Military Institute of Science & Technology (MIST), Dhaka

Department of Mechanical Engineering

ME 234
Manufacturing Technology Sessional

LEVEL-2, TERM-II
Contact Hr: 3 Credit: 1.5

Name of the Experiments:

1. Study of Different Types of Chip and Determination of Chip Reduction Coefficient.

2. Study and Determination of Tool Wear.

3. Gear Cutting on a Column & Knee Type Milling Machine.

4. Study of Shaper Machine

5. Study the Engine Lathes and Kinematic Diagram of an Engine Lathe

6. Study of Milling Machine and Dividing Head

7. Study and Operation of CNC Milling Machine

8. Study of Injection Molding Machine

9. Study of EDM (Electric Discharge Machining)

10. Manufacturing of an Industrial Part by Using Lathe & Shaper Machine.

1
Reports should contain:
1. Experiment Number and Name of the Experiment.
2. Objectives of the experiment.
3. Necessary Figures.
4. Name of the Equipment Used.
5. Data and Sample Calculation.
6. Results and Graphs (if necessary)
7. Discussions.
8. Assignments (if any).
General notes for the students:
1. Every student should read the supplied sheet thoroughly and try to understand it
conceptually.
2. Reports must be competent with the required contents.
3. The discussion of the report should be different.
4. The students should be familiar with the measuring instruments beyond these experiments.
5. The procedure for each experiment mentioned in the sheet is just a guideline. For details,
books are referred.
6. Reports must be submitted on every next class after an experiment.
7. While working in a group each student should participate equally.
General safety notes for the students:

1. The students must always use an apron, close-toed shoes, and safety goggles in the laboratory.
2. The chips generated are hot and therefore do not touch them immediately.
3. Female students should keep their hair tied and their scarfs pinned so that they do not come in
contact with the rotating and moving parts.
Operational Safety Notes:
1. Put safety glass On before starting anything for this lab.
2. Do not Touch the Rotating Chuck or Workpiece.
3. Make Sure the Workpiece is held tight by the chuck before starting the machine.
4. Make Sure the cutting tool is held tight by the tool holder before starting the machine.
5. Remove all tools, measuring instruments, and other objects from the saddle and lathe
machine bed before starting machining.
6. Do not change the spindle speed while the machine is running.
7. Stop the Lathe machine before taking any measurement.
8. Keep the working area around the lathe machine clean.

2
Potential Hazards
Hot Metal, Sparks, Noise, Eye Injuries, Entanglement, Sharp Edges, and Burrs.

Students Evaluation:

Reports and assignments 20%

Class Attendance 10%
Class Participation 10%
Quiz 40%
Viva 20%
Total 100%

Reference books:
1. Materials & Processes In Manufacturing; E. Paul DeGarmo, J.T.Black, Ronald A.
Kohser; Printice Hall
2. Manufacturing Engineering & Technology; S.Kalpakjian & S.R. Schmid
3. Shop Theory; James Anderson

3
 Experiment No: 1
Study of Different Types of Chip and Determination
of Chip Reduction Co-Efficient

Objective:
1. To study different types of chips.
2. To determine chip reduction coefficient.

Theory:
Chip formation:
When force is applied by the cutting tool against the workpiece, the uncut layer deforms first elastically
followed by plastic deformation due to the shearing action near the cutting edge of the tool as in figure
1.1. Shearing takes place along a shear zone and shear is maximum at the shear plane. After passing
out of the shear plane, the deformed material slides along the tool face as a chip as cutting progress.

Figure1.1: Schematic view of chip formation process Figure1.2: Piispanen’s idealized

model

The Shearing process in chip formation and its motion along the tool face can be visualized from
Piispanen’s idealized model of card analogy in which a stack of inclined cards is pushed against the
tool.

Types of chips:

Every machining operation involves the formation of chips. The nature of the chip differs with
operations, properties of workpiece material, and cutting conditions (such as cutting speed, feed rate,
depth of cut, cutting fluid, etc). The types of chips produced significantly influence the surface finish

4
of the workpiece and overall cutting operation (such as tool life, vibration, chatter, etc). A chip has
two surfaces- shiny and rough surfaces. Three main categories of chips are as follows:

1. Discontinuous Chips
These types of chips are usually produced when cutting more brittle materials like grey cast iron,
bronze, and hard brass. These materials lack the ductility necessary for appreciable plastic chips
formation. The material ahead of the tool edge fails in a brittle fracture manner along the shear zone.
This produces small fragments of discontinuous chips. Since the chips break up into small segments,
the friction between the tool and the chips reduces, resulting in a better surface finish. These chips
are convenient to collect, handle, and dispose of.

