Monday, July 29, 2013

miet mt lab-2






               


MADURAI INSTITUTE OF                     ENGINEERING & TECHNOLOGY
Pottapalayam Sivagangai District-630611.


DEPARTMENT OF MECHANICAL ENGINEERING

10122 ME407  MANUFACTURING TECHNOLOGY LABORATORY - II

As per the Anna University Syllabus from 2011-2012


     Prepared by
                       Mr.R.BALAJI
  Mr.S.PUNGAIYA


LIST OF EXPERIMENTS
S.NO
EXPERIMENTS
PAGE NO
SIGNATURE
I
INTRODUCTION OF SHAPING MACHINE


II
INTRODUCTION OF DRILLING MACHINE


III
INTRODUCTION OF GRINDING MACHINE


IV
INTRODUCTION OF SLOTTING MACHINE


V
INTRODUCTION OF MILLING MACHINE



VI

INTRODUCTION OF LATHE MACHINE















































INTRODUCTION OF SHAPING MACHINE

The main functions of shaping machines are to produce flat surfaces in different planes. The basic principle of generation of flat surface by shaping machine. The cutting motion provided by the linear forward motion of the reciprocating  tool and the intermittent feed motion provided by the slow transverse motion of the job along with the bed result in producing a flat surface by gradual removal of excess material layer by layer in the form of chips. The vertical infeed is given either by descending the tool holder or raising the bed or both. Straight grooves of various curved sections are also made in shaping machines by using specific form tools. The single point straight or form tool is clamped in the vertical slide which is mounted at the front face of the reciprocating ram whereas the work piece is directly or indirectly through a vice is mounted on the bed.



•   Shaping machines 
It is already mentioned that shaping  machines are neither productive nor versatile. However, its limited applications include :

Δ  Machining flat surfaces in different planes. Fig. 4.4.7 shows how flat surfaces are produced in shaping machines by single point cutting
tools in (a) horizontal, (b) vertical and (c) inclined planes.



Δ  Making features like slots, steps etc. which are also bounded by flat
surfaces. Fig. 4.4.8 visualises the methods of machining (a) slot, (b) pocket (c) T-slot
 and (d) Vee-block in shaping machine by single point tools.
Δ  Forming grooves bounded by short width curved surfaces by using
single point but form tools. Fig. 4.4.9 typically shows how (a) oil grooves and
(b) straight tooth of spur gears can be made in shaping machine.
Δ  Some other machining applications of shaping machines are cutting
external keyway and splines, smooth slitting or parting, cutting teethof rack for
repair etc. using simple or form type single point cutting tools.
Some unusual work can also be done, if needed, by developing and
using special attachments.





EX: NO:                                                                                                                  Date:

MACHINING OF SQUARE IN SHAPING MACHINE
Aim                                                                      
            To machine a square in the given work piece to the dimensions as shown in the figure using shapping machine.
Tools and equipments required
            Shaping machine
Scriber
Divider
Steel rule
Chalk piece
Bevel protractor
Procedure
1)     The given work piece is measured for its initial dimension.
2)     With the help of scriber, mark the hexagon dimensions in the work piece.
3)     Fix the work piece and the shaping tool allow the ram to reciprocate.
4)     Start the shaping process by giving the required depth by lowering the tool.
5)     Slowly increase the depth of cut and repeat the procedure to make the square shape.
6)     The work piece is now checked for final dimensions.

           


Result
            Thus a square was machined in the given work piece to the dimensions as shown in the figure using shaping machine.



INTRODUCTION OF DRILLING MACHINE

Drilling machines are generally or mainly used to originate through or blind straight cylindrical holes in solid rigid bodies and/or enlarge (coaxially) existing (premachined) holes.

• of different diameter ranging from about 1 mm to 40 mm

• of varying length depending upon the requirement and the diameter of the drill

• in different materials excepting very hard or very soft materials like rubber, polythene etc.

Application of drilling machines

Drilling machines of different capacity and configuration are basically used for originating cylindrical holes and occasionally for enlarging the existing holes to full or partial depth. But different types of drills are suitably used for various applications depending upon work material, tool material, depth and diameter of the holes.


Radial drilling machine

This usually large drilling machine possesses a radial arm which along with the drilling head can swing and move vertically up and down as can be seen in Fig. 4.2.4. The radial, vertical and swing movement of the drilling head enables locating the drill spindle at any point within a very large space required by large and odd shaped jobs. There are some more versatile radial drilling machines where the drill spindle can be additionally swivelled and / or tilted.




























