ME3382-MT Lab Manual Part-1

DEPARTMENT OF MECHANICAL ENGINEERING
ME 3382 – MANUFACTURING TECHNOLOGY LAB

SAFETY PRECAUTIONS
1. Always wear uniform, shoes and gloves for safety
2. Always wear goggles to protect your eyes from flying chips.
3. Do not operate any machine equipment unless you have been

instructed on its proper use and the safety risks involved with the
machining operation.
4. Never hold the job when the machine runs /Keep hands away from
moving/rotating machinery.
5. Never give heavy cut on longer job
6. Never change the gear and belt when the machine is running
7. Always use the correct size spanner and tool for fitting and removing
of tool
8. Never try to clear the chips when the machine is running
9. To prevent accident, clean the spilled oil and grease immediately
10. Always clear the area around the machine and machine tool surface
11. No open toed shoes or sandals are allowed in the shop. Wear closed
toe shoes (Leather shoes or boots with steel toes are recommended).
12. Do not wear loose clothing. Cotton clothes are best to wear. Always
wear an apron as it will protect your clothes and hold loses clothing
such as ties in place.
13. Remove all jewellery and tie back long hair.
14. Do not leave any machinery or power tools running and unattended.
15. Clean up metal shavings, oil, etc. from machine tools after use; pick
up after yourself and return tools to their proper storage area.
16. Always be patient, don’t run, push or surprise other students, you
could ‘bump’ into another pupil and cause an accident. No horse play
will be tolerated
17. Know where the emergency stop buttons are positioned in the
workshop. If you see an accident at the other side of the workshop
you can use the emergency stop button to turn off all electrical
power to machines.
18. When attempting practical work all stools should be put away.
19. When learning how to use a machine, listen very carefully to all the
instructions given by the teacher. Ask questions, especially if you do
not fully understand.
20. Always use a guard when working on a machine.
21. Use hand tools carefully, keeping both hands behind the cutting edge.
22. Bags should not be brought into a workshop as people can trip over
them.
CONTENTS
Marks
Ex. Page Sign. of
Date Experiment out of
No. No. Staff
10
Study of Centre Lathe
Study of Shaper
1 Taper Turning
2 External Thread cutting
3 Internal Thread Cutting
4 Eccentric Turning
5 Knurling
6 Square Head Shaping
7 Hexagonal Head Shaping
Study of Foundry
8 Mould For a Solid Pattern – Stepped Pulley
9 Mould for a split pattern – dumbbells
Study of Welding
10 Lap Joint using Gas Welding
11 Single V Butt Joint using Arc welding
12 T-Fillet Joint using Arc welding

Study No.:
Date:
STUDY OF LATHE
AIM
To study about the lathe Machine and its parts function.
INTRODUCTION
Machining is the process of converting the given work piece into the required shape
and size with help of a machine tool. The most widely used machine tool 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 operations on 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”.
BASIC WORKING PRINCIPLE OF LATHE
In lathe, the work piece is held in the chuck, a work holding device. The cutting tool
is mounted in the tool post. The chuck is rotated by means of power. When the chuck
rotates, the work piece also rotates. The tool is moved against the rotating work piece by
giving small amount of depth of cut. The material is removed in the form of chips.
Continuous feed and depth of cut is given until the required dimensions are obtained in the
work piece.
TYPES OF LATHE MACHINES
There are different types of lathe machines, they are
1. Centre lathe
2. Tool room lathe
3. Bench lathe
4. Capstan lathe
5. Turret lathe
6. Automatic lathe
CENTRE LATHE:
A centre lathe is also called an engine lathe or simply a lathe. It is one of the commonest
and oldest machine tools. It is also one of the most versatile and widely used machines.
Its main function is production of cylindrical profiles. A centre lathe is shown in Fig. 1.1.
DESCRIPTION OF LATHE
Lathe is a machine which has several parts in it. They are
1. Bed
It is the base of the machine. On its left side, the head stock is mounted and on its right
it has movable casting known as tailstock. Its legs have holes to bolt down on the ground.
2. Head stock
It consists of spindles, gears and speed changing levers. It is used to transmit the
motion to the job. It has two types one is the headstock driven by belt and the other one is
the gear driven.
3. Carriage
Carriage is used to carry a tool to bring in contact with the rotating work piece or to
with draw from such a contact. It operates on bed ways between the headstock and tail
stock.
4. Saddle
It is an ‘H’ shaped part fitted on the lathe bed. There is a hand wheel to move it on the
bed way. Cross slide, compound rest, tool post is fitted on this saddle.
a) Cross slide
It is on the upper slide of saddle in the form of dove tail. A hand wheel is provided to drive
the cross slide. It permits the cross wise movement of the tool (i.e.) movement of tool
towards or away from the operator
b) Compound rest
It is fitted over the cross slide on a turn table. It permits both parallel and angular
movements to cutting tool.
c) Tool post
It is fitted on the top most part of the compound rest. Tool is mounted on this tool post.
Cutting tool is fixed in it with the help of screws.
5. Apron
It is the hanging part in front of the carriage. It accommodates the mechanism of

hand and power feed to the cutting tool for carrying out different operations.
Fig. 2 Apron
6. Lead screw
It is a long screw with ACME threads. It is used for transmitting power for automatic
feed or feed for thread cutting operation.
7. Tail stock
It is located at the right end of the lathe bed and it can be positioned anywhere in the
bed. It is used for supporting lengthy jobs and also carries tool to carry out operations
such as tapping, drilling, reaming.
Fig. 3 Tailstock
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 head
stock spindle. Various types of chuck are
a) Two jaw chuck b) Three jaw chuck c) Four jaw chuck d) Collet chuck
e) Magnetic chuck
Fig. 4 Three Jaw Universal self-centering chuck
Fig. 5 Four Jaw Independent chuck
3. Face plate
Fig. 6 Face Plate

4. Catch plate
5. Lathe carriers or dog’s
6. Steady rest
7. Mandrel
8. Follower rest
CUTTING TOOLS USED
For making a finished job on lathe machine, various types of cutting tools are used. One
of them is single point cutting tool which is used to perform several operations on the work
piece. Various types of cutting tools are
Fig. 7 Cutting Tools
1. Facing Tool
It is used for facing the longitudinal ends of the job. Its shape is like a knife.
2. Rough Turning Tool
It is used to remove excess material from the work piece in quick time. It can be
used to give large depth of cut and work at coarse feed.
3. Finishing Tool
It is used for getting smooth finish on the work piece. Its point is a little more round.
4. Radius Tool
Jobs which need round cutting are done with this tool. Its types are
a) Convex radius tool b) Concave radius tool
5. Parting Tools
It is used to cut the jobs into two parts. It is also used for grooving.
6. Form Turning Tool
It is used for jobs which require both convex and concave turning.
7. Thread Cutting Tool
It is used for making internal or external threads on the work piece. The tool nose
is designed with a definite profile for taking threads.
8. Drill Tool
It is used for making holes of various diameters on the job. Drill bit of various sizes of
diameter are available.
Fig. 8 Drill Tool
9. Boring Tool
It used for enlarging the drill hole.
10. Knurling Tool
Drawing slanting or square projecting lines on the surface of a job is known as

knurling. It is used for making better grip on the surface of a job.
TOOL MATERIALS
1. The single point cutting tools are made of high speed steel. (H. S. S)
2. The main alloying elements in 18 – 4 – 1 HSS tools are 18 % tungsten, 4% chromium and
1 % Vanadium. 5 to 10 % cobalt is also added to improve the heat resisting properties of
the tool.
3. General purpose hand cutting tools are usually made from carbon steel or tool steel.
4. Carbide tipped tools fixed in tool holders, are mostly used in production shops.
NOMENCLATURE OF SINGLE POINT CUTTING TOOL
Fig. 9 Nomenclature of Single Point Cutting Tool
CUTTING TOOL ANGLES
1) Top rake angle (back rake angle)
a. If the slope is given to the face or surface of the tool and if this slope is along the
tools length then it is called top rake angle. It is usually 15° to 20°.
2) Side rake angle
a. If the slope is given to the face or top of the tool along the tools width then it is
called side rake angle. It lies between 6° and 15°.
3) Clearance angle (relief angle)
a. Types:
1. Side clearance angle

2. End clearance angle.
b. They are provided to keep surface of the tool clear of the work piece.
4) Cutting edge angle (Types)
1. Side cutting edge angle – (generally 15°) it is an angle, the side cutting edge
makes with the axis of the tool.
2. End cutting edge angle – (from 7° to 15°) it is an angle, the end cutting edge makes
with the width of the tool.
5) Lip angle (cutting angle)
a. It is the angle between the face and the end surface of the tool.
6) Nose angle
b. It is the angle between the side cutting edge and end cutting edge.
LATHE OPERATIONS
1. Facing
 It is done for getting fine finish (good surface finish) on the face of the job.
 Facing tool is set at an angle to the work piece.
 The tool is fed from the centre of work piece towards the outer surface against the
rotating work piece.
 Depth of cut is low for the facing operation.
Fig. 10 Facing
2. Plain Turning
 It is done for reducing the diameter of the work piece.
 A cutting tool with 70° setting angle is used for roughing operation.
 More feed is given for rough turning while less feed is given for finishing.
 Work piece is held in chuck and tool is set to center height of the work piece.
Fig. 11 Plain Turning
3. Step Turning
 It is similar to the process of turning but in this case different diameter in step of
various sizes is taken on the work piece.
4. Taper Turning
 It is different from the turning operation.
 Taper is defined as uniform change in the diameter of a work piece measured along
its length.
Fig. 12 Taper Turning
The angle is determined by using the formula
tanα = (D – d) / 2l
Where,
D – Large Diameter
d – Small diameter
l – Length of taper
5. Knurling
 It is process of making serrations on the work piece.
 Knurling tools of different shape and size are used to make grip on the work piece. It
has two hardened steel rollers.
 The tool is held in tool post and pressed against the rotating work piece.
 Work piece is rotated at lower speed and small amount of feed is given.
6. Drilling
 It is a process of making a hole on the work piece
 Job is held in chuck while the drill is held in the tail stock sleeve.
 Feed is given by rotating the hand wheel in the tail stock which pushes the tailstock
sleeve.
CUTTING SPEED
 It is the peripheral speed of the work past the cutting tool.
 It is the speed at which metal is removed by the tool from the work piece.
 It is expressed in meter / minute.
Cutting speed = (π x diameter x R.P.M) / 1000
Where, D – Diameter in
mm N – Spindle speed in rpm
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/revolution.
DEPTH OF CUT
• It is the perpendicular distance measured from the machined surface to the uncut surface of
work. It is expressed in mm.
Where, d1 = diameter of work before machining
d2 = diameter of work after machining.
RESULT
Thus the basic machining was studied.

