MACHINING SCIENCE AND

MACHINE TOOLS LAB

MANUAL

Department of industrial and production

engineering

Prepared By -: Dr Ravi Pratap Singh,

Madhusudan Painuly And Rishikant
Mishra

DR B R AMBEDKAR NATIONAL INSTITUTE

OF TECHNOLOGY, JALANDHAR
LIST OF EXPERIMENTS -:

1. To perform step turning, taper turning, thread cutting and knurling on lathe.
2. To produce a spur gear out of the given work piece using milling machine.
3. To cut a helical gear out of the given blank in milling machine.
4. To machine the given gear blank into a spur gear in gear shaper machine.
5. To cut dovetail groove and slot on a given mild steel block using shaping
machine.
6. To machine a given MS block for desired dimensioning on a shaper tool.
7. To make internal splines, space 90 degree apart on the given hollow
cylindrical work piece by using slotting machine.
8. To perform plain surface grinding on the given work piece to the required
dimensions.
9. To grind the cylindrical surface of the given work piece by cylindrical
grinding.
10. To study the Lathe Tool Dynamometer and Drill Tool Dynamometer and
determine the Resultant force act on the tool during turning operation and also
estimate the force and thrust required to perform drilling operation.
Experiment No -: 01

AIM -: To perform Step turning, taper turning, thread cutting and knurling on lathe.
MATERIAL REQUIRED -: Mild steel rod of 25 mm diameter and 100 mm
long.
TOOLS REQUIRED -: Vernier calipers, steel rule, spanner, chuck spanner, and
H.S.S. single point cutting tool.
SPECIFICATION OF LATHE -: Length of bed 1390 mm, Width of bed 200
mm, Height of centers 165 mm, Admit between centers 700 mm, Lead screw pitch
4TPI, Power of the motor 1 h.p.
THEORY -: Lathe removes undesired material from a rotating work piece in the
form of chips with the help of a tool which is traversed across the work and can be
fed deep in work. The tool material should be harder than the work piece and the
later help securely and rigidly on the machine.
The tool may be given linear motion in any direction. A lathe is used principally to
produce cylindrical surfaces and plane surfaces, at right angles to the axis of rotation.
It can also produce tapers and bellows etc.
A lathe (shown in fig.) basically consists of a bed to provide support, a head stock,
a cross side to traverse the tool, a tool post mounted on the cross slide.
The spindle is driven by a motor through a gear box to obtain a range of speeds. The
carriage moves over the bed guide ways parallel to the work piece and the cross slide
provides the transverse motion. A feed shaft and lead screw are also provided to
power the carriage and for cutting the threads respectively.
We will discuss sequence of operations in two sections. In first section discuss about
step turning and taper turning and in the second section we will discuss thread cutting
and knurling on lathe.

SECTION – I

SEQUENCE OF OPERATIONS -:
Centering
Facing
Plain turning
Chamfering
Step turning
Grooving
Taper turning
PROCEDURE -:

The work piece is fixed in a 3-jaw chuck with sufficient overhang.

Adjust the machine to run the job to a required cutting speed.
Fix the cutting tool in the tool post and centering operation is performed so
that the axis of the job coincides with the lathe axis.
Give the feed and depth of cut to the cutting tool
Facing operation is performed from the center of the job towards outwards or
from the circumference towards the center.
Plain turning operation is performed until the diameter of the work piece
reduces to 23 mm.
Check the dimensions by using vernier calipers.
Then chamfering is done on the 23mm diameter surface.
Reverse the work piece in the chuck and facing operation is performed to
reduce the length of work piece to the required dimensions.
Again, Plain turning operation is performed until the diameter of the work
piece reduced to 18mm.
Using V-cutting tool grooving operation is performed according to the given
dimensions and finish the groove using parting tool.
Swivel the compound slide to the required angle and taper turning operation
by rotating the compound slide wheel.
The angle can be measured by using the formula.
Finally check the dimensions by using vernier calipers.
PRECAUTIONS -:

The work piece should be held rigidly in the chuck before operating the
machine.
Tool should be properly ground, fixed at correct height and properly secured,
and work also be firmly secured.
Before operating the machine see whether the job and tool is firmly secured
in devices or not.
Optimum machining conditions should be maintained.
Chips should not be allowed to wound around a revolving job and cleared as
often as possible
Apply cutting fluids to the tool and work piece properly.

RESULT -: The job is completed successfully and safely.

SECTION – II
SEQUENCE OF OPERATIONS -:

Centering
Facing
Plain turning
Chamfering
Step turning
Grooving
Thread cutting
Knurling

PROCEDURE -:

The work piece is fixed in a 3 – jaw chuck with sufficient overhang.

Adjust the machine to run the job to required cutting speed.
Fix the cutting tool in the tool post and centering operation is performed so
that the axis of the job coincides with the lathe axis.
Facing is performed by giving longitudinal depth of cut and cross feed.

