SNS COLLEGE OF TEHCNOLOGY

(AN AUTONOMOUS INSTITUTION)

COIMBATORE – 35

DEPARTMENT OF MECHANICAL ENGINEERING

16ME211 MANUFACTURING TECHNOLOGY LAB

LABORATORY MANUAL

Name : ……………………………………

Register Number : ……………………………………

Year & Semester : ……………………………………

Branch : …………………………………….

Academic Year : …………………………………….

Prepared by: HOD/MECH

 LIST OF EXPERIMENTS

S.NO. TITLE OF EXPERIMENT

1 Mould With Split Pattern

2 Mould with Core

3 Step Turning

Taper Turning By Compound Rest Method, Taper Turning Attachment Method &
4
Tailstock Set Over Method

Making of butt and lap joint using MIG Welding

5 Making of butt and lap joint using TIG Welding

6 External Thread Cutting

7 Boring and internal threading

8 Eccentric Turning

9 Horizontal/Vertical Milling using Milling machine.

10 Gear cutting processes.

11 Exercise on cutting Key way and Splines using Slotter.

12 Plain Surface grinding and Cylindrical grinding.

13 Reciprocating Machines such as Shaper/Planer.

14 Upright and Radial Drilling machines.

15 Study of Plastic Injection Moulding.

Measurement of Cutting Forces and Surface Roughness in Turning / Milling

16
Process.
 INDEX

STAFF
EX.NO DATE NAME OF THE EXPERIMENT MARKS
SIGN
MOULD WITH SPLIT PATTERN
EX.NO:
MOULD WITH SPLIT PATTERN
DT:

AIM:
To prepare a green sand mould with the split pattern.

TOOLS REQUIRED:
Moulding board, moulding box, rammer, trowel, lifter, gate cutter, riser, runner, sprue pin and
other moulding tools.

INTRODUCTION:

SPLITPATTERN
 Patterns of complicated shape cannot be made of one piece because of inherent difficulties
associate with moulding operation. Such patterns are made as split or two piece pattern.
 The upper and the lower part of the split pattern are accommodated in the cope and drag
portions of the mould respectively.
 Dowel pins are used for keeping the alignment between the two parts of the pattern.
 Taps and Water stop-cocks are produced with the help of split pattern.

PROCEDURE:

1. The mould box, pattern, tools and the table/floor are cleaned.

2. The drag is filled with green sand after positioning the round on the table.

3. The greensand is rammed carefully and the excess sand is struck off.

4. Tilt the drag upside down and sprinkle river sand on top of it.

5. The cope is positioned on top of the drag.

6. Position the square pin, then fill the cope with sand and ramming is done and the
excess sand is struck off.

7. Remove the sprue pin and the riser pin carefully.

8. Apply water on the edges of the pattern and remove it carefully using the draw spike and
then finish the cavity.

9. Vent holes are made using vent wire.

10. A funnel shaped opening and gate is made to pour the molten metal.
RESULT:
Thus the mould cavity of the given split pattern is obtained.

VIVA QUESTIONS:

1. Define the term foundry.

2. What is a pattern?
3. What are the different types of patterns?
4. Explain the composition and the properties of moulding sand.
5. List the pattern materials used?
6. What are the various types of pattern allowance?
MOULD WITH CORE
EX.NO:
MOULD WITH CORE
DT:
AIM:

To prepare a sand mould, using core.

TOOLSREQUIRED:

Moulding board, moulding box, core box, rammer, trowel, lifter, gate cutter, riser, runner,
sprue pin and other moulding tools.

PROCEDURE:

1. The mould box, pattern, tools and the table/floor are cleaned.
2. The drag is filled with green sand after positioning the round on the table. 3.
The green sand is rammed carefully and the excess sand is struck off.
4. Tilt the drag upside-down and sprinkle river sand on top of it.
5. The cope is positioned on top of the drag.
6. Position the square pin, then fill the cope with sand and ramming is done and the
excess sand is struck off.
7. Remove the sprue pin and the riser pin carefully.
8. Apply water on the edges of the pattern and remove it carefully using the draw spike and
then finish the cavity.
9.Vent holes are made using vent wire.
10. A funnel shaped opening and gate is made to pour the molten metal.