Study No.:
Date:
STUDY OF SHAPING MACHINE
AIM
To study about the shaping machine.
INTRODUCTION
Both shapers and planers are machine tools which produce a flat surface. They are capable
of machining a horizontal, vertical or inclined flat surface. They employ single- point cutting
tools which are essentially similar to single-point cutting tools used on lathe. In both these
machine tools, the cutting tool is subjected to interrupted cuts, the tools cuts in forward
direction and is idle in the return direction.
NOTE:
1. Cutting tool is in moving condition where as workpiece is stationary
2. Small length work piece only workable in shapers these are the main difference
between planer and shaper
CONSTRUCTION AND WORKING PRINCIPLE
 Shaper is a reciprocating type of machine tool. It is used for machining the surfaces.
 The surface may be horizontal and vertical indeed. The shaper has the main parts such
as base, table, column, cross-rail, ram and tool head. The base bolted to the floor, it is
made of C.I and absorbs entire load.
 The column is box type in which return mechanism of ram is provided. At the top of the
column, there are two mechanical I guide ways. The ram reciprocating on their guide
ways in the front vertical guide ways in which the table the rectangular hallow block. It
slides rail is mounted guide ways of iron-rail. It has machine surface on the top and
slides. These surfaces have T slots for clamping work. The rail carries the tool head in
which the tool head is in vertical position. The ram reciprocation on the guide ways on
top of column.
 The work is held on the table by using correct work holding device. A single tool is in
vertical position of the cutting stroke (forward bias) the feed is given at the end of each
cutting stroke during the return stroke, no metal is cut. The cutting stroke takes place
at slow speed and the return stroke takes place at a faster speed. The faster feed rate is
obtained using quick return.
 By adjusting the work piece position as tool position step cutting, v-cutting, etc…., is
machined in shaping machine.
Principle of working principle parts of shaper are shown in fig.2.1 Shaper

CUTTING TOOLS USED IN SHAPING
The cutting tools for shapers are generally made of H.S.S., either solid or with brazed tips.
Due to interrupted cuts, tungsten carbide tools are not preferred for shaping work. These
tools are made sturdy with fairly generous size for shank and tip. Various types of tools
useful for shaping are shown in Fig. 2.3.
OPERATIONS PERFORMED ON SHAPERS:
On a shaping machine, relatively small jobs can be machined. The size of a shaper is
denoted by the maximum length of stroke of its ram and work pieces longer than the
maximum stroke cannot be machined. The first step in machining a job is to mount the job
on the shaper-table and clamp it tightly in the vice or on the table by means of T -bolts
etc. The second step is to adjust the stroke of ram according to the length of work piece.
The ram stroke is kept about 60–70 mm longer than job. The stroke can be reduced or
increased by altering the length of the crank AB (refer to Fig. 2.2). Now by changing the
position of the location where short link arm is connected to the ram, the stroke is made
to overlap the job, so that the stroke starts 30–35 mm before the job and covers the whole
length of work piece and ends 30–35 mm beyond it. A tool is now selected and clamped
in the tool post. The depth of cut is given by rotating the hand wheel and lowering the tool
slide. Depth of cut is not given by raising the table height. Table height is adjusted only at
the time of fixing the job according to the height of job. Feed is given by shifting the table
laterally. The feed to the table can be given either manually or automatically. The feed is
given during the return stroke of ram.
Contour cutting is a very skillful job as it calls for simultaneous operation of horizontal table
feed as well as vertical hand feed of the cutting tool. It can be performed only by a very
skilled operator.
Conclusion:
There are many accessories and fittings, which, if provided greatly improve the
performance and range of work which can be carried out on a shaping machine.
TAPER TURNING JOB DRAWING
EVALUATION OF JOB:
Dimensions Actual Dimension Obtained Dimension Deviation
Length (mm)
Diameter (mm)
MARKS
Materials Supplied: Mild Steel Rod Ø25x 102mm
Tool Material: High Speed Steel (H.S.S)
Model Calculation:
Compound Rest Method:
Tan Ө = (D-d)/ 2L or Ө =tan-1(D-d) / 2L
Where:
D = Major diameter of the work piece in mm
d = Minor diameter of the work piece in mm
L =Taper length of the work piece in mm

Ex. No:
Date:
TAPER TURNING
AIM:
To machine the given cylindrical rod as per the diagram, by using the lathe
machine.
TOOLS REQUIRED:
1. Chuck Key
2. Tool post spanner
3. Turning tool
4. Chamfering tool
5. Vernier caliper
6. Steel rule
MATERIALS REQUIRED:
Mild Steel Rod Ø25x 102mm
PROCEDURE:
1. The work piece is held in the lathe chuck.
2. The tool is set at lathe axis.
3. The work piece is rotated about lathe axis.
4. The facing and plain turning operations are carried out to the required
dimensions.
5. The step is machined at the end of the work piece.
6. The carriage is clamped on the bed at required place.
7. The compound rest base is swivelled to the required taper angle and it is
tightened.
8. By moving the cross slide the angular feed is given the required dimensions.
9. The taper cylindrical surface is machined.
10. Then both ends of the job are chamfered by chamfering tool.
RESULT:
The given work piece machined as per the diagram by using the lathe
machine.
EXTERNAL THREAD CUTTING JOB DRAWING
Materials Supplied: Mild Steel Rod Ø25x 102mm

Tool Material: High Speed Steel (H.S.S)
Parting diameter calculation
Parting diameter = Major diameter – 2 x 0.613 x pitch
= 15-2 x 0.613 x 2
= 15-2.452 mm
= 13 mm
EVALUATION OF JOB:
Length (mm)
OD ID Pitch OD ID Pitch OD ID Pitch

Diameter(mm)
MARKS
Ex. No:
EXTERNAL THREAD CUTTING
Date:
AIM:
To machine the given cylindrical rod as per the diagram, by using the lathe machine.
TOOLS REQUIRED:
1. Chuck Key
3. Turning tool
4. Chamfering tool
5. Vernier caliper
6. Centre gauge
7. Steel rule
PROCEDURE:
1. The work piece is held in the lathe spindle and it is rotated about lathe axis
2. By adopting usual procedure the facing and plain turning operations are carried
out to the required dimensions.
3. Next the taper turning operation is carried out to the required dimensions by
compound rest method
5. Remove the chamfering tool and insert the parting tool. Then calculate parting
diameter and remove the material as per dimension.
6. The gear ratio is calculated and the suitable size gears are fitted in the change gear
train
7. The “V” tool is clamped in the tool post and it is set perpendicular to lathe axis
8. The tool is moved away from job end. After giving suitable depth of cut the
Parting diameter calculation
Parting diameter = Major diameter – 2 x 0.613 x pitch
= 15-2 x 0.613 x 2
= 15-2.452 mm
= 13 mm
Change Gear Calculation:
Half nut is engaged.
9. The required depth of cut is given and the cycle is repeated to obtain the
required depth.
RESULT:
The given work piece machined as per the diagram by using the lathe machine.
INTERNAL THREAD CUTTING JOB DRAWING
EVALUATION OF JOB:
Length (mm)
OD ID Pitch OD ID Pitch OD ID Pitch

Diameter(mm)
MARKS
Ex. No:
Date:
INTERNAL THREAD CUTTING
AIM:
TOOLS REQUIRED:
1. Chuck Key
3. Turning tool
4. Chamfering tool
5. Boring tool
6. Vernier caliper
7. Drill bit
8. Steel rule
9. Thread Cutting Tool (Internal)
PROCEDURE:
2. The tool is held in the tool post and it is set to lathe axis
3. The facing and turning operations are carried out to the required dimensions
4. Insert drill bit in the tail stock
5. Then tail stock is moved and positional in a particular place.
6. Then the tool is moved towards the work piece to carriage out the drilling operations
7. Remove the turning tool and insert boring tool and carrying out boring operation
8. Remove the turning tool and insert the thread cutting tool
9. Calculate the change gear and to set it.

10. Make the thread cutting pitch using internal thread cutting procedure
11. Remove the work piece from the chuck and check the dimension
RESULT:
The given work piece is machined as per the diagram using lathe machine.
ECCENTRIC TURNING JOB DRAWNG
EVALUATION OF JOB:
Length (mm)
D1 D2 D1 D2 D1 D2
Diameter(mm)
MARKS
Ex. No:
Date:
ECCENTRIC TURNING
AIM:
TOOLS REQUIRED:
1. Chuck Key
3. Turning tool
4. Chamfering tool
5. Vernier caliper
6. Drill bit ø 10mm
7. Steel rule
PROCEDURE:
2. The tool is held in the tool post and it is set to lathe axis
3. The facing and turning operations are carried out to the required dimensions
4. Then the axis of the work piece is shifted to the required eccentricity
5. The longitudinal feed is given to the required length and job is eccentrically turned.
6. Two or more cuts with suitable depth of cut are given to obtain required diameter
RESULT:
KNURLING JOB DRAWNG
Ex. No:
Date:
KNURLING
AIM
To machine a work piece by facing, plain turning, knurling operations using a

lathe.
MATERIALS REQUIRED
Mild steel polished round rod -  25 X 100 mm
TOOLS REQUIRED
1. Turning tool
2. Knurling tool
3. Outside Caliper
4. Steel Rule
5. Vernier Caliper
FORMULA
Time taken for knurling:
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 speed of the work piece is reduced.
6. The knurling operation is done using knurling tool.

