SASTRA UNIVERSITY

(A University established under Section 3 of the UGC Act, 1956)

TIRUMALAISAMUDRAM,
THANJAVUR 613 401

SCHOOL OF MECHANICAL ENGINEERING

BMTCME 407
MACHINE SHOP
(For Mechatronics)
MANUAL

NAME
REG. NO.
CLASS
BRANCH
SCHOOL

LIST OF EXERCISES

SL.
NO.

NAME OF THE EXERCISE

Plain Turning

Step Turning

Taper Turning

Thread Cutting (Metric)

Drilling and Boring

Internal Thread cutting

Shaping Cube forming

Shaping V-groove and keyway cutting

Milling Spur Gear

10

Milling Helical Gear

11

Cylindrical Grinding

12

Surface Grinding

13

Slotting and Keyway cutting

14

Eccentric Turning

15

Hexagonal Milling

16

Plain and Gang Milling-Study & demonstration

17

Spur Gear Cutting in Gear Hobbing Machine

Study & demonstration

18

Spur Gear Cutting in Gear Shaper Study &

demonstration

19

Grooving and Letter Sinking - Study &

demonstration

MARKS
OBTAINED

STAFF
SIGN

PLAIN TURNING
Ex. No.:

Date:

Aim: To perform plain turning operation on the given work piece.

Detailed sketch:

All dimensions are in mm

Material given: MS 32 X 125 mm
Tools Required:
1. Chuck key
2. Tool post key
3. Vernier caliper 0-150mm
4. HSS tool (side cutting tool)
5. Double ended spanner 14-15
6. Drill chuck with key
7. CSK Drill bit 3.2x7.9mm(1/8 x 5/16)
8. Revolving centre
9. Cleaning brush 50mm
Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

3

STEP TURNING
Ex. No.:

Date:

Aim: To perform step turning operation on the given work piece.

Detailed Sketch:

All dimensions are in mm

Material given: MS 32 X 125 mm
Tools Required:
1. Chuck key
2. Tool post key
3. Vernier caliper 0-150mm
4. HSS tool (side cutting tool)
5. Double ended spanner 14-15
6. Drill chuck with key
7. CSK Drill bit 3.2x7.9mm(1/8 x 5/16)
8. Revolving centre
9. Cleaning brush 50mm
Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

TAPER TURNING
Ex. No.:

Date:

Aim: To perform taper turning operation on the given work piece.

Detailed Sketch:

All dimensions are in mm

Material given: MS 32 X 125 mm
Tools Required:
1. Chuck key
2. Tool post key

Taper angle,
= tan-1 ((D d) / 2L)

3.
4.
5.
6.
7.
8.
9.

Vernier caliper 0-150mm

HSS tool (side cutting tool)
Where D Major diameter (mm)
Double ended spanner 14-15
d Minor diameter (mm)
Drill chuck with key
L Taper length (mm)
CSK Drill bit 3.2x7.9mm(1/8 x 5/16)
Revolving centre
Cleaning brush 50mm

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

THREAD CUTTING (METRIC)

Ex. No.:

Date:

Aim: To perform thread cutting (metric) operation on the given work piece.
Detailed Sketch:

All dimensions are in mm

Material given: MS 32 X 125 mm
Tools Required:
1. Chuck key
2. Tool post key
3. Vernier caliper 0-150mm
4. HSS tool (side cutting tool)
5. Double ended spanner 14-15
6. Parting tool with holder
7. Thread cutting tool - 60
8. Revolving centre
9. Cleaning brush 50mm

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

DRILLING AND BORING

Ex. No.:

Date:

Aim: To perform drilling and boring operations on the given work piece.
Detailed Sketch:

All dimensions are in mm

Material given: MS 50 X 32 mm
Tools Required:
1. Chuck key
2. Tool post key
3. Vernier caliper 0-150mm
4. HSS tool (side cutting tool)
5. Double ended spanner 14-15
6. Drill chuck with key
7. CSK drill bit 3.2mm x 7.9mm (1/8 x 5/16)
8. HSS drill bit 10mm & 14mm
9. Boring tool with holder
10. Revolving centre
11. Cleaning brush 50mm
Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

