Machine Tools Lab
RAMACHANDRA COLLEGE OF ENGINEERING::VATLURU (V)
ELURU – 534 007
III B.TECH – I SEMESTER
MECHANICAL ENGINEERING
MACHINE TOOLS LAB MANUAL
2015-16
DEPARTMENT OF MECHANICAL ENGINEERING
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Machine Tools Lab
INDEX
S.No. LIST OF EXPERIMENTS Page No.
INTRODUCTION OF GENERAL PURPOSE MACHINES-LATHE,
DRILLING MACHINE, MILLING MACHINE, SHAPER,
1 04
PLANNING MACHINE, SLOTTING MACHINE, SURFACE
GRINDER ETC.
2 STEP TURNING AND TAPER TURNING ON LATHE MACHINE 10
3 THREAD CUTTING AND KNURLING ON LATHE MACHINE 13
4 DRILLING AND TAPPING 16
5 SHAPING AND PLANNIN G 18
6 SLOTTING 20
7 MILLING 22
8 CYLINDRICAL SURFACE GRINDING 24
9 GRINDING OF TOOL ANGLES 26
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1. INTRODUCTION OF GENERAL PURPOSE OF
MACHINES
Various machines used for machining are Lathe machine, Shaper machine,
Slotting machine, Planning machine, Drilling machine, Milling machine,
Grinding machine. These machines do various operations namely Facing,
Chamfering, Step turning, Taper turning, Plain turning, Knurling, Grooving,
Thread cutting, Drilling, Tapping, Grinding, Cylindrical grinding, Surface
grinding, grinding of tool angles e.t.c.
LATHE MACHINE:
A lathe is a machine tool which rotates the workpiece on its axis to
perform various operations such as cutting, sanding, knurling, drilling, or
deformation with tools that are applied to the workpiece to create an object
which has symmetry about an axis of rotation. Lathes are used in woodturning,
metalworking, metal spinning, and glass working. Lathes can be used to shape
pottery, the best-known design being the potter's wheel. Most suitably equipped
metalworking lathes can also be used to produce most solids of revolution,
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plane surfaces and screw threads or helices. Ornamental lathes can produce
three-dimensional solids of incredible complexity. The material can be held in
place by either one or two centers, at least one of which can be moved
horizontally to accommodate varying material lengths. Other work holding
methods include clamping the work about the axis of rotation using a chuck to a
faceplate, using clamps or dogs.
SHAPER MACHINE:
A shaper is a type of machine tool that uses linear relative motion
between the workpiece and a single-point cutting tool to machine a linear tool
path. Its cut is analogous to that of a lathe, except that it is linear instead of
helical. A shaper is analogous to a planner, but smaller, and with the cutter
riding a ram that moves above a stationary workpiece, rather than the entire
workpiece moving beneath the cutter. The ram is moved back and forth
typically by a crank inside the column; hydraulically actuated shapers also exist.
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PLANNING MACHINE:
A planer is a type of metalworking machine tool that uses linear relative motion
between the workpiece and a single-point cutting tool to machine a linear tool
path. Its cut is analogous to that of a lathe, except that it is linear instead of
helical. A planer is analogous to a shaper, but larger, and with the entire
workpiece moving on a table beneath the cutter, instead of the cutter riding a
ram that moves above a stationary workpiece. The table is moved back and
forth on the bed beneath the cutting head either by mechanical means, such as a
rack and pinion drive or a leadscrew, or by a hydraulic cylinder.
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DRILLING MACHINE:
A drill or drill motor is a tool fitted with a cutting tool attachment or driving
tool attachment, usually a drill bit or driver bit, used for drilling holes in various
materials or fastening various materials together with the use of fasteners. The
attachment is gripped by a chuck at one end of the drill and rotated while
pressed against the target material. The tip, and sometimes edges, of the cutting
tool does the work of cutting into the target material. This may be slicing off
thin shavings (twist drills or auger bits), grinding off small particles (oil
drilling), crushing and removing pieces of the workpiece (SDS masonry drill),
countersinking, counter boring, or other operations. Drills are commonly used
in woodworking, metalworking, construction and do-it yourself projects.
Specially designed drills are also used in medicine, space missions and other
applications.
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MILLING MACHINE:
A milling machine is a machine tool used to machine solid materials.