EX: NO:                                                                                                                  Date:

DRILLING HOLES ON PCD ON THE WORK PIECE
Aim
Aim of this practice is to machine holes on pitch circle drawn on a given work piece.
Tools and equipments required
Radial Drilling machine
Drill bit
Dot punch
Tap
Chalk piece and Hammer
Compass.
Procedure
1)     Draw A pitch circle on the given work piece using a compass.
2)     Separate its circumference by the number of holes to be cut.
3)     Each interval has to be drilled on this pitch circle.
4)     A punch is made to identify the place to be drilled.
5)     Work piece is fixed on the radial drilling machine and holes are made.







Result
Thus drilling operation is performed on the PCD Drawn on the work piece.


INTRODUCTION OF GRINDING MACHINE

Grinding Machines are also regarded as machine tools. A distinguishing feature of grinding machines is the rotating abrasive tool. Grinding machine is employed to obtain high accuracy along with very high class of surface finish on the workpiece. However, advent of new generation of grinding wheels and grinding machines, characterised by their rigidity, power and speed enables one to go for high efficiency deep grinding (often called as abrasive milling) of not only hardened material but also ductile materials.

Conventional grinding machines can be broadly classified as:
(a) Surface grinding machine
(b) Cylindrical grinding machine
(c) Internal grinding machine
(d) Tool and cutter grinding machine

Surface grinding machine:
This machine may be similar to a milling machine used mainly to grind flat surface. However, some types of surface grinders are also capable of producing contour surface with formed grinding wheel.
Basically there are four different types of surface grinding machines characterised by the movement of their tables and the orientation of grinding wheel spindles as follows:

• Horizontal spindle and reciprocating table

• Vertical spindle and reciprocating table

• Horizontal spindle and rotary table

• Vertical spindle and rotary table

Horizontal spindle reciprocating table grinder
This machine with various motions required for grinding action. A disc type grinding wheel performs the grinding action with its peripheral surface. Both traverse and plunge grinding can be carried out in this machine.



A: rotation of grinding wheel B: reciprocation of worktable C: transverse feed D: down feed





















EX: NO:                                                                                                                  Date:

SURFACE GRINDING OPERATION

Aim
To grind the work piece to the given tolerance using surface grinding machine.

Tools And Equipments Required
Surface Grinding machine
Micrometer
Procedure

1)     The given work piece is checked for its initial dimensions.
2)     The permanent magnet worktable is cleaned thoroughly.
3)     Keep the work piece over the worktable and push the lever to “ON” position to hold the work piece.
4)     The required depth of cut is given by raising the table.
5)     The reciprocating and cross feed is given to grind the required length and width of the work piece respectively.
6)     Finally, the finished work piece is checked for the given dimensions.








Result
Thus the given work piece is ground to the given tolerance using surface grinding machine.


INTRODUCTION OF SLOTTING MACHINE

Slotting machines can simply be considered as vertical shaping machine where the single point (straight or formed) reciprocates vertically (but without quick return effect) and the workpiece, being mounted on the table, is given slow longitudinal and / or rotary feed as can be seen. In this machine also the length and position of stroke can be adjusted. Only light cuts are taken due to lack of rigidity of the tool holding ram for cantilever mode of action. Unlike shaping and planing machines, slotting machines are generally used to machine internal surfaces (flat, formed grooves and cylindrical). Shaping machines and slotting machines, for their low productivity, are generally used, instead of general production, for piece production required for repair and maintenance. Like shaping and slotting machines, planing machines, as such are also becoming obsolete and getting replaced by plano-millers where instead of single point tools a large number of large size and high speed milling cutters are used.

The schematic view of slotting machine is typically.The vertical slide holding the cutting tool is reciprocated by a crank and connecting rod mechanism, so here quick return effect is absent. The job, to be machined, is mounted directly or in a vice on the work table. Like shaping machine, in slotting machine also the fast cutting motion is imparted to the tool and the feed motions to the job. In slotting machine, in addition to the longitudinal and cross feeds, a rotary feed motion is also provided in the work table.
The intermittent rotation of the feed rod is derived from the driving shaft with the help of a four bar linkage as shown in the kinematic diagram.It is also indicated how the intermittent rotation of the feed rod is transmitted to the leadsrews for the two linear feeds and to the worm – worm wheel for rotating the work table. The working speed, i.e., number of strokes per minute, Ns may be changed, if necessary by changing the belt-pulley ratio or using an additional “speed gear box”, whereas, the feed values are changed mainly by changing the amount of angular rotation of the feed rod per stroke of the tool. This is done by adjusting the amount of angle of oscillation of the paul The directions of the feeds are reversed simply by rotating the tapered paul by 180o as done in shaping machines.


