LATHE MACHINE

Introduction:A lathe is probably the oldest machine tool, stemming from the early
tree lathe, which was turned by a rope passed around the work a few times and attached to
a springly branch over head. The work was supported by two levels struck in adjacent
trees. The operators foot supplied the motion, which was intermittent and fluctuating. The
tool was held in the operations hand. Later a strip of wood called as Lathe was used to
support the rope and hence named as Lathe. From this crode beginning and over period
of more than two centuries, the modern engine lathe has evolved.
Working Principles:Lathe removes undesired material from a rotating work piece in the form
of chips with help of tool which is transverse across the work and can be deep in work.
The tool material should be harder than the work piece and lathe held securely and rigidly
on the machine. The tool may be given linear motion in any direction. A lathe is used
principally to produce cylindrical surfaces and planes, at right angles to axis of rotation. It
can also produce tapers and bellows etc operation of turning is done on parts as small as
these used by watches to huge parts weighing several tons.

Fig1: Working principle of lathe

Function:- The function of a lathe is to remove excess material in the form of chips by
rotating the work Piece against a cutting tool to produce cylindrical shapes. The tool
material should be harder than the work piece. The tool may be given liner motion along
work piece in any direction.

Fig2: Parts of Center lathe machine

Size (or) specification of lathe:1. The height of the centers measured form the lathe bed.
2. The swing diameter over bed.
3. Maximum job length held between the two centers.
4. The swing diameter over carriage.
Parts of Lathe:1. Base or Bed. 2. Head stock. 3. Tail stock. 4. Carriage. 5. Cross Slide. 6.Compound
rest. 7. Apron. 8. Lead Screw. 9. Tool Post.
Parts Description:
1. Bed: The bed is a heavy, rugged casting in which are mounted the working parts of the lathe. It
carries the headstock and tail stock for supporting the workpiece and provides a base for the
movement of carriage assembly which carries the tool.
2. Legs: The legs carry the entire load of machine and are firmly secured to floor by foundation
bolts.
3. Headstock: The headstock is clamped on the left hand side of the bed and it serves as housing
for the driving pulleys, back gears, headstock spindle, live centre and the feed reverse gear. The
headstock spindle is a hollow cylindrical shaft that provides a drive from the motor to work
holding devices.
4. Gear Box: The quick-change gear-box is placed below the headstock and contains a number of
different sized gears.

Fig3: Schematic diagram of lathe

5. Carriage: The carriage is located between the headstock and tailstock and serves the purpose
of supporting, guiding and feeding the tool against the job during operation. The main parts of
carriage are:
a) The saddle is an H-shaped casting mounted on the top of lathe ways. It provides support to
cross-slide, compound rest and tool post.
b) The cross slide is mounted on the top of saddle, and it provides a mounted or automatic cross
movement for the cutting tool.
c) The compound rest is fitted on the top of cross slide and is used to support the tool post and the
cutting tool.
d) The tool post is mounted on the compound rest, and it rigidly clamps the cutting tool or tool
holder at the proper height relative to the work centre line.
e) The apron is fastened to the saddle and it houses the gears, clutches and levers required to
move the carriage or cross slide. The engagement of split nut lever and the automatic feed lever at
the same time is prevented she carriage along the lathe bed.
6. Tailstock: The tailstock is a movable casting located opposite the headstock on the ways of the
bed. The tailstock can slide along the bed to accommodate different lengths of workpiece between
the centers. A tailstock clamp is provided to lock the tailstock at any desired position. The
tailstock spindle has an internal taper to hold the dead centre and the tapered shank tools such as
reamers and drills.

Lathe operations:S.NO.
1.

Sequence of operation
Facing Facing
Plain Turning
Step& Under cut.
Taper Turning.
Knurling.
Chamfering
Thread cutting
Types of lathe operations:

Cutting tool.
H.S.S.Single point tool
H.S.S.Single point tool
Single point tool / Parting tool.
H.S.S.Single point tool
Knurling Tool.
H.S.S.Single point tool
V- Thread cutting tool.

