Batch 4-Manufacturing Laboratory Record

BE / FT / Mech / IV / TM / ME 5461: Manufacturing Technology Laboratory 1
TAPER TURNING, THREAD CUTTING AND KNURLING
Ex. No. 01 Date: 25/03/2022
Aim:
To perform taper turning, thread cutting and knurling operation on the given
work piece to the required dimensions.
Apparatus Required:
➢ Cylindrical mild steel rod of 32 mm

➢ Spanner
➢ Measuring scale
➢ Cutting tool
➢ Chuck key
Formula:
𝐷−𝑑
𝜃 = 𝑡𝑎𝑛−1 ( )
2𝐿
𝜃 = 𝑇𝑎𝑝𝑒𝑟 𝐴𝑛𝑔𝑙𝑒
𝐷 = 𝐿𝑎𝑟𝑔𝑒 𝐷𝑖𝑎𝑚𝑡𝑒𝑟
𝑑 = 𝑆ℎ𝑜𝑟𝑡 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝐿 = 𝐿𝑒𝑛𝑔𝑡ℎ
Theory:
A lathe is a tool that rotates the workpiece about an axis of rotation to perform
various operations such as cutting, knurling, drilling, falling, turning which tools that
are applied to the workpiece to create an object with symmetry about the axes.
a. Taper Turning:
✓ A taper is defined as a uniform change in the diameter of workpiece measured
along its length, taper may be expressed in 2 ways.
Department of Mechanical Engineering || College of Engineering – Guindy || Anna University : : Chennai – 25.
✓ Ratio of difference in diameter to the length in degrees of half the induced

angle.
✓ Taper turning is the operation of producing conical surfaces on the cylindrical
workpiece on lathe.
b. Knurling:
✓ Knurling is the process of producing a diamond shaped patterns (or)
impressions on the surface of the workpiece. It is used to give a good
gripping surface on a workpiece.
✓ A Knurling tool has two hundred steel rollers. The rollers have teeth out on
their cylindrical surface. The tool is held on the tool post and pressed against
the rotating work.
c. Thread Cutting:
✓ It is a process of producing helical groves on a cylindrical workpiece. When
tool rotates, it is automatically longitudinal by using lock out and lead screw
arrangement. A definite ratio between relations of headstock spindle and
longitudinal feed is found.
✓ The lead screw and spindle are connected by number of gears which called
change gears.
Procedure:
✓ The workpiece is fixed in the chuck.

✓ Cutting tool is fixed in the tool post.
✓ Step turning is performed on the workpiece and the diameter is reduced to 30mm
for 90mm length.
✓ Then the compound disc is rotated to 6-degree right side to perform RH Turning.
✓ Right Hand turning is performed over the length of 25mm in 5mm step of
feeding.
✓ The above step is performed in LH Turning and tool is tilt to perform
chambering.
✓ Finally, workpiece is removed from chuck and checked for the dimensions.
Calculation:
𝐷−𝑑 30−25 5
𝜃 = 𝑡𝑎𝑛−1 ( ) = 𝑡𝑎𝑛−1 ( ) = 𝑡𝑎𝑛−1 ( ) = 𝑡𝑎𝑛−1 (0.1) = 5.7°~6º
2𝐿 2(0.5) 50
Diagram:
Fig 1.1 Taper Turning of R.H.T and L.H.T
Fig 1.2 Taper Turning
Fig 1.3 Thread Cutting
Fig 1.4 Taper Turning, Threading, Knurling
Result:
The taper turning, thread cutting and knurling operations were performed on the
given work piece and it was turned to the required dimensions as shown in fig 1.4.
ECCENTRIC TURNING
Ex. No. 02 Date: 26/03/2022
Aim:
To perform eccentric turning operations using a four-jaw chuck lathe.
Materials Required:
➢ Mild steel polished round rod - Φ 25 X 100 mm
Tools Required:
➢ Four jaw chuck lathe

➢ Outside Calliper
➢ Turning tool
➢ Vernier calliper
➢ Steel Rule
Procedure:
✓ The given work piece is held firmly in a lathe chuck.