7. Again the machine is switched on.
8. The machine is switched off.
9. The work piece is removed from the chuck and all the dimensions are
measured and checked.
RESULT
SQUARE HEAD SHAPING JOB DRAWNG
Materials Supplied: Cast Iron: 60mm X16mm

Tool Material: Carbide Tipped tool
EVALUATION OF JOB:
A1 A2 t A1 A2 t A1 A2 t
Size (mm)
MARKS
Ex. No:
Date:
SQUARE HEAD SHAPING
AIM
To machine the given rectangular block in the shaping machine
TOOLS REQUIRED
1. Round nose tool - 1 No
2. Vernier caliper - 1 No
3. Steel Rule - 1 No
4. Hammer, Punch, Scriber - 1 No
5. Try square - 1 No
6. Vernier height gauge - 1 No
PROCEDURE
1. The given raw material block is measured. The machining allowances are
noted. Then the job is coated with white chalk for marking purpose.
2. The job is position in the marking table. The vernier height gauge is set
to the correct dimensions as per the part drawing dimensions
3. After, the height -- mm is corrected in the vernier height gauge; the vernier
scriber is marked in the face sides of the rectangular block.
4. To identify the dimensions of the job, the marking lines are punched
5. The work piece is placed in the milling machine work holding device in
correct position. Tool is held in the head in suitable position.
6. The stroke length and initial cutting position are corrected by adjusting
the ram and table manually
7. The tool is held in the tool post in vertical position
8. Now, the machine is switched ON. The tool moves over the work, the
materials is removed from the work by the tool cutting force.
9. By giving cross-feed movement to the table, the total length of work is

machined, after completion of one cut, the depth of cut is adjusted in the
tool head. Then the next cut is taken.
10. By repeating the above same procedure, the other faces are machined
to the required dimensions
11. After completion of four faces, the work is removed from the vice, cleaned
and inspection is carried out. The job No / Roll No are punched in the face
side of the work.
RESULT
The given work piece is machined as per the dimension using milling
machine.
HEXAGONAL HEAD SHAPING JOB DRAWNG
Materials Supplied: Cast Iron: 60mm X16mm

Tool Material: Carbide Tipped tool
EVALUATION OF JOB:
A1 A2 t A1 A2 t A1 A2 t
Size (mm)
MARKS
Ex. No:
Date:
HEXAGONAL HEAD SHAPING
AIM
To produce hexagonal shaped block from a given cast iron block for the given
dimensions.
TOOLS REQUIRED
1. Handle
5. Centre punch
2. Spanner set
6. H.S.S. Shaping tool
3. Tri square
7. V shaped H.S.S. Shaping tool
4. Ball peen hammer
8. Scriber
INSTRUMENTS REQUIRED
1. Surface plate
2. Vernier height gauge
3. Angle plate
4. Vernier caliper
5. Degree protractor
MATERIALS REQUIRED
65 x 30 mm cast iron block- 1 no
SEQUENCE OF OPERATIONS
1. Job setting
2. Tool setting
3. Marking of hexagonal block
4. Machining of hexagonal block

PROCEDURE
1. Check the dimensions of the given block using Vernier caliper.
2. Hold the block in three jaw chuck in the lathe.
3. Using HSS turning/facing tool do the facing and turning operations on both the sides of
the work piece to the specified dimensions (60 x 16 mm)
4. After calculating the face of the hexagon for the given dimensions, marking hexagon
on the block is done using divider, center punch and hammer.
5. Hold the workpiece in the shaping machine vice so that one of the marked faces
is horizontal.
6. Fix the cutting tool in the tool post so that there is minimum over-hang from the
tool holder face.
7. The stroke length is adjusted according to the size of the block by rotating the
stroke adjusting hand wheel.
8. The calculated speed of the ram is adjusted by changing the position of V – belt on
the cone pulley.
Cutting speed =
Cutting speed = 18 m/min
9. The tool is moved away from the job and 1mm depth of cut is given.
10. First side of the hexagon is finished by moving (rotating) the longitudinal feed lead
screw (the feed should be to 1.25 mm per stroke).
11. The second side of hexagon is machined to the required dimensions by setting the
marked line of the hexagon parallel to the table as done in the first step.
12. This is repeated for all the six sides of the hexagonal block.
RESULT:
Thus the hexagonal shaped block is produced as per the given dimensions using
shaping machine.
STUDY OF FOUNDRY
INTRODUCTION:
Foundry is a process of shaping the metal components in their molten stage. It is the
also called as metal casting the shape and size of the metal casting is obtained
depends on the shape and size of the cavity produced in sand mould by using
wooden/ metal pattern.
Steps in foundry process
The Foundry process involves three steps.
(a) Making the required pattern
(b) Moulding process to produce the cavity in sand using pattern.
(c) Pouring the molten metal into the cavity to get casting.
PATTERN
A pattern is normally a wooden/ metal model or thermosetting plastic which is
replica of the cast product to be made. It is embedded in Moulding sand and suitable
ramming of moulding sand around the pattern is made. The pattern is then
withdrawn for generating cavity (known as Mould) in Moulding sand.
TYPES OF PATTERN
The types of the pattern and the description of each are given as under.
1. One piece or solid pattern
7. Follow board pattern
2. Two piece or split pattern
8. Gated pattern
3. Cope and drag pattern
9. Sweep pattern
4. Three-piece or multi- piece pattern
10. Skeleton pattern
5. Loose piece pattern
11. Segmental or part pattern
6. Match plate pattern
1. Single-piece or solid pattern: Solid pattern is made of single piece without joints,
partings lines or loose pieces. It is the simplest form of the pattern. Typical single
piece pattern is shown in Fig.
2. Two-piece or split pattern: When solid pattern is difficult for withdrawal from
the Mould cavity, then solid pattern is split in two parts. Split pattern is made in two
pieces which are joined at the parting line by means of dowel pins. The splitting at
the parting line is done to facilitate the withdrawal of the pattern. A typical example
is shown in Fig.
Pattern size:
Actual casting size +shrinkage allowance +shake allowance +finish allowance
1. Shrinkage allowance:
The liquid metal shrinks during solidification and it contraction to its room
temperature, so that the pattern must be made larger than the casting to provide for
total contraction.
2. Finishing allowance:
The casting is to be machined at some points then the casting should be
provided with excess metal for machining.
COMMON PATTERN MATERIALS
The common materials used for making patterns are wood, metal, plastic,
plaster, wax or Mercury.
Types of foundry sand
Moulding sands can also be classified according to their use into number of
varieties which are described below.
1. Natural sand:
Sand containing the silica grains and clay bond as found. It varies in grain size
and clay content. Collected from natural recourses.
2. Synthetic sand:
It is an artificial sand obtained by mixing relatively clay free sand, binder
(water and bentonoite). It is better moulding sand as its properties can be easily
controlled.
3. Facing sand:
Facing sand is just prepared and forms the face of the mould. It is directly next
to the surface of the pattern and it comes into contact molten metal when the mould
is poured. Initial coating around the pattern and hence for Mould surface is given by
this sand. This sand is subjected severest conditions and must possess, therefore,
high strength refractoriness.
4. Parting sand:
Parting sand without binder and moisture is used to keep the green sand not
to stick to the pattern and also to allow the sand on the parting surface the cope and
drag to separate without clinging
5. Green sand:
Green sand is also known as tempered or natural sand which is a just
prepared mixture of silica sand with 18 to 30 percent clay, having moisture content
from 6 to 8%. The clay and water furnish the bond for green sand. It is fine, soft,
light, and porous.
6. Dry sand mould:
Dry sand mould refers to a mould which is artificially dried before the molten
metal is poured into it. Dry sand moulds possesses more strength, rigidity and
thermal stability, which are costly, stronger, used for complicated castings, i.e. avoid
casting defects, casting gets smoother surface.
7. Loam sand:
Loam is mixture of sand and clay with water to a thin plastic paste. Loam sand
possesses high clay as much as 30-50% and 18% water.
8. Backing sand:
Backing sand or floor sand is used to back up the facing sand and is used to fill
the whole volume of the Moulding flask.
9. Core sand:
Core sand is used for making cores and it is sometimes also known as oil sand.
This is highly rich silica sand mixed with oil binders such as core oil which composed
of linseed oil, resin, light mineral oil and other bind materials.
MOULDING SAND
The general sources of receiving Moulding sands are the beds of sea, rivers,
lakes, granular elements of rocks, and deserts. Moulding sands may be of two types
namely natural or synthetic. Natural Moulding sands contain sufficient binder.
Whereas synthetic Moulding sands are prepared artificially using basic sand
Moulding constituents (silica sand in 88-92%, binder 6-12%, water or moisture
content 3-6%) and other additives in proper proportion by weight with perfect
mixing and mulling in suitable equipments.
Binder
In general, the binders can be either inorganic or organic substance. The
inorganic group includes clay sodium silicate and port land cement etc. In foundry
shop, the clay acts as binder which may be Kaolonite, Ball Clay, Fire Clay, Limonite,
Fuller’s earth and Bentonite. Binders included in the organic group are dextrin,
molasses, cereal binders, linseed oil and resins like phenol formaldehyde, urea
formaldehyde etc. Organic binders are mostly used for core making.
Among all the above binders, the Bentonite variety of clay is the most common.
However, this clay alone cannot develop bonds among sand grins without the
presence of moisture in Moulding sand and core sand.
Additives
Additives are the materials generally added to the Moulding and core sand
mixture to develop some special property in the sand. Some common used additives
for enhancing the properties of Moulding and core sands are discussed as under.
1. Coal dust:
Coal dust is added mainly for producing a reducing atmosphere during
casting.
2. Corn flour:
It belongs to the starch family of carbohydrates and is used to increase the
collapsibility of the Moulding and core sand
3. Dextrin:
Dextrin belongs to starch family of carbohydrates that behaves also in a
manner similar to that of the corn flour. It increases dry strength of the Moulds.
4. Sea coal:
Sea coal is the fine powdered bituminous coal which positions its place among
the pores of the silica sand grains in Moulding sand and core sand
5. Wood flour:
This is a fibrous material mixed with a granular material like sand; its
relatively long thin fibers prevent the sand grains from making contact with one
another.
6. Silica flour:
It is called as pulverized silica and it can be easily added up to 3% which
increases the hot strength and finish on the surfaces of the Moulds and cores
PROPERTIES OF MOULDING SAND

