Experiment No : 3 Job making on lathe machine.

(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 100 mm length.

TOOLS AND EQUIPMENT USED

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

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.

Taper angle (α) = Tan‾ (D – d)

2L
Where,
D = Diameter of bigger end, mm
d = Diameter of smaller end, mm
L = Length of taper, mm

SKECTH : Drawing that you have made on workshop book. This is

sample only not to draw.
Observation Table
Length Width Diameter
Raw Material Dimensions
Finished Product Dimensions

RESULT: Thus, the work piece for the required dimensions is obtained by performing step
turning and taper turning in a lathe machine.
Experiment No : 4.1 Job making on Shaper Machine.
(CONVERSION OF CIRCULAR ROD INTO SQUARE ROD)
AIM
To perform shaping operation of given mild steel rod.

MATERIAL REQUIRED
A Mild steel rod of 25 mm diameter and 100 mm length.

MACHINNE REQUIRED
Shaper machine

CUTTING TOOLS
H.S.S.Tool bit of the required slot size.

SEQUENCE OF OPERATIONS
1 .Fix the specimen in the machine vice
2 .By giving the required feed and depth of cut, the required cut is being made progressively.

PROCEDURE
 Dimension of the work piece is measured and made to the required dimensions.
 Fix the job in vice and adjust the tool in the tool head.
 Start the machine during forward stroke only remove the material and during the
return stroke is idle.
 Do the operation to get one side completely flat then repeat the process on four sides
of the work piece.
 Rotate the job after completion of each side is flat.
 Then check the flatness by using slip gauges. To get the required component.

PRECAUTION:

 Choose proper feed and depth of cut.

 Feed should be controlle4d to avoid to any damage to the cutting tool.
 Fix the work piece is properly into the vice.
 During cutting to supply coolant in between to the work piece and tool.
 Adjust the stroke length properly.
SKETCH :
 All dimensions are in mm.

Observation Table
Length Width Diameter
Raw Material Dimensions
Finished Product Dimensions

RESULT : Thus, the work piece for the required dimensions is obtained by performing shaping
operation on a shaper machine.
Experiment No : 4.2 Job making on Slotting Machine.
(SLOT MAKING)
AIM

To make a slot on the given work piece.

MATERIALS REQUIRED
M.S Round Block, Wooden Block

MACHINE REQUIRED
Slotting machine

MEASURING INSTRUMENTS
Vernier calipers slip gauges.

CUTTING TOOLS
H.S.S.Tool bit of the required slot size.

SEQUENCE OF OPERATIONS
 Fix the specimen in the three-jaw chuck of the slotting machine
 By giving the required feed and depth of cut, the required slot is being made
progressively

PROCEDURE

 Fix the work piece in the head stock chuck firmly

 Turning tool is fixed in the tool post and centering is to be done
 Turn the job to get a diameter of required length
 Facing is to be done on one side of the job
 Drill bit of 8 mm diameter is fixed on tail stock and centering of workPiece is to be done
by feeding through tail stock.
 Drill bit of 25 mm diameter is fixed in tail stock
 Drill through a hole of 25 mm diameter in the work piece feeding the tailstock.
 Boring tool is the fixed on tail stock to perform boring operation to get a hole of required
diameter
 Fit the job in reverse position in the chuck
 Facing of other side of the work piece is to be done to get the required length of the job
 Drilled work piece is fixed on slotting machine.
 A slot of required depth is made
 Slowly cross and longitudinal feed is given to obtain slots as per requirement.
PRECAUTIONS

 Choose proper feed and depth of cut.

 Feed should be controlled to avoid any damage to the cutting tool
 Lock the index table before starting the operation.
 Care has to be taken so as to maintain the right feed of the material.
 Work-wheel interface zone is to be flooded with coolant.

SKECTH :
Observation Table
Length Width Diameter
Raw Material Dimensions
Finished Product Dimensions

RESULT : Thus, the work piece for the required dimensions is obtained by performing slotting
operation on a slotting machine.
Experiment No : 5 Job making on Milling Machine.
(SPUR GEAR CUTTING)
AIM
To perform plane milling operation on the given specimen (mild steel)

MATERIALS REQUIRED
Mild steel specimen.

