UNESCO-NIGERIA TECHNICAL &

VOCATIONAL EDUCATION
REVITALISATION PROJECT-PHASE II

NATIONAL DIPLOMA IN
MECHANICAL ENGINEERING TECHNOLOGY

MACHINE TOOLS TECHNOLOGY

AND PRACTICE
COURSE CODE: MEC123

YEAR I- SEMESTER 2PRACTICAL

Version 1: December 2008
 UNESCO-NIGERIA TECHNICAL &
VOCATIONAL EDUCATION
REVITALISATION PROJECT-PHASE II

TABLE OF CONTENTS

WEEK 1:
Identification of cutting fluids used for machining different materials.
Selection of cutting tools for various operations.
WEEK 2:
No practical
WEEK 3:
- Identify cutting fluids used for machining different materials.
- Selection of cutting tools used for machining different materials.
WEEK 4
Identify types of lathe machines, its parts and attachments for various operations.
Demonstrate how to fix and remove attachments from machine.
. Turning a bush from mild steel bar.
WEEK 5
Turning operations on a mild steel bar
WEEK 6
Step turning of the mild steel bar.
WEEK 7
Threading of turned and drilled ends of the work piece
WEEK 8
Identification of the parts of shaping machine
WEEK 9
Identification of parts of horizontal milling machine
WEEK 10
Perform gear cutting using dividing head and index plate.
WEEK 11
Continuation of gear cutting
WEEK 12
To carry out internal grinding operation
WEEK 13
To balance a grinding wheel
WEEK 14
To true and dress a grinding wheel
WEEK 15
To grind a flat surface
WEEK 1
Identification of cutting fluids used for machining different materials.
Selection of cutting tools for various operations.

WEEK 2
No practical

WEEK 3
- Identify cutting fluids used for machining different materials.
- Selection of cutting tools used for machining different materials.
WEEK 4
1. Identify types of lathe machines, its parts and attachments for various operations.

Turning
The lathe is a machine tool used for shaping metal (and sometimes wood or other

Fig 1. The centre lathe

materials) by causing the work piece to be held and rotated by the lathe while a tool bit is
advanced into the work causing the cutting action.
Turning is the machining operation that produces cylindrical parts. In its basic form, it
can

be defined as the machining of an external surface:

 with the work piece rotating,

with a single-point cutting tool, and

with the cutting tool feeding parallel to the axis of the work piece and at a
distance that will remove the outer surface of the work.

A basic manual centre lathe is shown below. This type of lathe is controlled by a person
turning the various handles on the top slide and cross slide in order to make a product /
part.

Fig 2. Center Lathe Main Parts

Head Stock: Produce the main motion and houses the main spindle and its driving
arrangement. The gear trains give different revolution to the main spindle.

Lathe Bed: it carries the lathe parts and guides the carriage and tailstock.

The Carriage: Transmits the adjusting and feed motions to the tool and moves the
tool over the different surfaces of the work piece.
Tail Stock: It can be moved along the lathe bed and locked in any position to support
the long work pieces. Also, it can be used for centering, drilling, and taper operations.

Safety Precautions

A lathe can be very dangerous if not handled proper, even though it is equipped with
various safety guards. Below are some of the important safety regulation which should be
observed:
1) Always wear the approved safety working dress
2) Never attempt to run a lathe until you are familiar with its operation
3) Never wear rings or watches when operating lathe
4) Always stop the lathe before taking measurements
5) Always use a brush to remove chips. Do not use bare hands
6) Before mounting or removing accessories, always sheet off the power supply to
the motor.
7) Do not take heavy cuts on long slender pieces. It could cause the work to bend
and fly out of the machine.
8) Do not lean on the machine, but stand erect.
9) Keep the floor free of grease and oil, which could cause dangerous falls.
2. Demonstrate how to fix and remove attachments from machine.
Practical task taken: Mounting a lathe chuck with a tapered spindle nose.
Objective: Teach the students how to mount the lathe chuck on the spindle.
Materials and equipments: Lathe chuck key, block of wood, a cylindrical bar to fit the
spindle, and centre lathe machine.
Procedure:
- Clean the spindle nose and taper in the chuck.
- Turn the spindle until the key is at the top.
- Place a block of wood across the ways of the lathe.
- Hold the chuck with the keyway to the top and place it on the spindle.
- Tighten the slotted nut with a hook spanner or chuck key.
Fig 3 mounting a lathe chuck with a tapered spindle nose.

3. The fig below shows a bush to be produced from mild steel bar. Turn this bush in one
setting.

Fig 4 Turned bush.

Practical task taken; To turn a bush in one setting.

