D.

AGOVERNMENT POLYTECHNIC, Ongole M-

MACHINE SHOP Experiment: Spur Gear

OBJECTIVE To Prepare a Spur Gear on Horz. Milling Machine using Simple

Indexing method of the given gear blank, No of teeths required is 30.

SKETCH

1.Skill in selecting the correct no.cutter.

SKILLS TO BE 2.Skill in correct indexing.
DEVELOPED 3.Skill in setting the work piece and cutter.
4.skill in giving the depth of cut and feed.

SPECIFICATIONS 50mm dia x 32mm long M.S Rod.

OF MATERIALS
TOOLS & Horz.milling machine,mandrel,spanner,milling cutter,vernier
EQUIPMENT caliper,facing tool, lathe machine,universal dividing head.
SEQUENCE OF 1.Fix the job in lathe chuck and turn to the size.
OPERATIONS
2.Drill a hole, suitable to fix the mandrel.
3.Fix the milling cutter on the arbor.
4.Set the gear blank between the two centres using mandrel.
5.Check the alighnment of the cutter with the work axis.

6.Fix up proper index plate on the dividing head duly calculating the
no of turns and holes.

7.Switch the machine and feed the work table until the required
depth and tooth profile is obtained.
8.Turn the index crank for required no of turns/holes and feed the
table to cut next tooth.
9.Repeat step8 and until all the teeth are cut.

10.Set the dividing head to mill teeth on gear wheel blank.

Index crank movement=40/N

and where N=no of teeth required.,
40 is no of teeths provided on worm gear

Index crank movement= 40/N, 40/30, (1⅓ x 5/5 = (1 5/15)

i.e The index crank will be moved one complete turn and 5 holes to
be moved of 15 hole circle plate.
SAFETY
PRECAUTIONS
1.Fix the job tightlyin the mandrel.
2.Table feed should be slow and uniform.
3.use suitable coolant.
 4.Care is to be taken to give required indexing movement
ACCURACY OF FINISH
 M- WORKSHOP PRACTICE-IV

MACHINE SHOP Experiment: KEY WAY CUTTING ON SHAPER

To perform key way using C.I 50x50 square block on Shaping

OBJECTIVE Machine. size(10x10x60mm)

SKETCH

1.Skill in measuring and marking of work piece. 2.Skill to

SKILLS TO BE set the job and tool in the slotter. 3. Skill in
DEVELOPED
adjusting the stroke length adjustment.

SPECIFICATIONS OF Cast Iron square block.

MATERIALS
TOOLS & Shaping machine ,H.S.S Cutting tool, Try square, steel rule, Spirit level
EQUIPMENT and Work piece etc.
SEQUENCE OF Check the raw material for its size.
OPERATIONS

Apply the chalk and mark size of its sides of job.

Punch the dots along the marked lines.

Set the job in a machine vice and check the alignment properly on the
table.

Set the Tool bit in the tool holder and fix into the tool head.

Adjust the stroke length , stroke position of Ram as per the size of the
job

Adjust the speed and feed properly.

Adjust the depth of cut and cut the key wayas per given size.

SAFETY PRECAUTIONS Don’t adjust the stroke while machine is in motion.

Before starting the work check that the work piece and  tool
properly clamped.
Do not wear loose clothes and wear the shoes, goggles,                                         apron while working i
Do not remove chips with bare hands.
ACCURACY OF FINISH
MBTS GOVERNMENT POLYTECHNIC, GUNTUR M- WORKSHOP PRACTICE-IV
MACHINE SHOP Experiment: SURFACE GRINDING

OBJECTIVE To perpare a key on Horizontal surface grinding machine using MS

Flat.

SKETCH

SKILLS TO BE Skill in setting the Job.

DEVELOPED skill in operating the job to obtain fine finish.

SPECIFICATIONS
OF MATERIALS M.S Flat of 5mm × 5mm × 34mm

TOOLS & Surface grinding machine, electro magnetic chuck,V-Block, safety goggles,
EQUIPMENT vernier micrometer.                                   
SEQUENCE OF
OPERATIONS Fix the workpiece on the table with the help of spanner or on magnetic chuck.

Raise the table by vertical slide hand wheel till the work piece surface touching
with the wheel head which is mounted on column.
The grinding wheel rotates at constant speed and it is powered by built in
motor.
The work piece slides under the wheel head mounted on the table. The table
feeds axially between passes to produce fine flat surface.

The wheel will remove the metal until final height of the work piece.