•   Slotting machine

Slotting machines are very similar to shaping machines in respect of
Machining principle, tool-work motions and general applications. However, relative to shaping machine, slotting machines are characterized by :
Δ Vertical tool reciprocation with down stroke acting
Δ Longer stroke length
Δ Less strong and rigid
Δ An additional rotary feed motion of the work table
Δ Used mostly for machining internal surfaces.
The usual and possible machining applications of slotting machines are :
ο  Internal flat surfaces
ο  Enlargement and / or finishing non-circular holes bounded by a
number of flat surfaces.
ο  Blind geometrical holes like hexagonal socket.
ο  Internal grooves and slots of rectangular and curved sections.
ο  Internal keyways and splines, straight tooth of internal spur gears,
internal curved surface of circular  section, internal  oil grooves etc.
which are not possible in shaping machines.



However, it has to be borne in mind that productivity and process capability of slotting machines are very poor and hence used mostly for piece production required by maintenance and repair in small industries. Scope of use of slotting machine for production has been further reduced by more and regular use of broaching machine



























EX: NO:                                                                                                                  Date:

MACHINING OF INTERNAL KEYWAY USING SLOTTING MACHINE

Aim
            To machine an internal keyway in the givens work piece to the dimensions as shown in fig using slotting machine.

Tools and equipments required
            Slotting machine
Scriber
Divider
Steel rule
Procedure:

1)     The given work piece is measured for its initial dimensions
2)     With the help of scriber mark the keyway dimensions in the work piece.
3)     Fix the work piece in the vice of the slotting machine.
4)     After fixing the work piece and the slotting tool allow the ram to vertically reciprocal.
5)     Start the slotting process by giving the required depth by horizontally moving the vice
6)     Slowly increase the depth of cut and repeat the procedure to make the required shape.
7)     The work piece is checked for final dimensions.











Result:
            Thus the internal keyway is machined in the given work piece to the dimensions.


INTRODUCTION OF MILLING MACHINE

The basic function of milling machines is to produce flat surfaces in any orientation as well as surfaces of revolution, helical surfaces and contoured surfaces of various configurations. Such functions are accomplished by slowly feeding the workpiece into the equispaced multiedge circular cutting tool rotating at moderately high speed as indicated in Fig. 4.3.1. Upmilling needs stronger holding of the job and downmilling needs backlash free screw-nut systems for feeding.

Milling machines of various type are widely used for the following purposes using proper cutting tools called milling cutters :

• Flat surface in vertical, horizontal and inclined planes

• Making slots or ribs of various sections

• Slitting or parting

• Often producing surfaces of revolution

• Making helical grooves like flutes of the drills

• Long thread milling on large lead screws, power screws, worms etc and short thread milling for small size fastening screws, bolts etc.

• 2-D contouring like cam profiles, clutches etc and 3-D contouring like die or mould cavities

• Cutting teeth in piece or batch production of spur gears, straight toothed bevel gears, worm wheels, sprockets, clutches etc.

• Producing some salient features like grooves, flutes, gushing and profiles in various cutting tools, e.g., drills, taps, reamers, hobs, gear shaping cutters etc.

Classification of milling machines
Milling machines can be broadly classified;

(a)   According to nature of purposes of use :

• general purpose – most versatile commonly used mainly for piece or small lot production

• single purpose – e.g., thread milling machines, cam milling machines and slitting machine which are generally used for batch or lot production.

• Special purpose – these are used for lot or mass production, e.g., duplicating mills, die sinkers, short thread milling etc.

(b) According to configuration and motion of the work-holding table / bed

• Knee type : typically shown in Fig. 4.3.2. In such small and medium duty machines the table with the job/work travels over the bed (guides) in horizontal (X) and transverse (Y) directions and the bed with the table and job on it moves vertically (Z) up and down.


• Bed type : Usually of larger size and capacity; the vertical feed is given to the milling head instead of the knee type bed
                             

Machine parts :

1. column

2. bed

3. cross slide

4. work table

5. ram

6. ram support

7. arbour support

Table feed motions :


a. longitudinal feed

b. cross feed

c. vertical feed

• Planer type:
These heavy duty large machines, called plano-miller, look like   planing machine where the single point tools are replaced by one or a number of milling heads; generally used for machining a number of longitudinal flat surfaces simultaneously, viz., lathe beds, table and bed of planning machine etc.