The basic properties required in Moulding sand and core sand are described
as under.
1. Refractoriness:
Refractoriness is defined as the ability of Moulding sand to withstand high
temperatures without breaking down or fusing thus facilitating to get sound casting.
It is a highly important characteristic of Moulding sands. Refractoriness can only be
increased to a limited extent
2. Permeability:
It is also termed as porosity of the Moulding sand in order to allow the escape
of any air, gases or moisture present or generated in the mould when the molten
metal is poured into it. All these gaseous generated during pouring and solidification
process must escape otherwise the casting becomes defective
3. Cohesiveness:
It is property of Moulding sand by virtue which the sand grain particles
interact and attract each other within the Moulding sand
4. Green strength:
The green sand after water has been mixed into it, must have sufficient
strength and toughness to permit the making and handling of the mould. For this, the
sand grains must be adhesive, i.e. thev must be capable of attaching themselves to
another body
5. Dry strength:
As soon as the molten metal is poured into the mould, the moisture in the
sand layer adjacent to the hot metal gets evaporated and this dry sand layer must
have sufficient strength to its shape in order to avoid erosion of mould wall during
the flow of molten metal
6. Flowability or plasticity:
It is the ability of the sand to get compacted and behave like a fluid. It will
flow uniformly to all portions of pattern when rammed and distribute the ramming
pressure evenly all around in all directions
7. Adhesiveness:
It is property of Moulding sand to get stick or adhere with foreign material
such sticking of Moulding sand with inner wall of Moulding box
8. Collapsibility:
After the molten metal in the mould gets solidified, the sand mould must be
collapsible so that free contraction of the metal occurs and this would naturally
avoid the tearing or cracking of the contracting metal.
HAND TOOLS USED IN FOUNDRY SHOP
Hand riddle:
It consists of a screen of standard circular wire mesh equipped with circular

wooden frame. It is generally used for cleaning the sand for removing foreign
material such as nails, shot metal, splinters of wood etc. from it. Even power
operated riddles are available for riddling large volume of sand.
Shovel:
It consists of a steel pan fitted with a long wooden handle. It is used in mixing,
tempering and conditioning the foundry sand by hand. It is also used for moving and
transforming the Moulding sand to the container and Moulding box or flask.
Sprue pin:
It is a tapered rod of wood or iron which is placed or pushed in cope to join

Mould cavity while the Moulding sand in the cope is being rammed.
Lifter:
A lifter is a finishing tool used for repairing the mould and finishing the mould sand.
Lifter is also used for removing loose sand from mould.
Trowels:
These are used for finishing flat surfaces and comers inside a mould. Common
shapes of trowels are shown as under. They are made of iron with a wooden handle.
Rammers:
Rammers are shown in Fig. These are required for striking the Moulding sand
mass in the Moulding box to pack or compact it uniformly all around the pattern.
Strike off bar:
It is a flat bar, made of wood or iron to strike off the excess sand from the top
of a box after ramming. It’s one edge made bevelled and the surface perfectly smooth
and plane.
Vent wire:
It is a thin steel rod or wire carrying a pointed edge at one end and a wooden
handle or a bent loop at the other. After ramming and striking off the excess sand it
is
used to make small holes, called vents, in the sand mould to allow the exit of gases
and steam during casting.
Slicks:
They are also recognized as small double ended Mould finishing tool which
are generally used for repairing and finishing the Mould surfaces and their edges
after withdrawal of the pattern.
Swab:
Swab is shown in Fig. It is a small hemp fiber brush used for moistening the
edges of sand mould, which are in contact with the pattern surface before
withdrawing the pattern. It is used for sweeping away the Moulding sand from the
Mould surface and pattern.
Bellows:
Bellows gun is shown in Fig. It is hand operated leather made device

equipped with compressed air jet to blow or pump air when operated. It is used to
blow away the loose or unwanted sand from the surfaces of Mould cavities.
Gate cutter:
Gate cutter is a small shaped piece of sheet metal commonly used to cut
runners and feeding gates for connecting sprue hole with the Mould cavity.
Draw spike:
Draw spike is shown Fig. It is a tapered steel rod having a loop or ring at its
one end and a sharp point at the other. It may have screw threads on the end to
engage metal pattern for it withdrawal from the Mould.
MOULDING BOX:
Moulding box is also called moulding flask. It is frame or box of wood or
metal. It is made of two parts cope and drag as shown in figure.
MOULD FOR A SPLIT PATTERN – DUMBBELLS
Step: 1 Place Drag part of the pattern on mould board and filled with mould sand
Step -2: Turn drag box upside down and Place cope box over drag box
Step -3: place cope part of the pattern, riser, Sprue, runner in position and filled with
mould sand.
Step-4: Finally the Mould cavity is produced by removing the pattern
Ex. No: MOULD FOR A SPLIT PATTERN –
Date: DUMBBELLS
AIM:
To prepare a Sand Mould using the given Split piece pattern.
RAW MATERIAL REQUIRED:
Moulding sand, Parting sand, facing sand, baking sand, Pattern, Bottom board,
Moulding boxes.
TOOLS REQUIRED:
1. Moulding board
2. Drag and cope boxes
3. Moulding sand
4. Parting sand
5. Rammer
6. Strike-off bar
7. Bellows
8. Riser and sprue pins
9. Gate cutter
10. Vent rod
11. Draw spike
12. Wire Brush
SEQUENCE OF OPERATIONS:
1. Sand preparation
2. Placing the mould flask (drag) on the moulding board/ moulding platform
3. Placing the split pattern at the centre of the moulding flask
4. Ramming the drag
5. Placing the pattern at the centre of the moulding flask (Cope box)
6. Placing runner and riser
7. Ramming the cope
8. Removal of the pattern, runner, riser
9. Gate cutting
PROCEDURE: MOULD MAKING
1. First a bottom board is placed either on the Moulding platform or on the floor,
making the surface even.
2. The drag Moulding flask is kept upside down on the bottom board along with
the drag part of the pattern at the centre of the flask on the board.
3. Dry facing sand is sprinkled over the board and pattern to provide a non-
sticky layer.
4. Freshly prepared Moulding sand of requisite quality is now poured into the
drag and on the split-pattern to a thickness of 30 to 50 mm.
5. Rest of the drag flask is completely filled with the backup sand and uniformly
rammed to compact the sand
6. After the ramming is over, the excess sand in the flask is completely scraped
using a flat bar to the level of the flask edges.
7. Now with a vent wire which is a wire of 1 to 2 mm diameter with a pointed
end, vent holes are in the drag to the full depth of the flask as well as to the
pattern to facilitate the removal of gases during casting solidification. This
completes the preparation of the drag.
8. Now finished drag flask is rolled over to the bottom board exposing the
pattern.
9. Using a slick, the edges of sand around the pattern is repaired and cope half of
the pattern is placed over the drag pattern, aligning it with the help of dowel
pins
10. The cope flask on the top of the drag is located aligning again with the help of
the pins of the drag box.
11. Dry parting sand is sprinkled all over the drag surface and on the pattern
12. Sprue of the gating system for making the sprue passage is located at a small
distance of about 50 mm from the pattern. The sprue base, runners and in
gates are also located as shown risers are also placed. Freshly prepared facing
sand is poured around the pattern.
13. The moulding sand is then poured in the cope box. The sand is adequately
rammed, excess sand is scraped and vent holes are made all over in the cope
as in the drag.
14. The sprue and the riser are carefully withdrawn from the flask
15. Later the pouring basin is cut near the top of the sprue.
16. The cope is separated from the drag any loose sand on the cope and drag
interface is blown off with the help of the bellows.
17. Now the cope and the drag pattern halves are withdrawn by using the draw
spikes and rapping the pattern all around to slightly enlarge the mould cavity
so that the walls are not spoiled by the withdrawing pattern.
18. The runners and gates are to be removed or to be cut in the mould carefully
without spoiling the mould.
19. Any excess or loose sand is applied in the runners and mould cavity is blown
away using the bellows.
20. Now the facing paste is applied all over the mould cavity and the runners
which would give the finished casting a good surface finish.
21. A dry sand core is prepared using a core box. After suitable baking, it is placed
in the mould cavity.
22. The cope is placed back on the drag taking care of the alignment of the two by
means of the pins.
23. The mould is ready for pouring molten metal. The liquid metal is allowed to
cool and become solid which is the casting desired.
Result:
The required mould cavity is prepared using the given Split pattern
STUDY OF WELDING
INTRODUCTION
Welding is a process for joining two similar or dissimilar metals by fusion. It joins
different metals/alloys, with or without the application of pressure and with or
without the use of filler metal. The fusion of metal takes place by means of heat. The
heat may be generated either from combustion of gases, electric arc, electric
resistance or by chemical reaction.
Welding provides a permanent joint but it normally affects the metallurgy of the
components. It is therefore usually accompanied by post weld heat treatment for
most of the critical components. The welding is widely used as a fabrication and
repairing process in industries. Some of the typical applications of welding include
the fabrication of ships, pressure vessels, automobile bodies, off-shore platform,
bridges, welded pipes, sealing of nuclear fuel and explosives, etc.
Most of the metals and alloys can be welded by one type of welding process or
the other. However, some are easier to weld than others. To compare this ease in
welding term ‘weldability’ is often used. The weldability may be defined as property
of a metal which indicates the ease with which it can be welded with other similar or
dissimilar metals.
WELDING PROCESS
Pressure Welding Non Pressure Welding