The amount of feed is in 1/100th of millimtere. For steel rough finish ground is
0.002 to 0.05mm and finish ground is 0.005 to 0.01mm and for Grey C.I rough
grinding is 0.08 to 0.15 and finish grinding is 0.02 to 0.05mm.

SAFETY 1.Before starting check that the work piece should be properly clamped.
PRECAUTIONS 2. wear the shoes, safety goggles, apron while working in Machine.

ACCURACY OF FINISH
 M-

MACHINE SHOP Experiment: PLAIN MILLING

To Perform Plain Milling operation of the given job using Plain/slab

OBJECTIVE milling cutter on Horizontal Milling Machine.

SKETCH

SKILLS TO BE 1.Skill in Measuring and Marking of work piece.

DEVELOPED 2.Skill in setting the work piece and cutter.
3.skill in giving the depth of cut and feed.

SPECIFICATIONS
OF MATERIALS
TOOLS & Horz.Milling Machine,Plain Milling cutter,Vernier caliper,Machine
EQUIPMENT Vice, Steel rule,Spirit level.
SEQUENCE OF
OPERATIONS 1.Fix the work piece in Machine vice properly.

2.Check the alighnment of the work piece properly.

3.Adjust the depth of cut by rotating the Knee elevating handle.

4.Cross movement can be adjusted by rotating the table hand wheel.

5.Longitudinal feed can be adjusted by rotating the Table hand wheel.

6.Switch the machine and feed the work table.

7.Remove the excess material to get plain surface finish.

SAFETY
PRECAUTIONS
1.Fix the job firmly in the vice.
2.Table feed should be slow and uniform.
3.use suitable coolant.
4.Care is to be taken to give required indexing movement
ACCURACY OF FINISH
 M-

MACHINE SHOP Experiment: STEP MILLING

OBJECTIVE To Perform step milling operation of the given job using Plain/slab
milling cutter on Horizontal Milling Machine.

SKETCH

SKILLS TO BE 1.Skill in Measuring and Marking of work piece.

DEVELOPED 2.Skill in setting the work piece and cutter.
3.skill in giving the depth of cut and feed.

SPECIFICATIONS
OF MATERIALS

TOOLS & Horz.Milling Machine,Plain Milling cutter,Vernier caliper,Machine

EQUIPMENT Vice, Steel rule,Spirit level.

1.Fix the work piece in Machine vice properly.

2.Check the alighnment of the work piece properly.

3.Adjust the depth of cut by rotating the Knee elevating handle.

SEQUENCE OF 4.Cross movement can be adjusted by rotating the table hand wheel.
OPERATIONS

5.Longitudinal feed can be adjusted by rotating the Table hand wheel.

6.Switch the machine and feed the work table.

7.Remove the excess material to get the step surface finish.

SAFETY
PRECAUTIONS
1.Fix the job firmly in the vice.

2.Table feed should be slow and uniform.

3.use suitable coolant.

4.Care is to be taken to give required indexing movement

 M-

MACHINE SHOP Experiment: SLOTTER

OBJECTIVE To perform key way cutting operation using C.I square block on Slotter.
Size:10x10x50mm long)

SKETCH

SKILLS TO BE 1.Skill in measuring and marking of work piece.

DEVELOPED 2.Skill to set the job and tool in the slotter.
3. Skill in adjusting the stroke length adjustment.
SPECIFICATIONS OF 50mm x 50mm cast iron square block.
MATERIALS
TOOLS &
EQUIPMENT Slotting machine , Cutting tool, Try square, steel rule, Spirit level and Work piece etc.

SEQUENCE OF Check the raw material for its size.

OPERATIONS
Apply the chalk and mark size of its sides of job.
Punch the dots along the marked lines.
Set the job in a machine vice and check the alignment properly on the table.
After the work piece is properly held, set the tool bit in the tool holder and fix into
the tool head.
Set the stroke length , stroke position according to the size of the job
Adjust the speed and feed properly.
Other surfaces can be machined without disturbing the setting by simply rotating the
table and also gears can be machined in this machine.
Plane the surface of all sides

Mark the key way and cut the key way on one side of the job as per the dimensions

SAFETY PRECAUTIONS Don’t adjust the stroke while machine is in motion.

Before starting the work check that the work piece and  tool properly clamped.

Do not wear loose clothes and wear the shoes, goggles, apron while working in
Machine.

Do not remove chips with bare hands.

ACCURACY OF FINISH