Figure1.3: Discontinuous chip

Discontinuous chips usually form under the following conditions:

(1) Brittle workpiece materials, because they cannot undergo the high shear strains involved
in cutting.
(2) Workpiece materials that contain hard inclusions and impurities, or have structures such
as the graphite flakes in gray cast iron.
(3) Very low or very high cutting speeds.
(4) Large depths of cut.
(5) Low rake angles.
(6) Lack of effective cutting fluid.
(7) Low stiffness of the machine tool.

5
2. Continuous chips

These types of chips are produced when machining more ductile materials. Due to large
plastic deformations possible with ductile materials, longer continuous chips are produced.
This type of chip is the most desirable, since it is stable cutting, resulting in a generally good
surface finish. On the other hand, these chips are difficult to handle and dispose of. The chips
coil in a helix (chip curl) and curl around the work and the tool and may injure the operator
when breaking loose. Also, this type of chip remains in contact with the tool face for a longer
period, resulting in more frictional heat. These difficulties are usually avoided by attaching a
‘chip breaker’ to the tool face. The function of the chip breaker is to reduce the radius of
curvature of the chip and thus break it. The following cutting conditions also help in the
production of continuous chips:

(1) Small chip thickness.

(2) High cutting speed.
(3) The large rake angle of the cutting tool.
(4) Reducing the friction of the chip along the tool face, by imparting a high surface finish to
the tool face, use of tool material with low coefficient of friction, and use of good cutting
fluid.

3. Continuous chips with a built-up edge (BUE)

When machining ductile materials, conditions of high local temperature and extreme pressure in
the cutting zone and also high friction in the tool-chip interface may cause the work material to
adhere or weld to the cutting edge of the tool forming the built-up edge. When this edge becomes
larger and unstable, it breaks up and part of it is carried up the face of the tool along with the chip
while the remaining is left over the surface being machined, which contributes to the roughness of
the surface. The built-up edge changes its size during the cutting operation. It first increases, then
decreases, then again increases, etc. This cycle is a source of vibration and poor surface finish.
Although the built-up edge protects the cutting edge of the tool, it changes the geometry of the
cutting tool. Low cutting speed also contributes to the formation of the built-up edge. Increasing
the cutting speed, increasing the rake angle, and using a cutting fluid contribute to the reduction or
elimination of the built-up edge.

6
 Figure1.4: Continuous chip with BUE Figure1.5: Orthogonal cutting

Chip reduction co-efficient (ξ):

Chip reduction co-efficient (ξ) is the ratio of chip thickness (a2) to uncut chip thickness (a1) (Figure1.5).
Mathematically,

ξ = a2/a1 = cos(β-γ0)/sinβ

The inverse of ξ is known as cutting ratio, rc. ξ is an important index that indicates the degree of

deformation and hence the force required. ξ is affected by process parameters (i.e. Vc, S0, t, γ, etc) and
other variables (i.e. friction at the tool-chip interface, cutting fluid, tool material, work material, etc)

7
 Figure1.6: ξ vs Vc and ξ vs S0 Curve

Machine, Equipment & Material:

i. Lathe machine
ii. Work material
iii. Cutting tool
iv. Slide caliper
v. Universal bevel protractor

Procedure:
I. Turn the work material in an engine lathe with three different cutting speeds at a constant feed
rate.
II. Repeat the above procedure for three different feed rates.
III. Collect the chips obtained, study them to identify their types, shapes, and colors.
IV. Calculate ξ for each chip.

V. Plot ξ vs Vc and ξ vs S0.

Assignments:

1. Briefly explain the mechanism of different types of chip formation and why is it important to
investigate the chip formation during cutting material?
2. What are the various types of chips? Under what conditions each is formed?
3. Why continuous chips are not always desirable?
4. What is intermittent cutting in milling operations? Do you think intermittent cutting can
replace the conventional cutting method?
5. Do you know what is chatter in machining? Do you think chatter is good for machining?
Write a short note in the favour of your answer.

8
 Data Sheet
Experiment No.1

Date:………………...

1. Work Material:………………………………. Diameter:…………………mm

2. Tool material:…………………………

3. Cutting conditions:……………….

4. Environmental conditions: dry/wet Cutting fluid used:………………..

S0 Vc ξ = a2/ Chip
N a1 (mm) a2 (mm) Chip
(mm/rev) (rpm) (m/min) a1 type color

………………………………

Signature of the Teacher

9
 Experiment No: 2
Study and Determination of Tool Wear

Objective:
To study and determine different types of tool wear.

