Machine Shop Lab Manual 2018

LIST OF EXPERIMENTS
MACHINE SHOP PRACTICE LAB MANUAL - IV SEMESTER - Compiled By: - Dr. S B Mallur, Professor, MED, SDMCET, Dharwad. Page 1
JOB NO 01
STEP TURNING AND TAPER TURNING
AIM
To perform various lathe operations such as facing, plain turning, step turning and taper turning on a given
material made of Mild steel.
MATERIAL REQUIRED
A mild steel bar of 25 mm diameter and 110 mm length
TOOLS AND EQUIPMENT USED
H.S.S. single point cutting tool,
Chuck key,
Tool post key,
Outside caliper,
Steel rule.
Principle: Turning is a lathe operation in which an external cylindrical surface is produced by generating.
The cutting Tool is first adjusted for the desired depth of cut, using the cross slide. Then as the work piece
rotates, the cutting tool is advanced relatively slowly I a direction parallel to the rotational axis of the
spindle. The motion is known as the feed. These combined motions cause the work piece by adjusting the
feed so that the helical path of the tool tip overlaps and generates a cylindrical surface on the work piece.
A spindle rpm which gives a desired cutting speed at the circumference of the cylindrical surfaces should
be reflected
Drawing of job: Finished dimensions to be obtained after machining
SEQUENCE OF OPERATIONS
1. Facing H.S.S Single Point tool
2. Rough turning H.S.S Single Point tool
3. Finish turning H.S.S Single Point tool
4. Step turning H.S.S Single Point tool
5. Taper turning H.S.S Single Point tool
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.
 Perform the plain turning operation on the same work piece for the required length in order
to reduce the diameter to 18 mm so as to get the step turning.
 Using a V – cutting tool grooving operation is performed according to the given dimensions
and finishes the groove using parting tool.
 Swivel the compound slide to the required angle and perform taper turning operation by
rotating the compound slide wheel.
• The angle can be measured by using the formula Tanα = (D – d) / 2L.
• 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
MODEL CALCULATIONS
The amount by which the compound rest has to be swivel is estimated using the taper
angle. Taper angle is calculated as follows.
Where,
D = Diameter of bigger end, mm
d = Diameter of smaller end, mm
L = Length of taper, mm
Result The job is thus made according to the given dimensions.
JOB NO 02
PLANE TURNING AND STEP TURNING KURNLING AND THREAD CUTTING

AIM
To obtain required diameters (plane and steps) on a cylindrical work piece with the given lengths.
Tools & Equipment
Lathe machine. Mild steel bar, right hand cutting tool, box key or tool post key, chuck key, steel rule,
outside calipers or vernier calipers.
Raw material and size: M.S Round bar  25. x 115 mm length
Theory
Step turning is the operation of creating various cylindrical cross sections on a metal blank. Rough turning
operation is used where excessive stock is to be removed and surface finish is not critical. For such a
operation deep cuts with coarse feed are used. During rough machining maximum metal is removed and
very little oversize dimension is left for finishing operation.
Sketch
Procedure
1. The given work piece is held in the 3‐jawchuck of the lathe machine and tightened firmly with chuck
key.
2. Right hand single point cutting tool is taken tightened firmly with the help of box key in the tool
post.
3. Machine is switched on and the tool post is swiveled and the cutting point is adjusted such that it
positioned approximately for facing operation then the tool is fed into the work piece and the tool
post is given the transverse movement by rotating the hand wheel of the cross slide.
4. With this facing is completed and the tool post is swiveled and cutting point is made parallel to the
axis of work piece.
5. Depth of cut is given by cross slide to the tool post and the side hand wheel is rotated to give the
longitudinal movement for the tool post and job is turned to the required length and diameters
according to the sketch shown in figure.
6. After completion of the job it is inspected for the dimensions obtained with the help of steel rule
and outside caliper or vernier caliper.
Precautions
a. Work piece should be held firmly.
b. In rough turning operation do not over feed the tool, as it may damage the cutting point of the tool.
c. Exercise over hung of tool should be avoided as it results in chatter and causes rough machined
surface.
d. It is important to ensure that during facing operation the cutting is performed from center point to
the outer diameter of the work piece.
JOB NO 03
[Eccentric turning with internal threading]
Note: All dimensions are in mm only