RESULT:

Thus the mould cavity of the given core pattern is obtained

VIVA QUESTIONS:

1. What are the basic steps in core making process?

2. What is meant by core?
3. Name the three types of core binders?
4. What are the types of cores?
5. Specify the purpose of lifter and rammer in casting.
BUTT JOINT

LAP JOINT
EX.NO:
BUTT, LAP JOINT - WELDING
DT:

AIM:

To make a “Butt joint” & “Lap” on the given two mild steel plate by welding

MATERIALS REQUIRED:

Two mild steel plates 60 X 50 X 5 mm

TOOLS REQUIRED:

1. Welding machines & Arrangements

2. Electrode

3. Safety gloves

4. Welding shield and Goggles

5. Chipping hammer

6. Flat file and Wire brush.

PROCEDURE:

1. Two mild steel plates of size 60 X 50 X 5 mm are taken.

2. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint
and more strength.
3. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate
to be welded.
4. The plates to be welded are positioned by touching each other
(butting) and tag weld is done on the ends to avoid the movement of the plates during welding.
5. Now start welding from one end of the plates.
6. The electric arc produced melts the welding rod and joint the two metal plated maintain the
gap of 3 mm between the plates and the welding rod.
7. After welding process is over by using chipping hammer the slag over the welded portions are
removed. Then it is cleaned with the help of wire brush.
8. Now the joint is finished.

RESULT:

Thus the two metal plates are welded in square butt joint & lap joint
 STEP TURNING

BEFORE MACHINING

AFTER MACHINING

ALL DIMENSIONS ARE IN “mm”

TOLERANCE 0.5 mm
 EX.NO: STEP TURNING
DT:
AIM:
To obtain the required shape and size of the work piece, by machining operations.

MATERIAL SUPPLIED:
Φ 25 x 102mm length

TOOLS REQUIRED:
Lathe, cutting tool, Scriber, Vernier caliper, Vernier height gauge, Try-square.

SEQUENCE OF OPERATIONS:

1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Plain turning
6. Step turning
PROCEDURE:
1. The given work piece is checked first its dimensions.
2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly, ensuring
centering of work piece.
3. The single point cutting tool is held in the tool post and tightens the nuts using spanner
4. Facing is done with cutting tool moving from the Centre of work piece towards outside. It
is done until 120mm length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and it is
done until the Φ30mmdiameterof the job is obtained.
6. Then the step turning feedΦ26 and5 0mmlength is done in one end so that the work piece is
rest to other side and then the work piece is machined as Φ22X20mm.
7. Finally, the dimensions of work piece are again checked.

RESULT:
Thus the job is machined as per the drawing in the given work piece and the
dimensions are inspected using vernier caliper.
VIVA QUESTIONS:

1. Name some important lathe parts.

2. Where can we see C.I in lathe?
3. What is turning and facing.
4. Give the specification of lathe.
5. What is machining?
 TAPER TURNING BY COMPOUND REST METHOD

BEFOREMACHINING

AFTERMACHINING

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
EX.NO:
TAPER TURNING BY COMPOUND REST METHOD
DT:

AIM:
To obtain the required shape and size of the work piece, by machining operations.

MATERIALSUPPLIED:
Φ 32 x102mm length

TOOLS REQUIRED:
Lathe, cutting tool, Scriber, Vernier caliper, Vernier height gauge, Try-square.

SEQUENCEOF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Plain turning
6. Taper turning
PROCEDURE

1. The given work piece is checked first its dimensions.

2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly, ensuring
centering of work piece.

3. The single point cutting tool is held in the tool post and tightens the nuts using spanner

4. After setting the work piece and cutting tool in proper manner the tool is aligned then the
facing of work piece is done on both sides for the required length of100mm.

5. A countersinking hole is drilled in one face using combination drill chuck through tailstock.

6. Turning is done to reduce the diameter of the job. Sufficient depth of cut is given and it is
done until the Φ30mmdiameterof the job is obtained.

