Experiment no.

-1

Aim- Produce a rectangular block by face milling and prepare a slot on one face
with a slotter cutter/side and face cutter

Materials used- mild steel rectangular block as per drawing

Cutting tool used- slotter cutter, side and face cutter

Theory-A milling machine is one of the most important machine tools. It remove
metals from the work piece it fed against rotating cutting tool used. In milling
machine it has multiple cutting edge which removes metal at a faster rate milling
machine point of application in the production of gears and cutting tool.

TYPES OF MILLING MACHINE

The milling machine classified as follows:

1)Column and knee type

2)Horizontal milling machine
a)vertical milling machine
b)Universal milling machine
3)Bed type milling machine
4)planer type

PRINCIPLE OPERATIONS AND PARTS OF A MILLING MACHINE

The principle parts of the column and knee type milling machines are as follows:
BASE
It is a foundation of machine. It carries the column and give strength and rigidity to
the machine it serves as the reservoir for cutting fluid.
COLUMN
It is the main supporting frame movement vertically on the base.
KNEE
It projects from column and sides up and down on the vertical guide ways of
column in turns support the saddle and knee table. The vertical position of the knee
can be adjusted by an elevating screw provided at the bottom of the knee.
SADDLE
It support the table and can be adjusted transversely on the guide ways provided on
the top surface of the knee. These guide ways are exactly at 90o to the face of the
column.
TABLE
It slides on the guide ways of saddle and travels longitudinally in a horizontal
plane. It supports the work piece and other features on it
OVERHANGING ARM
It is mounted on the top of the column in turn extend beyond the column face.
ARBOR it may be considered as extension of the spindle.
MILLING OPERATIONS:
The different types of operations that can be performed in milling machine are
given below:
Plain milling
Angular milling
Face and side milling
Gang milling
End milling
Straddle milling.
PLAIN MILLING
It is a method of producing flat surface. It is parallel to the axis of the cutter. It is
held in the milling arbor.
FACE AND SIDE MILLING
It is a method of producing flat surface right angle to the axis of cutter and in turn
in this method large flat surface can be obtained.
GANG MILLING
It is a method of milling by using two or more cutters arrangement together on one
arbor. It is used the similar pieces must be made.
ANGULAR MILLING
It is a method if producing a flat surface at an angle to the axis of the cutter.
Angular surface are milled by tilting the spindle.
END MILLING
It is a method of milling slots keyway surface by end mills and also it is used in
milling cutters.
STRADDLE MILLING
It is a method of milling to parallel slides at a work by employing to side milling.

Procedure:-

1. Fix the work piece on the worktable and then fixing milling cutter on the tool
holder.

2. Select a suitable cutting speed and feed.

3. Work piece fed to the cutter atomically or manually.

4. The work piece is fed against the direction of the milling cutter.

5. The surface is cleaned with the help of brush to remove the chips.

6. This procedure is followed until the required dimension is obtained

. Result: The model is prepared as per the drawing given.

Verification: The measurement of the model reveals that there is a deviation of X
mm in L1, Y mm in L2 and Z mm in L3 & L4.
 Experiment no.-2

Aim: Prepare a V-block to +0.2 mm accuracy on shaper machine

Tools Required: V-tool, Shaping cutting tool, Machine vise etc.

Theory- The shaper which is having a reciprocating type of machine tool with
single point cutting tool used to produce flat surface. The flat surface may be
horizontal, vertical or inclined. It has three important parts such as
1.Table, 2.Tool head, 3. Ram
The tool head is fitted on the front on the ram while the job is rightly fixed on the
table. The tool is mounted on the tool post or head. The ram reciprocates along
with the tool to remove the metal in the forward stroke called as cutting stroke. The
tool does not cut the metal in the return stroke called as idle stroke. Therefore one
pass is nothing but the combination of one forward and return stroke or one cutting
and one idle stroke. So we are in a position to reduce idle stroke time by increasing
the speed of the return stroke. That is the speed of cutting stroke will be lower than
the speed of the return stroke.
CLASSIFICATION OF SHAPERS:
Generally, shapers are classified as follows
1.According to the type of driving mechanism
a. crank drive type
b. Whitworth driving mechanism type
c. Hydraulic drive type
2.According to the position of ram
a. Horizontal shaper
b. Vertical shaper
c. Travelling head shaper
3.According to the table design
a. standard or plain shaper
b. Universal shaper
4.According to the type of cutting stroke
a. Push out type
b. Draw cut type
SHAPER SPECIFICATIONS:
Generally, the specifications of a typical shaper are listed below:
1.Maximum length of stroke.
2.Maximum crosswise movement of the table.
3.Maximum vertical adjustment of the table.
4.Type of driving mechanism
5.Power of the motor
6.Speed and feed available
7.Type of shaper-plain or universal
8.Floor space required
9.Total weight of the shaper.
10.Ratio of cutting stroke time to return stroke time.

Procedure:

1. Initially, the square block is prepared to the required dimension on the shaping
machine.
2. The marking is carried out on the work piece for cutting V-groove.
3. The shaping cutting tool is set to the required angle to form V-groove.
4. Then the shaping machine is operated to perform the necessary cutting action
and ultimately complete the model as per the required dimensions.
Pre viva questions:

a. Which type of tool is used for v groove?

b. What is slotting?

c. specify slotter?

d. how to tilt the tool head doing slot cutting?