Material: M S bright rod
Size: Ø………. x ……………Length
Tolerance: ±0.50
Procedure:
1. Study the drawing.
2. Set the cutting tool for centre height.
3. Prepare the work piece for the Ø 48mm and to a length of 30 mm.
4. Mark the work piece center with the help of Vernier height gauge and V block with ‘C’ clamp and try
square.
5. Mark the 5 mm offset from centre of Ø48 mm by using Vernier height gauge and V block.
6. Punch the eccentric centre point with the help of centre punch.
7. Hold the job in four jaw chuck and true the job to eccentric centre point with the help of dead centre.
8. Do eccentric turning to a Ø30 mm to a length of 15 mm ( use slow speed)
9. With the help of centre bit and drill bit drill the hole to the eccentric point
Ø18 mm hole and bore it up to Ø23.8 mm.
10. Do internal threading by using internal threading tool.
Hole size (Minor Ø) = Major Ø – 2 x depth of thread
= 25 – 2 x 0.61
= 25 – 1.22
= 23.78 = 23.8
1. Finally check the dimensions as per given drawing.
JOB NO 04 SHAPING MODELS
Converting Circular Job In to Hexagonal Shape]
Aim – Prepare a ‘hexagonal’ shape on a circular block on shaping machine
Apparatus – Vernier height gauge, steel rule, shaping tool, centre punch, hammer, spanner set, and
Vernier caliper.
Operation – Marking, shaping
Note: All dimensions are in mm only