7. Using the formula Tan-1(D-d/2L) calculate the angle for the taper to be machined.

8. Then the taper turning operation is done on the workpiece according to the taper angle
calculated. The compound rest base is swirled and set a calculated taper angle, for this the tool
is moved by 45° to the lathe axis

9. Finally all the dimensions of work piece are again checked.

RESULT:
Thus the job is machined as per the drawing in the given work piece and the dimensions are
inspected using vernier caliper.
VIVA QUESTIONS:

1. What are the types of Taper Turning?

2. Name the tool material.
3. What are the different operations performed in lathe?
4. State the important requirements of capstan and turret lathe.
5. What is turret and capstan lathe?
 TAPER TURNING BY TAILSTOCK SET OVER METHOD

BEFORE MACHINING

AFTER MACHINING

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm

Calculate:
EX.NO:
TAPER TURNING BY TAILSTOCK SETOVER METHOD
DT:

AIM:
To obtain the required shape and size of the workpiece by machining operations.

MATERIALSUPPLIED:
Φ 32 x102mm length

TOOLSREQUIRED:
Lathe, cutting tool, Scriber, Vernier caliper, Vernier height gauge, Try-square.

SEQUENCEOFOPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Plain turning
6. Tail stock set over
7. Taper turning

PROCEDURE:

1. Loosen the tailstock clamp nut

2. Calculate tail stock offset

3. Offset upper part of tailstock by loosening one setscrew and tightening the other until required
amount is indicated on graduated scale at end of tailstock
4. Adjust tailstock spindle to distance, it will be used in machining setup and lock tailstock spindle
clamp
5. Set the cross-slide reading to zero, with no gap between the tool and workpiece
6. Give a depth of cut, say 0.1mm
7. Give feed using feed lever
8. When the desired taper length is reached, back off the cross slide hand wheel
9. Return the carriage to the taper start point
10. Increase the depth of cut, say by 0.1mm
11. Repeat the steps 7 to 11 until the taper of desired length is cut

RESULT:
Thus the job is machined as per the drawing in the given work piece and the dimensions are
inspected using vernier caliper.
VIVA QUESTIONS:

1. Write down the formula for calculating taper turning angle by compound rest method.
2. Write down the names of any four lathe accessories.
3. What is the application of air operated chuck?
4. What is self centering chuck?
5. Define the term ‘Conicity”.
6. What is the purpose of lathe dog?
 TAPER TURNING USING TAPER TURNING ATTACHMENT

BEFORE MACHINING

AFTER MACHINING

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm

Angle of swivel α = tan-1 (D-d) / 2L where, D = Larger end diameter

d = Smaller end diameter

L = Length of taper turning

EX.NO:
TAPER TURNINGUSING TAPER TURNING ATTACHMENT
DT:

AIM:
To obtain the required shape and size of the workpiece, by machining operations.

MATERIAL SUPPLIED:
Φ 32 x72mm length

TOOLS REQUIRED:
Lathe, cutting tool, Scriber, Vernier caliper, Vernier height gauge, Try-square.

SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Plain turning
6. Taper turning
PROCEDURE

1. The given work piece is checked first its dimensions.

2. The workpiece is held in the chuck. Chuck key is used to tighten the job firmly, ensuring
centering of work piece.

3. The single point cutting tool is held in the tool post and tightens the nuts using spanner

4. After setting the workpiece and cutting tool is proper manner the tool is aligned then the
facing of work piece is done on both sides for the required length of100mm.

5. A countersinking hole is drilled in one face using combination drill chuck through tailstock.

6. Turning is done to reduce the diameter of the job. Sufficient depth of cutis given and it is done
until the Φ30mmdiameterof the job is obtained.

7. Using the formula Tan-1(D-d/2L) calculates the angle for the taper to be machined.

8. Then cross slide is first made free from the lead screw by removing the binder screw.
9. Then the taper turning operation is done on the workpiece according to the taper angle
calculated. The taper turning attachment having plate is swilled and is set at the desired angle with
the lathe axis. The guide plate must be set at half taper angle

10. Finally all the dimensions of work piece are again checked.
RESULT:
Thus the job is machined as per the drawing in the given workpiece and the dimensions are
inspected using vernier caliper.