Perform plain turning operation until the diameter of the work piece reduced
to 20mm.
Chamfering operation is done according to the given dimensions.

Then reverse the work piece in the chuck and plain turning operation is
performed according to the given dimensions.
Using V-cutting tool and parting off tool perform grooving operation to the
required dimensions.
Reduce speed of the spindle by engaging back gear and use Tumbler
feed reversing mechanism to transmit power through the lead screw and
calculate the change gears for the required pitch to be made on the work
piece.
Using half nut mechanism perform thread cutting operation (right hand
threading) according to the given dimensions and continues it until required
depth of cut is obtained.
At the same speed knurling operation is performed using knurling tool.
For every operation check the dimensions using vernier calipers.
 PRECAUTIONS -:

Before starting the spindle by power, lathe spindle should be resolved by

one revolution by hand to make it sure that no fouling is there.
Tool should be properly ground, fixed at correct height and properly
secured, and work also be firmly secured.
Chips should not be allowed to wind around a revolving job and cleared as
often as possible.
Before operating threading operation, V-tool should be properly ground to
the required helix angle.
Apply cutting fluids to the tool and work piece property.
No attempt should be made to clean the revolving job with cotton waste.
On hearing unusual noise, machine should be stopped.

RESULT -: The job is completed successfully and safely.

Experiment No -: 02

Aim -: To produce a spur gear out of the given work piece using milling machine.
Apparatus Required -: Horizontal Milling machine, M10 – End Mill Cutter
(HSS), Gear tooth Vernier.
Materials Required -: Cast Iron Work piece – 55mm diameter, 20mm
thickness

Milling Machine
Introduction -:
Milling machine is one of the important machining operations. In this operation the
workpiece is fed against a rotating cylindrical tool. The rotating tool consists of
multiple cutting edges (multipoint cutting tool). Normally axis of rotation of feed
given to the workpiece. Milling operation is distinguished from other machining
operations on the basis of orientation between the tool axis and the feed direction,
however, in other operations like drilling, turning, etc. the tool is fed in the direction
parallel to axis of rotation.
The cutting tool used in milling operation is called milling cutter, which consists of
multiple edges called teeth. The machine tool that performs the milling operations
by producing required relative motion between workpiece and tool is called milling
machine. It provides the required relative motion under very controlled conditions.
These conditions will be discussed later in this unit as milling speed, feed rate and
depth of cut.
Normally, the milling operation creates plane surfaces. Other geometries can also be
created by milling machine. Milling operation is considered interrupted cutting
operation teeth of milling cutter enter and exit the work during each revolution. This
interrupted cutting action subjects the teeth to a cycle of impact force and thermal
shock on every rotation. The tool material and cutter geometry must be designed to
bear the above stated conditions. Depending upon the positioning of the tool and
workpiece the milling operation can be classified into different types.

WORKING PRINCIPLE -:
Working of a milling machine is based on the fact that milling cutter is fed against
workpiece. This is achieved by developing relative motion with precise control
between workpiece and rotating milling cutter. Feed motion is generally given to the
workpiece through its holding device. Cutting mechanism of the workpiece in
milling operations is same as that in turning operation on lathe. This cutting takes
place due to plastic deformation of metal by the cutting tool. Milling machine can
also hold more than one cutter at a time. The holding device is supported by
mechanism that can offer a selective portion of the workpiece to milling cutter for
its processing. Indexing is one of the examples of this type of processing.
CUTTING PARAMETERS -:

There are three major cutting parameters to be controlled in any milling operation.
These three parameters are cutting, speed, feed rate and depth of cut. These
parameters are described below.

Cutting Speed
Cutting speed of a milling cutter is its peripheral linear speed resulting from
operation. It is expressed in meters per minute. The cutting speed can be derived
from the above formula.

𝜋𝐷𝑁
𝑉=
1000
where D = Diameter of milling cutter in mm,
V = Cutting speed (linear) in meter per minute, and
N = Cutter speed in revolution per minute.
Spindle speed of a milling machine is selected to give the desired peripheral speed
of cutter.

Feed Rate
It is the rate with which the workpiece under process advances under the revolving
milling cutter. It is known that revolving cutter remains stationery and feed is given
to the workpiece through worktable.
Depth of Cut
Depth of cut in milling operation is the measure of penetration of cutter into the
workpiece. It is thickness of the material removed in one pair of cutters under
process. One pairs of cutter means when cutter completes the milling operation from
one end of the workpiece to another end. In other words, it is the perpendicular
distance measured between the original and final surface of workpiece. It is
measured in mm.

