2016 Machine Shop Manual PDF

MACHINE SHOP
LABORATORY MANUAL
Compiled by
LOKESH H.S
Assistant Professor
Department of Automobile
Engineering
Malnad College of Engineering
Hassan
MACHINE SHOP LABORATORY MANUL
CONTENT
1) Machine Shop Safety

2) Machine Shop Layout
3) Hand and Measuring Tools
4) Cutting and Machine Tools
5) Facing and countersinking operation
6) Plain turning and marking
7) Knurling
8) Step turning
9) Taper turning
10) External thread
11) Gear Cutting operation
12) Shaping operation
13) Eccentric operation
14) viva question
Machine Shop Safety 1-A
“Think Safe, Work Safe and be Safe”
Machine Shop Rules
1. Students are not allowed to work without a Supervisor in the Machine shop
2. Wear Safety Glasses
3. No Sandals or Open toes Shoes. Wear Shoes only
4. Do not enter the Shop under the influence of Drugs or Alcohol
5. Never wear loose clothing when operating any machine. Wear an Apron
6. Remove wrist watches, rings and Bracelets
7. Long Hair must be protected
8. All tools must be signed and returned
9. Accidents, Machine problems, must be reported immediately to the Supervisor
10. All Metal scrap and cuttings are to be disposed-off in the proper recycling drum
Safe Work Practices
1. Do not operate any Machine before understanding its Mechanism and knowing how to stop it
quickly
2. Always be sure that the Cutting Tool and the Work piece are properly mounted before starting
the Machine
3. Be sure the Work piece is clamped securely in the vise or to a Machine table
4. Never start a Machine until you are sure that the cutting tool and Machine parts will clear the
Work piece
5. Never have more than One Person operate a Machine at the same time
6. Keep Hands away from moving parts
7. Plan your work thoroughly before starting. Have all of the tools that will be needed at hand before
commencing work
8. Always stop a machine before Measuring, Cleaning, or making any Adjustments
9. Follow recommended Lifting procedures to avoid Back Injury
10. Stop the Machine immediately if some Odd Noise or Vibration develops while you are operating it
11. Get First Aid immediately for an Injury, no matter how small
12. Turn off Power to the Machine before Cleaning
13. Be Careful when you clean the Machine. Use a Cleaning Brush. Chips and Shaving are Sharp and
will cause serious cuts if you attempt to remove them with your Hands
Machine Shop / Automobile Engineering / Malnad college of Engineering

Aim: Study of Machine Shop Layout 2-A

Aim: Study of Hand and Measuring Tools 3-A
SCREWDRIVER
SCREWDRIVER: is a tool for driving screws and rotating other machine elements with
the mating drive system. A typical hand screwdriver comprises an approximately
cylindrical handle of a size and shape to be held by a human hand and an axial shaft fixed
to the handle, the tip of which is shaped to fit a particular type of screw. The tip is
hardened and tempered. The handle and shaft allow the screw driver to be positioned and
supported and, when rotated, to apply Torque
DOUBLE END SPANNER
DOUBLE END SPANNER: Spanners are used more than any other tool for tightening or
opening different jobs. These are generally made of drop forge steel or Carbon steel. A one-
piece spanner with a U-shaped opening grips two opposite faces of the bolt or nut. This
spanner is often Double-ended, with a different-sized opening at each ends. The ends are
generally oriented to an angle of around 15 degrees to the longitudinal axis of the handle.
This allows a greater range of movement in enclosed spaces by flipping the spanner over.
This type of Spanners are most widely used

Aim: Study of Hand and Measuring Tools 3-B
ALLEN KEY
ALLEN KEY: These are thin steels rods and used to turn screw or bolt Heads designed
with a hexagonal socket (Recess) to receive the key. The key comes in two common forms:
L-shaped and T-handles. The L-shaped keys are formed from hexagonal wire stock, while
the T-handles are the same hex wire stock with a metal or plastic handle attached to the
end. These are available in numbers and sets of different sizes
Foot-Rule/Scale
Foot-rule/Scale: Foot rule is used for physically measuring any article. These are made of
wood, cardboard, plastic, aluminum, spring steel or stainless steel. In engineering line
generally foot rules made of spring steel or stainless are used. Brown and sharp tool
company has made foot rules with 8 types of standard graduation.