Material: M S bright rod
Size: Ø…….x ……. Length
Tolerance: ±0.50
Details:
Side of the hexagon = …….. mm
Across corners of the hexagon = ……….. mm
Thickness = …….. mm
Procedure:
01. facing both the sides of work piece and maintain the total length.
02. Marking to be done on the face of the work piece as per the sketch.
03. Aligning the across flats lines in the four jaw chuck; facing to be done to achieve the flat surface.
04. Repeat the procedure for all the sides.
05. Finish the job as per the sketch.
JOB NO 05
Aim: To fabricate the model according to the figure given below.
Tools Required: Shaping tool, Square tool, Machine vise etc.
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 square groove.
3. The shaping tool is set to the required angle to form square groove.
4. Then the shaping machine is operated to perform the necessary cutting action & ultimately complete the
model as per the required dimensions.
JOB NO 06
MILLING MODEL
Aim: – To learn the generation of Spur gear cutting using simple indexing head on milling machine.
Apparatus – Universal milling machine, gear blank mandrel, indexing head and Vernier caliper.
Operation – Facing, plain turning, drilling, boring, chamfering, gear cutting.
Raw materials size: C.I. Blank ……x…………mm to be supplied by workshop
THEORY: Milling is the machining process of using rotary cutters to remove material from a work piece
advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of
different operations and machines, on scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes in industry and machine shops today for
machining parts to precise sizes and shapes.
Drawing of jobs: Finished dimensions to be obtained after machining.
ØD
Ø 15
Tolerance:  0.1 mm
Cutting speed: Selected by referring speed standard chart
Machine Accessories: 1. Universal indexing head with 3 jaws chuck &
tail stock
2. Mandrill
3. Lathe m/c.
4. 3-jaw chuck with key
Tools required: 1. H.S.S Spur gear cutter size C.No.3 module 4mm
x bore  27mm
2. ISO-1 1616P30R turning tools
3. Drills MT-2
4. Boring tool
5. Mandrill spanners set.
THEORY: Milling is the machining process of using rotary cutters to remove material from a work piece
advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of
different operations and machines, on scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes in industry and machine shops today for
machining parts to precise sizes and shapes.
Step by step procedure:
1. Mounting and aligning of the dividing head and tail stock on the horizontal milling machine.
2. Mounting of gear milling cutter on the cutter arbor and checking for concentric running.
3. Clamping of work piece between centre and setting to the centre of the cutter.
4. Adjusting the sector arms for the indexing head [dividing head]
5. Setting of revolution and feed for milling.
6. Cutter should have slightly on the work piece.
7. with drawing work piece out of range of the cutter and lifting.
8. Milling of first tooth space.
9. With drawing work from the cut, and turning the indexing handle by the tooth pitch, milling of the next
tooth space.
10. Milling of remaining tooth.
PRECAUTIONS
1. The milling machine must be stopped before setting up or removing a work piece, cutter or other
accessory
2. Never stop the feeding of job when the cutting operation is going on, otherwise the tool will cut
deeper at the point where feed is stopped.
3. All the chips should be removed from the cutter. A wiping cloth should be placed on the cutter to
protect the hands. The cutter should be rotated in the clockwise direction only for right handed tools.
4. The work piece and cutter should be kept as cool as possible (i.e. coolant should be used where
necessary to minimize heat absorption).
5. The table surface should be protected with a wiping cloth.
6. Tool must be mounted as close to the machine spindle as possible.
VIVA -VOCE
1. What is machine?
A device consisting of fixed and moving parts that modifies mechanical energy and transmits it in a more
useful form
2. What is machine tool?
Machine is a mechanical device which having a provisions for holding the work and tool with on a facilities
rotation of work and different feed of the tool.
3. Define the term turning?
Turning is a machining process to bring the raw material to the required shape and size by metal removal.
This is done by feeding a single point cutting tool against the direction of rotation of the work. The
machine tool on which turning is carried out is known as lathe.
4. What are the different types of lathes?
Centre lathe, bench lathe, capstan lathe, combination lathe, turret lathe, CNC lathes.
5. What are the differences between the center lathe and Capstan Lathe?
Centre lathe - It is a manually operated lathe, It has only one tool post tool changing time is more, It has
tail stock, Only one tool can be fitted in the tail stock, Number of speeds is less, Tool changing time is
more, The machine should be stopped for changing tool, It is not suitable for mass production, The tool is
centered manually after changing the tool,
Capstan/turret lathe - It is a semi-automatic lathe, Front and rear tool posts are available. Tool changing