VIVA QUESTIONS:

1. What is metal removal rate?

2. Define machinability of metal?
3. Classify the tool wear?
4. What are the properties of cutting fluid?
5. List the Different types of chips produced while machining.
6. Name any four cutting tool materials.
7. What are the factors should be considered for selection of tool materials
8. What are all the factors considered for selection of cutting speed?
9. How tool life is defined?
10. What is the difficulty for long and continuous chip?
11. What is cutting force?
12. Classify the types of metal cutting process?
13. When will the negative rake angles be used?
14. Explain the nose radius?
15. Classify the various angles in cutting tool?
 EXTERNAL THREAD CUTTING USING LATHE

BEFOREMACHINING

AFTER MACHINING

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
 EX.NO:
EXTERNAL THREAD CUTTING USING LATHE
DT:

AIM:
To perform the multi start V-Thread cutting operations on the given work piece as per the given
dimensions.

MATERIAL REQUIRED:
Mild steel rod

TOOLS REQUIRED:
Lathe
Steel rule
Vernier caliper
Cutting tool
Scriber
Chuck key
Tool post key
Multi start V- thread cutting tool

PROCEDURE:
1. The dimension of the given work piece are checked by Vernier caliper.
2. The work piece is held in the lathe chuck properly and it is tightened by chuck key.
3. The cutting tool is set in a tool post such that the point of the cutting tool coincides with the
lathe axis.
4. The machine is switched ON to remove the work piece at the selected speed.
5. By the giving cross feed and longitudinal feed to the cutting tool the facing and turning
operations are done respectively.
6. The speed of the work piece is reduced.
7. The external thread cutting operation is done using external V-thread cutting tool by engaging
thread mechanism.
8. The work piece is removed from the chuck and all the dimensions are measured and checked

RESULT:

Thus the required size and shape of the given work piece is obtained.

VIVA QUESTIONS:

1. What is the main requirement of a lathe bed?

2. What are the uses of headstock?
3. What is the main difference between live center and dead center?
4. State the various parts mounted on the carriage.
5. List any four types of lathes.
 BORING AND INTERNALTHREADING

FINISHED WORKPIECE

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
EX.NO:
BORINGAND INTERNAL THREADING
DT:
AIM:

To obtain the required shape and size of the workpiece, by machining operations.

MATERIALSUPPLIED:

Φ 45 x25mm length

TOOLSREQUIRED:

Cutting tool, Boring and thread cutting tool, Scriber, Vernier caliper, Vernier height gauge,
Try-square,

SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Drilling
6. Internal boring
7. Internal threading

PROCEDURE

1. The given work piece is checked first its dimensions.

2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly, ensuring
centering of work piece.

3. The single point cutting tool is held in the tool post and tightens the nuts using spanner

4. Facing is done with cutting tool moving from the centre of work piece towards outside.
It is done until the required length of the job is obtained.

5 A countersinking hole is drilled in one face using combination drill chuck through tailstock.

6. Drilling is done with the help of drill until the required diameter of the job is obtained.

7. Boring is done with boring tool after the drilling operation.

8. Internal thread cutting is done with internal cutting tool until the entire length of the job.

9. Finally all the dimensions of work piece and pitch of the thread are again checked.

RESULT:

Thus the job is machined as per the drawing in the given work piece and the
dimensions are inspected using vernier caliper.
VIVA QUESTIONS:

1. What is the difference between drilling and boring?

2. Name the drill material.
3. What are the different drilling machines?
4. Name the different work holding mechanisms in a drilling machine.
5. How drilling is being carried out in lathe?
6. Define feed.
7. List any four work holding devices.
8. Mention the use of chucks.
 ECCENTRIC TURNING

BEFORE MACHINING

AFTER MACHINING

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
 EX.NO:
ECCENTRIC TURNING
DT:
AIM:
To obtain the required shape and size of the workpiece, by machining operations.