Aim: Study of Hand and Measuring Tools 3-C
INSIDE CALIPER
INSIDE CALIPER: is used to measure the internal size of an object. It has adjusting screw
that permits it to be carefully adjusted without removal of the tool from the work piece.
The legs are turned outward so that it may be used for gauging inside diameters.
OUTSIDE CALIPER
OUTSIDE CALIPER: is used to measure the external size of an object. Both its legs are
turned inwards and between these legs the measurement is taken

Aim: Study of Hand and Measuring Tools 3-D
VERNIER CALIPER
VERNIER CALIPER: instrument for making very accurate linear measurements. It utilizes
two graduated scales: a main scale similar to that on a ruler and an especially graduated
auxiliary scale, the Vernier that slides parallel to the main scale and enables readings to be
made to a fraction of a Division on the main scale. It can take measurement of Internal and
external length, breath etc. This instrument was invented in 1630 A.D by a great
mathematician Parry Vernier in France.
VERNIER HEIGHT GAUGE
VERNIER HEIGHT GAUGE: is a height gauge with the additional refinement of a Vernier
scale for greater accuracy in reading or setting the Tool. An Off-set scriber is fitted on a
base with which height of a Job is measured or marking is done.

Aim: Study of Hand and Measuring Tools 3-E
MICROMETER
MICROMETER: A micrometer sometimes known as a micrometer screw gauge is a device

incorporating a calibrated screw used widely for precise measurement of small distances in
Mechanical Engineering and Machining as well as most mechanical trades. The Graduation
is indicated at Barrel or sleeve and Thimble on a micrometer.
DIVIDER
DIVIDER: divider calipers are used in the process of marking out suitable work pieces. The
points are sharpened so that they act as scribers, one leg can then be placed in the dimple
created by a center or prick punch and the other leg pivoted so that it scribes a line on the
work piece’s surface, thus forming an arc or circle. Their legs can be easily opened or
closed as required, by moving its nut.
Aim: Study of Hand and Measuring Tools 3-F
VEE BLOCK
VEE BLOCK: Vee block is a kind of equipment used to hold circular work pieces. By
clamping the the work piece on it we can find centre of the work piece very easily as it has a
right angle slot in it. It can be also used for check the roundness of a circular job using a dial
indicator. It is made of cast iron or tool steel.
DIAL GAUGE
DIAL GAUGE: is instruments used to accurately measure small linear distances, and are
frequently used in industrial and mechanical processes. They are named so because the
measurement results are displayed in a magnified way by means of a dial.

Aim: Study of Hand and Measuring Tools 3-G
SURFACE GAUGE
SURFACE GAUGE: is used to layout lines at a set height from the base. It is also known as
Marking block or scribing block. Parallel lines with high accuracy are drawn with surface
gauge.
SURFACE PLATE
SURFACE PLATE: is a solid, flat plate used as the main horizontal reference plane for
precision inspection, marking out (layout), and tooling setup. These plates are made of close
grain-cast iron and these are kept out at least for one year for the purpose of Seasoning.
Aim: Study of Hand and Measuring Tools 3-H
COMBINATION SET
COMBINATION SET: A tool that includes a steel rule, center head, square head, and
protractor head. The blade of the tool and square head forms a combination square, which
is used to lay out angles.
TRY SQUARE
TRY SQUARE: is a woodworking or a metal working tool used for marking and
measuring. The square refers to the tool's primary use of measuring the accuracy of a right
angle; to try a surface is to check its straightness or correspondence to an adjoining surface.

Aim: Study of Hand and Measuring Tools 3-I
FILES
FILE: is a metalworking and woodworking tool used to cut fine amounts of material from a
work piece. It most commonly refers to the hand tool style, which takes the form of a
hardened steel bar with a series of sharp, parallel ridges, called teeth. Most files have a
narrow, pointed tang at one end to which a handle can be fitted. Files of different types are
used in various jobs for different purposes. Files can be classified on the basis of length,
shape, grades and cut.