✓ The cutting tool is set in a tool post such that the point of the Cutting tool
coincides with the lathe axis.
✓ The machine is switched on to revolve the work piece at the selected speed.
✓ By giving Cross feed and longitudinal feed to the cutting tool, the facing and
turning operations are done respectively.
✓ The speed of the work piece is reduced.
✓ The four-jaw chuck is manually adjusted for the offset purpose to make the
eccentricity.
✓ Again, the machine is switched on.
✓ The machine is switched off.
✓ The work piece is removed from the chuck and all the dimensions are measured
and checked.
Diagram:
Fig 2.1 Eccentric Turning
Fig 2.2 Eccentric Turning
Result:
The eccentric turning was performed on the given work piece and it was turned
to the given dimensions as shown in fig 2.2.
GEAR SHAPING
Ex. No. 03 Date: 11/03/2022
Aim:
To generate (shape) a gear from the given blank to the required shape using gear
shaping machine.
Apparatus required:
➢ Vernier caliper
➢ Gear shaping machine
➢ Spanner
➢ Cutter
➢ Blank or workpiece
Material required:
➢ Workpiece
➢ Cast iron
➢ Cutter blank
➢ High speed steel
Theory:
✓ In gear Shapers, for shaping the cutter is used. The cutter is hardened disc shaped
and slightly dished at the bottom to facilitate cutting. The tooth has desired tooth
profile and pressure angle.
✓ The cutter is reciprocating with the required cutting speed and fed radially
plunge it for correct teeth depth by means of a CAM.
✓ A relieving mechanism enables the cutter to clear the work on non-cutting or
return Stroke. The continuous generation motion is obtained by feeding cutter
to full depth and rotating the cutter and the workpiece slowly in the exact ratio
of their respective number of teeth by means of chains of gears including change
gears. It could be seen that since an involute gear will roll with any other
involute gear will roll with any other involute gear of some normal base point.
Hence this principle is utilized in the gear shaper, for spur gear the reciprocating
motion is made parallel to the work axis, but for single helical gear the direction
of the cutting stroke follows a helical path and the cutter itself is provided with
helical teeth.
✓ Index change gears available:
20, 21, 24, 25, 26, 30, 31, 33, 34, 35, 37, 38, 39, 40(2), 42, 43, 45, 46, 47, 48,
50(2), 55(2), 58(2), 59, 60, 61, 62, 65, 68, 70, 73, 74, 79, 80(2), 85, 90, 92, 95,
96(2), 97, 100, 120.
𝑣 × 1000
𝑛=
2𝐿
Where,
𝑛 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑜𝑢𝑏𝑙𝑒 𝑠𝑡𝑟𝑜𝑘𝑒

𝐿 = 𝑆𝑡𝑟𝑜𝑘𝑒 𝐿𝑒𝑛𝑔𝑡ℎ
𝑣 = 𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 (𝑚/𝑚𝑖𝑛)
Formula:
𝑂𝐷 = (𝑍 + 2) × 𝑀
𝑂𝐷
𝑍= −2
𝑀
𝐶𝑑 = 2.157 × 𝑀
𝑎 𝑐 𝐾 × 𝑍𝑎
𝐼𝑛𝑑𝑒𝑥 𝐺𝑒𝑎𝑟 = × =
𝑏 𝑑 𝑍
Where,
𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘

𝑍 = 𝑁𝑜. 𝑜𝑓 𝑇𝑒𝑒𝑡ℎ 𝑡𝑜 𝑏𝑒 𝑐𝑢𝑡
𝐶𝑑 = 𝐷𝑒𝑝𝑡ℎ 𝑜𝑓 𝐶𝑢𝑡
𝑍𝑎 = 40.
𝑀 = 𝑀𝑜𝑑𝑢𝑙𝑒 = 2.5
𝐾 = 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 2.4
𝑎, 𝑏, 𝑐, 𝑑 = 𝐶ℎ𝑎𝑛𝑔𝑒 𝑜𝑓 𝐺𝑒𝑎𝑟
2.157 = 𝐴𝑑𝑑𝑒𝑛𝑑𝑢𝑚 + 𝐷𝑒𝑑𝑒𝑛𝑑𝑢𝑚 + 𝐶𝑙𝑒𝑟𝑎𝑛𝑐𝑒.
Procedure:
✓ The number of teeth, depth of cut, index gear is calculated by given formula
founded by calculation.
✓ The index gears are chosen such way of spanners with washer.
✓ The workpiece is held in position and tightened.
✓ The initial value of machine and initial value of reference are set.
✓ Finally, the multiple cutters reach the workpiece in rapid movement by key is
disengaged.
✓ Job is tested for dimensional accuracy and teeth correction.
Calculation:
Given,
𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 107.48 𝑚𝑚

𝐾 = 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 2.4
𝑍𝑎 = 40
𝑂𝐷 107.48
𝑍= −2= − 2 = 40.992 ~ 41
𝑀 2.5
𝐶𝑑 = 2.157 × 𝑀 = 2.157 × 2.5 = 5.3925 𝑚𝑚
𝑎 𝑐 𝐾 × 𝑍𝑎
𝐼𝑛𝑑𝑒𝑥 𝐺𝑒𝑎𝑟 = × =
𝑏 𝑑 𝑍
𝑎 𝑐 2.4 × 40 40 96
× = =2=1×2= ×
𝑏 𝑑 41 40 41
𝑎 = 40; 𝑏 = 40; 𝑐 = 96; 𝑑 = 41
Diagram:
Fig 3.1 Gear Shaping
Result:
The given blank has been generated (shaped) into a Spur Gear with the required
dimensions using the gear shaping machine as shown in fig 3.1
GEAR HOBBING
Ex. No. 04 Date: 01/04/2022
Aim:
To generate (hob) a gear from the given blank to the required shape using gear
hobbing machine.
Apparatus Required:
➢ Blank work piece
➢ Vernier caliber
➢ Spanner
➢ Index gear
Formula:
𝑂𝐷 = (𝑍 + 2) × 𝑀
𝑂𝐷
𝑍= −2
𝑀
𝐶𝑑 = 2.157 × 𝑀
𝑒 𝑎 𝑐 𝐾 × 𝑍𝑎
𝐼𝑛𝑑𝑒𝑥 𝐺𝑒𝑎𝑟 = × × =
𝑓 𝑏 𝑑 𝑍
Where,