MATERIAL SUPPLIED:
Φ 32 x52mm length

TOOLS REQUIRED:
Cutting tool, Boring and thread cutting tool, Scriber, Vernier caliper, Vernier height gauge,
Try-square.

SEQUENCE OF OPERATIONS:
1. Checking
2. Work piece setting
3. Tool setting
4. Facing
5. Drilling
6. Internal boring
7. Internal threading

PROCEDURE

1. The given work piece is checked first its dimensions.

2. The workpiece is held in the independent 4 jaw chuck. Chuck key is used to tighten the job
firmly, ensuring centering of work piece.

3. The single point cutting tool is held in the tool post and tightens the nuts using spanner.

4. Facing is done with cutting tool moving from the center of work piece towards outside. It is
done until the required length of the job is obtained.

5 A countersinking hole is drilled in one face using combination drill chuck through tailstock.

6. The plain turning operation is performed to get the required diameter first.
7. After plain turning using center gauge fix the eccentric center by adjusting the jaws of the
chuck.
8. Then eccentrically turn the work piece to the required diameter as shown in figure.

9. Finally all the dimensions of work piece are again checked.

RESULT:
Thus the job is machined as per the drawing in the given work piece and the
dimensions are inspected using vernier caliper.
VIVA QUESTIONS:

1. Define steady and follower rest.

2. What type of mechanism is used for indexing the turret head for the next operation?
3. Name any four work-holding devices.
4. Define the term depth of cut.
5. What is meant by eccentricity?
6. List the various types of chucks.
7. What is the use of Mandrels?
 KEYWAY MILLING USING
VERTICAL AND HORIZONTAL MILLING MACHINE

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
 KEYWAY MILLING USING
EX NO:
VERTICAL MILLING MACHINE
DATE :

AIM:
To perform a keyway milling operation on the given work piece using vertical milling machine.

TOOLS & EQUIPMENT REQUIRED:

1. Vertical Milling machine
2. Contour milling cutter
3. Outside Caliper
4. Steel Rule
5. Vernier Caliper.

PROCEDURE:
1. The given work piece is fixed in a table.
2. The form milling cutters are used for contoured milling.
3. The machine is switched on to revolve the cutter at the selected speed.
4. By giving Cross feed and longitudinal feed to the work table, the contour operations are
done respectively. The profile of the cutter coincides with that of the work piece.
5. After the work piece is milled as per the given drawing, the machine is switched off.
6. The work piece is removed from the work table and all the dimensions are measured and checked.

RESULT:
Thus the key way milling operation was done on the given work piece.
SPUR GEAR MILLING USING HORIZONTAL MILLING MACHINE

ALL DIMENSIONS ARE IN “mm”

EX NO: SPUR GEAR MILLING USING HORIZONTAL MILLING
DATE : MACHINE

AIM:
To form gear profile according to the given module and number of teeth in the given work piece.

TOOLS & EQUIPMENTS REQUIRED:

Milling machine, Vernier caliper, Mandrel.

PROCEDURE:

 Calculate the gear tooth proportions.

Blank diameter =(Z+2)m

Tooth depth = 2.25 m
Tooth width = 1.5708 m
where,
Z = Number of teeth required
m = module
Indexing calculation
Index crank movement = 40 / Z

 The dividing head and the tail stock are bolted on the machine table. Their axis must be set parallel
to the machine table.
 The gear blank is held between the dividing head and tailstock using a mandrel. The mandrel is
connected with the spindle of dividing head by a carrier and catch plate.
 The cutter is mounted on the arbor. The cutter is centred 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 in 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 gear teeth are cut.
SAMPLE CALCULATION:

Z = No. of teeth = ________

m = module = ________mm

Blank Diameter = (Z + 2) m

= ___________ mm

Tooth Depth = 2.25 m

= 2.25 * _______

= _________mm

Indexing Calculation = 40 / Z

= 40 / ____

RESULT :

Thus the required gear is machined using the milling machine to the required number of teeth.
KEYWAY MACHINING IN SLOTTER

ALL DIMENSIONS ARE IN “mm”

 EX NO: KEYWAY MACHINING IN SLOTTER
DATE :

AIM:
To form Key way in the given work piece

TOOLS Required:

Single point cutting tool, parting tool, spanner, hammer, parallel block, center punch, divider.