Theory:

Wear: Wear is defined as the progressive loss or removal of material from a surface. The cutting tools
are subjected to high localized stresses, high temperatures, sliding of the chip along the rake face, and
sliding of the tool along the freshly cut surface. These conditions induce tool wear, which, in turn,
adversely affects tool life, the quality of the machined surface, and its dimensional accuracy, and
consequently, the economics of cutting operations. After a certain degree of wear, the tool has to be
resharpened for further use. The rate of tool wear depends on the tool and workpiece materials, tool
shape, cutting fluids, process parameters (i.e. cutting speed, feed, and depth of cut), and machine-tool
characteristics.

Causes of wear:
The following basic causes, depending on cutting or environmental conditions, solely or in
combinations produce tool wear-

i. Abrasion: The inherently hard constituents present in a workpiece, the strain hardened chip
and workpiece or broken BUE can cause abrasive wear while sweeping over tool face and flank.
ii. Adhesion: If fracture takes place not along the interface of chip and tool during sliding at the
point of adhesion but in the tool material, a tool material is removed with the chip.
iii. Diffusion: Metal and carbon atoms may diffuse from the tool surface into work material and
chips. It depends on high temperature and pressure and the metallurgical relationship of tools
and work material.
iv. Attrition: Fragments of the tool may tear intermittently from the tool surface at a low cutting
speed where the flow of material past the cutting edge is irregular and less streamlined.
v. Corrosion: It is due to the chemical reaction between the tool surface and work material or
environment (i.e. cutting fluid).
vi. Electrochemical: It occurs when ions are passed between the tool and workpiece causing
oxidation of tool surface, cutting fluid action as electrolyte.

10
vii. Plastic deformation: When high compressive stresses act on the tool rake face, the tool may
be deformed downward (primarily in the nose area) which promotes other wear.
viii. Thermal cracking: Owing to thermal cyclical stresses at the cutting edge, short cracks called
comb cracks are often observed in the tool. These cracks start at the cutting edge and then widen
along the rake face and flank.
ix. Fatigue wear: It is due to cyclic loading.
x. Chipping: It is the sudden breaking away of a small piece from the cutting edge or nose of
the tool. It may be microchipping, microchipping, or fracture.

Types of wear:

The main wears in the cutting tool are as follows:

Flank wear: It occurs on the principal and auxiliary flanks of the tool and develops a wear land as
shown in figure2.1. It is mainly due to rubbing of the tool by the machined surface causing abrasion.
Adhesion is also a factor. When BUE has torn away, it takes particles of tool material with it. Thermal
cracking is also a cause of the breakdown of small particles in the flanks, predominant in brittle
material and cases of discontinuous chips. The width of the wear land is usually taken as the measure
of the amount of wear and can be readily determined using a toolmaker’s microscope.

Here, VN= notch wear

VB= average principal flank wear

VM= maximum principal flank wear

VS= average auxiliary flank wear

VSM= maximum auxiliary flank wear

Figure 2.1: Flank wear & Crater wear Figure 2.2: Crater wear

The tool life is generally determined by VB. If VB is greater than 300μm, the tool needs resharpening.

VB varies with machining time as show figure2.3. The curve can be divided into three regions:

11
 1. The region AB where the sharp cutting edge is quickly broken down and a finite wear land is
established.
2. The region BC where wear progresses at a uniform rate.
3. The region CD where wear occurs at a gradually increasing rate.

Region CD is thought to indicate the region where the wear of the cutting tool has become sensitive
to the increased tool temperatures caused by the presence of a wear land of such large proportions.
Clearly, in practice, it would be advisable to regrind the tool before the flank wear enters the last region
(region CD in figure2.3) where the rapid breakdown occurs.

Crater wear: It occurs on the rake face of the tool, where there is direct contact of the tool with the
chip, in the form of the cavity as shown in Figures 2.1 and 2.2. It is prominent in ductile materials like
steel and its alloys. It occurs at the point of impingement of the chip on the tool and widens with time.
It does not reach the cutting edge but causes rupture of the tool before reaching. It leads to the
weakening of the tool, increase in cutting temperature, friction, and cutting forces. The most significant
factors influencing crater wear are (a) temperature at the tool-chip interface and (b) the chemical
affinity between the tool and workpiece materials. Additionally, the factors influencing flank wear
also influence crater wear.

Figure 2.3: Development of flank wear with time

Crater wear has been described in terms of diffusion mechanism, that is, the movement of atoms across
the tool-chip interface. Since diffusion rate increases with increasing temperature, crater wear
increases as temperature increases.

12
Here, KL= crater length, KT=maximum crater depth, KB= crater width, and KM=
distance of maximum crater depth from cutting edge
Maximum KT is at the location of maximum temperature at the tool-chip interface. Crater wear is
characterized mainly by KT and KB. The change in the length of the crater (KT) is negligible.