𝑍𝑎 = 1
𝑀 = 𝑀𝑜𝑑𝑢𝑙𝑒 = 2
𝐾 = 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 8
𝑎, 𝑏, 𝑐, 𝑑 = 𝐶ℎ𝑎𝑛𝑔𝑒 𝑜𝑓 𝐺𝑒𝑎𝑟
𝑒 1
= (𝑢𝑝𝑡𝑜 50 𝑡𝑒𝑒𝑡ℎ)
𝑓 1
𝑒 1
= (𝑎𝑏𝑜𝑣𝑒 50 𝑡𝑒𝑒𝑡ℎ)
𝑓 2
𝑓 = 𝑓𝑒𝑒𝑑 = 0.4 𝑚𝑚/𝑟𝑒𝑣
2.157 = 𝐴𝑑𝑑𝑒𝑛𝑑𝑢𝑚 + 𝐷𝑒𝑑𝑒𝑛𝑑𝑢𝑚 + 𝐶𝑙𝑒𝑟𝑎𝑛𝑐𝑒.
Theory:
Hobbing is a machinery process for gear cutting, cutting splines and cutting on
a hobbing machine which is a special type of milling machine the teeth on species are
progressively cut into the forming process is a relatively inexpensive but still quite
accurate, thus if it is used for a breed range of parts and quantifiers.
Hobbing machine are known as hobber are fully automated machines that come
in many sizes each gear hobbing machines typically consists of a chuck and tailstock,
to hold the workpiece or a spindle, a drive motor.
Procedure:
✓ Measure the OD using a vernier caliper.
✓ Find the number of teeth that can be machined in the workpiece.
✓ Find the number of teeth required for the index gear.
✓ Find the blank in the middle.
✓ The required depth of use.
✓ Start the machine and wait until the gears have formed on the workpiece.
✓ Then, the gear is removed and the chips are cleared.
Calculation:
Given,
𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 74𝑚𝑚

𝐾 = 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 8
𝑍𝑎 = 1
𝑂𝐷 74
𝑍= −2= − 2 = 35
𝑀 2
𝐶𝑑 = 2.157 × 𝑀 = 2.157 × 2 = 4.314 𝑚𝑚
𝑒 𝑎 𝑐 𝐾 × 𝑍𝑎
𝐼𝑛𝑑𝑒𝑥 𝐺𝑒𝑎𝑟 = × × =
𝑓 𝑏 𝑑 𝑍
𝑒 𝑎 𝑐 8×1 1 24 30
× × = = 0.22857 = × ×
𝑓 𝑏 𝑑 35 1 42 75
𝑎 = 24; 𝑏 = 42; 𝑐 = 30; 𝑑 = 75
Diagram:
Fig 4.1 Gear Hobbing
Result:
The given blank has been generated (hobbed) into a Spur Gear with the
required dimensions using the gear hobbing machine as shown in fig 4.1.
GEAR CUTTING
Ex. No. 05 Date: 29/04/2022
Aim:
To generate (cut / mill) a gear from the given blank to the required shape using
gear cutting machine (Horizontal Milling Machine).
Apparatus Required:
➢ Horizontal Milling Machine

➢ Gear cutter
➢ Simple index
Formulae:
𝑂𝐷 = (𝑍 + 2) × 𝑀
𝑂𝐷
𝑍= −2
𝑀
𝐶𝑑 = 2.157 × 𝑀
Where,

Available index plates with circular holes are as follows:
a. Plate No: 15-16-17-18-19-20
b. Plate No: 21-23-27-29-31-33
c. Plate No: 37-39-41-43-47-49
Speed selection
𝜋×𝐷×𝑁
𝑉= 𝑚𝑝𝑚
1000
Where,
𝑉 = 𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 (𝑟𝑝𝑚)

𝐷 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑀𝑖𝑙𝑙𝑖𝑛𝑔 𝐶𝑢𝑡𝑡𝑒𝑟
𝑁 = 𝑁𝑜. 𝑜𝑓 𝑅𝑒𝑣.
Cutting speed for, Cast iron = 20 rpm
Steel = 30 rpm
Bronze = 30 rpm
Select the nearest available rpm for the machine
Speed steps are available as 68, 80, 96, 114, 135, 160, 190, 228, 270, 317,
380, 450, 540, 635, 650, 890, 1270.
Feed 15 to 30 mm/min (depending on the material)
Feed steps are available as 1, 3, 4, 5, 6, 8, 10, 11, 12, 15, 19, 24, 30, 38, 48,
60, 75, 95, 85 mm/min
Theory:
Milling is the cutting operation that removes neutral by feeding work against a
rotating, cutter having single or multiple cutting edges. The tool used is a multiple point
cutting tool. The milling machine can be classified as
1. Vertical milling machine
2. Horizontal Milling machine
In a horizontal milling machine, the cutting tool is mounted on a horizontal

spindle across the worktable. The use of multipoint cutting tool is for cutting gear from
workpiece.
Working Principle:
The workpiece is held on the worktable of the machine, the table movement
controls the feed on the workpiece against the rotating cutter, the cutter is mounted on
a spindle and revolves at high speed. Except for rotation, it has no other motion. The
cutter tooth removes the neutral from the surface of the workpiece and desired shape is
produced.
Calculations:
Given,
𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 80.4 𝑚𝑚