Facing:- Facing is the operation of machining the end of a piece of work to produce flat
surface With axis. This is also used to cut the work to the required length. The operation
involves Feeding the tool perpendicular to the axes of rotation of work piece.
Plain Turning:- The plain turning operation requires high cutting speed, small feed and a
very small depth of cut to generate a smooth surface. copious supply of coolant and
lubrication should be used to produce a smooth finish.
Step& undercut:-Step Turning is the operation of making different diameters of desired
length. Under cut is the operation of making a slot over the periphery of a circular job
.Taper Turning:-Taper turning may be defined as a uniform increase or decrease in
diameters of a piece of work, measured along its length. In a lathe , taper turning means to
Produce a conical surface by gradual reduction in diameter from a cylindrical work piece.
Tan = D-d / 2L
D= large diameter of taper in mm.
5

d = small diameter of taper in mm

L = Length of tapered part in mm.
2= full taper angle.
= half taper angle.
Methods of tapers:1.
2.
3.
4.
5.

Setting over the tail stock centre.

By swiveling the compound rest.
By a taper turning attachment.
By combining longitudinal and cross feed in a special lathe.
By forming tool method.

Fig4: Types Of Lathe Operations

Chamfering:- It is the operation of beveling the extreme end of the work piece. This is
done to remove burrs, to protect the end of the work piece from being damaged and to
have a better look.
Knurling:- Knurling is the process of embossing a diamond shaped pattern on the
surface of a work piece. The purpose of knurling is to provide an effective gripping
surface on a work piece to prevent it from slipping when operated by hand.
Thread cutting:- Thread cutting is one of the important operation performed on a lathe.
Both and External and internal threads can be cut. There should be a certain relation
between job revolution and revolution of lead screw to control liner movement engaged
with the screw. The tool should be grounded to a proper shape on profile of thread to be
cut. In all modern lathe quick change gear box is provided with different ratios of spindle
and lead screw revolution can be easely obtained by simply shifting the change gear lever.
The longitudinal feed should be equal to the pitch of the thread to be cut per revolution of
the work piece.
Pitch of the threads to be cut
Velocity ratio = ----------------------------------7

Pitch of the lead screw.

But velocity ratio = (Driver teeth / Driven teeth.)
Metal Cutting Parameters ;1. Cutting speed m/min = dn/1000 :
d= dia of work piece (mm); n= spindle speed (rpm)
2. Feed rate mm/min = tool travel speed with respect to work
piece
3. Depth of cut mm = depth of material removed by tool for
each pass

EXP.NO:1
STEP TURNING, TAPER TURNING ON LATHE MACHINE

AIM: -

To perform the following operations on the given work piece using lathe

machine
1. Step turning
2. Taper turning
TOOLS REQUIRED: 1. HSS-Single point cutting tool
2. Vernier calipers
3. steel rule and
MATERIAL REQUIRED: Mild Steel round bar
PROCEDURE:
TURNING:1. Measure the given material for its dimensional accuracy.
2. Fix the workpiece with in the three jaw chuck.
3. Hold the workpiece between headstock and tailstock.
4. Start the machine with direct speed.
9

5. Before turning the workpiece conical holes must be provided at the ends
and turning may be done with side cutting tool.
STEP TURNING:1. Arrange the workpiece between the headstock and tailstock.
2. The parting tool can be fixed to tool post perpendicular to the workpiece.
3. The machine is started after the workpiece is properly set. Give the
minimum feed and move the tool up to required length.
4. Repeat the process for attaining diameter 18mm & 14mm.
TAPER TURNING:1. The V-tool is selected for the taper turning and is fixed to the tool post.
The cutting edge should be perpendicular to the lathe axis.
2. Start with a minimum feed and rotation of compound slide screw which
cause tool to be feed at required taper angles.
3. For every feed measure the smaller dia. Which should be 18mm increase
the feed and rotate the compound slide screw once again for a good
surface finish.
PRECAUTIONS:1. Sliding parts of lathe should be cleaned and lubricated.
2. Speed selector control shouldnt be changed when spindle is rotating.
3. Chuck should be secured properly.
4. Chips should be cleaned using a brush.
5. Goggles should be used which working on lathe.
RESULT:The workpiece is step turned, taper turned, threaded & knurled as per the
dimensions shown in figure.

