PRODUCT REALIZATION LAB PRACTICE (MEC217P)

LABORATORY MANUAL
PRODUCT REALIZATION PRACTICE

MEC 217P Lab

MECHANICAL ENGINEERING

INDIAN INSTITUTE OF INFORMATION

TECHNOLOGY DESIGN AND MANUFACTURING
KURNOOL
YEAR-2018
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

S.NO Experiment name Date of Date of Page Lab in- Faculty Remarks
performance Record nos. charge
Submission
Realization of
Cylindrical Parts using
1 Traditional Lathe
Turning
Realization of
Cylindrical Parts using
2
Traditional Lathe Step
Turning
Realization of
Cylindrical Parts using
3
Traditional Lathe
Threading
Realization of
Cylindrical Parts using
4 Traditional Lathe Taper
Turning
Sheet Metal Bending
5 Practice

Practice on Universal
6 Milling Machine Facing

Gear Cutting by using

7 Universal Milling
Machine
Machining on CNC
8 Router cum Milling
Fusion Deposition
9 Modeling(3D Printer)
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

Realization of Cylindrical Parts using Traditional Lathe.

EXPERIMENT NO.: 1
TURNING OPERATION
DEFINITION:

Turning is a form of machining, a material removal process, which is used to create rotational
parts by cutting away unwanted material. Turning is the removal of metal from the outer
diameter of a rotating cylindrical work piece. Turning is used to reduce the diameter of the
work piece, usually to a specified dimension, and to produce a smooth finish on the metal bar.

AIM:
To perform lathe operations such as straight turning on a given material made of Mild
steel.

MATERIAL REQUIRED:

A round bar of mild steel having diameter 25 mm and 100 mm in length.

TOOLS AND MEASURING INSTRUMENTSREQUIRED:

▪ Single point cutting tool
▪ Vernier caliper
▪ Chuck key
▪ Steel rule
▪ Lathe machine

All Dimensions are in “mm”

 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

Tolerance for all dimensions ±0.2mm

PROCEDURE:

➢ Fix the job in three jaw chuckwith sufficient overhang

➢ Adjust the machine to run the job to a required cutting speed by adjusting gears.
➢ 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.
➢ Machine the excess volume of material using facing operation and conform to the dimension
➢ Give the feed and depth of cut to the cutting tool.
➢ Straight turning operation is performed until the diameter of the work piece
reduces to 23 mm.
➢ Check the dimensions by using vernier calipers.
➢ Finish machine the given part with chamfer at the end of thread and by maintaining the given
Tolerance.

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.

RESULT
The requireddiameter has been produced by turning operation on lathe machine.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 2
STEP TURNING OPERATION
DEFINITION:
Turning is the removal of metal from the outer diameter of a rotating cylindrical work piece.
Turning is used to reduce the diameter of the work piece, usually to a specified dimension, and
to produce a smooth finish on the metal. Step turning is an operation performed on lathe
machine where the excess material is removed from the work piece to obtain various steps of
different diameters.

AIM:
To perform lathe operations such as Step turning on a given material made of Mild
steel.

MATERIAL REQUIRED:
A round barof mild steel having diameter 25 mm and 100 mm in length.

TOOLS AND EQUIPMENT USED:

▪ H.S.S. single point cutting tool,

▪ Chuck key,
▪ Tool post key,
▪ Outside caliper,
▪ Steel rule,
▪ Lathe machine.

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.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)
➢ 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.
➢ Straight turning operation is performed until the diameter of the work piece
reduces to 21 mm to a length of 10mm from end.
➢ Perform the straight turning operation on the same work piece for the required length
10mm in order to reduce the diameter to 23 mm so as to get the step turning
➢ Check the dimensions by using verniercalipers.

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.
➢ Feed/release the work piece only in disengages position.
➢ Apply cutting fluids to the tool and work piece properly.

ALL DIMENSIONS ARE IN MM

RESULT:
The requiredSteps with different diameters produced by turning operation on lathe machine.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 3

THREADING OPERATION
AIM:
To make External Threads duringmachining process on traditional lathe.

TOOLS AND MEASURING INSTRUMENTS REQUIRED:

▪ H.S.S. single point cutting tool,
▪ Chuck key,
▪ Tool post key,
▪ Outside caliper,
▪ Steel rule.
▪ Lathe machine

All Dimensions are in “mm”

Tolerance for all dimensions ±0.2mm

PROCEDURE:
➢ Fix the job in three jaw chuck
➢ Machine the excess volume of material using facing operation and conform to the
dimension
➢ 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.
➢ Set the thread cutting gear in the lathe and proceed with cutting an external thread
➢ Finish machine the given part with chamfer at the end of thread and by maintaining the
givenTolerance.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

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.

RESULT:
The requiredexternal threads produced by turning operation on lathe machine.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 4

TAPER TURNING OPERATION

AIM:
To make tapered part while turning the work materialon a traditional lathe.