𝑂𝐷 80.4
𝑍= −2= − 2 = 38.2 ~ 38
𝑀 2
𝐶𝑑 = 2.157 × 𝑀 = 2.157 × 2.25 = 4.8353 𝑚𝑚
Procedure:
✓ The gear blank is held between the dividing head and tailstock using a mandrel.
✓ The cutter is mounted on the arbor and the cutter is centered accurately with the
gear blank.
✓ Set the speed and feed for machining. For giving depth of cut, the table is raised
till the periphery of the gear blank just touches the cutter.
✓ The Micrometer dial of vertical feed screw is set to zero at this position. Then
the table is raised further to give the required depth of cut.
✓ The machine is started and feed is given to the table to cut the first groove of the
blank.
✓ After the cut, the table is brought back to the starting position. Then the gear
blank is indexed for the next tooth space. This is continued till all the teeth are
cut.
✓ Dimensions of the gear teeth profile are checked using the gear tooth Vernier.
Diagram:
Fig 5.1: Gear Cutting
Result:
The given blank has been generated (cut / milled) into a Spur Gear with the
required dimensions using the gear cutting (horizontal milling) machine as shown in
fig 5.1.
CONTOUR MILLING
Ex. No. 06 Date: 01/04/2022
Aim:
To generate (mill) a contour profile on the given blank to the required shape
using Vertical Milling Machine.
Tools Required:
➢ Spanner
➢ Supporting Metal
➢ Brush
➢ Marking Gauge
➢ Hammer
➢ Marker
➢ Compass
➢ Blowing pipe
Machine Details:
Name : Vertical Milling Machine
Tool : End milling cutter (Multipoint tool)
ToolMaterial : High speed steel
Diameter : 16mm
Mechanism : Worm and Worm Wheel mechanism
Job Material : Cast Iron
Theory:
Milling is the maintenance process of using a rotor cutter to remove the material
from the material from the given workpiece by advancing (a feeding) the cutter into the
workpiece at a certain dissertation and the cutter may also be held at an angle relative
to the axis of the total. The word ‘contour’ defines an outline representing a bending the
shape or form of something.
Thus, the term contour milling refers to the machining of the required boundary
areas (marked with the help of tools) on the workpiece with the help of a rotary tool.
The tool used here is a multipoint cutting tool that rotates around its own axis is worm
and worm wheel mechanism, worm are special gears driver consisting of two elements.
1. Driving elements - screw (gear)

2. Driven element - helical (gear)
The driving element is the worm and the driven elements is the worm wheel. As
the worm rotates it is term rotates the worm wheel there by transmitting the power to
the other axis shaft rotates. This is the mechanism behind the rotatory motion of the
tool. In this machine, the cutting tool is mounted on a vertical spindle across the worm
table. Hence this is of a vertical milling machine type.
Procedure:
✓ To draw profile on the given job.

✓ The midpoint is punched using hammer.
✓ The workpiece is placed in the bed and the metal plate are kept for the different
thickness and the job is tightened.
✓ Using the compass and the marketing pin, the profile is drawn on the workpiece.
✓ The tool is brought of workpiece on the bed with clamps.
✓ The scale on the z-axis is brought to the zeroth division.
✓ The measurement of each division is 0.05 mm
✓ The scale is adjusted to 10 directions for 0.50 mm

✓ Using x-axis and y-axis which corresponds to turning wheel and bed rotatory
wheel, the required profile is milled on the surface.
✓ During the milling pixels, the metal clips are removed and thrown off using a
blowing pipe.
✓ Finally, once the required plates are obtained on the job, it is removed and the
bed is cleaned by using brush.
Diagram:
Fig 6.1 Contour Milling
Result:
The required contour profile was milled on the given blank using vertical milling
machine and is shown in fig 6.1.
SHAPING
Ex. No. 07 Date: 22/04/2022
Aim:
To shape the required hexagonal prism from the given cylindrical stock using
shaping machine.
Apparatus Required:
➢ Marking gauge
➢ Divider
➢ Steel scale
➢ Hammer
➢ Wrench
Theory:
A shaper is a type of machine tool that can use linear relative motion between
the workpiece and a single point cutting tool to a machine a linear tool plate. Its cut is
analogous to that of a lathe except that is linear instead held in the tool holder, which is
mounted on the ram. The workpiece is highly held in rice or directly clamped on the
table. The ram requires and this cutting tool head in the tool holder moves forward and
backward over the workpiece. In a standard shaper cutting off material takes place
during the forward stroke of the ram between mechanisms.
1. Crank and slotted link quick return mechanism