Aim: Study of Hand and Measuring Tools 3-J
SOFT HAMMER
SOFT HAMMER: is a tool meant to deliver an impact to an object. Hammers are often
designed for a specific purpose, and vary widely in their shape and structure. The usual
features are a handle and a head, with most of the weight in the head.
PLUG GAUGE
PLUG GAUGE: they are used in the manner of a plug. They are generally assembled from
standard parts where the gauge portion is interchangeable with other gauge pieces (obtained from
a set of pin type gauge blocks) and a body that uses the collet principle to hold the gauges firmly.
To use this style of gauge, one end is inserted into the part first and depending on the result of that
Test, the other end is tried. These gauges are manufactured according to different job
requirements and are known by their shape and use such as: cylindrical, Taper, Thread, Square
and Hexagonal Plug gauge.

Aim: Study of Hand and Measuring Tools 3-K
RADIUS GAUGE
RADIUS GAUGE: is a tool used to measure the radius of an object. The gauge is placed
against the edge to be checked and any light leakage between the blade and edge indicates a
mismatch that requires correction. The Leaves have concave or convex shape at their ends.
Size of their radius is indicated on the leaves. With this gauge the radii of fillets and
rounded corners can be measured. It is also known as fillet gauge. One radius gauge has
leaves of one range. Different ranges are available.
THREAD PITCH GAUGE
THREAD PITCH GAUGE: is used to measure the pitch or lead of a screw thread.
Thread pitch gauges are used as a reference tool in determining the pitch of a
thread that is on a screw or in a tapped hole. In a set a number of leaves are fitted
on either end of the gauge. In these leaves grooves are there according to the
number of threads and their pitch is also indicated. Different screw pitch gauges
are made for different kinds of threads. On the basis of threads these are classified
as: British standard or Whitworth, American National standard, Bicycle, Metric
and International standard screw pitch gauge.

Aim: Study of Hand and Measuring Tools 3-L
WIRE GAUGE
WIRE GAUGE: is a measurement of how large a wire is, either in diameter or cross
sectional area. It is a notched plate having a series of gauged slots. These are numbered
according to the sizes of wire and sheet metal manufactured. The number of the slot in
which wire or sheet fits properly is its gauge. There are eight types of standard gauges:
American (Brown and sharp) standard wire gauge, The Berming or stubs Iron wire Gauge,
Washburn and Moyen standard wire gauge, Washburn and Menoy steel wire Gauge,
S.W.American music wire gauge, Imperial standard wire gauge, Stubs steel wire gauge and
United States standard wire gauge. In all the wire gauges, slot numbers have their own
standard sizes.

Aim: Study of Hand and Measuring Tools 3-M
BRUSH
BRUSH: refers to devices with bristles wire or other filaments, used for cleaning,
surface finishing and for many other purposes.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-A
CUTTING TOOLS AND WORK HOLDING DEVICES
CUTTING TOOLS: are tools for cutting operation. They may be single or Multipoint cutting
Tools
TOOL BIT: The term tool bit generally refers to a non-rotary cutting tool used in Lathes,
Shapers, and Planers. Such cutters are also often referred to by the set-phrase name of single-
point cutting tool. The Cutting edge is ground to suit a particular machining operation and may be
resharpened or reshaped as needed. The ground tool bit is held rigidly by a tool holder while it is
cutting. Most tool bits today are made of HSS, cobalt steel, or carbide.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-B
DRILL BIT
DRILL BIT: are cutting tools used to create cylindrical holes. Bits are held in a Machine tool
called a drill, Press which rotates them and provides torque and axial force to create the hole.
Many different materials are used for or on drill bits, depending on the required application such
as Low carbon steel, High carbon steel, High speed steel, Cobalt steel, Tungsten carbide, Poly-
crystalline diamond etc .Drill is of three kinds: Flat drill, Straight fluted drill, Twist drill.
`