• Rotary table type :
Such open or closed ended high production milling machines possess one large rotary work-table and one or two vertical spindles as typically shown in Fig. 4.3.5; the positions of the job(s) and the milling head are adjusted according to the size and shape of the job.

(c) According to the orientation of the spindle(s).

• Plain horizontal knee type (Fig. 4.3.6)
This non-automatic general purpose milling machine of small to medium size possesses a single horizontal axis milling arbour; the work-table can be linearly fed along three axes (X,Y, Z) only; these milling machines are most widely used for piece or batch production of jobs of relatively simpler configuration and geometry

• Horizontal axis (spindle) and swivelling bed type
These are very similar to the plain horizontal arbour knee type machines but possess one additional swivelling motion of the work-table

• Vertical spindle type
In this machine, typically shown in Fig. 4.3.7, the only spindle is vertical and works using end mill type and face milling cutters; the table may or may not have swivelling features

• Universal head milling machine
These versatile milling machines, typically shown in Fig. 4.3.8, not only possess both horizontal milling arbour and the vertical axis spindle, the latter spindle can be further tilted about one (X) or both the horizontal axes (X and Y) enabling machining jobs of complex shape.

 (d) According to mechanisation / automation and production rate
Milling machines are mostly general purpose and used for piece or small lot production. But like other machine tools, some milling machines are also incorporated with certain type and degree of automation or mechanisation to enhance production rate and consistency of product quality. In this respect milling machines can be further classified as follows :

• Hand mill (milling machine) - this is the simplest form of milling machine where even the table feed is also given manually as can be seen in Fig. 4.3.9.

Fig. 4.3.9 Hand mill milling machine

• Planer and rotary table type vertical axis milling machines are not that automated but provide relatively higher production rate


• Tracer controlled copy milling machine, typically shown in Fig. 4.3.10, are mechanically or hydraulically operated semi-automatic milling machines used for lot production of cams, dies etc by copying the master piece


• Milling machines for short thread milling may be considered single purpose and automatic machine being used for mass production of small bolts and screws.

EX: NO:                                                                                                                  Date:
SPUR GEAR MILLING

Aim
         
To machine gear to the given module and number of teeth in the given work piece.






Tools and equipments required
Milling machine
Vernier caliper
Mandrel.
Procedure:
1.    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

2.    Indexing calculation
Index crank movement = 40 / Z

3.    The dividing head and the tail stock are bolted on the machine table. Their axis must be set parallel to the machine table.

4.    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.

5.    The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.

6.    Set the speed and feed for machining.

7.    For giving depth of cut, the table is raised till the periphery of the gear blank just touches the cutter.

8.    The micrometer dial of vertical feed screw is set to zero in this position.

9.     Then the table is raised further to give the required depth of cut.

10. The machine is started and feed is given to the table to cut the first groove of the blank.

11. After the cut, the table is brought back to the starting position.

12. Then the gear blank is indexed for the next tooth space.

13. This is continued till all the gear teeth are cut.

Calculation

Z = No. of teeth   = 23

m = module         = 2 mm

Blank Diameter   = (Z + 2) m
                             = (23 + 2) 2
                             = 50 mm

Tooth Depth        = 2.25 m
                             = 2.25 x 2
                             = 4.5 mm

Indexing Calculation   = 40 / Z
                                      = 40 / 23
                                      = 1 17/23





























Result:
Thus the required gear is machined using the milling machine to the required number of teeth.

EX: NO:                                                                                                                  Date:

MACHINE A KEYWAY USING END MILLING CUTTER IN VERTICAL MILLING MACHINE

Aim:
            To machine a cubic mild steel bar and make a keyway slot on the surface.

Tool required:
            Vertical milling machine,
Vernier caliper,
Machine Vice

Procedure:
1)     The cubic cast iron or ms bar is placed in material shaping machine.
2)     The blank is placed in the machine vice after shaping the work.
3)     The knee of the vertical milling machine is move towards the cutter.
4)     The machine vice is move by vertical slotter and then axis is setup on the work piece.
5)     The depth of the vertical milling cutter is given by means of spindle adjustment.
6)     The running action of cutter by using pulley the vertical milling cutter cuts the cubic bar.
7)     By moving the work by horizontal block table.
8)     The keyways on the machine vice work that by move the work table.
9)     The work is continuous on the work by moving the slotter from one region to another gender region.









Result:
            Thus the given work piece is and milled to the given dimension using vertical milling.