2. While worth builds quick return mechanism crank and slotted link quick
return mechanism
In this mechanism, the ram is activated by a gear driver associated with the
electric motor first the electric motor drives the pinion gear. Next the pinion gear drives
the bull gear which rotates in opposite direction due to external gear machining.
An important point to be noted is that the forward cutting shoes will be slower
than whereas the reverse tail stroke will be faster and consequently saves time.
Procedure:
✓ Mark the side of hexagon in the given mild steel rod of 40 mm diameter using
chalk piece puncher steel and hammer.
✓ Fix the mild steel rod on the bench wise of shaper.
✓ Adjust the ram and shaper head such that the cutting tool lightly touches the
workpiece.
✓ Switch on the shaper.
✓ Shaping the mild steel rod by adjusting the handle at the side of using the down
feed depth of cut can be increased such that a flat surface is obtained.
✓ Stop the process until the material up to the marked line is reached.
✓ Remove the workpiece and fix it on the bench wise to that the workpiece material
is to be removed facing the cutting tool.
✓ Remove the materials on the other side of the workpiece by following the above
procedures.
✓ Finally, remove the workpiece from the bench wise and check for its surface
finish.
Diagram:
Fig 7.1 Shaping Hexagonal Prism
Result:
The required hexagonal prism was shaped on the given cylindrical stock using
shaping machine and is shown in fig 7.1.
FLAT ROLLING
Ex. No. 08 Date: 29/04/2022
Aim:
1. To perform flat rolling process on a given flat bar.

2. To determine the percentage of reduction in thickness and the rolling force and
power.
Flat Rolling:
Rolling is a process of reducing the thickness of long workpiece by compressive

force applied through a set of heavy cylindrical rolls, each roll being powdered by
electric motors. The initial velocity of the strip Vo at the entry of the rollers’ gap
increases as its moves through the rollers’ gap. The final velocity Vf of the strip is high
at the exit rollers’ gap.
Tabulation:
Before-Hardness:
Thickness : 3.10 mm
Width : 25.12 mm
Height : 223 mm
Loaded Unloaded
66 15
69 24
67 18
Average: 67.33 Average: 19
After Hardness:
Thickness : 2.70 mm
Width : 25.50 mm
Height : 251 mm
Loaded Unloaded
91 35
94 37
94 38
Average: 93 Average: 36.66
Observation:
𝐹 = 1.2 × 𝐿𝑅 × 𝑊𝑆 × 𝑌𝑎𝑣𝑔
Where,
𝐹 = 𝑅𝑜𝑙𝑙𝑖𝑛𝑔 𝐹𝑜𝑟𝑐𝑒
𝐿𝑅 = 𝑅𝑜𝑙𝑙𝑖𝑛𝑔 𝑠𝑡𝑟𝑖𝑝 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑙𝑒𝑛𝑔𝑡ℎ (𝑚𝑚)
𝑊𝑆 = 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝
𝑌𝑎𝑣𝑔 = 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑡𝑟𝑢𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝
𝐿𝑅 = 𝐿𝑆 × √𝑇𝑖 − 𝑇𝑓
Where,
𝑇𝑖 = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝

𝑇𝑓 = 𝐹𝑖𝑛𝑎𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠𝑡𝑟𝑖𝑝
𝐾 × 𝑒𝑛
𝑌𝑎𝑣𝑔 =
1+𝑛
Where,
𝐾 = 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 180

𝑇𝑖
𝑒 = 𝑇𝑟𝑢𝑒 𝑠𝑡𝑟𝑎𝑖𝑛 = 𝑙𝑛
𝑇𝑓
𝑛 = 𝑆𝑡𝑟𝑎𝑖𝑛 ℎ𝑎𝑟𝑑𝑒𝑛𝑖𝑛𝑔 𝑟𝑎𝑡𝑖𝑜 = 0.2
𝜋 × 𝐹 × 𝐿𝑅 × 𝑁
𝑃=
6000
Where,
𝑃 = 𝑅𝑜𝑙𝑙𝑖𝑛𝑔 𝑃𝑜𝑤𝑒𝑟 (𝑘𝑊)

𝑁 = 𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑅𝑜𝑙𝑙𝑒𝑟 (𝑟𝑝𝑚) = 35 𝑟𝑝𝑚
Procedure:
✓ Take the aluminum metal, calculate the length, thickness, width and hardness
before rolling.
✓ After that, roll the strip and record the width, hardness, length, thickness, finally
take the maximum values.
✓ Approximately or till the width thickness decreases some amount of values, will
do that.
✓ Finally, take that hardness value final.
Calculation:
Given,
𝑇𝑖 = 3 𝑚𝑚; 𝑇𝑓 = 2.5 𝑚𝑚; 𝐿𝑆 = 50 𝑚𝑚
𝐿𝑅 = 𝐿𝑆 × √𝑇𝑖 − 𝑇𝑓 = 50 × √3 − 2.5
𝐿𝑅 = 35.5
Given,
𝐾 = 180; 𝑛 = 0.2
𝑇𝑖 3
𝑒 = 𝑙𝑛 = 𝑙𝑛 = 0.1823
𝑇𝑓 2.5
𝐾 × 𝑒 𝑛 180 × (0.1823)0.2
𝑌𝑎𝑣𝑔 = = = 106.723 𝑀𝑃𝑎
1+𝑛 1 + 0.2
Given,
𝑊𝑆 = 25.5 𝑚𝑚
𝐹 = 1.2 × 𝐿𝑅 × 𝑊𝑆 × 𝑌𝑎𝑣𝑔 = 1.2 × 35.5 × 25.5 × 106.723