time is less, It has turret head instead of tail stock, Six different tools can be fitted in the turret head.
Number of speeds is more, Tool changing time is less, Tool can be changed without stopping the machine,
It is suitable for mass production , The tool is centered automatically,
6. How the center lathe can be specified?
The maximum diameter of a work that can be held
The length of the bed
Distance of the between centers
The range of threads can be cut
Capacity of the lathe
Range of spindle speed
7. What are the functions of lead screw and feed rod?
lead screw – for thread cutting purpose.
feed rod – to provide automatic feeding either for facing or turning.
8. What are the different methods of taper turning?
1) Compound slide method
2) Tailstock offset method
3) Form tool method
4) Taper turning attachment method
9. What is meant by eccentric turning?
When different diameters are turned on different axis, it is said to be eccentric turning.
10. What is the difference between L.H. thread cutting R.H. thread cutting?
a) A right hand bolt thread screws into the nut when it is rotated clockwise.
b) A right hand bolt thread screws into the nut when it is rotated anticlockwise.
11. Why the knurling operations are necessary for the given models in m/c shop?
a) A good grip and make for positive handling
b) Good appearance
c) For raising the diameter to a small range for assembly to get a desired fit.
12. How the change gears calculations can be done during thread cutting operation for
British and Metric pitches?
Standard general formula is,
The gear ratio = driver/driven = pitch of the work/pitch of the lead screw
Gear ratio for cutting metric thread on British lathe
Gear ratio = driver/driven = pitch to be cut on the job/pitch of lead screw
= pitch to be cut in mm x TPI on lead screw x 5/127
Gear ratio for cutting British thread on metric lathe
Gear ratio = driver/driven = pitch to be cut on the job/pitch of lead screw in mm
= 127/5 x pitch of work (TPI)/pitch of lead screw in mm
Note: a translating gear of 127 teeth is provided for cutting metric and British threads
on different lead of lead screw i.e. TPI or mm.
13. What are the differences between 3-jaw chuck and 4-jaw chuck?
3 – Jaw chuck
Only cylindrical or hexagonal work center, internal and external jaws are available,
setting of work is easy, less gripping power, work pieces can’t be set for eccentric
turning, concentric circles are not provided on the face.
4 – Jaw chuck.
A wide range of regular and irregular shaped jobs can be held, jaws are reversible for external and internal
holdings, setting of work is difficult, more gripping power, work pieces can be set for eccentric turning,
concentric circles are provided.
14. What are the differences between lathe accessories and lathe attachments? Give examples.
a) The lathe accessories are machined, independent units supplied with the lathe, which are essential for
the full utilization of the lathe,
Example,
1) Work holding accessories – 4 – jaw chuck, 3 – jaw chuck, face plates, lathe mandrels.
2) Work supporting accessories – catch plate, driving plate, lathe centers, lathe carriers, fixed and travelling
steady rests.
b) Attachment is an optional extra attachments to produce tapers, contours, thread forming, grinding,
etc…
Example,
1) Taper turning attachment
2) Forming attachment
3) Cylindrical, grinding, thread, grinding attachment
15. What is meant by single point cutting tool?
Single point cutting tools have one cutting edge which performs the cutting action. Most of the lathe
cutting tools are single point cutting tools.
16. What is meant by multi point cutting tool? Give examples.
These tools have more than one cutting edge and they remove metal from the work piece simultaneously
by the action of all the cutting edges,
Ex. Files, hacksaw blade, twist drills, reamers, milling cutters, hand taps, and spilt dies, grinding wheels.
17. What are the properties of cutting tool material?
The most important basic properties of only cutting tool is,
- Cold hardness
- Red hardness
- Toughness
18. What is meant by H.S.S. tool? What are the elements present in that?
HSS (High Speed Steel) is an alloy of high carbon steel with an alloying elements like Tungsten 18%,
Chromium 4% and Vanadium of 1%.
19. What is meant by carbide tipped tool?
These tools are made of two different metals, the cutting portions of these tools are tungsten carbide
which are brazed to ordinary metal blank which are tough (low cost).
20. Define cutting speed. Feed and depth of cut?
a) Cutting speed – “The speed at which the cutting edge passes over material” which
is expressed in meters per minute is called the cutting speed.
V = ΠDN/1000 meter/min. (OR) V = ΠDN/12 feet/min.
Where – V = cutting speed in meters/min
Π = 3.14
D = diameter of work piece in mm
N = rpm
b) Feed – The feed of the tool is the distance it moves along the work for each
revolution of the work. and it is expressed in mm/revolution.
c) Depth of cut – It is the advancement of the tool at the beginning of the feed which
is perpendicular to the type of feed.
21. What is the spindle speed during thread cutting operation?