STEP TURNING
24

21

18

25.4

40

30

20

20

11
All dimensions are in mm

TAPER TURNING
24

21

18

25.4

30

40

EXP.NO:2

20

20

THREAD CUTTING AND KNURLING ON LATHE MACHINE

All dimensions are in mm

AIM: -

To perform the following operations on the given work piece using lathe

machine
1. Step turning
2. Taper turning
3. Thread cutting
4. Knurling& chamfering
TOOLS REQUIRED: 1. HSS-Single point cutting tool
2. V-tool, knurling tool,
3. Vernier calipers
4. steel rule and
MATERIAL REQUIRED: Mild steel round bar
PROCEDURE:
TURNING:1. Measure the given material for its dimensional accuracy.
2. Fix the workpiece with in the three jaw chuck.
3. Hold the workpiece between headstock and tailstock.
13

4. Start the machine with direct speed.

5. Before turning the workpiece conical holes must be provided at the ends
and turning may be done with side cutting tool.
STEP TURNING:a. Arrange the workpiece between the headstock and tailstock.
b. The parting tool can be fixed to tool post perpendicular to the workpiece.
c. The machine is started after the workpiece is properly set. Give the
minimum feed and move the tool up to required length.
d. Repeat the process for attaining diameter 18mm & 14mm.
TAPER TURNING:a. The V-tool is selected for the taper turning and is fixed to the tool post.
The cutting edge should be perpendicular to the lathe axis.
b. Start with a minimum feed and rotation of compound slide screw which
cause tool to be feed at required taper angles.
c. For every feed measure the smaller dia. Which should be 18mm increase
the feed and rotate the compound slide screw once again for a good
surface finish.
THREAD CUTTING:1. Change the gears and arrange them as per the required pitch. The gears
must be arranged as per the table mentions to respective pitch.
2. One part is selected on the screw and half nut lever is engaged now the
lever moves in the axis at the workpiece direction.
3. The depth of cut usually varies from 0.5 to 2mm is applied by advancing
the tool perpendicular to the axis at workpiece.
4. A pitch of 4mm say is usually set and pitch gauge is used to check the
correctness of the pitch.
CHAMFERING:1. Sliding parts, spindles, tools are lubricated sufficiently.
15

2. The workpiece must be fitted tightly in the chuck and tool advances.
3. The tool is fed and up to the end gets chamfered.
KNURLING:1. For this process, knurling tool is held rigidly on tool post.
2. The rollers are pressed against revolving workpiece to sqeeze the metal
against the multiple cutting edges producing impossible in a regular
pattern surface with slow speed.
PRECAUTIONS:6. Sliding parts of lathe should be cleaned and lubricated.
7. Speed selector control shouldnt be changed when spindle is rotating.
8. Chuck should be secured properly.
9. Chips should be cleaned using a brush.
10. Goggles should be used which working on lathe.
RESULT:The workpiece is step turned, taper turned, threaded & knurled as per the
dimensions shown in figure.

STEP TURNING
24

21

18

25.4

40

All dimensions are in mm

30

20

20

17

TAPER TURNING
24

21

18

25.4

30

40

20

20

All dimensions are in mm

THREAD CUTTING
24

21

18

25.4

40

30

20

20

All dimensions are in mm

19

KNURLING
24

21

18

25.4

40

30

20

20

.DRILLING MACHINE
All dimensions are in mm
Introduction: Drilling is the process of making cylindrical holes in the work piece. It is one of the most
important machine tool in the workshop. Drilling machine is one of the simplest,
moderate and accurate machine tool. It consists of a spindle, which imports rotary motion
to the drilling tool. The tool used for drilling holes is called the drill bit. In this the rotary
motion is given to the tool and the work is stationery. Drilling is a process of making a
hole in an object by forcing a rotating tool called drill. The same operation can be
performed in a lathe by holding the drill stationary and rotating work.

21

Fig5: RADIAL DRILLING MACHINE

Working principle: The rotating edge of the drill exerts a large force on the workpiece
and the hole is generated. The removal of metal in a drilling operation is by shearing and
extrusion.