TOOLS AND MEASURING INSTRUMENTS REQUIRED:

▪ H.S.S. single point cutting tool,

▪ Chuck key,
▪ Tool post key,
▪ Outside caliper,
▪ Steel rule.
▪ Lathe machine

All Dimensions are in “mm”

Tolerance for all dimensions ±0.2mm

PROCEDURE:
➢ Fix the job in three jaw chuck
➢ Machine the excess volume of material using facing operation and conform to the
dimension.
➢ 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.
➢ Set the angle of compound rest in the lathe and proceed with turning operation, the
angle can be measured by using the formula Tanα = (D – d) / 2L.
➢ Feed the tool by using cross slide instead of using carriage.
➢ Machining operation is performed until the diameter of the work piece reduces
to required dimensions.
➢ Check the dimensions by using vernier calipers.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

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.

RESULT:
The requiredtapered shape is produced by taper turning operation on lathe machine.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 5
SHEET METAL BENDING OPERATION
AIM:

(i) To prepare a desired shape using sheet metal forming operation (square container).
(ii) To report various parameters for various passes during the rolling of the given metal piece.

EQUIPMENT & MATERIAL:

Mallet, hand shear, bench shear, grooving and riveting tool, metal sheet, soldering equipment.

Demonstration
Self secured sheet metal joints

FIGURE 1 FIGURE 2 FIGURE 3

(a) Internal grooved joint

- Mark out portions of given sheets near edges to be joined with a marker (Fig. 1a)
- Fold the sheets at edges in the portion marked, first at right angles to the plane of the sheet
(Fig.1b) and then at 1800to the plane (Fig.1c)
- Insert one folded sheet into the other (Fig. 1d)
- Groove the seam using grooving die (Fig.1e)
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

(b) Double grooved joint

- Fold sheets after making them as per the instructions given (Fig. 2a)
- Cut a piece of sheet (called strap) of required width
- Strap width = (4x size of marked edges) + (4 x thickness of sheet)
- Close the edges of the strap slightly as shown in Fig. 2(b)
- Slip the strap on the bent edges of the sheets after bringing them together (Fig. 2c)

(c) Knocked-up joint

- Fold one sheet and close edges slightly (Fig. 3a)
- Bend one sheet to form a right angles band (Fig. 3b)
- Slip the second sheet in the folded one (Fig. 3c)
- Close the right angled sheet using a mallet (Fig. 3d)

OUTLINE PROCEDURE:
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

➢ Cut a sheet of 120 mm x 120 mm, and mark a center of 60 mm x 60 mm to indicate

bend lines.
➢ Mark bending lines of 4 mm and 6 mm on outer edge of square sheet as shown in figure
➢ Join the diagonals and mark 150 from corners of inner square (60 x 60 mm) …i.e. 7.50 on
the either 7 side of the diagonals
➢ Mark the intersection of 150 line with 10mm outside bending line, mark a 600 to the
bending line (for all four corners, or eight times).
➢ From 600 intersecting line at 4mm from outer edge, now mark 172.50 to bending line
(for corners, or eight times).
➢ Now remove the corner portions a. i.e. 600 till 6 mm (from inner corner edge towards
outside edge),and then b. 172.50 for last 4 mm till outer edge.
➢ Fold the sides of container (try avoiding waviness)
➢ Seam the edges at all corners and make sure it is leak proof.

PRECAUTIONS:
➢ Mark the dimensions appropriately using scriber and dot punch
➢ Should be careful while operating the snips and shearing machines.
➢ Make chamfer at the edges of sheets to avoid sharp edges.
➢ Make sure of usage of snips with respect of application.

RESULT:
The requiredsheet metal boxis produced by using sheet metal tools.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 6

FACING USING UNIVERSAL MILLING MACHINE

AIM:
To fabricate the given model as per the dimensions given in the figure.

APPARATUS:
Milling cutter, indexing head, vice, vernier caliper etc.

UNIVERSAL MILLING MACHINE

Fig: facing on milling machine

 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

PROCEDURE:
➢ Fix the work piece on the worktable and then fit the milling cutter on the tool holder
➢ Select a suitable cutting speed and feed.
➢ Work piece is fed to the cutter automatically or manually.
➢ The work piece is fed against the direction of the milling cutter.
➢ The surface is cleaned with the help of brush to remove the chips.
➢ Check the readout frequently to know the dimensions of work piece.
➢ This procedure is followed until the required dimension is obtained.

PRECAUTIONS:
➢ The work piece should be held rigidly in the vice before operating the machine.
➢ Tool should be properly fixed at correct position and properly 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 tool bit and cleared as often as
possible
➢ Apply cutting fluids to the tool and work piece properly.

RESULT:
The requiredfacing operation is produced by using Universal milling machine.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 7

GEAR CUTTINGBY USING UNIVERSAL MILLING MACHINE

AIM:
Spur gear cutting on a gear blank using milling machine.

TOOLS & INSTRUMENTS:

Universal milling machine, gear blank mandrel, indexing head and Vernier caliper.

