attachment (Model-VAS)
SHEAR STRENGTH TEST FOR MOULDING SAND

AIM: To determine the green shear strength of the given specimen for different percentages of
clay and moisture.
Materials used: Base sand, clay, water.
Apparatus used: Sand ramming machine (rammer), universal sand testing machine with
attachments, weighing pan.
Theory:
1. Shear strength is the ability of sand particles to resist the shear stress and to stick together.
2. Insufficient Shear strength may lead to the collapsing of sand in the mould or its partial
destruction during handling. The mould and core may also be damaged during flow of molten
metal in the mould cavity.
3. The moulding sand must possess sufficient strength to permit the mould to be formed to the
desired shape and to retain the shape even after the hot metal is poured into the mould
cavity.
4. In shearing, the rupture occurs parallel to the axis of the specimen.
Procedure:
1. Conduct the experiment in two parts:
a) Vary the clay content keeping the water content constant
92
b) Vary the water content keeping the clay content constant

2. Take weighed amount of foundry sand (mixture of sand, clay & water as specified).
3. Transfer the sand mixture into the tube and ram it with the help of a sand rammer thrice.
4. Fix the shackles to the universal sand testing machine.
5. Remove the specimen from the tube with the help of a stripper and load it into the universal
sand testing machine.
6. Apply the hydraulic pressure by rotating the handle of the universal sand testing
machine continuously until the specimen ruptures.
7. Read the shear strength directly from the scale and tabulate the readings.
TABULAR COLUMN
VARYING THE % OF CLAY
SL. NO Percentage of Percentage of Percentage of compression

VARYING THE % OF WATER
SL. NO Percentage of Percentage of Percentage of compression

Graphs:
a) Shear strength (Y-axis) V/s Percentage of clay (X-axis).
b) Shear strength (Y-axis) V/s Percentage of water (X-axis).
Results and Discussions:

The Graphs above reveal:
93
a) With the increase in the percentage of water the shear strength of the specimen
…………………………….
b) With the increase in the percentage of clay the shear strength of the specimen
…………………………….
SHEAR STRENGTH ATTACHMENT (Model-VHS)
CORE HARDNESS AND MOULD HARDNESS TEST

Mould and core hardness can be found out by the hardness – tester which is base on the same
principle as Brinell hardness tester. A steel ball of 50 mm diameter weighing 237 gm is pressed
on the mould surface. The depth of penetration of steel ball will give the hardness of mould
surface on the direct reading dial. This hardness test is useful in finding out the mould uniformity
The following are the moulding hardness numbers for
Moulding sand (1 number = 1/100 mm) Soft rammed

moulds = 100 Medium rammed moulds = 125 Hard rammed mould = 175
94
Tabular column for Core Hardness Test
% of sodium
SL. NO % of Sand silicate Core Hardness
Number
Tabular column for Mould Hardness Test
% of sodium
SL. NO % of Sand silicate Mould Hardness
Number
95
VIVA VOCE
1. Which machine records the change in length of specimen?
2. During hardness test where the indenter is used.
3. Where is Pyramid type diamond indenter used?
96
EXPERIMENT NO.-01
AIM: Hands on practice on spot welding

.
Material required : GI Sheet of 50 x 50 mm --- 2 Nos.
Apparatus required : Spot Welding Equipment, Snips and Gloves
Theory:
Spot welding is a resistance welding process in which overlapping sheets are joined by local fusion
at one or more spots by the heat generated by resistance to the flow of electric current through work
pieces that are held together under force by two electrodes, one above and the other below the two
overlapping sheets as shown in fig.
97
In resistance welding (RW) a low voltage (typically IV) and very high current (typically 15,000 A)
is passed through the joint for a very short time (typically 0.25 s).
This high amperage heats the joint, due to the contact resistance of the joint and melts it.The
pressure on the joint is continuously maintained and the metal fuses together under this pressure.
The heat generated in resistance welding can be expressed as
H = kl2 R t
Where
H = the total heat generated in the work, J
l = electric current, A
t = time for which the electric current is passing through the joint, s
r = the resistance of the joint, ohms
and k = a constant to account for the heat losses from the welded joint.
The resistance of the joint, R is a complex factor to know because it is

composed of i. The resistance of the electrodes,
ii. The contact resistance between the electrode and the work piece,
iii. The contact resistance between the two work piece plates,
iv. The resistance of the work piece plates.
The amount of heat released is directly proportional to the resistance. It is likely to be released at all
of the above-mentioned points, but the only place where a large amount of heat is to be generated
to have an effective fusion is at the interface between the two work piece plates. Therefore, the rest
of the component resistances should be made as small as possible, since the heat released at those
places would not aid in the welding.
Because of the squaring in the above, equation, the current, i needs to be precisely controlled for
any proper joint. The main requirement of the process is the low voltage and high current power
supply. This is obtained by means of a step down transformer with a provision to have different
tappings on the primary side, as required for different materials. The secondary windings are
connected to the electrodes which are made of copper to reduce their electrical resistance. The time
of the electric supply needs to be closely controlled so that the heat released is just enough to melt
the joint and the subsequent fusion takes place due to the force (forge welding) on the joint. The
force required can be provided either mechanically, hydraulically or pneumatically.
To precisely control the time, sophisticated electronic timers are available.The critical variable in a
resistance welding process is the contact resistance between the two work piece plates and their
resistances themselves. The contact resistance is affected by the surface finish on the plates, since
the rougher surfaces have higher contact resistance. The contact resistance also will be affected by
98
the cleanliness of the surface. Oxides or other contaminants if present should be removed before
attempting resistance welding.
Steps Involved in Spot welding:

The job is clean, i.e. free from grease, dirt, scale, oxide etc. Electrode tip surface is clean, since it
has to conduct the current into the work with as little loss as possible.
Very fine emery cloth may be used for routine cleaning. Proper welding current has been set on the
current selector switch. Proper time has been set on the weld-timer.
Step I: Electrodes are brought together against the overlapping work pieces and pressure applied so
that the surfaces of the two work pieces under the electrodes come in physical contact after
breaking any unwanted film existing on the work pieces.
Step II: welding current is switched on for a definite period of time. The current may be of the
order of 3000 to 100.000 A for a fraction of seconds depending upon the nature of material and its
thickness. As the current passes through one electrode and the work pieces to the other electrode, a
small area where the work pieces are in contact is heated. The temperature of this weld zone is
approximately 8150C to 9300C. To achieve a satisfactory spot weld the nugget of coalesced metal
should form with no meting of the material between the faying surfaces.
Step III: at this stage, the welding current is cut off. Extra electrode force is then applied or the
original force is prolonged. This electrode force forges the weld and holds it together while the
metal cools down and gains strength.
Step IV: The electrode force is released to remove the spot welded work pieces.
PROCEDURE:
99
1. The two pieces to be joined by spot welding are placed between the two electrodes
in the required position.
2. Set the timer for which the current flows through the electrodes with reference to the thickness
of the plates
3. Press the foot lever, so that the movable electrode moves towards the fixed electrode.
4. This causes to develop a pressure of about 200-1000 Kg / cm2 on the sheets.
5. A low voltage and very high current is passed through the joint for a very short time. The
duration of the current flow is for about 2 sec (This high amperage heats the joint, due to contact
resistance at the joint and melts it).
6. Then the metal under electrodes pressure is squeezed and welded
7. Pressure is then released and the process is repeated until the job is completed.
8. The welding is carried out in a regular pattern as shown in fig.
Precautions:
1. Proper pressure should be applied on the electrodes.
100
2. Correct electrode diameter needs to be chosen depending on the material thickness to be
joined.
3. Proper weld time should be selected for welding.
4. Use Gloves while doing operation.
Result:
VIVA VOCE
1. How spot welding is different from other forms of welding
2. Spot welding comes under which kind of welding process.
3. What are the applications of Spot Welding process.
101
102

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JAIPUR ENGINEERING COLLEGE AND RESEARCH CENTRE

JECRC Campus, Shri Ram Ki Nangal, Via-Vatika, Jaipur

LabName : Production Practice Lab

Branch : Mechanical Engineering

Year : 2rd Year

Jaipur Engineering College and Research Center, Jaipur

Department of Mechanical Engineering

(Rajasthan Technical University,KOTA)

S.NO CONTENTS PAGE

2. PROGRAM EDUCATIONAL OBJECTIVES (PEOs) IV

3. PROGRAM OUTCOMES (POs) V

4. COURSE OUTCOMES (COs) VI

9. LEARNING MATERIALS XII

10. ASSESSMENT OF OUTCOMES XIII

List of Experiments (RTU Syllabus)

Exp:- 1 To study lathe machine construction and various parts including

Exp:-5 To perform taper turning using compound rest.

Exp:-2 To machine a hexagonal /octagonal nut using indexing head on

Exp:-5 Cylindrical grinding using grinding attachment in a centre lathe

Demonstration and study

Exp:-1 Demonstration for job by eccentric turning on lathe machine.

Exp:-3 Demonstration on milling machine for generation of plane surfaces

Exp:-4 Grinding of milling cutters and drills.

Exp:-1 To prepare mould of a given pattern requiring core and to cast it in

Exp:-2 To perform moisture test and clay content test.

Exp:-3 To perform permeability test

Exp:-4 A.F.S. Sieve analysis test.

Exp:-5 Strength Test (compressive, Tensile, Shear Transverse etc. in green

Exp:-1 Hands-on practice on spot welding.

1. VISION & MISSION

2. PROGRAM EDUCATIONAL OBJECTIVES (PEOS)

4ME4-23 Production Practice Lab II

Class: IVSem.B.Tech. Branch:Mechanical Engineering Schedule per Week

On successful completion of this course the students will be able to:

Co 1: Students will able to recognized about various machining processes and

Co2: Students will able to understand instruction efficiently given by industry

Credit: 1.5 Max. Marks: 75

7.1 Text books:-

1.) Production Technology by P. C. Sharma , S. Chand Publication

8.1. Direct Instructions:

8.2. Interactive Instruction:

8.3. Indirect Instructions:

9.1. Lab Manual

9.2. Reference Books

10. ASSESSMENT OF OUTCOMES

11. INSTRUCTIONS SHEET

BEFORE ENTERING IN THE LAB

Fig.: Center Lathe

Basic working principle of lathe machine

Types of Lathe Machine

Classification of Lathe Machine

(i) Wood working (ii) polishing (iii) Centering (iv) spinning

2. Engine or Centre Lathe

(i) Light Work (a) Bench Lathe

(ii) Medium and heavy duty Lathe

(a) Belt Drive (b) Individual motor drive

3. Production type lathe

(i) semi automatic (a) Capstan (b) Turret

(d) screw cutting (e) Axle

Parts of Lathe Machine

cutting tool holder in a desired position.

WORK HOLDING DEVICES

Cutting speed V=ΠDN/1000