MACHINE REQUIRED
Milling machine

MEASURING INSTRUMENTS
Vernier calipers

CUTTING TOOLS
Plane (face) milling cutter

MARKING TOOLS
 Steel rule, scriber
 Work holding fixtures: work piece supporting fixtures
 Miscellaneous tools: Hammer, brush, Allen keys

SEQUENCE OF OPERATIONS

 Measuring of specimen
 Fixing of specimen in the milling m/c.
 Giving the correct depth and automatic feed cut the specimen
 Check the specimen with Vernier caliper at the end.

PROCEDURE

 Select and cut a piece of stock to make the blank. Allow at least 1/8 inch excess material
on the diameter and thickness of the blank for cleanup cuts.
 Mount the stock in a chuck on a lathe. At the center of the blank, face an area slightly
larger the than the diameter of the required bore.
 Drill and bore to the required size (within tolerance). Remove the blank from the lathe
and press it on a mandrel.
 Set up the mandrel on the milling machine between the centers of the index head and the
footstock. Dial in within tolerance.
 Select a involute gear cutter and mount and center it. Set the index head to index 24
divisions. Start the milling machine spindle and move the table up until the cutter just
touches the gear blank.
 Set the micrometer collar on the vertical feed handwheel to zero, then hand feed the table
up toward the cutter slightly less than the whole depth of the tooth. Cut one tooth groove.
  Then index the work piece for one division and take another cut. Check the tooth
dimensions with a vernier gear tooth caliper as described previously.
 Make the required adjustments to provide an accurately “sized” tooth. Continue indexing
and cutting until the teeth are cut around the circumference of the work piece.
 The top surface of the job is milled in stages; giving finish cuts towards the end such that,
the height of the job is exactly 40 mm.
 The burrs if any along the edges are removed with the help of the flat file.

MODEL CALCULATIONS

Indexing Ratio = n / N
Where, n = No. of slots on the periphery of the indexing plate.
N = Required number of divisions

Direct Indexing
Indexing Ratio = 24 / N
Where N= required number of divisions

Simple Indexing
Number of holes to move = 40 / N
Where N= required number of divisions

Standard Brown and Sharp Index Plates

No.1: 15, 16, 17, 18, 19, 20
No.2: 21, 23, 27, 31, 33
No.3: 37, 39, 41, 43, 47, 49
Example: It is required to divide the periphery of a job into 60 divisions. Crank Movement
(Indexing Ratio) according to simple Indexing = 40/60 = 2/3
2 / 3 = 2 /3 * 6 / 6 = 12 / 18

The crank has to move 12 holes on 18 holes circle.

PRECAUTIONS

 The milling machine must be stopped before setting up or removing a work piece, cutter
or other accessory
 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.
 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.
 The work piece and cutter should be kept as cool as possible (i.e. coolant should be used
where necessary to minimize heat absorption).
  The table surface should be protected with a wiping cloth.
 Tool must be mounted as close to the machine spindle as possible.

SKETCH:

RESULT : Thus, the work piece for the required dimensions is obtained by performing plain
milling operation on a milling machine.
Experiment No : 6 Job making on Drilling Machine
(DRILLING AND TAPPINNIG)
AIM
To perform drilling, boring, reaming and tapping operations on the given M.S Flat work piece.

APPARATUS
1. Drilling Machine with standard accessories – Steel Rule, Flat file (Smooth and Rough),
Drill bit ( 8mm, 10mm, 10.5mm), Reaming tool, Try Square
2. Work piece

MATERIAL
Mild Steel flat plate 50 mm × 50 mm ×10 mm

PROCEDURE
 The given work piece is first filed to get required length, breadth and thickness wet chalk
is applied on four sides and with the scriber lines are drawn to get center hole at required
location.
 The centers are punched with a Punch and hammer.
 The work piece is fixed firmly in the vice of the Drilling Machine
 3/8” drill bit is fixed firmly in the chuck and drilling is performed giving uniform depths.
 Boring was done one 10 mm hole using boring tool.
 The drill bit is removed from the drill chuck and is replaced by a reamer.
 The reaming operation is performed on the hole which has been previously drilled.
 The work is removed from the vice for performing tapping operation.
 The job is fixed firmly in a bench vice.
 Tap is fixed in the tap handle and pressure applied on the taps to obtain internal thread.