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-C
KNURLING TOOL
KNURLING TOOL: is a tool post-type toolholder on which pair of hardened-steel rolls is

mounted. These rolls may be obtained in Diamond and straight-line patterns and in coarse,
medium, fine pitches. They are used to form gripping Surface on the work piece
CENTER DRILL
CENTER DRILL: is a combination drill and countersink. On both its ends a cutting point is made
and its middle portion is plain. Drilling and counter sinking can be performed simultaneously with
this drill. A hole is drilled in each end of the work piece so that the work may be supported by the
lathe centers.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-D
PARTING TOOLS
PARTING TOOLS: are used when the work must be grooved or parted off. The long, thin
cutting-off blade is locked securely in the toolholder by means of either a cam lock or a locking
nut
THREADING TOOL BIT
THREADING TOOL: is of the same form as the thread to be generated. The tool moves linearly
while the precise rotation of the work piece determines the lead of the thread. The process can be
done to create external or internal threads (male or female).

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-E
PLAIN MILLING CUTTERS
PLAIN MILLING CUTTER: is a cylinder made of high-speed steel with teeth cut on the
periphery. It is used to produce a flat surface

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-F
SIDE MILLING CUTTERS (STAGGERED-TOOTH)
SIDE MILLING CUTTERS: are comparatively narrow cylindrical milling cutters with teeth on
each side as well as on the periphery. They are used for cutting slots and for face and straddle
milling operations. Staggered-tooth cutters have each tooth set alternately to the right and left
with an alternately opposite helix angle on the periphery. Staggered-tooth cutters are particularly
suited for milling deep, narrow slots.
FACE MILLING CUTTERS
FACE MILLING CUTTERS: have inserted teeth held in place by a wedging device. The teeth
may be of high-speed steel or cast tool steel, or they may be tipped with sintered-carbide cutting
edges.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-G
ANGULAR CUTTERS
ANGULAR CUTTERS: have teeth that are neither parallel nor perpendicular to the cutting axis.
They are used for milling angular surfaces, such as grooves, serrations, chamfers and reamer teeth
FORMED CUTTERS
FORMED CUTTERS: incorporate the exact shape of the part to be produced, permitting exact
and more economical duplication of irregularly shaped parts than most other means.
T-SLOT CUTTER
T-SLOT CUTTER: is used to cut the wide horizontal groove at the bottom of a T-slot after the
narrow vertical groove has been machined with an end mill or a side milling cutter

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-H
WOODRUFF KEYSEAT CUTTER
WOODRUFF KEYSEAT CUTTER: is similar in design to plain and side milling cutters.
REAMERS
REAMERS: is used to create an accurate sized hole. The process is called reaming. They may be
used as a hand tool or in a machine tool such as a milling machine or drill press. It is made by
cutting several straight grooves or flutes. The materials for Reamers are high-speed steels, high
carbon steels and tungsten carbide.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-I
BROACHES
BROACHES: is a multi-tooth cutting tool of the exact shape and size desired, is forced through a
hole in the work piece to reproduce its shape in the metal.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-J
GRINDING WHEELS
GRINDING WHEELS: Grinding is an abrasive machining process that uses a grinding wheel
as the cutting tool. A grinding wheel is an expendable wheel used for various grinding and
abrasive machining operations. It is generally made from a matrix of coarse abrasive particles
pressed and bonded together to form a solid, circular shape, various profiles and cross sections
are available depending on the intended usage for the wheel. Grinding wheels may also be
made from a solid steel or aluminium disc with particles bonded to the surface.
SLOTTING TOOL
SLOTTING TOOL: is single point cutting tool similar to shaping Tool