Fig6: Working principle of drilling machine

Types of drilling machines:-1. Portable drilling m/c.,2. Sensitive drilling m/c. 3Gang
drilling m/c. 4. Radial drilling m/c. 5. Automatic drilling m/c. Etc.
RADIAL DRILLING MACHINE:- It is intended for drilling small and large holes on a
heavy work piece. This consists of a heavy round vertical column, mounted on a large
base. The column supports a radial arm which can be raised and lowered to accommodate
work piece of different heights. The arm may be swung around to any position over work
bed. The three movements in radial drilling machines when combined together permit to
be located at any desired point on a large work piece for drilling.
PARTS OF A DRILLING M/C.:- Base, column, Radical arm, Elevating screw, Drill
head, Drill spindle, Table, Motor for elevating the arm, Motor for driving spindle.
1. Base: The base is a heavy casting that supports the machine structure; it provides rigid
mounting for the column and stability for the machine. The base is usually provided with
23

holes and slots which help to Bolt the base to a table or bench and allow the work-holding
device or the workpiece to be fastened to the base.
2. Column: The column is a vertical post that Column holds the worktable and the head
containing the driving mechanism. The column may be of round or box section.
3. Table: The table, either rectangular or round. Drill machine/press in shape supports the
workpiece and is carried by the vertical column. The surface of the table is 90-degree to
the column and it can be raised, lowered and swiveled around it. The table can be
clamp/hold the required the workpiece. Slots are provided in most tables to allow the jigs,
fixtures or large workpieces to be securely fixed directly to the table.

Fig7: PARTS OF A DRILLING MACHINE

4. Drilling Head: The drilling head, mounted close to the top of the column, houses the
driving arrangement and variable speed pulleys. These units transmit rotary motion at
different speeds to the drill spindle. The hand feed lever is used to control the vertical
movement of the spindle sleeve and the cutting tool.
The system is called the sensitive drilling machine/press as the operator is able to sense
the progress of drill with hand-faced.
Specifications:

Maximum size of the drill that the machine can operate

Table diameter

Maximum spindle travel

Number of spindle speeds and feeds available

Power input

Floor space required Net weight of the machine

Spindle Drive and Feed Mechanism :- There are two common methods of driving a
spindle.
25

a) Contact speed motor is mounted at extreme end of

radial arm.
b) Train
of
gearing
within
the
drill
head
S.NO.
Sequence of operation
Tool used
1.
Marking
Vernier height gauge, Surface plate.
2.
Punching
Dot punch, hammer.
3.
Pilot-holed drill
Drill bit.
4.
Drilling
Drill bit.
5.
Reaming
Reamer
6.
Boring
Boring tool.
7.
Counter Boring
Counter bore drill.
8.
Counter Sinking
Counter Sink drill
Marking:- Before drilling any hole on the given work piece, the center of the hole is
located by drawing two lines at angles to each by means of venire height gauge placed on
surface plate.
Punching:- After locating a center, identification is made at the point where the hole is to
be drilled. Pinching is done by means of center punch and ball peen hammer
Pilot-holed drill: Before drilling a hole of a larger diameter, a pilot hole of 3mm which
is slightly Grater then the width of the chisel edge must be drilled. The reason is that the
action of the chisel edge during drilling is more or less an extrusion process. So 80 to
85% of total thrust, i.e., vertically upward force will come on chisel edge which increases
the power required and decreases the tool life. This refers to eliminate the thrust acting on
the chisel edge pilot hole is made prior to drilling.
Drilling:- It is the operation of producing a cylindrical hole by removing metal by the
rotating
edge of a cutting tool called the drill. The drilling is the one of the simplest
methods of producing a hole. Drilling does not produce an accurate hole.
Reaming:- It is an aureate away of sizing and finishing a hole which has been already
drilled. In order to finish a hole and bring it to the accurate size. The hole reamer is made
half that of drilling and used for reaming is known as reamer, which has multiple cutting
edges, reamer can not originate a hole, its simply follows the path, which has been
previously drilled and removes small amount of metal, the materiel removed by this
process is around 0.395mm and for the accurate work, this should not exceed 0.125mm.
Boring:To enlarge a hole by means of an adjustable cutting tool with only one
cutting edge, this is necessary where suitable sized drilled is not available or whole
diameter is so large that it can be ordinary drilled. To finish a hole accurately and to bring
it to the required size. To machine the internal surface of the hole already producing. To
correct all of roundness of the hole. To correct the location of hole as be boring tool
follows as independent path with respect to the hole.
Counter Boring:- The enlarged hole forms a square shoulder with the original hole. This
is necessary is some cases to accommodate the heads of bolts, studs and pins. The tool
used for this is called counter bore. The counter bores are made with straight or tapered
shank to fit in the drills spindle. Counter boring can give accurately of about 0.005mm.
The cutting speed for counter boring is 25% less than that of drilling operations.