Nose wear: With the time of machining, the tool nose becomes blunt and round due to wear.
It is less significant for failure than flank or crater wear.

In the general case, both crater and flank wear increase in course of operation. But depending upon the
machining condition, one of them may predominate. The study of tool wear is important in finding
optimal tool wear before grinding, scheduling of production, correlating other factors of cutting etc.

Machine, equipment & Work Material:

i. Lathe machine
ii. Work material
iii. Cutting tool
iv. Microscope
v. Brush

Procedure:
1. Turn the work material for a predetermined duration and remove the chip particles from the
tool.
2. Observe the wear of the tool by microscope and measure VB.
3. Draw the wear diagram of the tool.
4. Take the above readings after turning for 3, 5, 10, and 15 minutes.
5. Plot VB vs Time in the report.

Assignment:
1. Why tool wear is important in metal cutting? Explain few modern methods that can reduce the

tool wears.
2. Discuss briefly the effect of BUE on tool wear.
3. Are the locations of maximum temperature and crater wear-related? If so, why?

4. When the tool needs resharpening? How do you sharpen a diamond tool as diamond is the

hardest material on earth?

5. What kind of diamond is used to make diamond tools?

13
 Data Sheet
on Experiment No.2

Date:………………...

1. Job material:………………………………. Diameter:…………………..

2. Tool material:……………………………...

3. Cutting conditions:…………….mm, S0=……………..mm/rev, Vc=……….....m/min

4. Environmental conditions: dry/wet Cutting fluid used:…………….

No of Jobs Time (min) VB

(µm)

………………………………..
Signature of the Teacher

14
 Experiment No: 3
Gear Cutting on a Column & Knee Type Milling Machine

Objectives:
i. To introduce different types of gears.
ii. To study and operate milling machine to manufacture a spur gear.

Theory:
Gears are used for the transmission of motion and power between two shafts without slippage. There
are different types of gear such as spur gear, bevel gear, helical gear, worm and worm wheel, rack and
pinion, etc. Each type of gear is suitable for certain purposes.

Gears can be manufactured by milling machines, gear shaper, gear hobber, powder metallurgy, etc.
The milling machine produces gear by form cutting method. A cutter, shaped like the tooth space of
the gear to be manufactured, cuts each tooth individually. After cutting a tooth of gear, the gear blank
is indexed. When cutting a helical gear, the table is swiveled at an angle, which is equal to the helix
angle of the gear. The main components of a milling machine are the column, arbor, arbor support,
table, dividing head, etc.

Machine, Equipment & Work Material:

i. Milling machine
ii. Milling cutter
iii. Gear blank

Procedure:
i. Be introduced to different types of gears and their functions.
ii. Study the different components of the milling machine.
iii. Operate milling machine to manufacture a spur gear.

Gear cutting methods:

Gear cutting methods may be dividing into two classes as follows:

1. Gear forming method, which uses a cutter having the same form as the space between the teeth
being cut. The cutter may be a single point tool on a planer or a shaper, a rotating cutter on a
milling machine.

2. The generating method, in which the cutting profile of the tool is like that of a mating gear or
rack tooth. The cutter and work roll together as though in the mash to develop the tooth form.

15
Column and Knee type Milling Machine:
Basic components: Column, Knee, Table, Spindle, etc.

Milling Machine Sizes: A Knee and Column type milling machine is designable by a number that
indicates longitudinal table travel.

Dividing heads: A dividing or index head is a mechanical device for dividing a circle accurately into
equal parts. This is called indexing.

Simple indexing: Here the workpiece is positioned by utilizing the step-index plate and the index crank.
The standard size index plate is provided with a number of circles having following number of holes:
24, 25, 28, 30, 34, 37, 39, 41, 42, 43, 45, 47, 49, 50, 53, 54, 57, 58, 59, 62 & 65.

The number of turns of the crank of a dividing head required to index the work one division is equal
to the ratio of the dividing head (40 for example) divided by the number of equally spaced divisions
required for one full turn of the workpiece. If now gear has 36 teeth, the indexing will be as follows:

40/36 = 1+4/36 = 1+6/54

Assignment:
i. What are the various types of gears and their functions?
ii. Name the different types of milling cutters and write short notes about their cutting
applications.
iii. What is plain indexing and how is it used?
iv. What is the difference between a plain milling machine & a universal knee & column
milling machine? Write down their uses, advantages, and disadvantages.
v. Draw a spur gear with an involute tooth profile and show various parameters of a gear tooth
(assume the gear parameters for drawing the spur gear).
vi. What is the difference between gear & pinion? Why do the gear and pinion is designed
together?