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-K
A KEY-TYPE DRILL CHUCK
DRILL CHUCKS: A drill chuck is a specialized self-centering, three-jaw chuck, usually with
capacity of less than 0.5 in (13 mm) and rarely greater than 1 in (25 mm), used to hold drill bits
or other rotary tools. This is the type of chuck that a machining layperson is most likely to be
familiar with.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-L
LATHE DOGS
LATHE DOGS: A lathe dog, also known as a lathe carrier, is a device that clamps around the
work piece and allows the rotary motion of the machine's spindle to be transmitted to the work
piece. Carriers may be of the straight leg or bent leg type. The straight leg requires the drive pin;
the bent leg fits into a slot machined into the drive plate. The bent leg type is considered safer as
there are (slightly) fewer protruding parts to cause accidents.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-M
THREE- JAW UNIVERSAL CHUCK WITH KEY
THREE-JAW UNIVERSAL CHUCK: These chucks are best suited to grip circular or hexagonal
cross-sections when very fast, reasonably accurate centering is desired. Also called as self-
centering chuck and scroll chuck, uses jaws interconnected via a scroll gear (scroll plate), to hold
onto a tool or work piece.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-N
FOUR-JAW INDEPENDENT CHUCK
FOUR-JAW INDEPENDENT CHUCK: has four jaws, each of which can be adjusted
independently by a chuck key. They are used to hold round, square, hexagonal and irregularly
shaped work pieces. The jaws can be reversed to hold work by the inside diameter
FACE PLATES
FACE PLATES: are used to hold work that is too large or of such a shape that it cannot be held in
a chuck or between centers. Faceplates are usually equipped with several slots to permit the use of
bolts to secure the work or angle plate so that the axis of the work piece may be aligned with the
lathe centers.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-O
STEADYREST
STEADY REST: is used to support long work held in a chuck or between lathe centers. It is
located on, and aligned by, the ways of the lathe and may be positioned at any point along the
lathe bed, provided it clears the carriage travel
FOLLOWER REST
FOLLOWER REST: mounted on the saddle, travels with the carriage to prevent work from
springing up and away from the cutting tool. The cutting tool is generally positioned just ahead of
the follower rest to provide a smooth bearing surface for the two jaws of the follower rest.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-P
MANDREL
MANDREL: holds an internally machined work piece between centers so that further
machining operations are concentric with the bore.
REVOLVING TAILSTOCK CENTERS
REVOLVING TAILSTOCK CENTERS: They are commonly used to support work held in a
chuck or when work is being machined between centers. This type of center usually contains
antifriction bearings, which allow the center to revolve with the work piece.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-Q
INDEX PLATE
INDEX PLATE: is a circular plate provided with a series of equally spaced holes into which the
index crank pin engages. The sector arms fit on the front of this plate and may be set to any
portion of a complete turn.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-R
MACHINE TOOLS
MACHINE TOOLS: A machine tool is one which while holding the cutting tools is able to
remove the metal from a workpiece in order to generate the requisite part of the given size,
configuration and finish. Machine tools are mother machines, since without them no
component can be finished
ENGINE LATHE
ENGINE LATHE

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-S
LATHE SPECIFICATIONS LATHE SPECIFICATIONS
Make: Chaitanya Machine Tools Make: Kirloskar Ltd, Mysore

Type/Model: Hitech Type: D-2
Specifications: Specification:
1.Height of Centers: 170 mm 1.Height of centres:165 mm
2.Swing over bed: 265 mm 2.Swing over bed:330 mm
3.Distance between Centres:600 mm 3.Distance between Centers: 1000 mm
4.Swing over Carriage:350 mm 4.Swing over bed ways:330 mm
5.Width of Bed: 235mm 5.Width of Bed: 238 mm
6.Length of Bed: 1040 mm 6.Length of Bed:1800 mm
7.Swing over Gap: 400 mm 7.Swing over Gap:495 mm
8.No of Spindle Speed:08 8.No of Spindle Speed:08
9.Range of Speed: 40-850 RPM 9.Range of Speed:22-750 rpm
10.Power Rating:0.75 kW(1440 RPM) 10. Range of feeds:0.213-2.128 mm
11.Power rating:0.75 kW (1440 rpm)
Lathe: A lathe is a machine tool which rotates the work piece on its axis to perform various
operations such as cutting, knurling, drilling or deformation with tools that are applied to the
work piece to create an object which has symmetry about an axis of rotation.
Bed: The Bed is a Heavy, rugged casting made to support the working parts of the lathe. On its
top section are machined ways that guide and align the major parts of the lathe.
Head stock: The headstock is clamped on the left-hand side of the bed. The headstock spindle, a
hollow, cylindrical shaft supported by bearings, provides a drive through gears from the motor
to work-holding devices. A live center, a faceplate, or a chuck can be fitted to the spindle nose
to hold and drive the work. Headstock spindles can be driven either by a stepped pulley and a
belt or by transmission gears in the headstock.
Feed rod and Lead Screw: The feed rod advances the carriage for turning operations when the
automatic feed lever is engaged. The Lead screw advances the carriage for thread-cutting
operations when the split-nut lever is engaged.
Carriage: consisting of three main parts: the saddle, cross-slide, and apron- is used to move the
cutting tool along the lathe bed. The saddle, mounted on the lathe ways, provides a means of
mounting the cross-slide and the apron. The cross-slide, mounted on top of the saddle, provides
cross movement for the cutting tool. The compound rest, fitted on top of the cross-slide, is used
to support the cutting tool. It can be swiveled to any angle for taper-turning operations and is