Milling machines are often classified in two basic forms, horizontal and
vertical, which refer to the orientation of the main spindle. Both types range in
size from small, bench-mounted devices to room-sized machines. Unlike a drill
press, this holds the workpiece stationary as the drill moves axially to penetrate
the material, milling machines also move the workpiece radially against the
rotating milling cutter, which cuts on its sides as well as its tip. Workpiece and
cutter movement are precisely controlled to less than 0.001 in (0.025 mm),
usually by means of precision ground slides and lead screws or analogous
technology. Milling machines may be manually operated, mechanically
automated, or digitally automated via computer numerical control (CNC).
Milling machines can perform a vast number of operations, from simple (e.g.,
slot and keyway cutting, planing, drilling) to complex (e.g., contouring, die
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sinking). Cutting fluid is often pumped to the cutting site to cool and lubricate
the cut and to wash away the resulting swarf.
GRINDING MACHINE:
A grinding machine, often shortened to grinder, is a machine tool used for
Grinding using an abrasive wheel as the cutting tool. Each grain of abrasive on
the wheel's surface cuts a small chip from the workpiece via shear deformation.
The grinding machine consists of a power driven grinding wheel spinning at the
required speed (which is determined by the wheel’s diameter and
manufacturer’s rating, usually by a formula) and a bed with a fixture to guide
and hold the workpiece. The grinding head can be controlled to travel across a
fixed work piece or the workpiece can be moved while the grind head stays in a
fixed position. Very fine control of the grinding head or tables’ position is
possible using a Vernier calibrated hand wheel.
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2. STEP TURNING AND TAPER TURNING
Aim: To perform step turning and taper turning (taper of 5: 100) operations on
the given work piece for given dimensions.
Material Required: Mild steel rod of 30mm diameter and 110 mm length.
Tools Required: H.S.S single point cutting tool, V-cutting tool, calipers, steel
rule, chuck key.
Sequence of Operations:
1. Centering
2. Measuring & Marking
3. Facing
4. Plain turning
5. Step turning
6. Finishing
7. Taper turning
8. Checking
Diagram:
Procedure:
1. The work piece is fixed on 3 jaw self centering chuck with sufficient over
hang.
2. Adjust the belt pulleys to run the job at a required cutting speed.
3. Fix the cutting tool in a tool post and give the feed and depth of cut of the
cutting tool.
4. Facing operation is performed from the centre hole
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5. Plain turning operation is performed until the dia of the work piece is
reduced to 30 mm.
6. Check the dimensions by using the outside calipers.
7. Step turning operation is performed with different depth to reach the
dimensions as shown in fig.
8. Check the dimensions using a Vernier calipers and a steel rule.
Calculations:
Calculate the angle of taper:
The angle is measured by using the formula
Tangent of the half of the taper angle = (Large Dia – Small Dia)/2 x (length of
the taper)
Tan α = (D-d) / 2L
Precautions:
1. The chuck key must be removed from the chuck before the spindle is
switched on
2. Chips should not be allowed to wound the revolving job an {must be
cleaned as often as possible using brush but not by hand}.
3. Apply cutting fluids to the tool and work piece properly.
4. Before starting the lathe spindle by power, lathe spindle should be
revolved through one revolution by hand to make sure that no failing
exists.
Result:
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3. THREAD CUTTING AND KNURLING
Aim: To perform thread cutting (TPI =12) and knurling operations on the given
work piece for given dimensions.
Material Required: Mild steel rod of 30 mm diameter and 110 mm length
Tools Required: H.S.S. Single point cutting tool, V-Cutting tool, outside
calipers, parting off tool, Vernier Calipers, Steel rule, Chuck key
Sequence of Operations:
1. Centering
2. Measuring & Marking
3. Facing
4. Plain turning
5. Chamfering
6. Parting
7. Thread cutting
8. Knurling
9. Checking
Diagram:
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Procedure:
1. The work piece is fixed on a 3 jaw self centering chuck with sufficient
over hang.
2. Adjust the belt pulleys to run the job at a required cutting speed.
3. Fix the cutting tool in a tool post and give the feed and depth of cut of the
cutting tool.
4. Perform facing, plain turning, chamfering operations to get the required
dimensions
5. Using the v- cutting tool and parting off tool to perform the step turning
operation to required dimensions.
6. Check the dimensions using a outside calipers and replacing the parting
tool by thread cutting tool in the tool post.
7. Reduce the speed of the spindle by engaging the back gear mechanism in
the head stock.