INDEXING METHOD -:
There are different indexing methods.
(a) Direct indexing
(b) Simple indexing
(c) Compound indexing
(d) Differential indexing

Direct Indexing
It is also named as rapid indexing. For this direct indexing plate is used which has
24 equally spaced holes in a circle. It is possible to divide the surface of workpiece
into any number of equal divisions out of 2, 3, 4, 56, 8, 12, 24 parts. These all
numbers are the factors of 24.
In this case first of all worm and worm wheel is disengaged. We find number of
holes by which spring loaded pin is to be moved. If we want to divide the surface
24
into 6 parts than number of holes by which pin is to be moved = for 6 parts N =
𝑁
26
6. So, number of holes = = 4 holes that is after completing one pair of milling
6
whole surface of workpiece we have to move the pin by 4 holes before next milling
operation, that is to be done for 5 number of times for making hexagonal bolt.

Simple Indexing
It is also named as plain indexing. It over comes the major limitation of direct
indexing that is possibility of dividing circumference of workpiece into some fixed
number of divisions. In this case worm and worm gear is first engaged. So, one
1
complete turn of indexing crank revolves the workpiece by th revolution. Three
40
indexing plates are used. These plates have concentric circles of holes with their
different numbers as described below:

Plate No. 1 15 16 17 18 19 20
Plate No. 2 21 23 27 29 31 33
Plate No. 3 37 39 41 43 47 49

These are the standard indexing plates followed by all machine tool manufacturers.

Indexing Procedure
(a) Divide 40 by the number of divisions to be done on the circumference of
workpiece. This gives movement of indexing crank.
40
Indexing crank movement =
𝑁
N is the number of divisions to be made on the circumference of workpiece.
(b) If the above number is a whole number, then crank is rotated by that much
number of revolutions after each milling operations, till the completion of the work.
For example, if we want to divide the circumference into 10 number of parts.
40
Indexing crank movement = = 4 revolutions.
10
That is the indexing crank is given 4 revolutions after each of milling operation for
9 more milling operations.
40
(c) If indexing crank movement calculated by is not whole number, it is simplified
𝑁
and then expressed as a whole number and a fraction.
(d) The fractional part of the above number is further processed by multiplying its
denominator and numerator by a suitable common number so that the denominator
will turn to a number equal to any number of holes available on the any of indexing
plates.
(e) That particular hole’s circle is selected for the movement of crank pin.
(f) The numerator of the process fraction stands for the number of holes to be moved
by the indexing crank in the selected hole circle in addition to complete turns of
40
indexing crank equal to whole number part of
𝑁
Let us do the indexing to cut 30 teeth on a spur gear blank that means we need to
divide the circumference of gear blank into 30 identical, parts. Crank movement is
calculated s given below.
40 40
Crank movement = =
𝑁 30
Here, N = 30
10 1
=1 =1
30 3

Let us multiply both numerator and denominator by 5.

5
=1
15
Denominator becomes ‘15’so we will select 15-hole circle of plate 1.

After each milling operation we will rotate indexing crank by one complete turn
and 5 holes in 15 holes circle. This way we do milling total 30 times.
In this case we can multiply numerator and denominator by ‘7’ the place of ‘5’ as
described below.
40
Indexing crank movement = (N = 30 teeth)
𝑁
40 10 1 7 7
= =1 =1 × =1
30 30 3 7 21
We will select the hole circle of 21 holes. After each milling operation indexing
crank will be rotated by 1 complete circle and 7 holes in 21 holes circle. This way
milling operation will be done by total 30 times.

Limitations -:

This method can used for indexing up to 50 for any number of divisions after 50 this
method is not capable for some numbers like 96, etc. Compound indexing overcomes
the limitations.

Compound Indexing -:

The word compound indexing is an indicative of compound movements of indexing

crank and then plate along with crank. In this case indexing plate is normally held
stationary by a lock pin, first we rotate the indexing crank through a required number
of holes in a selected hole circle, then crank is fixed through pin. It is followed by
another movement by disengaging the rear lock pin, the indexing plate along with
indexing crank is rotated in forward or backward direction through predetermined
holes in a selected hole circle, then lock pin is reengaged.

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.
 After Machining

Result -: Thus, a spur gear is made from the given work piece using milling
machine.
Experiment No -: 03

Aim -: To cut a helical gear out of the given blank in milling machine.
Apparatus Required -:
Horizontal Milling machine, M10 – End Milling cutter
Materials Required -: Cast Iron Blank – 65mm diameter and 20mm thickness

Milling Machine
Procedure -:
The M10 milling cutter is set on the mandrel.
The table is swiveled to an inclination of α (Helix Angle) with the axis of work
piece.
The required gear ratio is set between the work table and the mandrel holding
the work piece so that movement of the work table rotates the work piece
through the proper helix angle progressively.
The spindle is switched on and the required depth of cut is set before the tool
cuts the work piece.
Single teeth cavity is cut through the work piece.
After Indexing the next tooth is cut in similar fashion and so on.
The gear tooth dimensions are checked using a gear tooth Vernier.