Objective: To teach the students how to carry out simple turning.
Materials and equipments: Mild steel bar, facing tool, turning tool, centre drill, parting
tool, and a lathe machine.
Procedure
1. Chucking:
The bar is held in a three jaw chuck with sufficient material allowed to ensure that the
component can be removed from the lathe by parting off.
2. Face end:
The purpose of facing is to provide a datum face.
3. Rough turn 25mm diameter ×35mm.
4. Rough turn 35mm diameter×7mm.
5. Centre and rough drill hole 24mm ×48mm.
6. Finish turn outside diameters.
7. Finish drill hole.
8. Chamfer end 2×45˚.
9. Semi-part off and chamfer 2×45˚.
10. Part off.

Fig 5. Operational sequence for a turned bush.

WEEK 5
The fig 5.0 below is a plug shaft made from mild bar of diameter 40mm and length of
122mm. Produce the job as presented in the fig. All dimensions are in mm.

Fig 6.0 Machined piece

Practical task taken: Turning of a plug shaft
Objective: To teach the students how to carry out the following lathe operations; parallel
turning, taper turning, threading, drilling, parting and knurling.
Materials and equipments; Turning tool, knurling tool, parting tool, smooth file, vernier
caliper, and a lathe machine.
Procedure

-Cut off a piece of steel with at least 2mm in excess of the specified
dimension in length and diameter respectively.

Fig 6.1 Work piece material

-Hold the work (more than half of its length) in a three-jaw chuck.
-Clamp the cutting tool and set the tool to centre with the lathe centre.
Face one end square, and centre drill.

Fig 6.2 a

Fig 6.3b Setting lathe tool to centre prior to cutting.

 .

Fig 6.4Centre drills.

Fig 6.4 a
Fig 6.4 a and b, Centre drilling
Week 6

- Step turn to diameter φ40mm x 37.5mm.

Fig 7.0 Step turned bar

Note: The purpose of the rough cut is to remove excess metal as
quickly as possible.

Fig7.1 Step turned, parted bar

-Continue to step turn .

-Turn tapers on the φ 30mm x 30mm on the work piece by
Calculating the angle of as follows: Tan θ = 5/30
θ = tan-1 = 5/30

-Swivel the compound slide until 100 mark coincides with the
reference line, then control the tuning using only the top slide.
Fig 7.2 Step turned, taper turned bar.

-Use a knurling tool by holding it in a tool holder to knurl φ37mm x 17.5mm

given
-Rough drill a hole of φ 8.5mm x 20mm through the right side of the work.
Finish up hole with a reamer.
 Week 7

- Cut internal thread using a set of M10 taps and wrench.

- Cut external thread using die

Threading
A thread is a spiral or helical ridge found on nuts (Internal Thread) and bolts
(External threads).

Fig 8.0 Description of a thread form

Pitch: is the distance between corresponding points (crests)

Dicing (External Thread):
Dies are used for cutting external threads on round bar or tubes. Dies are made of
Hardened High Carbon Steel or High Speed Steel.

Fig 8.1 External threads die

Split die is held in place in the stock. The split permits a small amount of adjustment in
the size of the die by adjusting the screws in the stock. Since split dies cut their thread
complete in one cut, the die thread are tapered and back off for one third of their length.

Fig 8.2 A split die

Tapping (Internal thread):
Taps are used to cut the internal screw threads. Taps are made of hardened High Carbon
Steel or High Speed Steel. The ends of the shank are square to fit a wrench. Usually taps
are provided in set of three -- taper, second and plug tap.

Fig 8.3 Thread tap handle

Fig 8.4 Set of thread taps

Taper Tap
The tap is tapered off for a length of 8 to 10 threads and is the first tap to be used in a
hole to start the thread form.
Second Tap
The tap is tapered off for a length of 4 to 5 threads to facilitate picking up the threads cut
by the taper tap.
Plug Tap
This is fully threaded throughout its length and is called a 'bottoming' tap. This tap used
to cut the bottom of a blind hole.

Fig 8.5 Taper taps

Fig 9 Machined component

 WEEK 8
PRACTICAL TASK

Identification of the parts of shaping machine

OBJECTIVE:
For the students to be familiar with the various parts of shaping machine
EQUIPMENT
Shaping machine assembly

Fig 9.0 the shaping machine

A. Ram
B. Tool slide
C. Handle for clamping ram
D. Screw for adjusting position of ram
E. Screw for locking tool slide unit
F. Speed change lever
G. starting lever
H. Vertical/horizontal feed selector
I. Feed directional control
J. Lever for adjustment of feed
K. Horizontal table adjustment screw
L. Vertical table adjustment
M. Feed shaft
N. Tool box