8. Calculate the .size of change gear required to cut the thread of given pitch
using the relation
Gear ratio = (pitch to be cut on the work piece) / (pitch on the lead screw)
9. Engage half-nut mechanism for automatic feed to perform thread cutting
operation (Right hand threading )
10.Give the small exam feed and repeat the steps to complete the threading
for required depth.
11.Replace the thread cutting tool by a knurling tool and perform knurling
operation on required length of the job.
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Calculations
Calculate the number of gear teeth required on A,B,C&D gear to generate a
thread of 12-TPI in compound gear system and also calculate the pitch of the
thread in mm.
Gear ratio = Pitch of the work piece/ Pitch of the lead screw
= 2.11/6 = 0.3516666667
Precautions
1. The chuck key must be removed from the chuck before the spindle is
switched on.
2. Apply the cutting fluids to the tool and work piece properly.
3. The cutting tool point should exactly resemble the shape of the thread.
4. To avoid pitch errors the machining should be done properly
Result
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4. DRILLING AND TAPPING
Aim: To perform drilling and tapping operations on the given work piece.
Material Required: Mild steel flat of 50 x 50 x 10 mm
Tools Required: Steel rule, Dot Punch, Vernier height gauge, Jenny calipers,
Drill bit (dia 10 mm)
Sequence of Operations:
1. Measuring
2. Marking
3. Punching
4. Grinding
5. Drilling
6. Tapping
7. Surface grinding
Diagram:
Drilled and Tapped Work Piece
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Procedure:
1. Place the work piece on the surface plate and mark the required drill-
spots as per the sketch given using jenny calipers, scriber and steel rule.
2. Highlight scriber lines on the work piece by using dot punch and ball
peen hammer
3. Hold the work piece in the machine vice firmly
4. Select the drill bit as per the sketch and insert into the drill chuck by
means of align screw.
5. The drill chuck is inserted into the sleeve of radial drilling machine
6. Start the machine and lower the arm so the drill bit contacts the work
piece at the required position gently.
7. Apply the feed continuously to make a through hole.
8. Repeat the above process till all the holes are drilled as per the sketch.
9. Use reamer to finish the drilled holes
10.Use appropriate dill taps to make the internal threads.
Precautions:
1. Marking should be done accurately.
2. Apply cutting fluids to the tool and the work piece properly
3. Chips should not be allowed to wound the revolving job and must be
cleaned as often as possible using brush but not by hand.
Calculations:
Dd = dh-p where
Dd – dia. of drill bid, dh - dia. of the hole and p = pitch
Suitable drill size for required tapping
D=Dia. of tap
Tap Drill size = (D-1.3p) +0.2 =
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Result:
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5. SHAPING
Aim: To produce flat surface on the given work piece by performing shaping
operation using shaping machine.
Material Required: Cast Iron block 50 x 50x20 mm
Tools Required: Steel rule, dot punch, Ball peen hammer, Surface gauge,
Scriber, Vernier height gauge, V-block surface and H.S.S. Single point cutting
tool.
Sequence of Operations:
1. Measuring
2. Marking
3. Punching
4. Fixing
5. Machining
6. Checking
Procedure:
1. Place the work piece on the surface plate to mark the required size using
surface gauge, scriber and steel rule.
2. Convert scriber lines into the dots using dot punch and ball peen hammer.
3. The tool is fixed on the tool post such that the tool movement should be
exactly perpendicular to the table
4. Adjust the length of the stroke, depth of cut and start the machine.
5. The feed is given to the table only after the completion of the return
stroke.
6. Continue the process for all the sides until a block of required size is
obtained.
7. Finally produce flat surface on one side according to the dimensions.
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Diagram::
Precautions:
1. Marking should be done accurately.
2. Never attempt to remove the chips and reach across the feed in motion.
3. Apply cutting fluids to the tool and the work piece properly.
4. Always feed will be given to the tool after the completion of return stroke
only.
Result:
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6. SLOTTING
Aim: To produce Internal Keyways in the given work piece by using slotting
machine.
Material Required:: Mild steel rod of 30 mm diameter and 110 mm length
Tools Required: Steel rule, dot punch, ball peen hammer, surface gauge,
scriber, vernier height gauge, v-block surface and H.S.S single point cutting
tool.
Sequence of Operations:
1. Measuring
2. Marking
3. Punching
4. Fixing
5. Machining
6. Checking
Diagram::
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Procedure:
1. Place the work piece on the surface plate to mark the square of required
size using surface gauge, scriber and steel rule.
2. Convert Scriber lines into the dots using dot punch and ball peen
hammer.