MEASURING TOOLS:

Try square, Vernier caliper, Vernier height gauge, steel rule, and surface plate.

SEQUENCE Of Operation:

 Marking
 Job setting
 Tool setting
 Ram adjustment
 Speed adjustment
 Key way cutting
MARKING:

Marking is carried out after measuring diameter with the help of Vernier caliper. Marking is done
with the help of Vernier height gauge.

JOB SETTING:

Job is set in the vice. Proper support was given by the job by a supporting block.

TOOL SETTING:

The tool is held on the tool head such that it is at right angles to the job and it should be well
tightened.

RAM ADJUSTMENT:

Ram is adjusted depending upon the travel of the tool related to the job.

SPEED ADJUSTMENT:

The speed is adjusted by the levers placed in slotter, low speed is given for rough-cut and high
speed is given for finish cut.

SHAPING:

After fixing the work piece the tool, depth of cut is given which should not exceed 0.1mm, then
the feed is given in horizontal i.e., longitudinal feed. Then the keyway cutting is done for the given
dimensions.
SAFETY PRECAUTIONS:

 Before staring the machine it should be operated by hand in order to assure that rammer
table doesn’t strike anywhere.
 Hand should be held sufficiently away from the ram
 Depth of cut should not exceed 0.1mm mm.
 On the above situation the machine would be stopped and then resetting should be taken.
 Don’t remove the chips while in operation.

RESULT:

Thus the key way obtained in slotting machine.

SURFACE GRINDING

ALL DIMENSIONS ARE IN “mm”

 EX NO: SURFACE GRINDING
DATE :

AIM:
To make the surface operation on the given work piece by using surface grinding machine.

TOOLS REQUIRED:
Surface grinding machine
Magnetic chuck

PROCEDURE:
 The given work piece is held firmly on a magnetic chuck of a surface grinder.
 The machine is started and the grinding wheel is allowed to revolve at a selected speed.
 The required depth of cut is given by raising the table.
 After giving a depth of cut, the work piece is made to reciprocate under the grinding wheel.
 The table is fed axially between passes to produce a fine flat surface.
 The process is repeated for grinding another side until the desired dimension is achieved.
 Finally, the finished work piece is checked for the given dimensions.

RESULT :
Thus the given workpiece is grinded to the given dimension effectively using surface grinding
machine.
CYLINDRICAL GRINDING

ALL DIMENSIONS ARE IN “mm”

 EX NO: CYLINDRICAL GRINDING
DATE :

AIM:
To machine a work piece using a cylindrical grinding machine.

MATERIALS REQUIRED:
Mild steel polished round rod -  _______ x ________ mm

TOOLS REQUIRED:
Centre type cylindrical grinder
Vernier Caliper
Spanners

PROCEDURE:
 The given work piece is held between centers.
 The machine is switched on and the grinding wheel is allowed to revolve at a selected speed.
 By giving longitudinal and cross feeds the work piece is ground for the required dimensions.
 The work piece is removed from the machine and is checked for the given dimensions.

RESULT:

Thus the given work piece is grinded to the given dimension effectively using centre type
cylindrical grinding machine.
MACHINING A ROUND WORKPIECE TO A SQUARE BLOCK USING SHAPER

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
 EX NO: MACHINING A ROUND WORKPIECE TO A SQUARE
DATE : BLOCK USING SHAPER

AIM:

To make a square bar in a given work piece using shaping machine.

MATERIALS REQUIRED:

Dia. 30mm x 20mm CI rod

TOOLS REQUIRED:

Tungsten carbide tipped tool,

Finishing tool.

MEASURING TOOLS:

Try square, Vernier caliper, steel rule, Scriber

SEQUENCE OF OPERATION:

 Marking
 Job setting
 Tool setting
 Ram adjustment
 Speed adjustment
 Shaping operation
MARKING:

Marking is carried out after measuring diameter with the help of veriner caliper. Marking is done
as per the given dimensions.