(With or without filler metal) (With or without filler metal)
Elements of welding process used with common welding joints such as base metal,
fusion zone, weld face, root face, root opening toe and root are depicted in Figure.
EDGE PREPARATIONS
For welding the edges of joining surfaces of metals are prepared first. Different edge
preparations may be used for welding butt joints, which are given in Figure.
ARC WELDING
PRINCIPLE
The process, in which an electric arc between an electrode and a work-piece
or between two electrodes is utilized to weld base metals, is called an arc welding
process. The basic principle of arc welding is shown in Figure.
However the basic elements involved in arc welding process are shown in
Figure. Most of these processes use some shielding gas while others employ coatings
or fluxes to prevent the weld pool from the surrounding atmosphere.
The metal pieces to be joined are cleaned thoroughly by means of wire brush.
Suitable electrode and current required for the metal to be welded is selected and
electrode is held in electrode holder.
The electrode and the work piece are brought nearer with a small air gap (3mm).
When the current passed, an electric arc is produced between the electrode and
work piece. The work piece is melted by the arc. The electrode is also melted. Both
molten pieces of metal become on. The electrode also supplies the additional filler
metal into the joint. The temperature of the arc is about 4000°C. A transformer or
generator is used for supplying the current.
Electrode is used in arc welding are generally coated with flux. Fluxes are used to
prevent the formation of oxides during welding. Fluxes are different for different
metals.
Equipments needed for arc welding
1) Switch box. 10) Hand shield
2) Secondary terminals 11) Channel for cable protection.
3) Welding machine. 12) Welding cable.
4) Current reading scale. 13) Chipping hammer.
5) Current regulating hand wheel. 14) Wire brush.
6) Leather apron. 15) Earth clamp.
7) Asbestos hand gloves. 16) Welding table (metallic).
8) Protective glasses strap 17) Job.
9) Electrode holder.
Arc Welding Equipment
Arc welding equipment, setup and related tools and accessories are shown in Figure.
However some common tools of arc welding are shown separately through Figure.
Few of the important components of arc welding setup are described as under.
1. Arc welding power source
Both direct current (DC) and alternating current (AC) are used for electric arc
welding, each having its particular applications. DC welding supply is usually
obtained from generators driven by electric motor or if no electricity is available by
internal combustion engines. For AC welding supply, transformers are
predominantly used for almost all Arc-welding where mains electricity supply is
available. They have to step down the usual supply voltage (200-400 volts) to the
normal open circuit welding voltage (50-90 volts). The following factors influence
the selection of a power source:
a. Type of electrodes to be used and metals to be welded
b. Available power source (AC or DC)
c. Required output
d. Duty cycle
e. Efficiency
f. Initial costs and running costs
g. Available floor space
h. Versatility of equipment
2. Welding cables
Welding cables are required for conduction of current from the power source
through the electrode holder, the arc, the work piece and back to the welding power
source. These are insulated copper or aluminum cables.
3. Electrode holder
Electrode holder is used for holding the electrode manually and conducting
current to it. These are usually matched to the size of the lead, which in turn matched
to the amperage output of the arc welder. Electrode holders are available in sizes
that range from 150 to 500 Amps.
4. Welding Electrodes
An electrode is a piece of wire or a rod of a metal or alloy, with or without

coatings. Electrode is used to create an arc. In general, flux coated electrodes are
used. Flux is a thin layer of some chemical component. The flux coating provides the
following
a) Protect the joint.
b) Stabilize arc.
c) Increase deposition accuracy.
d) Improves arc penetration.
e) Add alloying element to weld metal
An arc is set up between electrode and workpiece. Welding electrodes are
classified into following types-
(i) Consumable Electrodes
(a) Bare Electrodes
(b) Coated Electrodes
(ii) Non-consumable Electrodes
(a) Carbon or Graphite Electrodes
(b) Tungsten Electrodes
Consumable electrode is made of different metals and their alloys. The end of this
electrode starts melting when arc is struck between the electrode and workpiece.
Thus consumable electrode itself acts as a filler metal. Bare electrodes consist of a
metal or alloy wire without any flux coating on them. Coated electrodes have flux
coating which starts melting as soon as an electric arc is struck. This coating on
melting performs many functions like prevention of joint from atmospheric
contamination, arc stabilizers etc.
Non-consumable electrodes are made up of high melting point materials like
carbon, pure tungsten or alloy tungsten etc. These electrodes do not melt away
during welding. But practically, the electrode length goes on decreasing with the
passage of time, because of oxidation and vaporization of the electrode material
during welding. The materials of non-consumable electrodes are usually copper
coated carbon or graphite, pure tungsten, thoriated or zirconiated tungsten.
5. Hand Screen / Protection Shield
As the rays of arc welding are very harmful for naked eyes, hence a shield which
has special glasses is used by the welder for protection of eyes and supervision of
weld bead.
6. Goggles
Goggles are used to protect the eyes while removing the slag or flux from the
welding.
7. Chipping hammer
Chipping Hammer is used to remove the slag by striking.

8. Wire brush
Wire brush is used to clean the surface to be weld.

9. Gloves
Hand gloves are used to protect the arms from spark and ultraviolet rays and
electrical shock.
10. Protective clothing / Apron
Operator wears the protective clothing such as apron to keep away the
exposure of direct heat and from spark to the body.
11. Tongs
It is used to handle the hot metal or welding job for cleaning and hammering.
Safety Recommendations for ARC Welding:
The beginner in the field of arc welding must go through and become familiar with
these general safety recommendations which are given as under.
1. The body or the frame of the welding machine shall be efficiently earthed. Pipe
lines containing gases or inflammable liquids or conduits carrying electrical
conductors shall not be used for a ground return circuit All earth connections
shall be mechanically strong and electrically adequate for the required current.
2. Welding arc in addition to being very is a source of infra-red and ultra-violet
light also; consequently the operator must use either helmet or a hand-shield
fitted with a special filter glass to protect eyes
3. Excess ultra-violet light can cause an effect similar to sunburn on the skin of the
welder
4. The welder’s body and clothing are protected from radiation and burns caused
by sparks and flying globules of molten metal with the help of the following:
5. Gloves protect the hands of a welder.
6. Leather or asbestos apron is very useful to protect welder’s clothes and his trunk
and thighs while seated he is doing welding.
7. For overhead welding, some form of protection for the head is required
8. Leather skull cap or peaked cap will do the needful.
9. Leather jackets and 1ather leggings are also available as clothes for body
protection.
10. Welding equipment shall be inspected periodically and maintained in safe
working order at all times.
11. Arc welding machines should be of suitable quality.
12. All parts of welding set shall be suitably enclosed and protected to meet the
usual service conditions.
GAS WELDING
OXY – Acetylene welding
In gas welding, gas flame is used to melt the edges of metals to be joined. The
flame is produced at the tip or a welding torch. Oxygen and acetylene are the gases
used to produce the welding flame. The flame will only melt the metal. So additional
metal to the weld is supplied by a filler rod. A flux is used during welding to prevent
oxidation and to remove impurities. Metals 2mm to 50mm thick are welded by gas
welding. The temperature of oxy-acetylene flame is about 320°C.
Gas Welding Equipments
Gas Cylinders
For gas welding we need oxygen and acetylene. These two gases are stored in
separate cylinders. Oxygen cylinder is generally painted black colour. Acetylene
cylinder is generally painted maroon colour. Pressure of oxygen in the cylinder is
125kg/cm2. Pressure of acetylene in the cylinder is 16kg/cm2.
Regulators
There is one regulator on the oxygen and another on the acetylene cylinder. The
regulators are used to reduce and control the working pressure of the gases. The
working pressure of oxygen is around 1kg/cm2. The working pressure of acetylene is
around 0.15kg/cm2. The working pressure of both gases varies depending upon the
thickness of the work pieces welded.
Pressure Gauges
There are two pressure gauges on the oxygen cylinder regulator and two on the
acetylene cylinder regulator. One pressure gauge will show the cylinder pressure.
The other one will show the working pressure for welding.
Hoses
Oxygen cylinder regulator is connected with a long hose. It is generally black in
colour. The acetylene regulator is connected to a long hose generally red in colour.
The hose takes the gas from regulator to the torch.
Welding Torch
Oxygen and acetylene enter the torch from the hose in separate passages. Both
the gases mix in the mixing chamber of the torch. When ignited, a flame is produced
at the tip of the torch. There are two control valves on the welding torch. They are
used to control the quantity of oxygen and acetylene to adjust the flame. The tip of
the welding torch can be changed for welding different thickness of metal.
Types of Flame
The correct adjustment of the flame is important for getting the desired result. By
varying the ratio of oxygen and acetylene the following three types of flames can be
obtained.
1. Neutral flame 2. Carburizing flame 3. Oxidizing flame
1. Neutral flame
This name has equal quantities of oxygen and acetylene. Maximum temperature
of about 3200°C is produced. Neutral flame has two zones viz, one sharp bright inner
cone and one bluish outer cone. Neutral flame is used for most welding operations.
Because this flame has minimum chemical effect on heated metal.
2. Carburizing flame
This name is also reducing flame. Carburizing flame has more acetylene than
oxygen. This flame has three zones. (a) Sharp inner cone. (b) White intermediate
feather cone. (c) Blue outer cone. Carburizing flame is used for welding very low
carbon steel, a few alloy steels and aluminium.
3. Oxidizing flame
This name has more oxygen than acetylene. This flame has two zones, viz, one
smaller inner cone and one outer cone. This flame is used for welding brass and
bronze.
Filler Rods for Gas Welding
Filler rod is the rod which is used in gas welding to supply additional metal to
make joint. It is melted by the heat or the gas flame and the molten metal is
deposited over the base metals. The metal or the filler rod depends upon the base
metal. The diameter of the filler rod depends upon the thickness of the work piece.
Different alloying elements such as chromium and nickel can be added to the filler
rod. Filler rods are lightly coated with copper to prevent oxidation of the hot metal.
Flux can be used in powder or liquid form.
Welding joints
Some common welding joints are shown in Figure. Welding joints are of generally of
two major kinds namely lap joint and butt joint. The main types are described as
under.
1. Lap weld joint
Single-Lap Joint
This joint, made by overlapping the edges of the plate, is not recommended
for most work. The single lap has very little resistance to bending. It can be used
satisfactorily for joining two cylinders that fit inside one another.
Double-Lap Joint
This is stronger than the single-lap joint but has the disadvantage that it
requires twice as much welding.
Tee Fillet Weld
This type of joint, although widely used, should not be employed if an
alternative design is possible.
2. Butt weld joint
a. Single-Vee Butt Weld
It is used for plates up to 15.8 mm thick. The angle of the Vee depends upon
the technique being used, the plates being spaced approximately 3.2 mm.
b. Double-Vee Butt Weld
It is used for plates over 13 mm thick when the welding can be performed on
both sides of the plate. The top Vee angle is either 60° or 80°, while the bottom
angle is 80°, depending on the technique being used.
Welding Positions
As shown in Fig., there are four types of welding positions, which are given as:
a. Flat or down hand position
b. Horizontal position
c. Vertical position
d. Overhead position
Flat or Down-hand Welding Position
The flat position or down hand position is one in which the welding is
performed from the upper side of the joint and the face of the weld is approximately
horizontal.
Horizontal Welding Position
In horizontal position, the plane of the workpiece is vertical and the deposited
weld head is horizontal. This position of welding is most commonly used in welding
vessels and reservoirs.
Vertical Welding Position
In vertical position, the plane of the work-piece is vertical and the weld is
deposited upon a vertical surface. It is difficult to produce satisfactory welds in this
position due to the effect of the force of gravity on the molten metal.
Overhead Welding Position
The overhead position is probably even more difficult to weld than the
vertical position. Here the pull of gravity against the molten metal is much greater.
LAP JOINT
Ex. No:
Date:
LAP JOINT
AIM:
To make a Lap joint, using the given two M.S pieces and by Gas welding.
MATERIAL SUPPLIED:
Mild steel plate of size 60 x 50 x 5 mm – 2 No’s
WELDING EQUIPMENT:
1. Gas Cylinders
2. Regulator
3. Pressure Gauge
4. Welding Torch
5. Lighter
6. Filler rod
7. Hose
TOOLS AND ACCESSORIES REQUIRED:
1. Flat file
2. Steel rule
3. Try square
4. Tongs
5. Face shield / Goggles
6. Apron
7. Chipping hammer.
1. Edge preparation (Removal of rust, scale etc.) by filling
2. Try square levelling
3. Welding
4. Cooling
5. Chipping
6. Cleaning
PROCEDURE:
1. The given M.S pieces are thoroughly cleaned of rust and scale.
2. The two pieces are positioned on the welding table such that, the two pieces
overlapped one over the other as shown in drawing.
3. Select proper size tip for the job and fix into the torch.
4. Select the filler rod for required size.
5. Adjust the welding equipment and light the torch
6. Adjust the torch for Neutral flame
7. Hold the torch with the inner cone 3 mm away from the metal and tack well
the piece at the ends.
8. Weld the work piece by moving the torch zigzag and with the filler rods.
9. The scale formation on the welds is removed by using the chipping hammer.
RESULT:
The Lap joint is thus made, using the tools and equipment as mentioned.
SINGLE V BUTT JOINT
Ex. No:
Date:
SINGLE V BUTT JOINT
AIM:
To make a Butt joint using the given two M.S pieces by arc welding.
MATERIAL REQUIRED:
Mild steel plate of size 100X50X5 mm – 2 No’s
WELDING ELECTRODES:
M.S electrodes 3.1 mm X350 mm
WELDING EQUIPMENT:
Air cooled transformer
Voltage-80 to 600 V 3 phase supply, amps up to
350
TOOLS AND ACCESSORIES REQUIRED:
7. Welding electrode
1. Mild steel electrode and electrode
8. Chipping hammer
holder
9. Gloves
2. Ground clamp
10. Wire brush
3. Tongs
11. Safety goggles
4. Face shield
12. Steel rule
5. Apron
6. Chipping hammer.
1. Edge preparation (removal of rust, scale, etc)
2. Tacking
3. Welding
4. Cooling
5. Chipping
6. Cleaning
PROCEDURE:
1. The given M.S pieces are thoroughly cleaned of rust and scale.
2. One edge of each piece is believed, to an angle of 30°, leaving nearly ¼ th of
the flat thickness, at one end.
ME3382- MANUFACTURING TECHNOLOGY LAB
3. The two pieces are positioned on the welding table such that,
they are separated slightly for better penetration of the weld.
4. The electrode is fitted in the electrode holder and the welding
current is ser to be a proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron and using the face shield, the arc is struck
and holding the two pieces together; first run of the weld is
done to fill the root gap.
7. Second run of the weld is done with proper weaving and with
uniform movement. During the process of welding, the
electrode is kept at 15° to 25° from vertical and in the direction
of welding.
8. The scale formation on the welds is removed by using the chipping hammer.
9. Filling is done to remove any spanner around the weld.
RESULT:
The single V-butt joint is thus made, using the tools and equipment
as mentioned above
77
INTRODUTION TO GEARS AND MACHINES
Bevel gears Bevel gears are used mostly in situations that require power to be
transmitted at right angles (or applications that are not parallel). Bevel
gears can have different angles of application but tend to be 90°
Helical gears Helical gears are very similar to spur gears except the teeth are not
perpendicular to the face. The teeth are at an angle to the face giving
helical gears more tooth contact in the same area.
Helical gears can also be used on non-parallel shafts to transmit motion.
Helical gears tend to run quieter and smoother than spur gears due to the
increased number of teeth in constant contact at any one period of time
Herringbone Herringbone gears resemble two helical gears that have been placed side
gears by side. They are often referred to as "double helicals".
One benefit of herringbone gears is that it helps to avoid issues related to