16
 EXPERIMENT NO: 4
STUDY OF SHAPER MACHINE

Student No.: Name: Group:

Date of performance: Date of submission:

Objective of the experiment:

Function of the machine:

Assignments (Consider the shaper machine shown in the laboratory to complete the assignments):

1. What are the main specifications of the shaper machine?

A. Maximum ram stroke: _____________
B. Work table surface:
Width: ____________
Length: ___________
C. Number of ram double strokes per min.: ____________
D. Main drive motor power: ______________ Kw

2. Define different components & briefly discuss their function and show the direction of feed and motion of them in
the following figure:

17
3. Briefly discuss the Bull gear mechanism with neat sketch.

4. Briefly discuss the shaper machine operation with neat sketch

18
5. What is the function of clapper box?

6. What is the strain back effect?

7. How can you adjust the stroke length of the ram?

19
8. What are the differences between Shaper and Planer machine?

(Signature of the Teacher)

20
 EXPERIMENT NO: 5
STUDY THE ENGINE LATHES AND KINEMATIC DIAGRAM OF AN ENGINE
LATHE
Student No.: Name: Group:

Date of performance: Date of submission:

OBJECTIVE OF THE EXPERIMENT:

Label the engine lathe units from the following figure

Construction arrangement and principle units of engine lathes:

All engine lathes have practically the same arrangement of the principle units. In a typical engine lathe, the principle
units are:

FUNCTION

1. Headstock:

21
2. Tailstock:

3. Spindle:

4. Slide ways:

5. Saddle:

6. Tool post:

7. Compound rest:

8. Power feed clutch:

9. Feed rod:

10. Bed:

11. Lead screw:

12. Break clutch control:

13. Half nut:

14. Apron:

15. Rack:

16. Motor drive:

22
 17. Gear box:

Lathe Accessories:

FUNCTION

1. Lathe centers:

2. Lathe dogs:

3. Tool holder:

4. Cutting tools:

5. Steady rest:

6. Follower rest:

7. Knurling tools:

8. Chucks:

9. Face plates:

10. Mandrels:

11. Taper attachment:

Modern lathe operation:

All lathes have same basic basis design. Their components serve one of three primary functions:
a) Driving the lathe-line of power
b) Holding and rotating work
c) Holding and moving tool

23
ASSIGNMENT: Draw the Block diagram of these primary functional divisions and their parts and purpose.

Please attach a new sheet for these diagrams.

Procedure for Taper turning:

1. Turning a taper by setting over the Tailstock
2. Turning a taper by taper turning attachment
3. Turning a taper by two feed method
4. Turning a taper by swiveling the swivel plate with the top slide

SPECIFICATIONS OF ENGINE LATHE:

MOTOR:
Type: _________________________________

Power: ________________________________

Speed: _________________________________

Voltage: ________________________________

Belt and Pulley type: ______________________

CHUCK CAPACITY:
Maximum dia: ___________________________
Minimum dia: ___________________________

Maximum job length: _____________________

SPINDLE SPEEDS:
Short gear train:
Long gear train:
ASSIGNMENT: Draw the setup for taper turning attachment using the above method.
Please attach a new sheet for these diagrams.

ASSIGNMENT:
1. How to center work in a four-jaw independent chuck?
2. Give motor specification.
3. Give belt specification.
4. Discuss about feeds in engine lathe.
5. Discuss about speeds in engine lathe.

24
References:
1. Machine tools technology by Repp/McCarthy
2. Machine tool by Chernov
3. Machine tool by Acherkan

Draw the kinematic diagram of Engine Lathe for:

a) short gear train and long gear train,
b) feed motion to feed rod (forward motion) and feed motion to lead screw,
c) Feed motion to feed rod and feed motion to lead screw (reverse motion).

(Signature of the teacher)

25
 EXPERIMENT NO: 6
STUDY OF MILLING MACHINE AND DIVIDING HEAD
Student No.: Name: Group:

Date of performance: Date of submission:

Assignments (Consider the milling machine and indexing head shown in the laboratory to complete the assignments):

1. Draw schematic diagram of the milling machine and level the following parts:

a) Column

26
 b) Table
c) Knee
d) Cross slide or saddle
e) Swivel plate
f) Main motor
g) Spindle
h) Over arm
i) Speed gearbox
j) Feed gearbox etc.

2. What are the main specifications of the milling machine?

A. Dimensions of the table working surface,(mm/inch)
Width: _________
Length: _________
B. Maximum table travel,(mm/inch)
Longitudinal: _________
Cross: _________
Vertical: _________
C. Maximum angle of table swivel: ___________________
D. Number of spindle speeds: ___________________
E. Number of spindle speeds, rpm: ___________________
F. Number of table feeds: ___________________
G. Feeds, mm/min
Longitudinal: _____________
Cross: _____________
Vertical: _____________
H. Power, KW: _____________

3. Identify different guide ways and their locations in the milling machine.

Name Location
1.