27

Fig8: Types Of Drilling Operations

Counter Sinking:- It is the operation of making a cone shaped enlargement of the end of
a hole to Provide a recess of a flat head screw or counter sink rivet fillet in the hole. The
Tool used for counter sinking is called counter sink standard counter sinkers have 60 0 , 820
and 900 inclined angle that the cutting edges of tool are formed at the conical surface. The
cutting speed in counter sinking is 25% less than that of drilling.
Drill Chucks:- A drill chuck is a device intended for holding smaller size drills. It has
two or more adjustable jaws set radially to hold straight shank drills. It is provided with a
taper
shank which is fitted in the tapered hole of the spindle. These are made in
various sizes.
Twist Drills:- It is an end cutting tool. It is the most common type of tool used in drilling.
It consists of a cylindrical piece of steel with special grooves called flutes
Types twist drills: - 1) Parallel shank twist drill. 2) Taper shank twist drill.
Drills materials: - Cutting portion---- High speed steel
Shank portion. ----Carbon steel.
Cutting speed: - It is a measure of peripheral speed of the drill in operation expressed in
m/min.
Cutting speed (S) = D N / 1000 m/min.
D is the diameter of the drill in mm
N is the r.p.m of the drill spindle.
Feed = the feed of a drill is the distances the drill moves into the work at each
revolution of the spindle. It is expressed in mm/ revolution or per min
The feed for min. = Feed per revolution X rpm
Depth of cut = the depth of cut in drilling is equal to one half of the drill
diameter.

EXP NO:3(a)

DRILLING OPERATION

AIM: To drill a hole on the given workpiece as per dimensions.

TOOLS REQUIRED: Drill bit 12 mm.
MATERIAL: C. I. circular blank.
29

PROCEDURE: 1. The given plate is fixed in the machine vice perfectly.

2. On the metal plate a point is marked at the central of the plate.
3. The drill feed handle is rotated counter clockwise so that the tool comes down
and make that the tool point coincide with marked point.
4. The motor id started and slowly the feed is given to the tool.
5. The hole had been done by the tool id checked by making the spindle up and
down.
6. The hole is checked for given dimension.
7. While removing plate first switch off the motor and the removed.
8. The hole is slightly higher in dia as the fit.
PRECAUTIONS: 1. The feed must be adequate otherwise the drill bit may damage.
2. Use goggles when the operation is going.
3. When the operation is going, hold the metal tightly with benchvise jaws.
RESULT: The hole is drilled on the plate as per given dimensions.

80mm
& 20mm Thick

14mm

EXP.NO:3(b)

TAPPING OPERATION
AIM: To tap the given hole internally and to make threads and external threads on the rod.
TOOLS REQUIRED: Internal tapping tool, External threading die.
31

MATERIAL: -

C.I circular blank

INTERNAL THREADING PROCEDURE: 1. The tool is inserted in the hole.

2. The tool is turned in the forward direction for same rotation and reversed to
remove the chips that are in minute form.
3. The oil is applied mean while for smooth operation.
4. The procedure is repeated until the hole gets threaded cleanly.
EXTERNAL THREADING PROCEDURE: 1. The external tapping die is mounted on the rod and oil is applied.
2. The die is rotated until the thread impression occurs on rod and then rotated in
anticlockwise direction to remove the chips.
3. The procedure is repeated until the rod gets fully threaded.
RESULT: The internal threads and external threads are produced and the rod is inserted into the
hole.

80mm
& 20mm Thick
14mm

33

INTERNAL THREADING

M12 X p1.75 mm

EXTERNAL THREADING

SHAPING MACHINE
35

Introduction:- The shaping machine is used for producing flat surfaces. Machining on
shaper more economical with easier work setting and cheaper tooling. On a shaper job is
fixed on able and the cuing tool reciprocates across the work piece. The tool cuts on
forward stroke and the return stroke remain idle. As there is no cutti9ng action in return
stroke, we deploy quick return mechanism to reduce cutting time. To produce flat
surfaces, channel sections, V- channels and gear teeths.etc.