𝐹 = 115443.33 𝑁
Given,
𝑁 = 35 𝑟𝑝𝑚
𝜋 × 𝐹 × 𝐿𝑅 × 𝑁 𝜋 × 115443.33 × 35.5 × 35
𝑃= =
6000 6000
𝑃 = 7474.88 𝑊
𝑇𝑖 − 𝑇𝑓 3 − 2.5
% 𝑇𝑅𝑒𝑑 = × 100 = × 100
𝑇𝑖 3
% 𝑇𝑅𝑒𝑑 = 16.66%
Diagram:
Fig 8.1 Flat Rolling
Result:
The flat rolling process on the given flat bar was performed and is shown in Fig.
8.1. The changes in thickness and width of the given flat bar was observed. The rolling
force and power was determined. The percentage of reduction in thickness was observed
to be 16.67 %.
WIRE DRAWING
Ex. No. 09 Date: 29/04/2022
Aim:
1. To perform wire drawing process on the given cylindrical work piece.

2. To determine the percentage of reduction in area, maximum drawing force, and
power.
Theory:
Large quantities of wires are produced by wire drawing process which is

basically cold working process. In this process, materials pulled through a die in order
to maintain the desired shape and size. It is similar, to the extrusion process except work
is pulled through the die in drawing. Both tensile and compressive stress act and deform
the metal as it passes through the die opening.
Apparatus Required:
Cylindrical workpiece (Rod), Vernier Caliper, Wire drawing machine.
Calculation:
Given,
𝐷𝑖 = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑟𝑜𝑑 = 8.0975 𝑚𝑚

𝐷𝑓 = 𝐹𝑖𝑛𝑎𝑙 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑟𝑜𝑑 = 7.8975 𝑚𝑚
𝐴𝑖 − 𝐴𝑓 𝐷𝑖2 − 𝐷𝑓2
% 𝐴𝑅𝑒𝑑 = × 100 = × 100
𝐴𝑖 𝐷𝑖2
Where,
%𝐴𝑟𝑒𝑑 = 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝐴𝑟𝑒𝑎 𝑅𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛

𝜋
𝐴𝑖 = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑟𝑜𝑑 = 𝐷𝑖2
4
𝜋 2
𝐴𝑓 = 𝐹𝑖𝑛𝑎𝑙 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑟𝑜𝑑 = 𝐷
4 𝑓
8.09752 − 7.89752
% 𝐴𝑅𝑒𝑑 = × 100 = 4.33%
8.09752
Calculate, 𝑒 = 𝑇𝑟𝑢𝑒 𝑆𝑡𝑟𝑎𝑖𝑛
2
𝐷𝑖
𝑒 = 𝑙𝑛 ( )
𝐷𝑓
8.0975 2
𝑒 = 𝑙𝑛 ( ) = 0.05
7.8975
Calculate, 𝑌𝑎𝑣𝑔 = 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑡𝑟𝑢𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝐾 × 𝑒𝑛
𝑌𝑎𝑣𝑔 =
1+𝑛
Where,
𝐾 = 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 180

𝑒 = 𝑇𝑟𝑢𝑒 𝑠𝑡𝑟𝑎𝑖𝑛 = 0.05
𝑛 = 𝑆𝑡𝑟𝑎𝑖𝑛 ℎ𝑎𝑟𝑑𝑒𝑛𝑖𝑛𝑔 𝑟𝑎𝑡𝑖𝑜 = 0.2
180 × 0.050.2
𝑌𝑎𝑣𝑔 = = 82.392
1 + 0.2
Calculate, 𝜎 = 𝑊𝑖𝑟𝑒 𝑑𝑟𝑎𝑤𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠
𝜎 = 𝑌𝑎𝑣𝑔 × 𝑒 = 82.392 × 0.05 = 4.1196
Calculate, 𝐹𝐷 = 𝐷𝑟𝑎𝑤𝑖𝑛𝑔 𝐹𝑜𝑟𝑐𝑒
𝜋
𝐹𝐷 = 𝜎𝐴𝑓 = 𝜎 × × 𝐷𝑓2
4
𝜋
= 4.1196 × × (7.8975)2
4
= 201.896 (𝑁)
Calculate, 𝑉 = 𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑅𝑜𝑙𝑙𝑒𝑟
𝜋𝐷𝑅 𝑁
𝑉=
60
Where,
𝐷𝑅 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑅𝑜𝑙𝑙𝑒𝑟 = 90 𝑚𝑚
𝑁 = 𝑅𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒 = 20
𝜋 × 90 × 20
𝑉= = 94.2 = 0.0942 𝑚/𝑠.
60
Calculate, 𝑃 = 𝑃𝑜𝑤𝑒𝑟
𝑃 = 𝐹𝐷 × 𝑉 = 201.826 × 0.0942 = 19.012 𝑊
Hardness:
Before in B scale = 18 HRB
After in B scale = 294 RB
Procedure:
✓ The aluminium rod with dimension such as diameter and length is measured
using Vernier caliper.
✓ The rod is pulled through die in the order to reduce the diameter.
✓ Again, and the rod is pushed through die in order to reduce it to the final
diameter.
✓ Calculated the true strain, Percentage reduction of area, average-flow stress, wire
drawing forces and power of wire drawing component for the both conditions.
Observations:
Before After
Diameter: 7.94 7.86
Length :224mm 228mm
Hardness Before:
Loaded Unloaded
77 28
80 20
82 28
Average: 79.66 Average: 25.33
Hardness After:
Loaded Unloaded
84 31
83 30
81 27
Average: 82.66 Average: 24.33
Diagram:
Fig 9.1 Wire Drawing
Result:
The wire drawing process was performed on the given cylindrical work piece to
specified dimension and is shown in Fig 9.1. The percentage of reduction in area was
found to be 4.33%, The maximum drawing force, and power was determined to be
201.896 N and 19012 W respectively.
DRILLING, REAMING, & BROACHING
Ex. No. 10 Date: 29/04/2022
Aim:
1. To drill a hole to the specified dimension on the given work piece using drilling
machine.
2. To ream the above hole to specified dimension on the given work piece using
drilling machine
3. To broach a key slots to specified dimension on the given work piece using
broaching machine.
Apparatus Required:
➢ Workpiece (cast iron)