JOB SETTING:

Job is set in the vice. Proper support was given by the job by a supporting block.

TOOL SETTING:

The tool is held on the clapper box such that it is at right angles to the job and it should be well
tightened.

RAM ADJUSTMENT:

Ram is adjusted depending upon the travel of the tool related to the job.

SPEED ADJUSTMENT:

The speed is adjusted by the levers placed in shaper, low speed is given for rough-cut and high
speed is given for finish cut.
SHAPING OPERATION:

The one side of the workpiece is machined and workpiece is rotated.

Now according to the requirement the depth of cut is given as needed and the feed is given as course for
roughing tool operation and fine for finishing operation.

Then the final workpiece is in the cubical form

RESULT:
Thus the required cubical block is machined by machining the given round job using shaping
machine.
MACHINING A ROUND WORKPIECE TO A SQUARE BLOCK USING PLANER

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
 EX NO: MACHINING A ROUND WORKPIECE TO A SQUARE BLOCK
DATE : USING PLANER
AIM:

To make a square block from the given round rod workpiece using planer machine.

MATERIALS REQUIRED:

Diameter of 70mm x 100mm Length.

TOOLS REQUIRED:

V- tool, parting tool, spanner, hammer, parallel block, center punch, Machine vice

MEASURING TOOLS:

Try square, Vernier caliper, Vernier height gauge, steel rule, and surface plate, Divider, depth
gauges.

SEQUENCE OF OPERATION:

 Marking
 Job setting
 Tool setting
 Planer operation
MARKING:

Marking is carried out after measuring diameter with the help of Vernier caliper. Marking is done
with the help of veriner height gauge.

JOB SETTING:

Job is set in the vice. Proper support was given by the job by a supporting block and stroke length
is adjusted to the work piece. The machining is carried out by Planer machine by removing the material
as per the marking done on the workpiece.

TOOL SETTING:

Tool is fitted in the tool head to required height position.

PLANER OPERATION:
 Switch ON the Planning machine and the depth of cut are given to the work piece.
 After one side is completed we have to set the other side and check the line.
 The operation is repeated up to other three sides machining.
 The machined work piece is checked for the sides of the square with the help of vernier caliper.
RESULT:

Thus the square block of required size is made from round bar by using the Planer machine.
DRILLING AND TAPPING

ALL DIMENSIONS ARE IN “mm”

TOLERANCE = 0.5 mm
 EX NO:
DRILLING AND TAPPING
DATE :

AIM:

To make holes of given diameter by drilling using Radial drilling machine and internal thread
cutting using taps.

MATERIALS REQUIRED:

DIA 60mm x 10mm thick – MS rod.

TOOLS REQUIRED:
Drill chuck with key, drill bit, scriber punch, hammer and taps.

MEASURING TOOLS:
Steel rule, vernier caliper and vernier height gauge.

SEQUENCE OF OPERATION:
 Marking and center punching
 Drill bit setting
 Job setting
 Drilling
 Taping
MARKING:
The given work piece is marked foe the given dimensions using vernier height gauge and the
center points of the hole is punched by using center punch.

DRILL BIT SETTING:

The drill bit of 5/16-inch was fixed into the drill chuck and tightened by means of a key.

JOB SETTING:
The job is fixed in the table of radial drilling machine with the help of clamp and bolt assembly
fitting in to the T-slots of the table.

DRILLING:
The drill tip is made to come in line with the punched center of hole and by radial and longitudinal
and lateral adjustment the drill bit is rotated and by downward feed the hole was made.

TAPPING:
The job is then removed to set in a vice for tapping internal thread. The taps according to the order
of finish are fixed in the tap wrench and by rotation and pressing, lowered in to the holes for cutting
internal threads.

RESULT:

Thus the drilling and tapping operation was done on the given job.
INJECTION MOLDING MACHINE
EX NO:
STUDY OF INJECTION MOLDING MACHINE
DATE :
PRINCIPLE

An Injection molding machine, also known as an injection press, is a machine for manufacturing
plastic products by the injection molding process. It consists of two main parts, an injection unit and a
clamping unit.