Result -: Thus, a helical gear is cut out of the given blank using milling machine.
Experiment No -: 04

Aim -: To machine the given gear blank into a spur gear in gear shaper machine.
Apparatus Required -: Gear Shaper Machine, Shaper cutter
Material required -: Cast iron blank

Introduction -: A shaper Machine is a reciprocating type of machine that is used

for producing horizontal, vertical flat surfaces. The workpiece is fixed on the table
and the Ram holds the single point cutting tool. During forwarding stroke, (the single
point tools attached to the ram and workpiece is fixed on a table). Shaper Machine
is a production machine in which the single point cutting tools are attached and the
workpiece is fixed and while moving forward the tool cuts the workpiece and in
return, there is no cut on the workpiece and used for producing flat and angular
surfaces.

Shaper Machine Parts -: Shaper Machine consists of following parts.

• Base
• Column
• Table
• Cross rail
• Ram
• Clapper Box
• Elevating Screw

Base:

The base is the most important part of the shaper because it holds all the loads of the
machine. It is made up of cast iron. It absorbs vibration and other forces that occur
while performing shaping operations.

Column:

The column is mounted on the base. It is also made up of cast iron. Column supports
the ram that is moving forward and backward for operation. It also acts for covering
the drive mechanism.
Table:

It is mounted on the saddle. It is also one of the important parts of the machine. The
table can be moved crosswise by rotating the cross-feed rod and also for vertical by
rotating the elevating screw. It is a box-like casting with an accurately machined side
and top surfaces. These surfaces having T-Slots for clamping the work. In heavier
type shaper machines, the table clamped with table support to make it more rigid.

Cross rail:

It is also mounted on the column on which the saddle is mounted. The vertical
movement and Horizontal movement are given to the table by raising or lowering
the cross rail using the elevating screw and by moving the saddle using the cross-
feed screw.

SHAPER MACHINE
Theory -:
This process uses a pinion shaped cutter carrying clearance on the tooth face
and sides and a hole at its center for mounting it on a stub arbor or spindle of
the machine. The cutter is mounted by keeping its axis in vertical position.
It is made to reciprocate up and down along the vertical axis up to a pre
decided amplitude.
Both the cutter and the gear blank are set to rotate at a very low RPM about
their axis.
The relative rpm of both (cutter and blank) can be fixed to any of the available
value with the help of a gear train.
This way all the cutting teeth of cutter come is action one-by-one giving
sufficient time for their cooling and incorporating a longer tool life.
The principle of gear cutting by this process as explained above is depicted in
the Figure below
The main parameters to be controlled in the process are described below
Cutting Speed -:
Shaper cutter can move vertically upward and downward during the operation.
The downward movement of the cutter is the cutting stroke and its speed
(linear) with which it comes down is the cutting speed.
Length of cutting stroke can be adjusted to any value out of available values
on the machine.
Indexing motion -:
Indexing motion is equivalent to feed motion in the gear shaping operation.
Slow rotations of the gear cutter and work piece provide the circular feed to
the operation. These two rpms are adjusted with the help of a gear train.
Depth of Cut -:
The required depth is maintained gradually by cutting the teeth into two or
three pass.
In each successive pass, the depth of cut is increased as compared to its
previous path.
This gradual increase in depth of cut takes place by increasing the value of
linear feed in return stroke.

A Schematic representation of gear shaper is shown above with various parts.

The main advantage of gear shaper is that the process can be used to make a
variety of gears and the cycle time for producing one work piece is very less
compared to many other processes. Close tolerances can be maintained.
The main disadvantage is that there is no cutting in the return stroke. The
process cannot be used to manufacture worm and worm wheel, which is a
special type of gear.
Procedure -:
The given gear blank is mounted on the work piece spindle.
The shaper cutter having the necessary cutting teeth in the shape if tooth
spacing of the required work piece is mounted on the cutter spindle.
Necessary gear ratio is set between the work piece spindle and the cutter
spindle for the purpose of indexing.
Machine is switched on and shaping process of the tooth spacing of the gear
profile is done with the shaper cutter, in two to four passes per teeth. This feed
motion is given during the return stroke.
With the indexing done through a gear train, the cutter gradually rotates and
the work piece rotates in accordance with the cutter, as if they are two gears
in mesh.
With one complete revolution of the work piece on its spindle the gear shaping
process will be complete.
The dimensions of the gear teeth are checked using a gear tooth Vernier.

Result -: Thus, the required spur gear is cut from the given blank by gear shaping
process.
Experiment No -: 05

Aim -: To cut dovetail groove and slot on a given mild steel block using shaper
machine.
Material required -: Mild steel block of 82 x 60 x 40 mm.

Tools required -: Roughing tool, finishing tool, Dovetail cutting tool, parting or
slotting tool, try square, vice, scriber, vernier height gauge.