➢ Lever and vice
➢ Multipoint cutting tool
➢ Broaching tool (MSS)
Theory:
Drilling is the cutting the field process that uses a drill to cut a hole of circular
cross section in solid materials. The drill pit is usually a rotating cutting tool of 10
multiplication. The drill pit pressed against the workpiece and is rotated and this forces
the cutting edge against the workpiece, cutting the chips from the hole as it is drilled
the universal drilling essentially consist of a spindle which turn the load which can be
advanced in work this automatically by hand. A workpiece which holds the workpiece
rigid in position.
Working Principle:
The rotating edge of drill exert a large force on workpiece and hole is drilled in
removal of metal by drilling.
Broaching is a machining operation that used a toothed tool called broach to

remove material. These are two types namely linear and rotatory. In linear broach run
linearly against workpiece.
Procedure:
✓ Workpiece is held in bed and heightened.

✓ Reference point is made on workpiece.
✓ Drilling operation term is set by level.
✓ Machine starts and automatic drilling starts.
✓ Hole is produced and it is broached.
✓ Due to forward and backward movement of tool by hydraulic the bed slots are
produced.
Diagram:
Fig 10.1 Drilling, Reaming and Broaching
Result:
A hole was drilled to the specified dimension on the given work piece using
drilling machine. The above hole was reamed to specified dimension on the given work
piece using drilling machine. A key slots was broached to specified dimension on the
given work piece using broaching machines and is shown in fig 10.1.
GRINDING
Ex. No. 11 Date: 29/04/2022
Aim:
1. To reduce the surface of the given flat workpiece to specified dimension using
surface grinding machine
2. To reduce the outer diameter of the given cylindrical workpiece to specified
dimension using cylindrical grinding machine.
Apparatus Required:
Surface grinding:
➢ Cylindrical rod or workpiece

➢ Screw gauge
➢ Workpiece or driver dog
Cylindrical grinding:
➢ Workpiece
➢ Surface grinding machine
➢ Abrasive surface silicon carbide
➢ Coolant air
Machine:
Surface grinding:
Name : Surface grinding machine
Type : 3-dimensional movement
Grinding surface : Abrasive surface made of silicon carbide
Mode of operation : Hydraulics
Coolant ratio : 3 points of water + 1 part of coolant
Operation : Manual and Automatic
Least count : Y-axis = 0.02 mm
X-axis = 0.01 mm
Cylindrical grinding:
Grinding wheel diameter = 355*40*137 mm
Grinding wheel speed = 1600*2000 rpm
Power:
Wheel head = 3 HP
Work head = 2.5 HP
Table head = 0.5 HP
Hydraulic speed = 1.5 HP
Theory:
Grinding is the operation of removing the metals by using rotating abrasive

wheels grinding is commonly used on a least iron and various type of steel as they can
be hold by the electromagnetic or simply magnetic commonly used on grinding machine
and don't melt in the wheel.
These cools the workpiece. It acts as a lubricant and reduce the friction between
the chips, workpiece and grinding wheel. It removes the chips from the constant area.
The grinding wheel used in this process is an expandable wheel used for various
grinding and abrasive machining separation. The use of fluids in a grinding process is
often necessary to cool and lubricant the wheel and the workpiece as well as remove
the chips product in the grinding process. The fluid used here is of water solute oil.
Important point to be noted that the rotation of the grinding wheel and that of the
workpiece are in opposite directions.
Procedure:
Surface Grinding:
✓ Place the workpiece made of mild steel or the given electromagnet.