PRECAUTIONS
 Reaper should be free from moisture
 Marking is done without parallax error
 Care should be taken while cutting and drilling.
 While performing drilling and tapping operations lubricant should be used to minimize
the friction.
SKETCH :

Before Machining

After Machining
All dimensions are in mm.
Observation Table
Length Width Diameter
Raw Material Dimensions
Finished Product Dimensions

RESULT : Thus, the work piece for the required dimensions is obtained by performing drilling,
boring, reaming and tapping in a drilling machine.
Experiment No : 7 Job making on Grinding Machine
(PRECISION SURFACE GRINDING)
AIM: To perform surface grinding operation on the given (50*50*20) work piece.

MATERIALS REQUIRED: mild steel specimen.

MACHINE REQUIRED: surface grinding machine

MEASURING INSTRUMENTS:
 Vernier calipers,
 Micrometer.

CUTTING TOOLS: Diamond point dressing block

WORK HOLDING FIXTURES: Magnetic chuck

Experimental Diagram Surface Grinding:

All Dimensions are In mm

MISCELLANEOUS TOOLS:
 Wire brush (for cleaning the formed chips),
 Lubricant (coolant),
PROCEDURE:

 Work piece is mounted on magnetic table, so that the line along face of grinding wheel
coincides with the edge of work piece.
 Depth of cut is given to work piece by down feed hang wheel.
 The work piece is reciprocates under wheel and the table feeds axially between passes to
produce flat surface and to get required size of work piece.

PRECAUTIONS:

1. Coolant usage is compulsory as the speeds employed are very high and continuous
application of coolant is necessary for ductile materials like-steel etc.
2. The grinding tools are first dressed properly.
3. Care has to be taken so as to maintain the right feed of the material.
4. Work-wheel interface zone is to be flooded with coolant
5. Dressing of grinding wheel to be done before commencement of cutting action, intermittent
dressing also to be done if wheel is loaded.

RESULT: Thus, the work piece for the required dimensions is obtained by performing grinding
operation in a grinding machine.
Experiment No : 8 Alignment Test on a Lathe Machine
Aim: - To study the principle of Machine tool Alignment Test.

Prior requisition: Required detail study of straightness and flatness measuring instruments.
Apparatus: - Mechanical comparator (dial gauges), Magnetic stand, Lathe Machine., tests
mandrels, straight edges and squares, spirit levels, etc.

Introduction: - The dimensions of a gauge, its surface finish and geometry are dependent upon
the inherent quality and accuracy of the machine tool for its manufacture. Also in mass
production the various components produced must be of such accuracy that they may be
assembled on a non-selective basis. The accurate production of the component parts depends
upon the accuracy of the machine tools. The continuously increasing demand for highly accurate
machined components has led to considerable research towards means by which the geometric
accuracy of machines may be improved and maintained. It is very important, therefore, that
under static conditions, the alignment accuracy of the machine tools is checked by some
geometric tests. The tests which check the alignment accuracy of the various parts of a machine
tool are called static rests. A machine tool, at the same time must be able to display the desired
behavior and characteristics under normal operating conditions as operator is concerned with the
actual working of machine tool. Therefore, some alignment tests are performed under dynamic
loading conditions and these are referred to as dynamic tests. Thus it is obvious that the
satisfactory working of a machine under static loading only is not sufficient but account should
be taken of the vibration and deflection of various machine parts under actual dynamic loading
also. In dynamic tests, the various members are actually loaded and alignment tests are carried
out. Also various parts are excited at working frequency and behavior of machine observed. In
other words it could be said that machine tools for the workshop must be able to produce work-
pieces of given accuracy within prescribed limits consistently and without requiring artistic skill
on the part of the operator and that the quality of work pieces depends upon :