Fig 14:Shaping Machine

Working Principle: The job is rigidly fixed on the machine table. The single point
cutting tool held properly in the tool post is mounted on a reciprocating ram. The
reciprocating motion of the ram is obtained by a quick return motion mechanism. As the
ram reciprocates, the tool cuts the material during its forward stroke. During return, there
is no cutting action and this stroke is called the idle stroke. The forward and return
strokes constitute one operating cycle of the shaper.
Tool

Work piece

Fig15: Working Principle Of Shaping Machine

Types of mechanisms:- 1. Crank shaper: In construction the crank shaper employs a
crank mechanism to change circular motion of the bull gear to reciprocating motion of the
37

ram. The bull gear receives power either from an individual motor from an over head line
shaft if it is a bell drive shaft.
2. Gear type shaper: this type of shaper carries a rack under it is ram which is driven by a
spur gear. The pinion(spur gear) machining with the rack is driven by a gear drive. The
speed andthe direction in which the machine traverse depend on the number of gears in
the gear train.
3. Hydraulic type: In these shapers hydraulic pressure is used for driving the ram .it has
become very popular and is also more efficient than the both of the above tool.
Parts of the shaper:
1. Base. 2. Column 3. Cross slide 4, saddle 5. Table 6. Clapper box 7.
Ram 8. Tool head. 9. Feed disc. Elevating screw. etc
Construction: The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column),
Cross rail, Ram and tool head (Tool Post, Tool Slide, Clamper Box Block).
Base: The base is a heavy cast iron casting which is fixed to the shop floor. It supports the body
frame and the entire load of the machine. The base absorbs and withstands vibrations and other
forces which are likely to be induced during the shaping operations.
Body (Pillar, Frame, Column): It is mounted on the base and houses the drive mechanism
compressing the main drives, the gear box and the quick return mechanism for the ram
movement. The top of the body provides guide ways for the ram and its front provides the guide
ways for the cross rail.
Cross rail: The cross rail is mounted on the front of the body frame and can be moved up and
down. The vertical movement of the cross rail permits jobs of different heights to be
accommodated below the tool. Sliding along the cross rail is a saddle which carries the work
table.
Ram and tool head: The ram is driven back and forth in its slides by the slotted link mechanism.
The back and forth movement of ram is called stroke and it can be adjusted according to the
length of the workpiece to be-machined.

Fig16: Parts Of A Shaper

39

Cutting sped:- In a shaper the cutting action is intermittent and is considered only during
the forward cutting stroke.
Length of cutting stroke.
Cutting sped:- -------------------------------------------Time required by the cutting stroke.
Feed:It is the relative movement of the tool or work in a direction perpendicular to
the axis of reciprocation of the ram for double stroke. In is expressed in
mm. The feed is always
given at the end of return stroke when the tool is not cutting the metal.
Depth of cut:- It is the thickness of metal that is removed in one cut. It is the
perpendicular distances measured between machined surface and non
machined surface of the work piece.
Specifications:
1.
2.
3.
4.
5.

Maximum length of the stroke of ram

Cutting to return stroke ratio.
No and amount of feed
Type of speed reduction.
Type of drive and quick mechanism

EXP.NO:4
41

MAKING OF FLAT SURFACE ON SHAPING MACHINE

AIM: To generate flat surface according to the given dimensions by using shaping
machine.
TOOLS REQUIRED: 1. V-tool,
2. scriber,
3. steel rule and
4. center punch.
MATERIAL REQUIRED: C.I square bar
PROCEDURE:1. Measure the dimensions of a given mild steel block.
2. Fix the block in the shape vice and tight it fully.
3. By providing a depth of cut of say 0.4 for rough finish and 0.2mm for finish
remove the excess material on block by a H.C.C tool until the required
dimensions are obtained.
4. Apply chalk on the face of the block and mark the dimensions as shown in
figure.
5. Punching is done by pilot punch along the marking lines.
6. Adjust the tip of tool such that it touches the metal piece and by providing
required depth of cut, the machine is started.
7. Shape the material by increasing the feed and depth of cut
PRECAUTIONS:Check the tool not to cross the face of the material.
1.

Slowly increase the feed of tool.

2. Check dimensions for every stroke.

3. Set the workpiece exactly below the tool before starting the machine.
RESULT:- Shaping operation is performed for the given workpiece.