Equipment required -: Shaper

Measuring instruments required -: Vernier caliper, steel rule.

Sequence of operations chart -:

Sr. No Operation Cutting Tool used

1. Machining horizontal surface Roughing & Finishing tool.
2. Machining vertical surface Side cutting tool
3. Machining angular [dovetail] Dovetail cutting tool
surface.
4. Slotting Parting or slotting tool

Machining Horizontal Surface-:

A shaper is mostly used to machine a flat, true surface on a work piece held in a vice
or other holding devices. After the work is properly held on the table, a planning tool
is set in the tool post with minimum overhang. The table is raised till there is a
clearance of 25 to 30 mm between the tool and work piece. The table length and
position of stroke are then adjusted. The length of stroke should be nearly 20 mm
longer than the work and the position of stroke is so adjusted that the tool begins to
move from a distance of 12 to 15 mm before the beginning of the cut and continues
to move 5 to 8mm after the end of the cut. Proper cutting speed and feed is then
adjusted.
Types of operation performed in shaper machine
Short strokes should be given with high speed while long strokes with slow speed.
Both roughing and finishing cuts are performed to complete the job. For roughing
cut speed is decreased but feed and depth of cut is increased. Depth of cut is adjusted
by rotating the down feed screw of the tool head. The amount of depth of cut is
adjusted by a micrometer dial. The depth of cut for roughing work usually ranges
from 1.5 to 3mm, while for finishing work it ranges from 0.075 to 0.2 mm. Feed is
adjusted about one half the width of the cutting edge of the tool so that each cut will
overlap the last cut giving a smooth surface finish.

Machining Vertical Surface -:

A vertical cut is made while machining the end of a work piece, squaring up a block
or cutting a shoulder. The work is mounted in the vice or directly on the table and
the surface to be machined is carefully aligned with the axis of the ram a side cutting
tool is set on the tool post and the position and length of stroke is adjusted. The
vertical slide is set exactly at zero position and the apron is swiveled in a direction
away from the surface being cut. This is necessary to enable the tool to move
upwards and away from the work during return stroke. This prevents the side of the
tool from dragging on the planed vertical surface during return stroke. The down
feed is given by rotating the down feed screw by hand. The feed is about 0. 25 mm
given at the end of each return stroke. Both roughing and finishing cuts are
performed to complete the job.

Machining Angular Surface -:

An angular cut is made at any angle other than a right angle to the horizontal or to
the vertical plane. The work is set on the table and the vertical slide of the tool head
is swiveled to the required angle either towards left or towards right from the vertical
position. The apron is then further swiveled away from the work so that the tool will
clear the work during return stroke. The down feed is given by rotating the down
feed screw.

Cutting Slots -:

For cutting slots, a square nose tool similar to a parting tool is selected. The width
of the cutting-edge ranges from 3 to 12 mm. As the tool penetrates deep into the
work, clearance is provided all around the tool cutting edge to prevent it from
rubbing against the work surface. As the tool is purely end cutting it has no side rake;
slight back rake may be provided on the tool to promote easy flow of the chips. The
speed is reduced while cutting a slot. The clapper block is locked in the clapper box
to prevent the tool from lifting during return stroke. Lubrication is necessary on the
work to prevent the cutting edge of the tool from wear due to dragging.

All dimensions are in mm.

Procedure -:

The work piece is firmly held in a vice fitted to the table and a roughing tool
is set in the tool post with minimum over hang.
Excess material on the horizontal surface [approximately 2mm depth] is
removed in one or two cuts using roughing tool.
Roughing tool is replaced by finishing tool and the horizontal surface is
finished up to about 0.5mm depth.
Finishing tool is replaced by side cutting tool and vertical surfaces of the work
piece are machined to ensure squareness of the block.
The work piece is removed from the vise and its squareness is checked using
try-Square.
Slot and dovetail grooves are marked on the work piece using vernier height
gauge, surface plate and scriber. Again, the work piece is firmly held in a vice
fitted to the shaper table.
Side cutting tool is replaced by dovetail cutting tool and the vertical slide of
the tool head is swiveled to 75 ° angle to the horizontal plane towards right.
Angular surface or dovetail groove is machined at the right end of the work
piece.
Dovetail groove on the other side is machined by changing the position of the
work piece in the vice.
Dovetail cutting tool is replaced by slotting tool and the slot is cut on the
horizontal surface of the work piece.
The job is checked for its dimensions.

Precautions -:

Lubricant should be used during slotting to prevent the cutting edge of the
tool from wear due to dragging.
Work surface to be machined should be carefully aligned with the axis of the
ram.
The length and position of stroke should be carefully adjusted.
Experiment No -: 06

Aim -: To machine a given MS block for desired dimensioning on a shaper tool.

Materials required -: Mild steel

Machine required -: Shaping machine

Measuring instruments -: Vernier calipers, Vernier height gauge, Dial

indicator

Cutting tools -: H.S.S tool bit, Plain tool.

