Lab Exercise 1.

To prepare a single point turning tool and single point threading tool by
grinding the bar stock and measure its rake and relief angles.

Requirement
Bar stock, Pedestal grinder, Angle protractor, Mild steel bar

Turning Tool

The various angles of single point turning tool are as follows

Back rack angle: 2°

Side rack angle: 9°

End relief angle: 5°

Side relief angle: 5°

End cutting edge angle: 9°

Side cutting edge angle: 11°

Nose radius: 1/8 inch,

The nomenclature of tool (in ASA system will be)

2°-9°-5°-5°-9°-11°-1/8(inch)
Threading Tool
More about tooling:

Cutting tool geometry lathe

and milling

Grinding HSS tools

Profiles of threads.

(Middle East Technical

University)
Lab Exercise 2
To find the shear plane angle while turning mild steel with HSS tool

Requirement
MS rod, micrometer, angle protractor, Lathe machine, HSS turning tool

Concept of shear plane angle

Formula
𝑟 cos 𝛼
tan 𝜑 =
1 − 𝑟 sin 𝛼
Where,

Φ is shear plane angle,

α is rake angle
 𝑡
r is chip thickness ratio .( 𝑟= )
𝑡𝑐
t is uncut thickness and
tc is chip thickness

Parameter during turning

Lathe parameter Relates to

Feed(mm/revolution) Uncut thickness
Depth of cut Width of the chip

Calculation of feed
1. Record the time taken(in minutes) for longitudinal travel
of 100mm with automatic feed.
2. Calculate feed(mm/min)
3. Note the spindle RPM.
Feed (mm/ revolution) = feed(mm/min)/Spindle RPM.
Pre-Requisite

i. Make sure that tool is sharp.

Lab Exercise 3
i. To analyze the effect of cutting parameter on the surface finish
during turning operation on mild steel with HSS tool
ii. To analyze the effect of sharp tool and tool with nose radius on
the surface finish of the mild steel specimen

Theory
i. Increase in depth of cut, increases the force and deteriorates
the surface finish

ii. Increase in feed increase the cutting force and deteriorates the
surface finish
 iii. Increase in cutting speed decrease the cutting force and
improves the surface finish except in the case of chatter.

Surface roughness by sharp tool and radius tool

i. A radius tool gives better surface finish than a sharp tool.
ii. Nose radius also improves the tool life.
More Information

Determining the effect of cutting

parameters on surface roughness in
hard turning using the Taguchi
method

Surface roughness for a sharp edge tool

Surface roughness for a radius tool

Lab Exercise 4
i. To analyze the effect of up milling (Conventional milling) and
down milling (Climb Milling) on the cutting forces and surface
finish.
ii. To prepare Hexagonal Head of a bolt using simple indexing on
milling machine.

Requirement
Milling machine, Mild steel rod, Indexing and dividing head, End mill
cutter

Theory
In down milling, the cutting force is directed on to the work table, which
allows thinner parts to be machined without susceptibility to breakage.
Better surface finish is obtained in the down milling but the stress load
on the teeth is abrupt, which may damage the cutter. Backlash eliminator
has to be used in this operation

In up milling, the cutting action tends to lift the work piece and hence,
proper fixture is required in this operation.
Simple indexing
Three indexing plates are used (only one at a time). These plates have
concentric circles of holes with their different numbers as described
below:
More Information
Up milling and down milling
–NPTEL

simple indexing video

Simple and compound indexing

NPTEL
Lab Exercise 5
i. To study the characteristics of shaper machine.
ii. To prepare dovetail slides on shaper machine

Requirements
Shaper Machine, HSS cutting tool, mild steel block

Theory
Quick return mechanism

The slotted link mechanism is used for converting the linear motion of a
slider into rotational motion or vice-versa. This mechanism is generally
found on shaping machines where single point cutting tool is mounted on
the front of the slider or ram, in a hinged tool post. The tool cuts on the
slow forward stroke and lifts over the work piece on the quick return
stroke. The slotted link rocks from side to side, driven by the sliding block
on the bull wheel.

The bull wheel as shown in the above figure 1 rotates at a constant speed,
the angle through which bull wheel rotates on the forward stroke is
greater than the angle through which it rotates on the return stroke. This
imparts the slow forward and quick return motion to the slotted link and
slider. The distance of the sliding block from the centre of the bull wheel
can be altered to vary the length of stroke of the slider.

Dovetail slides,

The angle for dovetail slides is 60°.

A 38.1 mm
G 15.4 mm
H 17.5 mm
I 15.9 mm
J 9.5 mm

Increase surface contact makes Dovetails slides a good choice for taking
higher bearing loads.
More Information
Quick return Mechanism
animation (explained)

Dovetail cutting using milling

cutter (another method of
cutting dovetails)
Lab Exercise 6
i. To study the characteristics of Wire EDM machine
ii. To make a spur gear using Wire EDM machine
iii. To make a key chain with name initials using wire EDM
(Individual job).

Requirements

Wire EDM machine, CAD software, MS flat

Theory
Wire EDM

In wire electrical discharge machining (WEDM), also known as wire-cut

EDM and wire cutting, a thin single-strand metal wire, usually of copper
or brass, is fed through the work piece, submerged in a tank of dielectric
fluid, typically deionized water. Wire-cut EDM is typically used to cut
plates as thick as 300mm and to make punches, tools, and dies from hard
metals that are difficult to machine with other methods.

The wire, which is constantly fed from a spool, is held between upper and
lower diamond guides. The guides, usually CNC-controlled, move in the
XY plane. On most machines, the upper guide can also move
independently in the ZUV axis, giving rise to the ability to cut tapered and
transitioning shapes (circle on the bottom square at the top for example).
The upper guide can control axis movements in XYUVIJKL. This allows the
wire-cut EDM to be programmed to cut very intricate and delicate
shapes.

The machine offers a module for cutting spur gears. Various parameters
of the gear need to be given to prepare a 2D drawing of the gear. After
that a program is generated to make the gear.

The machine also allows the drawing made from other CAD softwares to
be imported using a .DXF file format.

Parameters of EDM machine

Wire φ180µm, molybdenum

Table travel X-320 mm, Y-400mm, Z-320mm
Wire speed 1400 rpm
Max current 5 amps
Max feed 100 mm2/min
Imported Drawing format DXF
Max Taper 3° (using U and V directions)
More Information
Wire EDM-introduction

Wire EDM explained