43

ALL DIMENSIONS ARE IN mm

SLOTTING MACHINE
45

Introduction: The slotting machine is a reciprocating machine tool in which, the ram
holding the tool reciprocates in a vertical axis and the cutting action of the tool is only
during the downward stroke.
Construction: The slotter can be considered as a vertical shaper and its main parts are:
1. Base, column and table
2. Ram and tool head assembly
3. Saddle and cross slide
4. Ram drive mechanism and feed mechanism.

The base of the slotting machine is rigidly built to take up all the cutting forces. The front
face of the vertical column has guide ways for Tool the reciprocating ram. The ram
supports the tool head to which the tool is attached. The workpiece is mounted on the
table which can be given longitudinal, cross and rotary feed motion.
The slotting machine is used for cutting grooves, keys and slotes of various shapes
making regular and irregular surfaces both internal and external cutting internal and
external gears and profiles The slotter machine can be used on any type of work where
vertical tool movement is considered essential and advantageous.
The different types of slotting machines are:
1. Punch slotter: a heavy duty rigid machine designed for removing large amount of
metal from large forgings or castings
2. Tool room slotter: a heavy machine which is designed to operate at high speeds. This
machine takes light cuts and gives accurate finishing.
3. Production slotter: a heavy duty slotter consisting of heavy cast base and heavy
frame, and is generally made in two parts.

EXP.NO:5
47

SLOTTING OPERATION
AIM: To cut a keyway on given circular blank according to the given dimensions by
using slotting machine.
TOOLS REQUIRED: 1. Slotter
2. scriber,
3. steel rule
4. center punch.
MATERIAL REQUIRED: C.I circular blank of dimensions (80 DIA x 20 THICK) mm.
PROCEDURE: 1. The given blank is checked for given dimensions.
2. Mark the given dimensions on the blank by using scriber and steel rule.
3. Marked lines are dotted with the help of a center punch and hammer.
4. The tool is fitted into the machine and check motion is correct or not.
5. Start the motor of the machine and speed is adjusted.
6. The blank is fitted in the jaws of the slotting machine.
7. The forward motion is given to the blank by rotating the longitudinal feed
handle.
8. At the same time to and fro motion is given to the blank by circular feed handle.
9. The feed is given to the tool in the range of 0.1 to 0.5 mm for every time.
10. The machine id started and the tool removes the material of the blank.
11. The operation is done to get the exact dimensions of the blank.
12. Now the blank is removed from the machine and checks the dimensions.
PRECAUTIONS: 1. Never attempt to adjust a machine while it is in motion.
2. Always keep the machine clean and well oiled.
3. Adjust the stroke of slotter as the length of work to be machined.
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4. Never attempt to remove chips or reach across the table while the ram is in
motion.
RESULT: The required groove is obtained on mild steel plate according to given dimensions.

80mm
& 20mm Thick

KEY WAY
6 X 4 mm

51

MILLING MACHINE
Introduction:- Milling is a machining process in which metal is removed by rotating
multi-edge cutting tool called milling cutter, while the work piece fed against to it. A
milling
machine is a machine tool that removes metal chips. Work is fed against a
rotation multipoint cutter. It removes metal at a very fast rate. The job movement is
horizontal, vertical and cross feeding.
GENERAL MILLING MACHINES
A milling machine is a machine tool that removes metal as the work is fed against a
rotating multipoint cutter. The cutter rotates at a high speed and because of the multiple
cutting edges it removes metal at a very fast rate. The machine can also hold one or more
no of cutters at a time. This is why a milling machine finds wide application in production
work. This is superior to other machine as regards accuracy and better surface finish and
is designed for machining a variety of tool room work.

Fig 9 : Knee And Column Type Milling Machine

Principle:-The milling machine mechanism is composed of spindle drive mechanism and
the table feed mechanism. The spindle drive mechanism is incorporated in the column.
All modern machines are driven by individual motors housed within the column, the
spindle receives power from a combination of gears and clutch assembly. Multiple speed
of the spindle may be obtained by attaining the gear ratio.