(i) Stiffness and rigidity of the machine tool and its components parts.
(ii) The alignment of various machine parts in relation to one another. This is very
important because the geometry of various shapes is based on the relative motion
between various machine parts and hence on alignment of various parts.
(iii) The quality and accuracy of the control devices and the driving mechanism. Stiffness
and rigidity are a matter for designer and once tests on a prototype of a certain design
have given satisfactory results, there is no need to test the machine of same design
over and over again. The accuracy of manufacture, the precision of controldevices
and driving mechanisms such as lead screw of lathe, all should have relative
alignment as accurate as possible.

Importance of Machine Tool Metrology :

 a) The alignment test on a machine tool is carried out to check the grade of manufacturing
accuracy of the machine tool.

b) The geometrical checks made on machine tools are: Straightness and flatness of guide ways
and slide ways of machine tool, Flatness of machine tables, Parallelism, equidistance and
alignment of the slide ways, True running and alignment of shaft and spindle, Lead of lead screw
or error in pitch.

c) The geometrical test is carried out to check the grade of manufacturing accuracy of the
machine tool.

d) Practical test is carried out to check the accuracy of the finished component.

e) Geometrical test consists of checking the relationship between various machine elements
when the machine tool is idle.

f) Practical test consists of preparing the actual test jobs on the machine and checking the
accuracy of the jobs produced.

g) Importance of alignment test are the geometry of various shapes is based on the relative
motion between various machine parts and hence on alignment of various parts.

h) Other parameters subjected to tests are Stiffness and rigidity of the machine tool and its
components parts, the quality and accuracy of the control devices and the driving mechanism.

Machine Tools Tests

In most cases the production or machining of a given geometric surface is achieved

through a combination of work-tool movements. In other words, the machined surface is
generated, and the accuracy of the surface depends on the accuracy of the mating elements
present in the machine tool. The various tests applied to any machine tool could be grouped as
below –

(a) Tests for the level of installation of machine in horizontal and vertical planes.

(b) Tests for flatness of machine bed and for straightness and parallelism of bed ways or

bearing surfaces.

(c) Tests for perpendicularly of guide ways to other guide ways or bearing surfaces.

(d) Tests for the true running of the main spindle and its axial movements.

(e) Tests for parallelism of spindle axis to guide ways or bearing surfaces.

(f) Tests for the line of movement of various members e.g., saddle and table cross-slides
 etc., along their ways.

(g) Practical tests in which some test pieces are machined and their accuracy and finish is

checked.

Alignment Test on Lathe Machine

1. Leveling of the machine :

Before the various tests on any machine tool are carried out, it is very essential that it should
be installed in truly horizontal and vertical planes. In horizontal plane, both longitudinal and
transverse directions are equally important. If, say, any long lathe bed is not installed truly
horizontal the bed will undergo a deflection, thereby producing a simple bend and undesirable
stresses will be introduced. If the bed is not installed truly horizontal in transverse direction,
twist will be introduced. Thus the movement of the saddal can’t be in a straight line and true
geometric cylinder can’t be generated. The level of the machine bed in longitudinal and
transverse directions is generally tested by a sensitive spirit level. The saddle is kept
approximately in the centre of the bed support feet. The spirit level is then placed at a-a the
ensure the level in the longitudinal direction. It is then traversed along the length of bed and
readings at various places noted down. For test in transverse direction the level is placed on a
bridge piece to span the front and rear guide ways and then reading is noted. It is preferable to
take two readings in longitudinal and transverse directions simultaneously so that the effect of
adjustments in one direction may also be observed in the other. The readings in transverse
direction reveal any twist or wind in the bed. It may be noted that the two guide ways may be
perfectly leveled in longitudinal direction, but might not be parallel to each other. Transverse
level may be in any direction, but no twist can be tolerated.
2. True Running of main spindle.