OPERATION:
Facing, plain turning, drilling, boring, chamfering, gear cutting.

Figure 1: Nomenclature of the Gear

 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

UNIVERSAL MILLING MACHINE

PROCEDURE:
➢ Mounting and aligning of the dividing head and tail stock on the Universal milling
machine.
➢ Mounting of gear milling cutter on the cutter arbor and checking for concentric running.
➢ Clamping of work piece between centres and setting to the centre of the cutter.
➢ Adjusting the sector arms for the indexing head [dividing head]
➢ Setting of revolution and feed for milling.
➢ Cutter should have slightly on the work piece.
➢ With drawing work piece out of range of the cutter and lifting.
➢ Milling of first tooth space.
➢ With drawing work from the cut, and turning the indexing handle by the tooth pitch,
milling of the next tooth space.
➢ Milling of remaining tooth.

PRECAUTIONS:
➢ The work piece should be held rigidly in the vice before operating the machine.
➢ Tool should be properly fixed at correct position and properly secured.
➢ Before operating the machine see whether the job and tool is firmly secured in
devices or not andOptimum machining conditions should be maintained.
➢ Chips should not be allowed to wound around a tool bit and cleared as often as
possible
➢ Apply cutting fluids to the tool and work piece properly.
RESULT:
The required spurgear cutting on blank is produced by using Universal milling machine.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 8

MACHINING USING CNC ROUTER CUM MILLING MACHINE

AIM:
To machine the given soft wooden materials part using CNC router cum milling machine

OBJECTIVE:
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

Fig:: CNC router cum milling machine

APPRATUS REQUIRED:
Autodesk Fusion360 Software with System,Universal G Code sender, Rectangular Specimen,
Vernier Caliper, Steel rule, Pen drive, End Milling Cutter, Spanner Setetc,

OUTLINE OF PROCEDURE:

➢ Open the Autodesk Fusion360 Software package and draw the 2D sketch of machinable
features.
➢ Draw the sketch new creative modelSimulate the process and generate CAM model for
the 2D sketch
➢ Save the drawing with .nc format and upload it Universal G Code sender to get connect
with CNC milling machine.

➢ Select the proper feed and speed

➢ Set the work piece at center point before starting the operation make sure that offset
should be given to proper machining
➢ Start the CNC router machine the part using appropriate End mill cutting tools and
process parameters.
➢ Do the safety precaution using the CNC router machine
➢
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

PRECAUTIONS:
➢ Check all the connections of the stepper motors in the milling machine.
➢ The work piece should be held rigidly in the vice before operating the machine.
➢ Tool should be properly fixed at correct position and properly secured.
➢ Avoid the manual operating in between machining.
➢ Before operating the machine see whether the job and tool is firmly secured in
devices or not.

RESULT:
Machining on soft wooden part has been performed by using CNC milling
machine.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

EXPERIMENT NO.: 9

FUSION DEPOSITION MODELLING (3D PRINTING)

AIM:
Fabrication of the given component using 3D printer

APPRATUS REQUIRED:

Fracktorysoftware, PLA material, .stl File, .gcode file Template

SPECIFICATIONS:
➢ Model Material: PLA material
➢ Support Material: soluble
➢ Build Size: 254 x 254 x 305 mm (10 x 10 x 12 in)
➢ Layer Thickness: 0.33 mm (0.013 in) or 0.254 mm (0.010 in)
➢ Power Requirements: 100 ‐ 120 VAC, 60 Hz, min 15A dedicated circuit
➢ Temperatures: 99⁰C (model and support) 72⁰C (inside chamber)

OUTLINE OF PROCEDURE:
➢ Upload your drawing using the Fracktorysoftware for the Dimension printers With STL
file/gcode file.
➢ In Fracktory software may check on the orientation, time, and amount of material that
will be used.
 PRODUCT REALIZATION LAB PRACTICE (MEC217P)

➢ Start in the General tab and select the proper print resolution, scale, number of copies,
and set the support material fill.
➢ Check and make sure that part is in the proper UNITS!
➢ In the Orientation tab you will decide how the part will be printed. Prior to printing, it is
important to check the print file will be continuous.
➢ Make sure the temperature of the nozzle and bed should keep based on the melting
temperature of the respected filament material. Suppose for PLA material melting
temperature is 200 0C.
➢ Start at the bottom and step up until you reach the top to ensure that all layers are set
correctly and there are no gaps or undesired features.
➢ In the Pack tab, you may orient the part on the printing bed as well as examine how long
your print will take and how much support and model filament material it will take.
➢ After the completion of printing the nozzle reaches to its home position and bed and
nozzle starts cool down.
➢ Clean the printer bed after the product taken out.

PRECAUTIONS:
➢ Maintain proper temperature of the nozzle and bed to get accurate print
➢ Do not touch the melting filament and nozzle while it is printing
➢ Avoid wastage of Filament.
➢ Avoid intermediate power disturbances to the printer.

RESULT:
The required component is fabricated by using 3D printer considering the procedure
Steps.