side thrust created with the use of helical gears
Worm Gears
Worm gears are used to transmit power at 90° and where high reductions
are required. The worm resembles a thread that rides in concaved or
helical teeth
Spur Gears Spur gears are by far the most common type of gear and with the
exceptions of the "cog" the type of gear that has been around the longest.
Spur gears have teeth that run perpendicular to the face of the gear
Internal Gears
Internal gears typically resemble inverted spur gears but are occasionally
cut as helical gears
Racks
A rack is basically a straight gear used to transmit power and motion in a

linear movement.
Face Gears
Face gears transmit power at (usually) right angles in a circular motion. Face
gears are not very common in industrial application
Sprockets
Sprockets are used to run chains or belts. They are typically used in
conveyor systems
78
MILLING MACHINE
2. MILLING MACHINE
Milling is the process of removing metal by feeding the work piece through a rotating
multipoint cutter. Milling machine can be used for machining flat surfaces, complex and irregular
areas, surface of revolution, external and internal threads, gear cutting, helical surface of cross
sections.
1. Base
2.Column
3.Knee
4.Saddle
5.Table
6.Spindle
7.Arbor
2.1. BASE:
It is the foundation of the machine and is that part upon which all parts are mounted.
It gives the machine rigidity and strength.
79
2.2. COLUMN:
It is the main supporting frame. The motor and other driving mechanisms are contained
within it.
2.3 KNEE:
The knee projects from the column and slides up and down on its face. It supports the
saddle and table and partially supported by the elevating screw which adjusts its height.
2.4. SADDLE:
The saddle supports and carries the table and is adjustable transversely on ways on top
of the knee. It is provided with graduations for exact movement and operated by power or hand.
2.5. TABLE:
The table rests on ways on the saddle and travels longitudinally in a horizontal plane.
It supports the works piece, fixtures and all other equipment’s.
2.6. SPINDLE:
The spindle obtains its power from the motor through motors. Cutters are mounted
directly in the spindle nose.
2.7. ARBOR:
The arbor is an accurately machined shaft for holding and driving the arbor cutter.
It is tapered at one end to fit the spindle nose and two slots to fit the nose keys for locating and
driving it
80
SHAPER
1. Table support
2. Table
3. Clapper box
4. Apron clamping bolts
5. Down feed hand wheel
6. Swivel base degree graduations
7. Position of stroke adjustment hand wheel
8. Ram block locking handle
9. Ram
10. Column
11. Driving pulley
12. Base
13. Feed disc
14. Pawl mechanism
15. Elevating screw
3. SHAPER
The shaper is a reciprocating type of machine tool intended primarily to produce flat
surfaces. These surfaces may be horizontal, vertical, or inclined.
The principal parts of a standard shaper are:

1. Base
81
2. Column
3. Cross rail
4. Saddle
5. Table
6. Ram
7. Tool head
3.1 BASE
The base is the necessary bed or required for all machine tools. The base may be rigidly
bolted to the floor of the shop or on the bench according to the size of the machine. It is so
designed that it can take up the entire load of the machine and the forces set up by the cutting
tool over the work. It is made of cast iron to resist vibration and take up high compressive
load.
3.2 COLUMN
The column is a box like casting mounted upon the base. It encloses the ram driving
mechanism. Two accurately machined guide ways are provided on the top of the column on
which the ram reciprocates. The front vertical face of the column, serves as the guide ways for
the cross rail. The lid on the left side of the column may be opened for inspection and oiling of
the internal mechanism.
3.3 CROSSRAIL
The crossrail is mounted on the front vertical guide ways of the column. It has two
parallel guide ways on its top in the vertical plane that is perpendicular to the ram axis. The
table may be raised or lowered to accommodate different sizes of jobs by rotating elevating
screw, which causes the cross rail to slide up and down on the vertical face of the column. A
horizontal cross feed screw, which is fitted within the cross rail and parallel to the top guide
ways of the cross rail actuates the table to move in a crosswise direction.
3.4 SADDLE
The saddle is mounted on the crossrail, which holds the table firmly on its top.
Crosswise movement of the saddle by rotating the cross feed screw by hand or power causes
the table to move sideways.
3.5 TABLE
The table is bolted to the saddle receives crosswise and vertical movements from the
saddle and cross rail. It is a box like casting having T-slots both on the top and sides for
82
clamping the work. In a universal shaper the table may be swiveled on a horizontal axis and
the upper part of the table may be tilted up or down.
3.6 RAM
The ram is the reciprocating member of the shaper. This is semi cylindrical in form and
heavily ribbed inside to make it more rigid. It slides on the accurately machined dovetail
guide ways on the top of the column and is connected to the reciprocating mechanism
contained within the column. It houses a screwed shaft for altering the position of the ram
with respect to the work and holds the tool head at the extreme forward end
83
Gear Hobbing Machining

GEAR HOBBING
Gear Hobbing is a technique that is employed to create gear teeth configurations that are
ideal for use in a wide range of machinery components. In cases where the gear hobbing takes
place in a mass producing environment, gear hobbing is accomplished through the use of
precision gear hobbing machines that ensure that the cut of each tooth on each gear produced
meets the specifications set by the producer.
Generally, a gear hobbing machine will make use of a series of customized bits that help
to create the specific types of cutting and shaping necessary to create gears those posses
exactly the right pitch and circle to work in various types of equipment. A customized bit is
used for a particular size and type of gear hobbing, which helps to ensure that the cuts that
are made into the blank surface of the circle of metal are relatively smooth and uniform.
*********************************************************************
CNC MACHINES
84
G-CODES AND M-CODES