Observation -: Record the following in a tabular form.

Machine Tool Specifications (Table A)

Machine Type & Size Speed given to Feed given to Type of

Make Surface
Tool work Tool work Produced

Shaper
M/c.

Speed and Feed Data (Table 2)

No. Shaper M/c.

Speed Feed
1.
2.
3.
4.
5.
Procedure -:

Run the machine at low speed and observe the motions, which control the
shapes of the surfaces produced. Note particularly the features, which control
the geometrical form of the surface.

Learn the names of the major units and the components of each machine.
Record these details (Table A). (Please ensure that the main isolator switch is
off and check that the machine cannot be inadvertently started. Do not remove
guards). Use the manufacture's handbook for details that cannot be inspected.

Record the obtainable speed and feed values (Table B).

Note down the special features of the speed and feed control on each machine.

Measuring of specimen.
Fixing of specimen in the machine vice of the shaping machine
Giving the correct depth and automatic feed for the slot is to be made.

Check the slot with the Vernier calipers & precision measurement by slip
gauges at the end.

Precautions -:

1. The shaping machine must be stopped before setting up or removing the work
piece.
2. All the chips should be removed from the cutter.

Advantages -:

1. Single point cutting tools used in shaper are expensive these tools can be easily
grounded to any desirable shape.
2. Shaper set-up is very quick and easy and can be readily changed from one job to
another.
Disadvantages -:

1. The shaper is unsuitable for generating the flat surfaces on very large parts because
of limitations on the stroke and overhang the ram.
2. The primary motion is accomplished by rack and pinion drive using a variable
speed motor.

Applications -:

A shaper machine is a cutting machine that cuts a linear tool path using a linear
relative motion between a single-point cutting tool and the piece of work. This type
of machine is usually used to machine flat, straight surfaces, although it is also able
to perform more complex tasks including the machining of dovetail slides, gear teeth
and internal spline, keyways in the boss of either gears or pulleys and many other
forms of work that take advantage of the machines linear relative motion.
Experiment No -: 07

Aim -: To make internal splines, space 90 degree apart on the given hollow
cylindrical work piece by using slotting machine.
Required material -: M.S. Hollow Cylindrical work piece of 65 mm diameter
and 70 mm length
Required tools -: H.S.S. Cutting tool, Adjustable wrench, Scriber
Specification of the machine -: Stroke 150 mm Rotary table 275 mm
Longitudinal Movement 200 mm Cross Movement 200 mm Power of the motor 1
hp.
Theory -: A Slotting machine or slotter has its own importance for a few particular
classes of work. Its main use is in cutting different types of slots and it certainly
proves to be most economical so far as this kind of work is concerned. Its other uses
are in machining irregular shapes, circular surfaces and other premarket profiles,
both internal as well as external. Its construction is similar to that of vertical shaper.
Its ram moves vertically and the tool cuts during the downward stroke only.
Main Parts of a Slotter -:
Base -: It is heavy cast iron construction and is also known as bed. It acts as support
for the column, the driving mechanism, ram, table and all other fittings. At its top it
carries horizontal ways, along which the table can be traversed.
Column -: It is another heavy cast iron body which acts as a housing for the driving
mechanism. At its front carries vertical ways, along which the ram moves up and
down.
Table -: Usually a circular table is provided on slotting machines. In some heavy-
duty slotters, either rectangular or circular table can be mounted. On the top of table
are provided T- slots to clamp the work or facilitate the use of fixtures etc.
Ram -: It moves in vertical direction on the guide ways provided in front of the
column. At its bottom, it carries the tool post in which the tool is held. The cutting
action takes place during the downward movement of the ram.

Slotting machine
Procedure -:

The tool is fixed to the tool post such that the movement should be exactly
perpendicular to the table.
The work piece is then set in the vice such that the tool is just above the
work piece. Adjust the length of the stroke of the ram.
 Slotting operation is performed and make one slot on the work piece to the
required dimensions.
Then bring the tool to the initial position.
Rotate the work table by an angle 900 and continue the process for the
second slot.
Repeat the process for the remaining slots.

Precautions -:

The work piece should be set securely and rigidly in the vice.
Before starting the machine make sure that the work, vice, tool, and ram
are securely fastened.
Check that the tool and tool holder will clear the work and also clear the
column on the return stroke.
Make sure that the axis of the work piece is parallel to the line of action of
tool.
Never attempt to adjust a machine while it is in motion.
Suitable feeds and depth of cut should be maintained uniformly.
Always feed will be given to the work in the backward stroke only.

Result -: The job is completed successfully and safely.