Set the spindle speed to about 1/4th of the normal turning speed.
22. What is difference between orthogonal cutting and oblique cutting?
Orthogonal cutting – Is a process of cutting operation where only two forces
i.e. tangential and axial forces are acting on the tool while turning
Oblique cutting - Is a process of cutting operation where three forces
i.e. Tangential, axial and radial forces are acting on the cutting tool while turning.
23. Why steady rest and follower rest are used?
A steady rest and follower rest are the lathe accessories used to give extra support for
a long slender work piece in addition to the centre support during turning.
24. Why the mandrels are used?
Lathe mandrels are devices used to hold the job for machining on lathes. They are
mainly used for machining outside diameters with reference to bores which have
been duly finished by either reaming or boring on a lathe.
25. What are the measuring (limit) gauges used while doing/machining components on lathe?
Internal features check External features check
Cylindrical plug gauge Plain ring gauge
Taper plug gauge Taper ring gauge
Screw threaded plug gauge Screw pitch gauge
Fillet gauge Radius gauge
26. What is the formula for calculating the machining time on lathe?
Time to turn = length of cut x no. of cuts / feed x r p m minutes
(OR)
T = L x n/ f xN min.
27. Which are the factors governing the cutting speed?
Finish required
Depth of cut
Tool geometry
Properties of cutting tool material
Properties of work material
Type of cutting fluid used
 Rigidity of the machine tool
28. What is a lathe?
Lathe is a machine, which removes the metal from a piece of work to the required shape &size
29. What are the various operations can be performed on a lathe?
1. Turning 6. Thread cutting 11. Grooving 2. Facing 7. Drilling 3. Forming 8. Boring 4. Knurling 9. Recessing
5. Chamfering 10. Tapping
30 What are principle parts of the lathe?
Red, headstock, tailstock, carriage, cross slide, tool post
31. What are the types of headstock?
Back geared type, all geared type
32. State the various parts mounted on the carriage?
Saddle, compound rest, cross slide, tool post 6. What are the four types of tool post? 1. Single screw 2.
Open side 3. Four bolt 4. Four way
33 What is an apron?
The integral part of several gears, levers clutches mounted with the saddle for moving the carriage along
with lead screw while thread cutting
34 State any two specification of lathe?
1. The height of centers from the bed 2. The maximum length of the bed
35. List any four types of lathe?
1. Engine lathe 2. Bench lathe 3. Tool room lathe 4. Semi automatic lathe 5. Automatic lathe
Viva Voce Questions
1. What is the difference between Machine tool & Cutting tool. ?
2. Name the different types of cutting tools used in machine shop. ?
3. Name the different types of Lathes?
4. What are the different types of Operations that can be performed on Lathe?
5. Name the different types of Taper turning methods?
6. What is the difference between Mild steel & Cast Iron?
7. Name the different parts of Lathe and by which material, which it is made of. ?
8. What is the difference between 3-jaw chuck and 4-jaw chuck?
9. What are the different types of cutting fluids used?
10. What is the formula for calculating Taper angle?
11. What is the formula for cutting speed?
12. What is difference between Feed & Depth of cut?
13. What is the Unit of feed?
14. Name the different parts of Milling machine and their usage?
15. Name the different parts of Shaping machine & usage?
16. By which mechanism, shaping and Milling machine works. ?
17. What is the difference between Left-hand thread cutting & Right-hand thread cutting?
18. What is the importance of Lock nut in Lathe?
19. What is the importance of Gear box in Lathe?
20. What is the procedure for producing gear teeth‟s in Milling machine?
21. What do you mean by Slotting machine?
22. Name the different parts of Slotting machine and their usage?
23. What do you mean by Eccentric turning?
24. What do you mean by Live-center and Dead-center?
25. How do you specify a lathe?
26. What do you mean Cutting tool nomenclature?
27. Name the different types of Cutting tool materials?
28. What do you mean by internal thread cutting, Boring, Reaming?
29. Name the different types of Chips produced in Lathe?
30. What are the factors caused to get different types of Chips?
31. What are different types of Gears?

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LIST OF EXPERIMENTS

Drawing of job: Finished dimensions to be obtained after machining

Result The job is thus made according to the given dimensions.

PLANE TURNING AND STEP TURNING KURNLING AND THREAD CUTTING

Result The job is thus made according to the given dimensions.

Note: All dimensions are in mm only

Result The job is thus made according to the given dimensions.

Note: All dimensions are in mm only

Result The job is thus made according to the given dimensions.

Result The job is thus made according to the given dimensions.

Step by step procedure:

Result The job is thus made according to the given dimensions.

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