Fig10:Working principle of milling machine

53

PARTS DESCRIPTION:
Parts of milling m/c:1.Base. 2. Column. 3. Knee. 4. Saddle. 5. Table. 6. Spindle. 7. Arbor. 8. Elevating
screw.
9. Overhanging arm. Etc.
1. Base: It gives support and rigidity to the machine and also acts as a reservoir for the cutting
fluids.
2. Column: The column is the main supporting frame mounted vertically on the base. The column
is box shaped, heavily ribbed inside and houses all the driving mechanisms for the spindle and
table feed.
3. Knee: The knee is a rigid casting mounted on the front face of the column. The knee moves
vertically along the guide ways and this movement enables to adjust the distance between the
cutter and the job mounted on the table. The adjustment is obtained manually or automatically by
operating the elevating screw provided below the knee.
4. Saddle: The saddle rests on the knee and constitutes the intermediate part between the knee and
the table. The saddle moves transversely, i.e., crosswise (in or out) on guide ways provided on the
knee.

Fig11:Different Type Of Parts Of Milling Machine

5. Table: The table rests on guide ways in the saddle and provides support to the work. The table
is made of cast iron, its top surface is accurately machined and carriers T-slots which
accommodate the clamping bolt for fixing the work. The worktable and hence the job fitted on it
is given motions in three directions:
a). Vertical (up and down) movement provided by raising or lowering the knee.
b). Cross (in or out) or transverse motion provided by moving the saddle in relation to knee.
c). Longitudinal (back and forth) motion provided by hand wheel fitted on the side of feed screw.
In addition to the above motions, the table of a universal milling machine can be swiveled 45 to
either side of the centre line and thus fed at an angle to the spindle.

55

6. Over arm: The Over arm is mounted at the top of the column and is guided in perfect
alignment by the machined surfaces. The Over arm is the support for the arbor.
7. Arbor support: The arbor support is fitted to the Over arm and can be clamped at any location
on the Over arm. Its function is to align and support various arbors. The arbor is a machined shaft
that holds and drives the cutters.
8. Elevating screw: The upward and downward movement to the knee and the table is given by
the elevating screw that is operated by hand or an automatic feed.

Types of milling m/c.:- Column and knee type.

1. Horizontal milling. 2. Vertical milling.
4. Omniversal milling.
Milling m/c. mechanism:-

3. Universal milling.

The spindle drive mechanism is incorporated in the column. All modern machines are
driven by individual motors housed within the column, and the spindle reeves power from
a combination of gears and clutch assembly. Multiple speeds of the spindly may be
obtained by altering the gear ratio.
Work holding devices:- T- bolts and clamps, V-blocks, Angle plate, Vices, etc.
Cutter holding devices:- Arbors, collets, Adapters, Spring collets, Bolted cutters, Screw
( a ) Up milling : The up milling which is also called conventional milling, is the process
of
removing the metal by a cutter which is rotated against the direction of travel of the
work piece.
( b ) Down milling : The down milling which is also called climb milling, is the process
of removing the metal by a cutter which is rotated in the same the direction of travel of
the work piece.
Cutting speed:- The cutting speed of a milling cutter is its peripheral linear speed
resulting from rotation. It is expressed in meters per minute. The cutting speed can be
derived formula.
V= d n / 1000 minutes per min.
V= the cutting speed in inch per min.
d= the diameter of the cutter in mm.
n= the cutter speed in rpm.
Feed:- The feed in a milling machine is defined as the rate with which the work piece
Advances under the cutter.
Depth of cut:- The depth of cut in milling is the thickness of the material moved in one
pass of the work under the cutter.

57

EXP.NO:6
GEAR CUTTING ON MILLING MACHINE
AIM:To cut a spur gear on a given wooden specimen.
MATERIAL:- Circular wooden specimen.
TOOLS REQUIRED :1. Gear tooth vernier
2. Milling cutter
3. Steel rule
PROCEDURE:1. The given workpiece is checked for dimensions.
2. From the calculations no. of holes and no. of hole circles are known.
3. The workpiece is set in the machine correctly.
4. Number of holes and no. of hole circles are set on the index plate of the dividing
head.
5. The cutter is first made to touch the workpiece and then the feed of 5mm is given.
6. After cutting one teeth the feed removed to cut next teeth, the index circle is
rotated for one revolution as per remained number of tools.
7. the process is repeated, the remained number of teeth are cut.
PRECAUTIONS:
1. Check the straightness of the axis of work piece within the live centre of the
dividing head
2. should be careful while performing the indexing
RESULT:
Gear cutting on milling machine is performed successfully.

59

80

20

20

61

63