3. The tool is fixed on the tool post such that the tool movement should be
exactly perpendicular to the table.
4. Adjust the length of the stroke, depth of cut and start the machine.
5. The feed is given to the table only after the completion of the return
stroke.
6. Continue the process for all the sides until a block of required size is
obtained.
7. Finally make a keyway on one side according to the dimensions.
Precautions:
1. Marking should be done accurately.
2. Never attempt to remove the chips and reach across the feed in motion.
3. Apply cutting fluids to the tool and the work piece properly.
4. Always feed will be given to the tool after the completion of return stroke
only.
Result:
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7. MILLING
Aim: To machine a slot or the Keyway for the given work piece using Milling
Machine.
Material Required: Cast Iron block of 50 X 50 X 20mm
Tools Required:
1. Formed tooth cutter
2. Vernier Calipers
3. Spanners of different sizes
Sequence of Operations:
1. Measuring
2. Fixing
3. Milling
4. Checking
Diagram:
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Procedure:
1. Take the work piece and check, note down the dimensions
2. Fix the tool by fixing the arbor by adjusting the rings.
3. Then place the work piece in the work holding devices.
4. Machine has the horizontal, transverse and vertical feeds.
5. By using these feeds remove the material as per dimensions.
6. Finally check the dimensions by Vernier calipers.
Precautions:
1. Tight the vice screws on the table.
2. Use coolant while machining
Result:
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8. CYLINDRICAL SURFACE GRINDING
Aim: To prepare a flat surface 50 x 50 x 20 mm by using the surface grinding
machine
Equipment Required: Surface grinder, Coolant
Material required: 50 x 50 x 10 mm Mild steel plate
Sequence of Operations:
1. Measuring
2. Marking
3. Fixing
4. Surface Grinding
5. Checking
Diagram::
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Procedure:
1. Remove turns and any projection on the flat plate by filling on the one
side of the plate for accurate location of the work piece with respective to
the given grinding wheel on the chuck.
2. After filing place the work piece on the magnetic table and operate the
level such that because rigidly magnetization of that table surface the
work piece rigidly held on the table.
3. Start the machine and also switch on the coolant pump.
4. Initially by adjusting the wheel head by using down feed handle make the
wheel just in contact with the work piece.
5. After contact with the work piece give the required depth by adjusting
wheel head.
6. Then give the longitudinal feed for removing the material along the
length of work piece
7. After the material is removed along the length of work give cross feed to
the new surface along the width of work piece such that overall width of
work piece should be machined.
8. After finishing the surface on one side of the plate stop the machine and
move the table to the extreme position of the longitudinal travel to the
clear of the grinding wheel and demagnetizing the table
9. Then repeat the steps 3-7 to finish the next side also
10.Then both sides of work piece is finished by surface grinder
11.Check whether the required thickness is obtained or not by using Vernier
calipers
12.Stop the machine and coolant pump.
Precautions:
1. Check whether the coolant flows to the cutting zone.
2. Do not operate the magnetic table lever during grinding operation
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3. Check whether the work piece on magnetic table rigidly clamped or not
before starting the grinding operation.
Result:
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9. GRINDING OF TOOL ANGLES
NOMICULATEOF SINGLE POINT CUTTING TOOL
1: Side Cutting Edge Angle:
The angle between side cutting edge and the side of the tool shank is called side
cutting edge angle. It is often referred to as the lead angle.
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2: End Cutting Edge Angle:
The angle between the end cutting edge and a line perpendicular to the shank of
the tool shank is called end cutting edge angle.
3: Side Relief Angle:
The angle between the portion of the side flank immediately below the side
cutting edge and a line perpendicular to the base of the tool.
4: End Relief Angle:
The angle between the end flank and the line perpendicular to the base of the
tool is called end relief angle.
5: Back Rake Angle:
The angle between the face of the tool and line perpendicular to the base of the
tool measures on perpendicular plane through the side cutting edge. It is the
angle which measures the slope of the face of the tool from the nose, towards
the rack. If the slope is downward the nose it is negative back rake.
6: Side Rake Angle:
The angle between the face of the tool and a line parallel to the base of the tool
measured on plane perpendicular to the base and the side edge. It is the angles
that measure the slope of the tool face from the cutting edge, if the slope is
towards the cutting edge it is negative side rake angle and if the slope is away
from the cutting edge, it is positive side rake angle. If there is no slope the side
rake angle is zero.
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