WEEK 9
1. Identification of parts of horizontal milling machine
2. Selection and mounting of different types of cutters for different jobs.
3. Selection and uses of various types of work and cutter holding devices for
different types of jobs.
WEEK 10
PRACTICAL TASK
Perform milling exercises using dividing head and index plate.
OBJECTIVE;
To rotated a job through required angle in other to cut gear.
MATERIAL/ EQUIPMENT
- Mild steel block
- Dividing head assembly
- Horizontal milling machine
- Set of spanners
- Cutting fluid
- Cutting tools (gear cutters)
- Vernier caliper

PROCEDURE
- The dividing head assembly is bolted to the milling machine table at
the right hand end.
- The work is held on the dividing head between the head and tailstock
centers.
- Set the arbor of the machine.
- Lock the table.
- Mount the work-piece between centers using driving dog.
- Calculate the indexing.
- Select the index plate.
- Calculate the whole depth.
- Cut the first tooth to confirm the land.
- Index round the work-piece.
- Debarred the work-piece for good surface finish.

Calculation:
A 52-tooth gear with an 8 diametric pitch (DP) is required.
Solution:
a. Outside diameter =N+2/DP
54/8 =6.750in.
b. Whole depth of tooth =2.157/DP
=2.157/8 =0.2697in.
c. Cutter number = 3 (35 to 54 teeth).
d. Indexing (using Cincinnati standard plate)
= 40/N
= 40/52
 = 1013 × 33 = 30 holes on the 39-hole circle.
Turn the gear blank to the proper outside diameter (6.750in.)
- Mount the index head and footstock, and check the alignment of the
index centers (fig11.2)
- Set the dividing head so that the index pin fits into a hole on the 39-
hole circle and the sector arms are set for 30 holes.
- Move the table close to the column to keep the setup as rigid as
possible.
- Mount an 8DP#3 cutter on the milling machine arbor over the
approximate center of the gear. Be sure to have the cutter rotating in
the direction of the indexing head.
- Center the gear black with the cutter by either of the following
methods;
(a) place a square against the outside diameter of the gear as
in fig11.3. With a pair of inside calipers or a rule, check the distance
between the square and the side of the cutter. Adjust the table until the
distances from both sides of the gear blank to the sides of the cutter are
the same.
(b) A more accurate method of centralizing the cutter is to
use gage blocks instead of the inside calipers or rule.
-Lock the cross slide.

Fig 10.1 Worm shaft & the lead screw are connected for helical milling.
Fig 11.2 Centering a gear cutting and the work-piece
WEEK 11

(CONTINUATION OF GEAR CUTTING)

- Raise the table until the cutter just touches the work. This can be done
by using a chalk mark on the gear blank or a piece of paper between the
gear blank and the cutter to indicate when the cutter is just touching the
work. (fig 11.3)
- Set the graduated feed collar on the vertical feed to zero.
-Move the work clear of the cutter by means of the longitudinal feed
handle and raise the table to about two-third the depth of the
tooth(0.180in.); then lock the knee clamp.
- Slightly notch all gear teeth on the end of the work to check for correct
indexing fig. 11.4.
- Rough out the first tooth and set the automatic feed trip dog after the
cutter is clear of the work.
- Return the table to the starting position.
NOTE: Clear the end of the work with a cutter.
- Cut the remaining teeth and return the to the stating position.
- Loosen the knee clamp, raise the table to the proper depth of 0.270in.,
and lock the knee clamp.
- Finish cut all the teeth.
NOTE: After each tooth has been cut, the cutter should be stopped before
the table is returned to prevent marring the finish on the gear teeth.
Fig12.1 setting the cutter to the diameter of the work-piece.
Fig 12.2 notching all gear teeth eliminates errors.
WEEK 12
PRACTICAL TASK
To carry out internal grinding operation
OBJECTIVE
To demonstrate to the students how to carry out internal grinding operation
EQUIPMENT/ MATERIALS
-Internal grinding machine
-cylinder
PROCEDURE
-mount the work piece in a universal chuck.
-Swing the internal grinding attachment into place and mount the proper spindle in the
quill.
-Mount the proper grinding wheel, as large as possible, for the job.
-Adjust the spindle height until its centre is in line with the centre axis of the hole in the
work piece.
-True and the grinding wheel.
-Adjust the table dogs so that only one-third of the wheel width overlaps the end of the
work at each end of the stroke.
- Start the work on the grinding wheel.
- Touch the grinding wheel to the diameter of the hole.
-Turn on the coolant.
- Grind until the hole just cleans up, feed the wheel not more than 0.05mm per table
reversal.
- Check the hole size.
- Reset the feed to 0.005mm.
- Withdraw the wheel from the work piece.
- Check the hole diameter and finish grind if necessary.
Fig12.1 Internal Grinding machine