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-T
moved manually. The apron, fastened to the saddle, houses the gears and mechanism required
to move the carriage or cross-slide. The apron hand wheel can be turned manually to move the
carriage along the lathe bed. This hand wheel is connected to a gear that meshes in a rack
fastened to the lathe bed.
Tailstock: consisting of the upper and lower tailstock castings-can be adjusted for taper or
parallel turning by two screws set in the base. The tailstock can be locked in any position along
the bed of the lathe by tailstock clamp. The tailstock spindle has an internal taper to receive the
dead center, which provides support for the right-hand end of the work. A spindle clamp is
used to hold the tail-stock spindle in a fixed position. The tailstock hand wheel moves the
tailstock spindle in or out of the tailstock casting.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-U
CAPSTAN AND TURRET LATHES
CAPSTAN AND TURRET LATHES: has six sided (hexagonal) block mounted on one end of
the bed replacing the normal tailstock. This allows for mounting six tool blocks. Further on the
cross slide, two tool posts are mounted .The turret lathe consists of an all gear, heavy duty
headstock with a greater range of spindle speeds. The turret is mounted on a saddle which in
turn is sliding on the bed

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-V
SHAPING MACHINE
Shaping Machine Shaping Machine
Make: Sagar Engg Works Make: Cooper Engg Ltd

Type/Model:SM12 Type/Model: AS-12
Specification: Specification:
Length of stroke: 300 mm Length of Stroke:300mm
Length of Ram: 630 mm Length of Ram: 760mm
Working Surface of Table: 370 X 230 mm2 Working Surface of Table: 300 X 250 mm2
Max Table Traverse Max Table Traverse
Horizontal: 350mm Horizontal:350 mm
Vertical: 365 mm Vertical:365 mm
Range of Ram Speeds: 21-110 stroke/minute Range of Ram Speeds: 21-110mm Stroke/min
Power: main Drive motor:1.5 KW(1410 RPM) Power of motor: 1.5 KW(1410 RPM)
SHAPER: The shaper is a relatively slow machine tool with very low metal removal capability.
The shaper uses a single point tool which is clamped to a tool post mounted to a clapper box
which in turn is mounted to a reciprocating Ram. The ram while under taking the cutting
stroke pushes the cutting tool through the work piece to remove the material. When the ram
returns, no cutting takes place. In between the return and cutting strokes, the table moves in
the horizontal direction perpendicular to the cutting direction which is termed as the feed
direction. One typical mechanism used in shapers is the quick return mechanism. Here the
Ram holding the Tool move at a comparatively slower speed during the forward cutting stroke,
the cutting speed depending upon the type of material and machining condition, whereas
during the return stroke the ram move at a faster rate to reduce the idle return time
 The Base is the necessary bed or support required for all machine tools. It is made of cast
iron to resist vibration and take up high compressive load