 Experiment no.-3
Aim: Preparation a job through eccentric turning

Tools Required: Lathe machine,workpiece

Theory- Eccentric work is work that is turned off center, or not on the normal
center axis. An engine crankshaft is a good example of an eccentric workpiece.
Crankshafts normally have a main center axis, called a main journal, and offset
axes, which produce the throw and the eccentric diameters of the mechanism. An
eccentric shaft may have two or more diameters and several different center axes.
The amount of eccentricity, or half of the throw, is the linear distance that a set of
center holes has been offset from the normal center axis of the workpiece.
Eccentric turning on the lathe is used for the following eccentric turning situations:

When the throw is large enough to allow all centers to be located on the workpiece
at the same time.

When the throw is too small to allow all centers to fit into the end of a workpiece
at the same time. (The center drilled holes are too large.)

When the throw is so great that all centers cannot be located on the work, or in
other words, a throw larger than the largest diameter of the workpiece. (This type
of crank is usually made in separate pieces and connected together, since the cost
of wasted material would be too great if constructed from one piece on the lathe).

PROCEDURE :
1. Before an eccentric workpiece can be machined, it is necessary to center-drill
both ends of the workpiece, including the offset centers. If the workpiece is large
 enough to position all center axes on the work at the same time, the machining
operation will be simple and easy.
2. First determine the stock required by adding the throws plus 1/8 inch for
machining .
3. Face the work to length in a chuck.
4. Remove the piece and apply layout dye to both ends.
5. Mount the work in a V- block and, using a surface plate and venire height
scriber, lay out the normal center axis and the offset center axes on both ends.
6. Accurately prick punch the intended centers, check for accuracy, and then
enlarge the punch marks with a center punch.
7. Center- drill both sets of center punch marks by using a milling machine, a
drilling machine, or the four-jaw independent chuck of the lathe with a dial
indicator to line up the centers.
8. Mount the work in the lathe between centers and turn the largest diameter first.
If all diameters are the same, turn the middle diameter journal first.
9. After turning the center journal down to the required diameter, remount the work
in an offset center hole and machine the throw diameter to the finished size.
10. Accurately prick punch the intended centers, check for accuracy, and then
enlarge the punch marks with a center punch.
11. Center- drill both sets of center punch marks by using a milling machine, a
drilling machine, or the four-jaw independent chuck of the lathe with a dial
indicator to line up the centers.
12. Mount the work in the lathe between centers and turn the largest diameter first.
If all diameters are the same, turn the middle diameter journal first.
13. After turning the center journal down to the required diameter, remount the
work in an offset center hole and machine the throw diameter to the finished
size.
14. Additional throws are machined in the same manner. Throw positions may be
started by cutting with a parting tool to establish the shoulders, which may aid
the turning operation. The tool bit selected will depend on the material to be
machined and on the depth of cutdesired.
Result: The model is prepared.
 Experiment no. -04

Aim- Cutting a T slot by milling operation

Theory -Cutting T-slots in a workpiece holding device is a typical milling

operation. The size of the T-slots depends upon the size of the T-slot bolts which
will be used. Dimensions of T-slots and T-slot bolts are standardized for specific
bolt diameters.

Two milling cutters are required for milling T-slots, a T-slot milling cutter and
either a side milling cutter or an end milling cutter. The side milling cutter
(preferably of the staggered tooth type) or the end milling cutter is used to cut a
slot in the workpiece equal in width to the throat width of the T-slot and equal in
depth to slightly less than the head space depth plus the throat depth). The T-slot
milling cutter is then used to cut the head space to the prescribed dimensions

Procedure:

1. The position of the T-slot is laid out on the workpiece. The throat depth is
determined by considering the thickness of the workpiece and the maximum and
minimum dimensions allowable (Table 8-6. Appendix A).

2 .A side milling cutter or an end milling cutter is then selected. The cutter should
be of proper size to mill a slot equal in width to the throat width prescribed for the
T-slot size desired. Cut a plain groove equal to about 1/16 inch less than the
combined throat depth and head space depth.

3.Select a T-slot milling cutter for the size T-slot to be cut. T-slot milling cutters
are identified by the T-Slot bolt diameter and remanufactured with the proper
diameter and width to cut the head space to the dimensions given in Table 8-6 in
Appendix A. Position the T-slot milling cutter over the edge of the workpiece and
align it with the previously cut groove. Feed the table longitudinally to make the
cut. Flood the cutter and workpiece with cutting oil during this operation. Figure 8-
38 shows a T-slot milling cutter and dimension locations for T-slots.

Result: The model is prepared

 Experiment no- 05

Aim-Demonstration of grinding operation(surface/cylindrical)

Theory-
Surface Grinding Machine

The horizontal spindle surface grinder has a horizontal spindle. The horizontal
spindle provides primary motion to the wheel. The worktable reciprocates. This is
the principal feed motion. The work is mounted on the worktable. This motion is
known as ‘Traverse’ motion. This is brought hydraulically. The wheel head can be
moved up & down. This feed motion of the wheel head is known as ‘Cross –
Feed”. This feed motion also is operated hydraulically. This feed motion is applied
after each stroke (or) pass of the table.

CYLINDRICAL GRINDING:
Cylindrical Grinding is similar to Cylindrical Turning.
1. In this cylindrical surface is being generated using the traverse motion
2. In this single point a grinding wheel replaces cutting tool

3. In this the work piece is supported & rotated between centers. The headstock
provides the low – speed rotational derives to the work piece. The headstock & the
tailstock are mounted on a worktable. The worktable is reciprocated horizontally
using a hydraulic drive