✓ New magnetic, the electromagnetic bed by providing electric current and the
result in temporary attachments of workpiece on bed.
✓ The grinding tool is made to maintain a gap between the workpiece on bed.
✓ Now the machine bed is demagnetized and the workpiece is removed.
✓ Finally, the required surface is grinded the workpiece is obtained.
Cylindrical Grinding:
✓ Measure the diameter of the workpiece.

✓ Fix the job in the carrier (driven-dog) and place it in the machine.
✓ Switch on the machine.
✓ Make sure that the grinding wheel is touching the job and the scale is to be fixed
as zero.
✓ Then the rod is grinded by increasing the depth and giving the feed.
Diagram:
Fig 11.1 Cylindrical Grinding
Result:
The outer diameter of the given cylindrical workpiece was reduced to specified
dimension using cylindrical grinding and is shown in fig 11.1.
GREEN SAND MOULDING
Ex. No. 12 Date: 22/04/2022
Aim:
To prepare Green Sand Mould for the given pattern.
Tools Required:
➢ Moulding Board
➢ Flat rammer
➢ Trowel
➢ Gate cutter
➢ Lifter
➢ Moulding box
➢ Strike of the box
➢ Vent wire
➢ Draw spike
➢ Sprue
Procedure:
✓ The Moulding box is cleaned and placed on a moulding board.
✓ Place the pattern in the down position as the center of the box sprinkle facing
sand around the pattern.
✓ Fill the sand around the pattern.
✓ Using a flat rammer, ram the sand uniformly in the drag.
✓ Fill the sand in the mould and strike off the excess sand.
✓ Pierce vent holes.
✓ Drag is lifted upside-down and placed on the board.
✓ Cope is placed over drag.
✓ Position the sprue and the riser in the correct place and fill moulding Sand in the
cope uniformly.
✓ Strike the excess sand and Pierce vent holes in the cope.
✓ Withdraw the pattern gently from the mould using a draw pipe.
✓ Cut the gating system and do repair work if needed and assemble boxes in right
position.
Diagram:
Fig 12.1 Green Sand Moulding
Result:
The green sand mould for the given pattern was made and is shown in fig 12.1.

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BE / FT / Mech / IV / TM / ME 5461: Manufacturing Technology Laboratory 1

TAPER TURNING, THREAD CUTTING AND KNURLING

Ex. No. 01 Date: 25/03/2022

➢ Cylindrical mild steel rod of 32 mm

✓ Ratio of difference in diameter to the length in degrees of half the induced

✓ The workpiece is fixed in the chuck.

Fig 1.1 Taper Turning of R.H.T and L.H.T

Fig 1.2 Taper Turning

Fig 1.3 Thread Cutting

Fig 1.4 Taper Turning, Threading, Knurling

Ex. No. 02 Date: 26/03/2022

To perform eccentric turning operations using a four-jaw chuck lathe.

➢ Mild steel polished round rod - Φ 25 X 100 mm

➢ Four jaw chuck lathe

✓ The given work piece is held firmly in a lathe chuck.

Fig 2.1 Eccentric Turning

Fig 2.2 Eccentric Turning

Ex. No. 03 Date: 11/03/2022

𝑛 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑜𝑢𝑏𝑙𝑒 𝑠𝑡𝑟𝑜𝑘𝑒

𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘

𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 107.48 𝑚𝑚

Fig 3.1 Gear Shaping

Ex. No. 04 Date: 01/04/2022

➢ Blank work piece

𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘

✓ Measure the OD using a vernier caliper.

✓ Find the number of teeth that can be machined in the workpiece.

✓ Find the number of teeth required for the index gear.

✓ Find the blank in the middle.

✓ The required depth of use.

✓ Then, the gear is removed and the chips are cleared.

𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 74𝑚𝑚

Fig 4.1 Gear Hobbing

Ex. No. 05 Date: 29/04/2022

➢ Horizontal Milling Machine

𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘

a. Plate No: 15-16-17-18-19-20

b. Plate No: 21-23-27-29-31-33

c. Plate No: 37-39-41-43-47-49

𝑉 = 𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 (𝑟𝑝𝑚)

Cutting speed for, Cast iron = 20 rpm

Select the nearest available rpm for the machine

Feed 15 to 30 mm/min (depending on the material)

1. Vertical milling machine

2. Horizontal Milling machine

In a horizontal milling machine, the cutting tool is mounted on a horizontal

𝑂𝐷 = 𝑂𝑢𝑡𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 80.4 𝑚𝑚

Fig 5.1: Gear Cutting

Ex. No. 06 Date: 01/04/2022

Name : Vertical Milling Machine

Tool : End milling cutter (Multipoint tool)

ToolMaterial : High speed steel

Mechanism : Worm and Worm Wheel mechanism

Job Material : Cast Iron

1. Driving elements - screw (gear)

✓ To draw profile on the given job.

✓ The scale is adjusted to 10 directions for 0.50 mm

Fig 6.1 Contour Milling

Ex. No. 07 Date: 22/04/2022

1. Crank and slotted link quick return mechanism

Grinding wheel diameter = 35540137 mm