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-W
 The Column is a box like casting mounted upon the base. It encloses the Ram driving
mechanism
 The Crossrail is mounted on the front vertical guideways of the column. The table may be
raised or lowered to accommodate different sizes of jobs by rotating an elevating screw which
causes the crossrail to slide up and down on the vertical face of the column. A horizontal cross
feed screw which is fitted within the crossrail and parallel to the top guideways of the crossrail
actuates the table to move in a crosswise direction
 The saddle is mounted on the crossrail which holds the table firmly on its top. Crosswise
movement of the saddle by rotating the cross feed screw by hand
 The table which is bolted to the saddle receives crosswise and vertical movements from the
saddle and crossrail
 The Ram is the reciprocating member of the shaper. It houses a screwed shaft for altering
the position of the ram with respect to the work and holds the toolhead at the extreme forward
end
 The Toolhead of a shaper holds the tool rigidly, provides vertical and angular movement of
the tool and allows the tool to have an automatic relief during its return stroke.
PLANNING MACHINE

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-X
PLANING MACHINE
PLANING MACHINE
Make: Sant Engg Works, Jallandar

Type/Model: Champion
Specification:
Length of Stroke: 1200 mm
Length of Table: 1220 mm
Width of Table: 520 mm
Power of Motor: 2.2 kW (970 rpm)
PLANING MACHINE: is very similar to the shaper in terms of the surfaces that can be
generated. A planer is generally used for machining large work pieces which cannot be held in a
shaper. In a shaper the cutting tool reciprocates during the cutting motion, while in the case of a
planer the work table reciprocates. The feeding motion in a planer is given to the cutting tool,
while remains stationary during the cutting motion.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-Y
SLOTTING MACHINE
SLOTTING MACHINE
Make: EIFCO, Coimbatore
Type/Models:ESM-105
Specifications:
Stroke of Ram: 105 mm
Range of Ram Speed: 55,85 & 115 Stroke/min
Dia of Table:250 mm
Table Traverse:250X125X275 mm3
Motor Capacity:0.75kW
SLOTTING MACHINE: is basically a vertical axis shaper. The work pieces which cannot be
conveniently held in a shaper can be machined in a slotter. Generally keyways, splines,
rectangular grooves and similar shapes are machined in a slotting machine. The stroke of the ram
is smaller in slotting machines than in shapers to account for the type of the work that is handled
in them.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-Z
RADIAL DRILLING MACHINE
RADIAL DRILLING MACHINE

Make: ICM Tool Room, Erode
Type:RO40
Specification:
Drilling capacity
For steel:40 mm
For CI: 45 mm
Max Drilling Depth: 162 mm
Max Drilling radius:490 mm
Min Drilling radius: 140 mm
Dia of the column:200 mm
No of Spindle speed:16
Range of Spindle speed: 45-1450 rpm
No of Spindle Speed;02
Power: 1.5kW
RADIAL DRILLING MACHINE: is more versatile. The drill head can move along the radial
arm to any position while the radial arm itself can rotate on the column, thus allowing for
reaching any position range of the machine. They are convenient for large work pieces which
cannot be moved easily because of their weight, such that the drill head itself is moved to the
actual location on the work piece, before carrying the drilling operation.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-AA
PILLAR DRILLING MACHINE
PILLAR DRILLING MACHINE

Make: Investa Machine Tools Ltd
Type/Model:PD50
Specification:
Drilling Capacity
For steel: 50 mm
Max Drilling Depth: 220 mm
Dia of Column: 200 mm
Dia of Spindle: 65 mm
No of Spindle speed: 95-1060 rpm
No of Spindle feeds:04
Range of Spindle feeds:0.1-0.4 mm/rev
Dia of Table: 550 mm
Power rating: 3.75 kW(1430 rpm)
PILLAR DRILLING MACHINE: is a fixed style of drill that may be mounted on a stand or
bolted to the floor. It consists of a base, column (or pillar), table, spindle and drill head, usually
driven by an induction motor. The head has a set of handles (usually 3) radiating from a central
hub that, when turned, move the spindle and chuck vertically, parallel to the axis of the column.
The size of a drill press is typically measured in terms of swing. Swing is defined as twice the throat
distance, which is the distance from the center of the spindle to the closest edge of the pillar.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-BB
VERTICAL MILLING MACHINE
VERTICAL MILLING MACHINE