7

INTERNAL THREAD CUTTING

Ex. No.:

Date:

Aim: To perform internal thread cutting operation on the given work piece.
Detailed Sketch:

All dimensions are in mm

Material given: MS 50 X 32 mm
Tools Required:
1. Chuck key
10. Internal thread cutting tool
2. Tool post key
11. Revolving centre
3. Vernier caliper 0-150mm
12. Cleaning brush 50mm
4. HSS tool (side cutting tool)
5. Double ended spanner 14-15
6. Drill chuck with key
7. CSK drill bit 3.2mm x 7.9mm (1/8 x 5/16)
8. HSS drill bit 10mm & 14mm
9. Boring tool with holder

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

SHAPING CUBE FORMING

Ex. No.:

Date:

Aim: To perform cube forming operation on the given work piece using shaping machine.
Detailed Sketch:

All dimensions are in mm

Material given: CAST IRON 55 X 55 X 55 mm
Tools Required:
1. Try square 100mm
2. Vernier caliper 150mm
3. Dot punch - 60
4. Double ended spanner 10-11,14-15,18-19&21-23
5. Hammer
6. Cleaning brush 50mm

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

SHAPING V-GROOVING AND KEYWAY CUTTING

Ex. No.:

Date:

Aim: To perform V-grooving and key way cutting operations on the given work piece using shaping
machine.
Detailed Sketch:

All dimensions are in mm

Material given: CAST IRON 55 X 55 X 55 mm
Tools Required:
1.
2.
3.
4.
5.
6.

Try square 100mm

Vernier caliper 150mm
Dot punch - 60
Double ended spanner 10-11,14-15,18-19&21-23
Hammer
Cleaning brush 50mm

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

10

MILLING SPUR GEAR

Ex. No.:

Date:

Aim: To perform spur gear milling operation on the given work piece.
Detailed Sketch:

All dimensions are in mm

Material given: Cast Iron Blank 100 X 20 mm
Tools Required:
1. Lathe Chuck key
2. Tool post key
3. Turning tool
4. Drill chuck with key
5. Mandrel
6. Revolving centre
7. Drill bits 13mm, 22.5mm, 25mm
8. Double ended spanner 27-32
9. Reamer 25.4mm

10. Milling cutter

11. Cleaning Brush 50mm

Spur Gear Milling Calculations:

Given data:
1. Number of teeth (z) =
2. Module (m)

Formulae:
Outer diameter = PCD + 2m =
Tooth depth

= Addendum + Dedendum = 2.25m =

11

Indexing:
Index Crank Movement (ICM) = 40 / N =
Where N number of divisions required

Illustrations:
ICM = 40 / 30 = 1(1/3) = 1(1x7 / 3x7) = 1(7/21)
i.e. Index crank should be moved for one complete turn and 7 hole spaces in 21
hole circle of the index plate
Selection of Cutter
Equivalent no. of teeth = z/cos3
Select the cutter using the table.
Cutter
No
No of
teeth

Result:

Marks:

135 to
rack

55-134

35-54

26-34

21-25

17-20

14-16

12-13

Given
dimensions (mm)
Obtained
dimensions (mm)

/ 10

Staff I/C sign

12

MILLING HELICAL GEAR

Ex. No.:

Date:

Aim: To perform helical gear milling operation on the given work piece.
Detailed Sketch:

All dimensions are in mm

Material given: Cast Iron Blank 100 X 20 mm
Tools Required:
1. Lathe Chuck key
2. Tool post key
3. Turning tool (Tipped)
4. Drill chuck with key
5. Drill bits 13mm, 21.5mm& 25mm
6. Sleeves 2
7. Reamer 25.4mm
8. Revolving centre
9. Double ended spanner 27-32

10.Cleaning Brush 50mm

11. Mandrel

Helical Gear Milling Calculations:

Given data:
1. Number of teeth (z) =
2. Module (m)