G00 - Positioning at rapid speed; Milling and Turning
G01 - Linear interpolation (machining a straight line); Milling and Turning
G02 - Circular interpolation clockwise (machining arcs); Milling and
Turning G03 - Circular interpolation, counter clockwise; Milling and
Turning
G04 - Milling and Turning, Dwell
G09 - Milling and Turning, Exact stop
G10 - Setting offsets in the program; Milling and Turning
G12 - Circular pocket milling, clockwise; Milling
G13 - Circular pocket milling, counterclockwise; Milling
G17 - X-Y plane for arc machining; Milling and Turning with live tooling G18
- Z-X plane for arc machining; Milling and Turning with live tooling G19 - Z-
Y plane for arc machining; Milling and Turning with live tooling G20 - Inch
units; Milling and Turning
G21 - Metric units; Milling and Turning
G27 - Reference return check; Milling and Turning
G28 - Automatic return through reference point; Milling and Turning
G29 - Move to location through reference point; Milling and Turning (slightly
different for each machine)
G31 - Skip function; Milling and Turning
G32 - Thread cutting; Turning
G33 - Thread cutting; Milling
G40 - Cancel diameter offset; Milling. Cancel tool nose offset; Turning
G41 - Cutter compensation left; Milling. Tool nose radius compensation left;
Turning G42 - Cutter compensation right; Milling. Tool nose radius
compensation right; Turning
G43 - Tool length compensation; Milling
G44 - Tool length compensation cancel; Milling (sometimes G49)
G50 - Set coordinate system and maximum RPM; Turning
G52 - Local coordinate system setting; Milling and Turning
G53 - Machine coordinate system setting; Milling and Turning
G54~G59 - Work piece coordinate system settings #1 t0 #6; Milling and
Turning
G61 - Exact stop check; Milling and Turning
85
G65 - Custom macro call; Milling and Turning

G70 - Finish cycle; Turning
G71 - Rough turning cycle; Turning
G72 - Rough facing cycle; Turning
G73 - Irregular rough turning cycle; Turning
G73 - Chip break drilling cycle; Milling
G74 - Left hand tapping; Milling
G74 - Face grooving or chip break drilling; Turning
G75 - OD groove pecking; Turning
G76 - Fine boring cycle; Milling
G76 - Threading cycle; Turning
G80 - Cancel cycles; Milling and Turning
G81 - Drill cycle; Milling and Turning
G82 - Drill cycle with dwell; Milling
G83 - Peck drilling cycle; Milling
G84 - Tapping cycle; Milling and Turning
G85 - Bore in, bore out; Milling and Turning
G86 - Bore in, rapid out; Milling and Turning
G87 - Back boring cycle; Milling
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Milling
G92 - Thread cutting cycle; Turning
G94 - Per minute feed; Milling
G95 - Per revolution feed; Milling
G96 - Constant surface speed control; Turning
G97 - Constant surface speed cancel
G98 - Per minute feed; Turning
G99 - Per revolution feed; Turning
86
CNC M Codes
M00 - Program stop; Milling and Turning

M01 - Optional program stop; Turning and Milling
M02 - Program end; Turning and Milling
M03 - Spindle on clockwise; Turning and Milling
M04 - Spindle on counterclockwise; Turning and Milling
M05 - Spindle off; Turning and Milling
M06 – Tool change; Milling
M08 - Coolant on; Turning and Milling
M09 - Coolant off; Turning and Milling
M10 - Chuck or rotary table clamp; Turning and Milling M11 - Chuck or rotary
table clamp off; Turning and Milling M19 - Orient spindle; Turning and
Milling
M30 - Program end, return to start; Turning and Milling M97 - Local sub-
routine call; Turning and Milling M98 - Sub-program call; Turning
and Milling
M99 - End of sub program; Turning and Milling
87
Contour milling using vertical milling machine
ALL DIMENSIONS ARE IN mm
88
Contour milling using vertical milling machine
Ex No:
AIM:
To cut a Key way as given in diagram a Contour milling using vertical milling machine
MATERIALS REQUIRED:
Casting square block 50 * 50 mm
TOOLS REQUIRED:
Vernier height gauge, Vernier caliper, parallel block, Milling cutter
PROCEDURE:
1. The marking was made on the job by placing the work piece and Vernier height gauge on the
surface plate. The Vernier height gauge was used for marking
2. The work piece was placed on the vice using the parallel block for the required height
3. Before placing it on the vice the punch was made on the marking
4. The end milling cutter was fixed and the table was adjusted until the axis of work piece and
cutter coincides
5. The machine was started and the table was moved right to left
6. The feed was given and the same operation was done until to get the required depth as given in
the diagram
RESULT:
Thus the key way was made using the Contour milling using vertical milling machine
89
SPUR GEAR CUTTING IN MILLING MACHINE
90
SPUR GEAR CUTTING IN MILLING MACHINE

Ex No:
AIM
To perform spur gear cutting using vertical milling machine on a work piece.
INTRODUCTION:
Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk with the
teeth projecting radially, and although they are not straight-sided in form (they are usually of special form to
achieve constant drive ratio, mainly involute), the edge of each tooth is straight and aligned parallel to the axis of
rotation. These gears can be meshed together correctly only if they are fitted to parallel shafts.
MATERIAL USED:
Cast iron blank
TOOLS REQUIRED:
Vertical Milling machine, Vernier caliper, Holding Materials, Milling Tools and Mandrel
PROCEDURE:
1. The dividing head and the tail stock are bolted on the machine table. Their axis must be set parallel to the
machine table.
2. The gear blank is held between the dividing head and tailstock using a mandrel. The mandrel is
connected with the spindle of dividing head by a carrier and catch plate.
3. The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank. Set the
speed and feed for machining.
4. For giving depth of cut, the table is raised till the periphery of the gear blank just touches the cutter.
5. The micrometer dial of vertical feed screw is set to zero in this position. Then the table is raised
further to give the required depth of cut.
6. The machine is started and feed is given to the table to cut the first groove of the blank.
7. After the cut, the table is brought back to the starting position. Then the gear blank is indexed for
the next tooth space.
8. This is continued till all the gear teeth are cut.
91
SPUR GEAR CALCULATION:
Given:
No of Teeth [T]= 18
Module[m] = 2.5mm
Outer Diameter OD = [T+2] mm
Depth of Cut = Constant Value * Module
= 2.25 * 2.5
= 5.625
Indexing Formula = 40
----
N
40 4
= --------- = 2 -------
18 18
RESULT:
The given work piece as is subjected to gear generating operation to become a finished work piece
92
HELICAL GEAR CUTTING IN MILLING MACHINE
GEAR HOP CUTTER MODULE = 3

NO OF TEETH = 20
HELICAL O.D = 14˚ [RH]
BLANK O.D = 60
TOOTH DEPTH = 6.75
DEPTH OF CUT = 4.3
HELICAL GEAR BEFORE MILLING
93
HELICAL GEAR AFTER MILLING
94
HELICAL GEAR CUTTING IN MILLING MACHINE

Ex No:
Aim:
To perform Helical Gear Cutting using milling machine on a work piece.
INTRODUCTION:
Helical or "dry fixed" gears offer a refinement over spur gears. The leading edges of the teeth are not
parallel to the axis of rotation, but are set at an angle. Since the gear is curved, this angling causes the tooth
shape to be a segment of a helix. helical gears can be meshed in parallel or crossed orientations.
MATERIAL USED:
Cast iron
TOOLS REQUIRED:
Vertical Milling machine, Vernier caliper, Holding Materials and Milling Tools
DIAGRAM:
95
HELICAL GEAR FORMULAS
To Obtain Having Formula

Number of Teeth (N) & Pitch p = N/D
Transverse Diametral Pitch Diameter (D)
(P)
Normal Diametral Pitch (Pa) P = PNCOSw
Helix Angle (w )
Number of Teeth (N) &
Pitch Diameter (D Transverse Diametral Pitch D=N/P
(P)
Normal Transverse Diametral Pitch
PN = P / COS
Diametral Pitch (PN) (P) & Helix Angle
Normal Circular Tooth Normal Diametral Pitch (PN) = 1.5708/PN
Thickness (t)
Transverse Circular Pitch (pt) Diametral Pitch (P) Pt = /P
(Transverse
Normal Transverse Circular Pitch (p) Pn = pt Cos
Circular Pitch (pn)
Pitch Diameter and Pitch
Lead (L) L= D/ Tan
Helix Angle
PROCEDURE:
1. The dividing head and the tail stock are bolted on the machine table.
2. Their axis must be set parallel to the machine table.
3. The gear blank is held between the dividing head and tailstock using a mandrel. the mandrel is
connected with the spindle of dividing head by a carrier and catch plate.
4. The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.
5. Set the speed and feed for machining.
6. For giving depth of cut, the table is raised till the periphery of the gear blank just touches the cutter.
7. The micrometer dial of vertical feed screw is set to zero in this position.
8. Then the table is raised further to give the required depth of cut.
9. The machine is started and feed is given to the table to cut the first groove of the blank.
10. After the cut, the table is brought back to the starting position. Then the gear blank is indexed for
the next tooth space.
11. This is continued till all the gear teeth are cut.
96
HELICAL GEAR CALCULATION:
Given:
No of teeth [T] = 25
Cutter Module [m] = 2mm
Helix Angle [α] = 15°
Normal Module [mn] = m cos α
= 2 * cos15°
= 2 * 0.965 = 1.931mm
Outer Diameter[OD] = PCD + 2mm
= 50 + 2 * 1.931 =53.86mm
Depth of Cut = Constant Value * Normal Value
= 2.25 * 1.931 = 4.3mm
Gear Ratio = Lead of Helix [Driven Gear]
------------------------------------------
Lead of Machine [Driven Gear]
27
= ------
10
3 9
= -------- * ---------
2 5
3*16
= -------
2*16
48 9 5 72 [driven]
-------- ; -------- * -------- = ----------- -------------
32 8 8 40 [driver]
RESULT:
The given work piece as is subjected to gear generating operation to become a finished work piece
97
GEAR GENERATION IN HOBBING MACHINE
HELICAL GEAR BEFORE HOBBING
HELICAL GEAR AFTER HOBBING
98
GEAR GENERATION IN HOBBING MACHINE