2.

27
3.

4.

5.

4. Show calculation for indexing _______ number of teeth.

Helical gear with the helix angle of _____.
i. Number of the rotation of the crank handle_____________________
ii. Number of the hole in the selected circle of the index plate________
iii. Number of holes required to complete indexing _________________
iv. Number of teeth of the change gears a)____b)_____ c)_____d)_____

5. Draw and name the types of milling operations and milling cutter used on vertical milling machine. When
a machine tool is called “Universal”?
6. What is indexing? What are the types of the setups of universal dividing heads? Describe them with
necessary sketches.

References:
“”Machine Tools” by N. Chernov

(Signature of the Teacher)

28
 EXPERIMENT NO: 7
STUDY AND OPERATION OF CNC MILLING MACHINE

Student No.: Name: Group:

Date of performance: Date of submission:

1. What is G code and M code in CNC machine?

2. Discuss the Function “G” and “M” codes in the figure.

G00 –
G01 –
G02 –
G03 –
G04 –
G28 –
G43 –
G49 –
G53 –
G54 –
G73 –
G74 –
G80 –
G81 –
G82 –
G83 –
G84 –

29
 G85 –
G86 –
G87 –
G90 –
G91 –
G99 –
M00 –
M01 –
M03 –
M04 –
M05 –
M06 –
M08 –
M09 –
M30 –
M97 –
M98 –
M99 –
3. Discuss the Program Structure shown in the figure.
% t
O00023 t
Mill Part Program Example t
N1 t
T1 M06 t
G90 G54 G00 X-1.5 Y1.5 S1400 M03 t
G43 H01 Z1 M08 t
G73 G99 Z0.625 Q0.2 R0.1 F5 t
Y-1.5 t

30
 X1.5 t
Y1.5 t
G80 G00 Z1 M09 t
G28 G91 Z0 M05 t

4. Discuss the Alphabetical address codes.

D t
E t
F t
G t
H t
M t
N t
O t
P t
S t
T t
X t
Y t
Z t

(Signature of the Teacher)

31
 EXPERIMENT NO: 8

NAME OF THE EXPERIMENT: STUDY OF PLASTIC INJECTION MOULDING MACHINE.

OBJECTIVES:
The plastic material is heated above its melting point, resulting in the conversion of the solid
polymer to a molten fluid with a reasonably low viscosity. It is then forced into a closed mould that
defines the shape of the article to be produced. and know it’s the Hydraulic system, cooling system,
and another operation.

THEORY:
There are 5 types of plastic moulding that is considered to be the most effective and most popular.
These 5 types are extrusion moulding, compression moulding, blow moulding, injection
moulding and rotational moulding. Injection moulding becomes an easily-repeatable process
consisting of six discrete steps:
Clamping. The first step of the injection molding process is clamping. ...
Injection. ...
Dwelling. ...
Cooling. ...
Mold opening. ...
Ejection.

APPPARATUS:
Plastic injection moulding machine Model YS-2280V6

PROCEDURE:
Running of Pump Motor
Set the machine to manual mode
Set all other selector switches to the neutral position.
Confirm that emergency stop button is unlocked.
Set the pump motor power switch (circuit breaker) to on position.
Start the pump, and then stop it.

Mold Clamp
Close the safety gates. Set the machine to Manual Mode. Press down the MOLD CLAMP button or
set the MOLD selector switch to CLOSE position. Mold Clamp starts.

Mold Open
Set the machine to manual mode. Press down the MOLD OPEN button, or set the MOULD selector
switch to OPEN position. Mold Open starts.
Manual Operation
After adjustment and confirmation of the respective movements of the injection molding machine by
manual operation have been completed, confirm the series of movements by manual operation again.