Experiment No -: 08

Aim -: To perform plain surface grinding on the given work piece to the required
dimensions.
Apparatus required -: Grinding machine, Grinding Wheel, Vernier Caliper
Material Required -: MS / CI plate 12mm X 50mm X 75mm

Theory -: It consists of the main driving motor situated over the housings. This
motor drives the countershaft through an open V- belt. The countershaft, at its
extreme carries two driving pulleys; one for open belt and the other for cross belt.
The main driving shaft is provided below the bed. One end of it passes through the
housing and carries a pinion, which meshes with the rack provided under the table
of the machine as shown. The other end of this shaft carries two pairs of pulleys –
each pair consisting of a fast pulley and loose pulley. One of these pairs is connected
to one of the driving pulleys by means of a open belt and the other to the second
driving pulley by means of a cross belt. A speed reduction gear box is mounted on
the main driving shaft and the same is incorporated between the pinion and the pairs
of driven pulleys. One set of the above pulleys is used for the forward motion of the
table and the other set for backward or return motion. the cross belt will be used for
forward motion and the open belt for return motion. Note that the driving pulley on
the counter shaft for cross belt is smaller than the pair of fast and loose pulleys for
the same. Against this the driving pulley on the countershaft for open belt is bigger
than the pair of fast and loose pulleys for the same. Consequently, therefore for the
same speed or number of revolutions of the countershaft the main driving shaft will
run faster when connected by open belt than when the cross belt is used. It is obvious
therefore that the return stroke will be faster than the forward stroke. It should also
be noted here that the pulleys are so arranged that when the cross belt is on the fast
pulley, i.e., in forward stroke the open belt will be on the loose pulley and its reverse
will take place during the return stroke. In order that this relative shifting of belt may
take place automatically at the end of each stroke, without stopping the machine, a
belt shifter and its operating lever are provided on the machine. Trip dogs are
mounted one each at both ends, on the table. At the end of each stroke these dogs
strike against the operating lever alternately and the belt shifted accordingly. Thus,
the table movement is reversed automatically.

Surface grinding machine

Procedure -:
First the work piece is placed on the magnetic chuck.
The positioning of the work piece is aligned at right angles to the grinding
wheel and exactly parallel to the sides of the magnetic chuck by using slip
gauges if necessary.
The magnetic chuck is switched on and the powerful electromagnet holds the
job firmly in position.
Now the spindle is turned on and the grinding wheel is just touched the work
piece surface to mark its zero / reference position.
Now the required feed, either totally or in steps, is given to the grinding wheel
and the wheel is traversed all over the work piece.
Same procedure is repeated until the required dimensions are achieved.
Care should be taken for maintaining the surface finish.
Finally, the dimensions are checked using either a Vernier caliper or a screw
gauge.

Result -: Thus, plain surface grinding is performed on the given work piece up to
the required Dimensions.
Experiment No -: 09

Aim -: To grind the cylindrical surface of the given work piece by cylindrical
grinding.
Apparatus Required -: Grinding machine, cylindrical grinding wheel setup
Steel Rule, Vernier Caliper.
Materials Required -: Cast iron work piece

Cylindrical grinding machine

Procedure -:

First the given work piece is preliminarily finished to the pre-required

dimensions on a lathe before beginning the grinding process.
Now the work piece is fitted in the chuck of the cylindrical grinding machine.
The grinding wheel is just touched with the work piece and is taken as the
zero reference.
Coolant circulation is switched on and the grinding wheel is engaged with the
work piece.
Both the work piece and the grinding wheel roll on contact with each other
like two gears in mesh.
Now slowly the wheel is moved over the entire length of the work piece to get
the grinded finish.
After one feed is over, the grinding wheel is moved further towards the axis
of the work piece and the process is repeated until the required dimensions are
achieved.
Finally, the dimensions are checked using a Vernier caliper.

Result-: Thus, cylindrical grinding is performed on the given work piece to the
given dimensions.
Experiment No-10

Aim -: To study the Lathe Tool Dynamometer and Drill Tool Dynamometer and
determine the Resultant force act on the tool during turning operation and also
estimate the force and thrust required to perform drilling operation.

Apparatus required-: Lathe tool Dynamometer and Drill tool dynamometer.

Tools & material required -: HSS tool with tool holder, Φ25mm MS bar, and
10mm thick MS flat and 10mm drill.

Theory -: In machining or metal cutting operation the device used for

determination of cutting forces is known as a Tool Dynamometer or Force
Dynamometer. Majority of dynamometers used for measuring the tool forces use the
deflections or strains caused in the components, supporting the tool in metal cutting,
as the basis for determining these forces. In order that a dynamometer gives
satisfactory results it should possess the following important characteristics:

It should be sufficiently rigid to prevent vibrations.

At the same time, it should be sensitive enough to record deflections and
strains appreciably.
Its design should be such that it can be assembled and disassembled easily.
A simpler design is always preferable because it can be used easily.
It should possess substantial stability against variations in time, temperature,
humidity etc.
It should be perfectly reliable.
The metal cutting process should not be disturbed by it, i.e., no obstruction
should be provided by it in the path of chip flow or tool travel.