Ex No:
INTRODUCTION:
Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets on a Hobbing
machine, which is a special type of milling machine. The teeth or splines are progressively cut into the work piece
by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively
inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities.
AIM:
To machine a Spur Gear using a gear Hobbing machine.
MATERIALS REQUIRED:
Cast iron blank
TOOLS REQUIRED:
1. Gear Hobbing machine
2. Hob
3. Gear tooth vernier
4. Spanners
PROCEDURE:
1. The given work piece is held firmly on the spindle of the gear HOBBING machine
2. The Hob is set at an angle to the hob helix angle for cutting spur gear.
3. The change gears are set for the desired speed of work piece and Hob and feed of the Hob.
4. The machine is switched on.
5. The work piece and Hob are allowed to rotate at the desired speed.
6. The hob or work piece is given full depth of cut equals to the tooth depth.
7. The cutter is given feed for the full width of the work.
8. After machining all gear teeth on the blank the machine is switched off.
9. The gear teeth are checked using a gear tooth Vernier.
99
CALCULATIONS:
Given:
No of Teeth [T] = 45
Module [M] = 2mm
Helix Angle [α] = 15˚
Normal Module [mn] = m cos[α]
= 2*cos 15
= 2* 0.965
= 1.931mm
Outer Diameter [OD] = MT + 2mm
= 2*45 + 2*1.931
= 93.86mm
Depth of Cut = Constant Value * Normal Value
= 2.25 * 1.931
= 4.3mm
RESULT:
The given work piece as shown in fig (1) is subjected to gear generating operation to become a finished
work piece as shown in fig (2).
100
GEAR GENERATION IN SHAPER MACHINE
101
GEAR GENERATION IN SHAPER MACHINE

Ex No:
AIM:
To machine a Spur Gear using a gear shaper machine.
MATERIALS REQUIRED:
Cast iron blank
TOOLS REQUIRED:
1. Gear Shaper machine
2. Gear tooth Vernier
3. Spanners
PROCEDURE:
1. The given work piece is held firmly on the spindle of the gear shaping machine
2. The work piece is set at an angle to shaping tool angle for cutting spur gear.
3. The change gears are set for the desired speed of work piece and
4. The machine is switched on.
5. The work piece and Shaper are allowed to remove the metal at the desired speed.
6. The work piece is given full depth of cut equals to the tooth depth.
7. The cutter is given feed for the full width of the work.
8. After machining all gear teeth on the blank the machine is switched off.
9. The gear teeth are checked using a gear tooth Vernier.
102
CALCULATIONS:
Given
No of teeth = 27
Cutter Module = 8DP
Outer Diameter No of teeth in Job + 1.6

= -----------------------------------
8DP
27+1.6
= -------
8DP
28.6
= ------- = 3.575”
8
= 90.80 mm
No of Teeth on Cutter A C 1
Gear Setting Formula = --------------------------------- * -------- * ----------- - -------
No of Teeth on Gear [Job] B D 1
32 81 30 1
= -------- * --------- * ------- - -------
27 32 90 1
1.8 1.8
Depth of Cut = ------ = ------- = 0.225” = 5.715 mm
DP 8
RESULT:
The given work piece as shown in fig (1) is subjected to gear generating operation to become a finished
work piece as shown in fig (2). In gear Shaping Machine
103
PLAIN SURFACE GRINDING
ALL
DIMENSIONS ARE IN mm
104
PLAIN SURFACE GRINDING

Ex No:
AIM:
To perform a Plain surface grinding operation on the given work piece for the given dimensions.
PRINCIPLE:
The principle involved in this process is to make flat surface on the given work piece.
The cutter is moved perpendicular to the work piece and the grinding is done.
REQUIREMENTS
1. Surface Grinding Machine
2. Work Piece 50x50x5.8 mm
3. Grinding Wheel
PROCEDURE:
1. At first work piece is placed in the magnetic chuck.

2. The work piece should be light weight so that it cannot be removed from the magnetic chuck easily.
3. Various arrangements regarding the positions of work piece is done.
4. Grinding wheel and grinding spindle are kept in position with the work piece.
5. Before switching on the motor, necessary steps should taken. For proper grinding process wheel
speed, work speed, transverse speed of the wheel in feed, area of contact is to be noted.
6. While running the area of contact is adjusted accordingly to the spindle in order to remove the
surface.
7. It is done slowly to remove the materials on the both sides.
8. In surface grinding the stock removal rate is given by Q = bdy Where d =depth of cut (m) b =width of
cut (m) y =work velocity (m/s) q =rate of stroke (m3/s)
RESULT:
Thus the surface grinding is done for the given dimensions
105
CYLINDRICAL GRINDING
ALL
DIMENSIONS ARE IN mm
106
CYLINDRICAL GRINDING
Ex No:
AIM:
To grind the cylindrical surface of the given materials as per the given dimensions
REQUIREMENTS:
1. Grinding Machine
2. Grinding Wheel
3. Work Piece
4. Steel rule.
5. Outside calipers.
6. Cutting tool.
PROCEDURE:
1. The given work piece is first fitted in the chuck of the lathe.
2. By fitting the tool in tool post the work piece will be reduced to given dimensions.
3. First reduce the diameter to 25mm size then reduced the diameter to 24.5mm
4. By facing the work piece to the tool work piece is reduced to 110mm.
5. After the preliminary lathe operation, the work piece is held in the ends of the cylindrical grinder.
6. The grinding wheel is turned on and it is moved towards the work piece such that the surfaces of the
cylindrical position are grinded to +-0.2mm.
RESULT:
Thus the required dimension of cylindrical surface is obtained.
107
MEASUREMENT OF CUTTING FORCES IN MILLING

TURNING PROCESS
S.No. Depth of Cut X-Force Y-Force Z-Force Speed r.p.m.

Axial Force Radial Force Tangential
Force
1
2
3
4
5
6
7
9
108
MEASUREMENT OF CUTTING FORCES IN MILLING

TURNING PROCESS
Ex No:
AIM:
To measure the cutting forces for the given cutting conditions.
TOOLS AND EQUIPMENTS REQUIRED:
Lathe, Milling Tool Dynamometer
PROCEDURE:
1. The Lathe Tool Dynamometer is initially set to zero reading.

2. The known depth of cut is given and take the readings of P x and Pz force components from the
Lathe Tool Dynamometer.
3. Calculate the resultant cutting force
P = Sqrt (Px2 + Pz2)
4. Repeat the same procedure to get few more readings and calculate the mean cutting force.
5. Repeat the same procedure for different depth of cuts.
CALCULATIONS:
t1 = Uncut Chip Thickness

t2 = Chip Thickness
Ft {Fx} = Thrust Force
Fc {Fy} = Cutting Force
Thrust Force, Ft = N
Cutting Force, Fc = N
a, t1 {Uncut Chip Thickness} = mm
b, t2 {Chip Thickness} = mm
RESULT:
Thus the cutting forces are measured for different depth of cuts.
109
Centerless Grinding Machine
110
Centerless Grinding Machine
Ex No:
INTRODUCTION
Centerless grinding is a machining process that uses abrasive cutting to remove material from a work
piece. Centerless grinding differs from centered grinding operations in that no spindle or fixture is used to locate
and secure the workpiece. the workpiece is secured between two rotary grinding wheels, and the speed of their
rotation relative to each other determines the rate at which material is removed from the workpiece
AIM:
To reduce the size of outer diameter of given workpiece using centreless grinding machine
REQUIREMENTS:
1. Regulating wheel
2. Work Piece
3. Grinding Wheel
PROCEDURE:
1. The given circular specimen is placed in between regulating wheel and grinding wheel.
2. Regulating wheel is support the specimen and grinding wheel will remove the material
3. The specimen stands in the work rest
4. Regulating wheel and grinding wheel is rotating together with specimen in work rest.
5. Specimen also rotating in the mean while grinding process done
6. Finally reduce is the diameter of the specimen
RESULT:
Thus the reduce the size of outer diameter is made on a given specimen as per the dimensions required
using centreless grinding machine
111
112

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DEPARTMENT OF MECHANICAL ENGINEERING

ME 3382 – MANUFACTURING TECHNOLOGY LAB

1. Always wear uniform, shoes and gloves for safety

2. Always wear goggles to protect your eyes from flying chips.

3. Do not operate any machine equipment unless you have been

5. Never give heavy cut on longer job

8. Never try to clear the chips when the machine is running

9. To prevent accident, clean the spilled oil and grease immediately

13. Remove all jewellery and tie back long hair.

20. Always use a guard when working on a machine.

2 External Thread cutting

3 Internal Thread Cutting

6 Square Head Shaping

7 Hexagonal Head Shaping

8 Mould For a Solid Pattern – Stepped Pulley

9 Mould for a split pattern – dumbbells

10 Lap Joint using Gas Welding

11 Single V Butt Joint using Arc welding

12 T-Fillet Joint using Arc welding

To study about the lathe Machine and its parts function.

BASIC WORKING PRINCIPLE OF LATHE

TYPES OF LATHE MACHINES

There are different types of lathe machines, they are

2. Tool room lathe

Lathe is a machine which has several parts in it. They are

It is the hanging part in front of the carriage. It accommodates the mechanism of

WORK HOLDING DEVICES

Fig. 4 Three Jaw Universal self-centering chuck

Fig. 5 Four Jaw Independent chuck

Fig. 6 Face Plate

5. Lathe carriers or dog’s

CUTTING TOOLS USED

Fig. 7 Cutting Tools

2. Rough Turning Tool

6. Form Turning Tool

7. Thread Cutting Tool

Fig. 8 Drill Tool

It used for enlarging the drill hole.

10. Knurling Tool

Drawing slanting or square projecting lines on the surface of a job is known as

NOMENCLATURE OF SINGLE POINT CUTTING TOOL

Fig. 9 Nomenclature of Single Point Cutting Tool

CUTTING TOOL ANGLES

1) Top rake angle (back rake angle)

2) Side rake angle

3) Clearance angle (relief angle)

1. Side clearance angle

4) Cutting edge angle (Types)

5) Lip angle (cutting angle)

 Facing tool is set at an angle to the work piece.

 Depth of cut is low for the facing operation.

 It is done for reducing the diameter of the work piece.

Fig. 11 Plain Turning

 It is different from the turning operation.

The angle is determined by using the formula

 It is process of making serrations on the work piece.

 It is a process of making a hole on the work piece

 It is expressed in meter / minute.

Cutting speed = (π x diameter x R.P.M) / 1000

mm N – Spindle speed in rpm

 It is defined as the rate of tool travel across a surface cutting it.

Where, d1 = diameter of work before machining

d2 = diameter of work after machining.