Fig 12.2
Fig 12.3 operations on internal grinding machine
WEEK 13
PRACTICAL TASK
To balance a grinding wheel
OBJECTIVE
To balance a grinding wheel using a static balancing method
MATERIAL/ EQUIPMENT
- A grinding wheel
- An adapter
- Surface grinder
- Set of screwdriver
- A taper balance arbour
PROCEDURE
- Mount the wheel and adapter on the surface grinder and true the wheel
with a diamond dresser.
- Remove the wheel assembly and mount a special tapered balancing
arbour in the hole of the adapter.
- Place the wheel and arbour on a balancing stand (fig 13.1) which has
been levelled.
- Allow the wheel to rotate until it stops. This indicates that the heavy
side is at the bottom. Mark this point with chalk.
- Rotate the wheel and stop it at three positions, one-quarter, one-half,
and three-quarters of a turn, to check the balance. If the wheel moves
from any of these positions, it is not balanced.
- Loosen the setscrews in the wheel counterbalances, in the grooved
recess of the flange, and move the counterbalances opposite the chalk
mark(fig. 13.2)
- Check the wheel in the four positions mentioned in steps 4 and 5 above.
- Move the counterbalances around the groove an equal amount on each
side of the centreline and check for balance again.
- Continue to move the balance away from the heavy side until the wheel
remain stationary at any position.
- Tighten the counterbalances in place.
 WEEK 14
PRACTICAL TASK
To true and dress a grinding wheel
OBJECTIVE
To improve the surface finish and accuracy of the work.
MATERIALS /EQUIPMENT
- A grinding wheel.
- A diamond dresser.
- A magnetic chuck.
- Surface grinder.
PROCEDURE
- Check the diamond for wear, if necessary, turn it in the holder to expose
a sharp cutting edge to the wheel.
- Clean the magnetic chuck thoroughly with a cloth and wipe it with the
palm of the hand to remove all grit and dirt.
- Place a piece of paper, slightly larger than the base of the diamond
holder, on the left-end of the magnetic chuck. This prevents scratching
of the chuck when the diamond holder is being removed.
- Place the diamond holder on the paper, covering as many magnetic
inserts as possible, and energize the chuck. The diamond should be
pointing in the same direction as the grinding wheel rotation (fig.14.2).
- Raise the wheel above the height of the diamond.
- Move the table longitudinally so that the diamond is off set
approximately 6.35mm to the left of the centreline of the wheel.
- Adjust the table laterally so that the diamond is positioned under the
high point on the face of the wheel (fig. 14.3). This is important since
grinding wheels will wear more quickly on the edges of the wheel,
leaving the centre of the face higher than the edges.
- Start the wheel revolving and carefully lower the wheel until the high
point touches the diamond.
- Move the table laterally, using the cross feed hand
wheel to fit the diamond across the face of the wheel.
- Lower the grinding wheel about (0.02 to 0.05mm) per pass and rough
dress the face of the wheel until it is flat and has been dressed all
around the circumference.
- Lower the wheel o.o1mm and take several passes across the face of the
wheel. The rate of cross feed will vary with the structure of the wheel. A
rule of thumb is to use a fast cross feed with coarse wheels and a slow,
but regular, cross feed for fine, closely spaced grains.
Fig. 14.1 A diamond dresser used in dressing grinding wheel.

Fig. 14.2 A proper positioning of the diamond dresser in relation to the grinding wheel
 WEEK 15

PRACTICAL TASK
To grind a flat surface
OBJECTIVE
To demonstrate surface grinding operation
MATERIAL/ EQUIPMENT
- Mild steel rectangular block of about 230 150mm
- Surface grinding machine
- Grinding wheel
PROCEDURE
- Remove all burrs and dirt from the work pieces and the face of the
magnetic chuck.
- Mount the work on the chuck, placing a piece of paper between the
chuck and the work piece.
- Check to see that the work is held firmly.
- Set the table reverse dogs so that the centre of the grinding wheel
clears each end of the work by approximately 25.4mm.
- Set the cross feed for the type of grinding operation-roughing cuts, 0.76
to 1.27mm; finishing cuts, 0.12 to 0.50mm.
- Bring the work under the grinding wheel by hand, having about 3.17mm
of the wheel edge over the work (fig. 15.1).
- Start the grinder and lower the wheel head until the just sparks the
work.
- The wheel may have been set on a low spot of the work . It is good
practice, therefore, to always raise the wheel about 0.12mm.
- Start the table travelling automatically and feed the entire width of the
work under the wheel to check for high spots.
- Lower the wheel for every cut until the surface is completed-roughing
cuts0.12 to 0.38mm, finishing cuts 0.02 to 0.05mm.
- Release the magnet and remove the work piece by raising one edge, to
break the magnetic attraction. This will prevent scratching the chuck
surface.

.
Fig 15.1 steel blocks or parallels are placed around short work
to prevent it from moving during grinding.

Fig15.3 The edge of the wheel should overlap the work by about 3.17mm
Fig. 14.3 Positioning