Types of Dynamometers -: Irrespective of their design and the technique used

for strain measurement, most of the force dynamometers used today carry a
measuring system which is recalibrated for its stiffness.

The cutting forces are measured by these dynamometers by measuring the strain or
deflection caused in this system due to the force under measurement. The different
types of commonly used dynamometers can be broadly classified as:
 Mechanical dynamometers
Strain Gauge type dynamometers
Pneumatic and Hydraulic dynamometers
Electrical Dynamometers
Piezoelectric dynamometers

Procedure -:

Lathe Tool Dynamometer:

Lathe tool dynamometer is used to measure cutting forces acting at the machining
zone during turning with a single point cutting tool. All the three directional forces
are measured simultaneously. Forces on a single point tool in turning: In case of
oblique cutting in which three component forces act simultaneously on the tool point
as shown.

The components are:

𝐹𝑡 = The feed force or thrust force acting in horizontal plane parallel to the axis of
the work.
𝐹𝑟 = The radial force, also acting in the horizontal plane but along a radius of Work
piece i.e., along the axis of the tool.
𝐹𝑐 = The cutting force, acting in vertical plane and is tangential to the work surface.
Also called the tangential force.
 The work piece is fixed in a 3-jaw chuck with sufficient overhang.
Fix the dynamometer cutting tool in the tool post in such a way that the tip
of the tool coincides with the lathe axis.
Select proper cutting speed, feed and depth of cut.
Perform turning operation on the work.
Directly measure the three components of forces acting on the tool using
lathe tool dynamometer.
Repeat the procedure for varying the above three parameters (CS, F & DC).

The resultant force can be calculated by

𝑅 = √𝐹𝑐2 + 𝐹𝑡2 + 𝐹𝑟 2

Observe the effect of cutting speed, feed and depth of cut on force.

Drill Tool Dynamometer -: This is strain gauge Drill Tool Dynamometer

designed to measure thrust and torque during drilling operation. This dynamometer
is suitable for drilling a hole up to 25mm size in Mild Steel. Drilling tool
dynamometer is a Rigid in construction, Compact Unit, Easy in handling and
Assessment of cutting forces by giving due consideration to various parameters like
depth of cut, material, speed and feed.

Force system in drilling:

During the process of drilling a lot of axial pressure (Thrust force) is applied on it in
order to make it penetrate into the material. On account of this pressure all the drill
elements are subjected to one or other type of force.

The principal forces are:

𝐹𝐻 – An equal and opposite horizontal force acting on both lips of the drill and thus
neutralizing each other.
𝐹𝑉 - Vertical force acting at the center of the drill in a direction opposite to that of
the applied pressure.
𝐹𝑉1 - Vertical force acting in the same direction as F, on the lips of the drill it is the
main cutting force in the operation.

𝐹𝑓1 - Frictional force due to rubbing of upward flowing chips against wall of the
hole and flutes of the drill.
𝐹𝑓2 - frictional force due to rubbing between the drill margin and the hole surface.
P – The applied axial pressure or thrust force acting along the axis of drill to press it
into the work piece material.

In order that the drill penetrates into the work piece the applied pressure P, should
be able to overcome all the resistive forces acting against it.
P > (𝐹𝑉 + 2𝐹𝑉1 +𝐹𝑓1 + 𝐹𝑓2 )
It is reckoned that as compared to𝐹𝑉 and 𝐹𝑉1 the magnitudes of the frictional forces
𝐹𝑓1 and 𝐹𝑓2 are too small to be considered for practical purposes. Hence, they are
considered negligible.
 Therefore P = 𝐹𝑉 + 2𝐹𝑉1

Thrust force acting on the drill,

M = C 𝑑1.9 𝑓 0.8 N-mm

Where d is the diameter of the drill in mm f is the feed per revolution, mm/rev C is
a constant depends upon the material to be machined.

For Steel, C = 616 Aluminum alloys, C = 180 Magnesium alloys, C = 103 Brasses,
C = 359

Torque acting on the drill is given by

T = K 𝑑 𝑓 0.7 N

For Steel, K = 84.7

Cast Iron = 60.5

Fix the drill of a particular diameter in the drill chuck.

Fix the work piece in vice mounted on the bed of the machine.
Attach the drill tool dynamometer to the machine.
Perform drilling operation on the work.
Note down the values of thrust force and torque acting on the drill directly
from drill tool dynamometer.
Repeat the procedure by varying the speed, feed and depth of cut of the drill.
Observe how these parameters will affects the force and torque.

Precautions -:
The tool should be rigidly mounted on the lathe tool post.
Make sure that there should not be any vibrations in the tool.
Readings should be noted carefully.
Select the cutting speed, feed and depth of cut properly.

Result -: The job is completed successfully and safely.