INTRODUCTION OF LATHE MACHINE

Turning is a machining process to produce parts round in shape by a single point tool on lathes. The tool is fed either linearly in the direction parallel or perpendicular to the axis of rotation of the workpiece, or along a specified path to produce complex rotational shapes. The primary motion of cutting in turning is the rotation of the workpiece, and the secondary motion of cutting is the feed motion.




























Cutting conditions in turning

Cutting speed in turning V in m/s is related to the rotational speed of the workpiece by the equation:V = πDN where D is the diameter of the workpiece, m; N is the rotational speed of the workpiece, rev/s.

For machining in machine tools the job and the cutting tool need to be moved relative to each other.

The tool-work motions are :
• Formative motions : - cutting motion
- feed motion
• Auxiliary motions : - indexing motion
- relieving motion etc

In lathes
o Cutting motion is attained by rotating the job
o Feed motion by linear travel of the tool
- either axially for longitudinal feed
- or radially for cross feed

It is noted, in general,

• The job gets rotation (and power) from the motor through the belt-pulley, clutch and then the speed gear box which splits the input speed into a number (here 12) of speeds by operating the cluster gears.

• The cutting tool derives its automatic feed motion(s) from the rotation of the spindle via the gear quadrant, feed gear box and then the appron mechanism where the rotation of the feed rod is transmitted

- either to the pinion which being rolled along the rack provides the longitudinal feed

- or to the screw of the cross slide for cross or transverse feed.

• While cutting screw threads the half nuts are engaged with the rotating leadscrew to positively cause travel of the carriage and hence the tool parallel to the lathe bed i.e., job axis.

• The feed-rate for both turning and threading is varied as needed by operating the Norton gear and the Meander drive systems existing in the feed gear box (FGR). The range of feeds can be augmented by changing the gear ratio in the gear quadrant connecting the FGB with the spindle

• As and when required, the tailstock is shifted along the lathe bed by operating the clamping bolt and the tailstock quil is moved forward or backward or is kept locked in the desired location.

• The versatility or working range of the centre lathes is augmented by using several attachments like

- Taper turning attachment
- Thread milling attachment
- Copying attachment




































EX: NO:                                                                                                                  Date:
CAPSTAN AND TURRET LATHE

Aim:
            To machine the work piece to the given dimension using capstan lathe.

Tools required:

            Capstan lathe
            Counter sink bit
            Drill bit
            Stopper
            Drill chuck

Procedure:

1)     Prepare tooling layout for the given work piece.
2)     Set the tools in the respect position of the tool rotation.
3)     The adjustment to the lathe  of  head for each tool is adjusted by rotating the adjusted 
4)     Feed the tools in the required sequences to machine given work piece for the given dimension using capstan lathe.













Result:
            Thus the tools in the required sequences to machine given work pieces for the given dimension using capstan lathe.

EX: NO:                                                                                                                  Date:

MACHINING THE COMPONENTS FOR INTERFACING FIT ASSEMBLY

Aim:
            To machine the components for interference fit assembly using a lathe and a drilling machine.

Materials required:
           
Mild steel polished rod 32 x 16mm

Tools required:
            Turning tool
            Parting off tool
            Drill bit
            Vernier caliper
            Outside caliper
            Inside caliper

Procedure:
1)     The given work piece is held originally in the chuck.
2)     The single point cutting tool is set on the tool post.
3)     The machine is switched on.
4)     The straight turning and facing operations are done on the one half the work piece as per the given dimensions.
5)     Then the drill bit of required drill size is held in tail stock and drilling is done for the required depth in the work piece.
6)     The two parts are assembled for getting a clearance fit assembly.







Result:
            The given work piece as shown in figure is subjected to machining operations to become a finished work piece.

EX: NO:                                                                                                                  Date:

MACHINING THE COMPONENTS FOR CLEARANCE FIT ASSEMBLY

Aim:
            To machine the components for clearance fit assembly using lathe.

Materials required:
            Mild steel
            Polished round rod 32 x 110mm

Tools required:
            Turning tool
Parting off tool
Drill bit
Outside  caliper
Vernier caliper
Inside caliper

Procedure:
1)     The given work piece is hold rigitly in the chuck.
2)     The single point cutting tool is set on the tool post.
3)     The machine is switched on
4)     The straight turning and facing operations are done on the one half if the workpiece as per the given dimension.
5)     The machine is switched off.
6)     The parting tool is fixed and by parting off operation the work piece is cut into two parts as per the dimensions
7)     Two parts are assembled per getting a clearance fit assembly.









Result:

            The given workpiece is subjected in machine operations to become a finished workpiece.

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