32
Step 1: Set the OPERATION selector switch to the MANUAL position, and the MOLD, NOZZLE
and SCREW selector switches to the NEUTRAL position. Or press down the MANUAL
push button.
Step 2: With the safety gate closed, set the MOLD selector switch to the CLOSE position, and close
the mold. Or press down the “MOLD MOVEMENT/CLOSE” push button to close the mold.
Step 3: Set the NOZZLE selector switch to the ADVANCE position, and allow the nozzle to touch.
Or press down the “INJECT UNIT/ADV” push button to allow the nozzle to touch.
Step 4: Set the SCREW selector switch to the INJ position and perform injection movement. Or
press down the “SCREW /INJECT” push button to perform injection.
Step 5: Set the SCREW selector switch to the NEUTRAL position.
Step 6: Set the SCREW selector witch to the CHARGE position and perform instantaneous rotation.
Or press down the “SCREW /CHARGE “push button to perform instantaneous rotation.
These steps complete the confirmation by manual operation.
Step 7: Set the SCREW selector switch to the NEUTRAL position.
Step 8: Set the NOAALE selector switch to the RETRACT position. Or press down the “INJECT
UNIT/RET” push button to move the inject unit to the end limit.
Step 9: Set the NOZZLE selector switch to the NEUTRAL position.
Step 10: Set the MOLD selector switch to the OPEN position. Or press down the “MOLD
MOVEMENT/OPEN” push button to open the mold.
Step 11: Set the HYD EJECT selector switch to the EJECT position, then set it to the NEUTRAL
position. Or press down the HYD.EJECT/ADV” push button.
Step 12: Open the safety gate.

Experimental Findings:
Specification
Parameters of YS-2280V6

Item Unit Model YS-2280V6

Injection Unit
Screw type A B C
Screw diameter mm 42 45 50
Screw L/D ratio L/D 23.8 22.2 20
Theoretical shot volume cm3 387 445 549

33
Shot weight (PS) g 352 404 500
Injection pressure Mpa 225 196 159
Screw rotation speed r.p.m 5-200
Clamping Unit
Clamping force KN 2280
Opening stroke mm 480
Mould thickness mm 200-565
Space between tie-bars (H*V) mm 520*500
Mold register hole force mm φ160
Ejector force KN 60
Ejector stroke mm 150
Ejector quantity pcs 5
Others
Motor power KW 19
Heater capacity KW 12.6
Machine dimensions(L*W*H) m 5.58*1.34*2.08
Machine weight t 6.4
Oil tank capacity L 400

34
35
36
Discussion:
1.
2.

37
 EXPERIMENT NO: 9

NAME OF THE EXPERIMENT: STUDY of Electrical Discharge Machining (EDM)

OBJECTIVES: Determine the material removal rate (MRR) and tool wear rate (TWR) in electro
discharge machining of mild steel using copper electrode

THEORY:
A) Introduction to EDM machining:
Electro Discharge Machine is a process of repetitive sparking cycle. A series of electrical pulses
generated by the pulse generator unit is applied between the work piece and the tool electrode. In the
event of spark discharge, there is a flow of current across the tool electrode-work piece gap. Energy
content in a tiny spark discharge removes a fraction of work piece material, leaving behind a small
crater on the work piece surface. Material removal is assisted with the spark discharge plasma
temperature ranging is excess of few thousands of degrees of centigrade. Better work piece material
removal and low tool electrode wear can be achieved by using appropriate machining conditions,
e.g., by increasing the spark energy one can achieve an increase in material removal rate but not so
good surface finishing. By lowering spark energy (lower IP and lower Ton values) one can obtain
better surface finish. Best surface finish, however can be achieved at cost of machining time. This
because of lower material removal rate achieved with lower spark energy setting. To achieve
optimum result of material removal rate, over cut or surface finish, the machining parameter should
be properly set.

B) Construction and machining parameters:

Construction:
EDM is comprised a machine tool, a power supply unit and a dielectric supply unit. It comprises of a
base, column, work table and work head. Work table is mounted inside a work table. Workpiece is
mounted and clamped on the work table (with or without a flushing pot). An electrode is mounted on
the platen using an axis controller. Work tank is filled with dielectric. As the machining proceeds the
Z quill comes down till the pre-set distance is reached.

38
APPPARATUS:
EDM machine

Machine parameters:
IP: Machining peak current.
IB: By pulse current.
Ton: Pulse on time or period.
Toff: Pulse off period.
t (τ): Pulse duty factor (work time).
Vg: Upper gap voltage.
SEN: Sensitivity of z-axis speed.
ASEN: Anti arc sensitivity.
Rd: Retract distance.

C Measurements:
Material removal rate (g/s):
MRR (g/s) = (Weight of workpiece before machining−Weight of work piece after machining) / Machining time
Tool (electrode) wear rate (g/s):
TWR (g/s) = (Weight of electrode before machining−Weight of electrode after machining) / Machining time

39
Experimentation procedure:
1. Stabilizer MCB ON with stabilizer green button ON.
2. Release emergency button (rotate clock wise) and hold power switch once again.
3. After main display visible, press auto position on remote.
4. After the auto position go to job set (press F9). F2-X, F3-Y, F4-Z
5. Before spark all axis be in zero set. After that (ESC Red color) press ←←←
6. Go to Z position, give the depth in minus (-) and set the different parameter.
7. Start pump for dielectric supply (press pump symbol on remote).
8. Adjust the flushing pressure according to requirement.
9. After fill of dielectric press spark symbol on remote.