OPERATION
Injection molding machines can fasten the molds in either a horizontal or vertical position. The
majority of machines are horizontally oriented, but vertical machines are used in some niche applications
such as insert molding, allowing the machine to take advantage of gravity. Some vertical machines also
don't require the mold to be fastened. There are many ways to fasten the tools to the platens, the most
common being manual clamps (both halves are bolted to the platens); however hydraulic clamps (chocks
are used to hold the tool in place) and magnetic clamps are also used. The magnetic and hydraulic clamps
are used where fast tool changes are required.
TYPES OF INJECTION MOLDING MACHINES
 Hydraulic
 Mechanical
 Electric
Injection molding machines consist of two basic parts, an injection unit and a clamping unit. Injection
molding machines differ in both injection unit sizes and clamping units used. Several manufactures offer
hydraulic clamps, toggle clamps or electric driven machines. The clamping mechanism moves either
horizontal or vertical. Majority of the plastic injection molding machines purchased today are horizontal
machines with a very similar layout to the diagram below.

INJECTION MOLDING MACHINE

Plastic injection molding is a manufacturing technique for making parts from plastic material.
Molten plastic is injected at high pressure into a mold, which is the inverse of the desired shape. The mold
is made from metal, usually either steel or aluminum, and precision-machined to form the features of the
desired part. Plastic injection molding is very widely used for manufacturing a variety of parts, from the
smallest component to entire body panels of cars. It is the most common method for the production of
plastic parts.

INJECTION MOLDING APPLICATIONS

 Injection molding is used to create the following things
 Wire spools,
 Packaging,
 Bottle caps,
 Automotive dashboards,
 Pocket combs, and most other plastic products available today.

RESULT
The principles and operations of Injection molding machine has been studied.
 MEASUREMENT OF CUTTING FORCE ON LATHE

Px
Py

Px
Pz

Py
Pz

DEPTH HORIZONTAL VERTICAL RESULTANT

SL. AVERAGE
NO. OF CUT COMPONENT COMPONENT P = Sqrt (Px2 + Pz2)
(mm) Px (kg) Pz (kg) (Kg) (Kg)
1
2
3
4

1
2
3
4
EX NO: MEASUREMENT OF CUTTING FORCE ON LATHE
DATE :

AIM :

To measure the cutting forces in turning process for the given cutting conditions.

TOOLS AND EQUIPMENTS REQUIRED :

Lathe, Lathe Tool Dynamometer.

PROCEDURE :

1. The Lathe Tool Dynamometer is initially set to zero reading.

2. The known depth of cut is given and take the readings of Px and Pz force components from the
Lathe Tool Dynamometer.

3. Calculate the resultant cutting force

P = Sqrt (Px2 + Pz2)

4. Repeat the same procedure to get few more readings and calculate the mean cutting force.

5. Repeat the same procedure for different depth of cuts.

NOTE :

1. Pz – the main or tangential component, determines the torque on main drive mechanism, the
deflection of the tool and the required power. This component acts in the direction of the cutting
speed.

2. Px – the axial component, acts in the direction of the tool traverse and it is at right angles to P z. It
contributes very little to the power consumption.

3. Py – the radial component, acts along the tool shank and perpendicular to the other two
components. It has no share in the power consumption.

RESULT :

Thus the cutting forces are measured for different depth of cuts.
 EX NO: DETERMINATION OF SURFACE ROUGHNESS USING SURFACE
DATE : ROUGHNESS TESTER

AIM

To measure the roughness of the machined component using surface roughness tester.

TOOLS REQUIRED

 Surface roughness tester.

 Table setup.

PROCEDURE

 Initially the given workpiece is to be turned in a lathe for the required dimension and cylindrical
grinding operation is to be performed.

 Then the workpiece is placed in a suitable position on the table.

 Five places to be marked on the workpiece and then by using surftest instrument the roughness
of the marked places to be measured and entered in the table.

Sl.No. Roughness value in µm

Mean roughness
value

RESULT

Thus the roughness of the machined surface was measured using surface roughness instrument.