13

3. Helix angle ()
4. Pitch

= 20
= 6mm

Formulae:
Blank diameter = zxm + 2xmxcos =
Tooth depth

= Addendum + Dedendum = 2.25x mxcos =

Indexing:
Index Crank Movement (ICM) = 40 / N =
Where N number of divisions required
Illustrations:
ICM = 40 / 30 = 1(1/3) = 1(1x7 / 3x7) = 1(7/21)
i.e. Index crank should be moved for one complete turn and 7 hole spaces in 21
hole circle of the index plate
Cutter Selection = z/cos3
Gear Train Arrangement = (40xP)/(D/tan)
Selection Of Cutter
Equivalent no. of teeth = z/cos3
Select the cutter using the table.
Cutter
1
2
3
No
No of
135 to 55-134 35-54
teeth
rack

Result:

Marks:

26-34

21-25

17-20

14-16

12-13

Given
dimensions (mm)
Obtained
dimensions (mm)

/ 10

Staff I/C sign

14

CYLINDRICAL GRINDING
Ex. No.:

Date:

Aim: To perform cylindrical grinding operation on the given work piece.

Detailed Sketch:

All dimensions are in mm

Material given: MS Polished Rod of 32 X 125 mm
Tools Required:
1. Lathe Chuck key
2. Tool post key
3. Turning tool
4. Drill chuck with key
5. CSK bit 3.2mm X 7.9mm (1/8 X 5/16)
6. Revolving centre - 60
7. Vernier caliper 150mm
8. Double ended spanner 14-15
9. Cylindrical grinding machine chuck key
10. Cleaning Brush 50mm

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

15

SURFACE GRINDING
Ex. No.:
Aim: To perform surface grinding operation on the given work piece.

Date:

Detailed Sketch:

All dimensions are in mm

Material given: MS Square Rod of 20 X 200 mm
Tools Required:
1. Micrometer 0-25mm
2. Cleaning Brush 50mm

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

16

SLOTTING AND KEY WAY CUTTING

Ex. No.:

Date:

Aim: To perform slotting and key way cutting on the given work piece.
Detailed Sketch:

All dimensions are in mm

Material given: MS Flat of 62 X 50 X 6 mm
Tools Required:
1. Vernier caliper 150mm
2. Double ended spanner
3. Ring spanner 2427
4. Divider
5. Dot punch - 60
6. Hammer
7. Drill chuck with key
8. Sleeve 2-3 &3-4
9. CSK drill bit

10. Hacksaw frame with blade

11. Vernier height gauge
12. Flat rough file 300mm
13. Try square 100mm
14. Drill bit 10mm & 16mm
15. Angle plate
16. Drift
17 Cleaning Brush 50mm

Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

17

ECCENTRIC TURNING

Ex. No.:

Date:

Aim: To perform eccentric turning on the given work piece.

Detailed Sketch:

All dimensions are in mm

Material given: MS 50 X 75mm
Tools Required:
1. Chuck key
10. Revolving centre
2. Tool post key
11. Cleaning brush
3. Vernier caliper 0-150mm
4. HSS tool (side cutting tool)
5. Double ended spanner 14-15
6. Vernier height gauge
7. V-block with U-clamp
8. Marking gauge
9. Try square 100mm
Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

18

HEXAGONAL MILLING
Ex. No.:

Date:

Aim: To perform hexagonal milling operation on the given work piece.

Detailed Sketch:

All dimensions are in mm

Material given: Cast Iron Blank 100 X 20 mm
Tools Required:
1. Lathe Chuck key
10. Milling cutter
2. Tool post key
11. Vernier caliper
3. Turning tool
12. Reamer 25.4mm
4. Drill chuck with key
13. Cleaning Brush 50mm
5. CSK drill bit 3.2mm X 7.9mm (1/8 X 5/16)
6. Mandrel 25.4mm
7. Revolving centre
8. Drill bits 13mm, 22.5mm, 25mm
9. Double ended spanner 27-32
Result:
Given
dimensions (mm)
Obtained
dimensions (mm)

Marks:

/ 10

Staff I/C sign

19