Locating cylinder is provided to locate the chuck or face plate. However locating surface
can’t be threaded one as threads get worn out soon and thus introducing play in face plate or
chuck. Thus locating surface is cylindrical and this must run truly; for only then the face plate
etc., can run truly. The dial indicator is fixed to the carriage and the feeler of the indicator
touches the locating surface. The surface is then rotated on its axis and indictor should not show
any movement of needle.
3. True Running of Headstock Centre.

Headstock centre is live centre and the work piece has to rotate with this centre. If it is
not true with the axis of movement of the spindle, eccentricity will be caused while turning a
work, as the job axis would not coincide with the axis of rotation of main spindle. For testing this
error, the feeler of the dial indicator is pressed perpendicular to the taper surface of the centre
and the spindle is rotated. The deviation indicated by the dial gauge gives the trueness of the
centre.

4. Parallelism of the Main Spindle to Saddle Movement.

This has to be checked in both vertical and horizontal planes. In this we require the use of
mandrel. An important precaution in the use of mandrels and dial indicator is mentioned here.
The mandrel must be so proportioned that its overhang does not produce appreciable sag, or else
the sag must be calculated and accounted for. The rigidity indicator set up is also very important
and must be carefully watched. If axis of the spindle is not parallel to bed in horizontal direction,
a tapered surface is produced. Any deviation from parallelism of spindle axis from bed in vertical
axis will produce a hyperboloid surface. For this test, a mandrel is fitted in the taper socket of the
spindle. Mandrel has a concentric taper shank which is close fit to the spindle nose taper. The
feeler of the dial indicator is pressed on the mandrel and the carriage is moved. The indication in
horizontal plane is given by dial and in vertical plane by dial in vertical plane the mandrel should
be rising towards the free end in order to counteract the weight of mandrel and job. But for
counter-acting cutting forces, it should be lower towards free end. In horizontal plane, mandrel
should be inclined in a direction opposite to the direction of tool pressure.

5. True running of taper socket in main spindle.

If the axis of tapered hole of the socket is not concentric with the main spindle axis,
eccentric and tapered jobs will be produced. To test it, a mandrel is fitted into the tapered hole
and readings at two extremes of the mandrel are taken by means of a dial indicator as shown in
Fig.
6. Parallelism of tailstock guide ways with the movement of carriage.

Sometimes the job is held between head-stock and tail stock centre for turning. In that
case the job axis must coincide with the tailstock centre. If the tailstock guide ways are not
parallel with the carriage movement there will be some offset of the tailstock centre and this
results in taper turning. To check the parallelism of tailstock midways in both the planes i.e.,
horizontal and vertical, a block is placed on the guide ways as shown in Fig. 16.7 and the feeler
of the indicator is touched on the horizontal and vertical surfaces of the block. The dial indicator
is held in the carriage and carriage is moved. Any error is indicted by the pointer of dial
indicator.
7. Alignment of both the centers in vertical plane.

Besides testing the parallelism of the axes individually (main spindle axis and tailstock
axis) it is-necessary to check the relative position of the axes also. Boththe axes may be parallel
to carriage movement but they may not be coinciding. So when a job is fitted between the
centres, the axis of the job will not be parallel to the carriage movement. This test is to be carried
out in vertical plane only. A mandrel is fitted between the two centres and dial gauge on the
carriage. The feeler of the dial gauge is pressed against the mandrel in vertical plane as shown in
Fig. and the carriage is moved and the error noted down.

Observation Table :

Sr. Objective of Test Reading of dial Permissible error Remarks

No. gauge in mm
1 Test for leveling of lathe bed.
2 Parallelism of tailstock moment 0.02 to 0.04
to carriage movement.
3 Parallelism of spindle axis to the 0.05 to 0.02
bed
4 Difference in height between 0.03
tailstock and head stock
movement
5 Parallelism of longitudinal 0.05 to 0.02
movement of tool slide to
spindle axis
6 True running of spindle 0.02 to 0.04
7 Squareness of the cross slide to 0.02 to 0.04
spindle axis
Result & Conclusion:- In this experiment we done the machine tool alignment of lathe m/c and
there is no error found in any parameters.