40
 Experiment: 10
Manufacturing of an Industrial Part by Using Lathe & Shaper Machine.

Objectives:
To introduce with lathe machine and shaper machine
To operate lathe and Shaper Machine to produce an assigned job

Theory of Lathe Machine:

In a lathe machine, the material is removed from a workpiece by rotating it when a cutting tool is
moved longitudinally with a depth of cut. Lathe machines are widely used to work on cylindrical
workpieces. Various lathe operations are turning (straight & taper), facing, threading, chamfering,
parting, boring, drilling, knurling, etc.

Figure 1: Engine lathe with principle parts named

The principal movement of the lathe is the rotation of the spindle. The feed is given by the
longitudinal travel of carriage and cross traverse of the cross slide. The auxiliary movement is the rapid
traverse of carriage & cross slide. Various operations can be done using a lathe. Among them turning,

41
facing, boring, parting, drilling, reaming, knurling, etc are notable. Turning is the process of machining
external cylinders and conical surfaces. It is usually performed on a lathe. Relatively simple work and
tool movements are involved in turning a cylindrical surface. The workpiece is a rotated longitudinally
fed, single-point cutting tool. If the tool is fed at an angle to the axis of rotation, an external conical

surface is resulted, which is called “taper turning”. If the tool is fed at 900 to the axis of rotation, using
a tool that is wider than the width of the cut, the operation is called “facing”. Boring is internal turning.
Boring can use single-point cutting tools to produce internal cylinder or conical surfaces. It does not
create the hole but rather machines or opens the hole up to a specific size. Parting is the operation by
which one section of a workpiece is severed from the remainder using a cutoff tool. Because parting
tools are quite thin and must have a considerable overhang, this process is more difficult to perform
accurately.

Principle units of the lathe:

All engine lathes have practically the same arrangement of the principal units. In a typical engine lathe
the principle units are:
Bed Motor drive Feed gearbox
Head Stock Tailstock Spindle
Slide Ways Lead screw Feed rod
Saddle Carriage Cross slide
Swivel Plate Compound rest Top slide
Tool Post Half nut
Lathe accessories:
Lathe centers Lathe dogs Chuck
Steady rest Follower rest Faceplate
Mandrels Tool holders Taper attachments

Dimensions of a Lathe machine:

The size of a lathe is designated by two dimensions. The first is known as swing. This is the maximum
diameter of work that can be rotated on a lathe. The second size dimension is the maximum distance
between centers. This indicates the maximum length of the workpiece that can be mounted between
centers.

Assignments:

1. Write down the functions of bed, headstock, tailstock, cross slide, swivel plate, compound
rest, top slide, and tool post.
2. In which cases rest is used? What is the difference between steady rest & follower rest?

42
 3. What is the difference between a dead center & a live center?
4. What is the purpose of setting up work on a faceplate?
5. Discus about types of taper turning processes.

Theory of Shaper machine:

The process of shaping is among the oldest single-point machining processes that use a
straight-line cutting motion with a single-point cutting tool to generate a flat surface. In shaping, the
workpiece is fed at right angles to the cutting motion between successive strokes of the tool. The
cutting tool reciprocates over the workpiece to remove metal by digging deep into it. The workpiece
remains rigidly clamped on the table. Cutting motion takes place only in the forward stroke. The tool
is held in the clapper box which prevents the cutting edge from being damaged on the return stroke of
the tool.

The shaping machine is a versatile machine able to produce flat surfaces, grooves, T-Slots,
dovetails, and may be used to produce curved surfaces. The size of components that may be machined
is normally limited by the length of the stroke of the shaping machine which can vary up to a maximum
of about 1500mm. The shaping machine is not generally used as a production tool because of its slow
cutting speed and the unproductive return stroke.

Figure 2: Bull gear mechanism

43
The height of the table can be adjusted to suit the work piece, and the table can traverse sideways. The
ram slides back and forth above the work. At the front end of the ram, there is a vertical tool-slide that
may be adjusted to either side of the vertical plane. This tool-slide holds the clapper box and tool post
from where the tool can be positioned to cut the straight, flat surface on the top of the workpiece.

The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster on the return
(non-cutting) stroke than on the forward, cutting stroke. This action is via a slotted link and bull gear
mechanism.

Figure 3: Different parts of shaper machine.

Assignments:
1. What is a clapper box? Why it is used?
2. What is a bull gear mechanism? Why it is used?
3. What are the differences between shaper and planner machines? State one’s advantage and
disadvantages over another.
4. Name the various operations used in the experiment sequentially.

44