Make: BFW, Bangalore
Type/Model:FV-1
Specifications:
Table Size: 1000 X 225 mm2
Power Traverse: 560 X 220 X 370 mm3
No of Spindle Speed: 08
Range of Spindle Speed: 56-1400 rpm
No. of feeds: 09
Power:
Main Motor:03 kW
Coolant Motor:0.11kW
VERTICAL MILLING MACHINE: The spindle is located in the vertical direction and suitable
for using the shank mounted milling cutters such as end mills. The vertical axis milling machine
is relatively more flexible and suitable for machining complex cavities such as die cavities in
tool rooms. The milling head can be swiveled.

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-CC
HORIZONTAL MILLING MACHINE
HORIZONTAL MILLING MACHINE: The machine is suitable for general milling work. Its
characteristic is the horizontally mounted milling spindle. The column bears the horizontally
mounted milling spindle, the main and feed drive, the knee with cross slide and milling table,
and the supporting arm which is frequently supported by the supporting bracket

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-DD
HORIZONTAL MILLING MACHINE HORIZONTAL MILLING MACHINE
Make: HMT Ltd Make: HMT Ltd

Type/Model: M2/U Type/Model:FN2U
Specifications: Specifications:
Table size: 1100x275 mm2 Table Size:1520x310 mm2
Power Traverse:650x225x365 mm3 Power Traverse:800x265x400 mm3
Swivel of table: 450 on either side Swivel of the table: 450 on either side
No. of spindle:18 No. of spindle speed:18
Range of spindle speed: 34-635 rpm Range of spindle speed:35.5-1800 rpm
No. of feeds:16 No. of feeds:18
Power: Power
Main Motor:5.5 kW(1500 rpm) Main Motor:5.5kW(1500 rpm)
Feed Motor:1.25kW(1500 rpm) Feed Motor:1.5kW(1500 rpm)
 The base gives support and rigidity to the machine and acts as a reservoir for the cutting
fluids
 The Column face is a precision-machined and scraped section used to support and guide the
knee when it is moved vertically
 The Knee is attached to the column face and may be moved vertically on the column face
either manually or vertically. It houses the feed mechanism
 The saddle is fitted on the top of the knee and may be moved in or out either manually by
means of the cross feed hand wheel or automatically by the cross feed engaging lever
 The Swivel table housing, fastened to the saddle ,enables the table to be swiveled 450 to either
side of the centerline
 The table rests on guide ways in the saddle and travels longitudinally in a horizontal plane.
It supports the vise and the work piece
 The Cross feed hand wheel is used to move the table toward or away from the column
 The table hand wheel is used to move the table horizontally left and right in front of the
column
 The Feed Dial is used to regulate the table feeds
 The Spindle provides the drives for arbors, cutters, and attachments used on a milling
machine
 The Over arm provides for correct alignment and support of the arbor and various
attachments
 The Arbor support is fitted to the over arm and can be clamped at any location on the over
arm
 The Spindle Speed dial is set by a crank that is turned to regulate the spindle speed

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-EE
CUTTER AND TOOL GRINDER
UNIVERSAL TOOL AND CUTTER GRINDER: The Universal cutter and tool grinder is
designed primarily for the grinding of cutting tools such as milling cutters, reamers and taps. Its
Universal feature and various attachments permit a variety of other grinding operations to be
performed. Other operations that may be performed are internal, cylindrical, taper, and
surface grinding; single-point tool grinding; and cutting-off operations
UNIVERSAL TOOL & CUTTER GRINDER

Make: Bam kin, England
Specification:
Capacity between the centers: 8"   18" long
Movement of the Wheel Head (vertical): 9”
"
Table dimensions: 17 "  4 1
4
"
Longitudinal travel of the table: 10 1
2
Table swing around the column(traverse):23”
"
Motor Power: 1 HP
2
Speed:4250-5500 rpm
Size of Grinding Wheel: 5”Ø

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-FF
HYDRAULIC CYLINDRICAL GRINDER
CYLINDRICAL GRINDER: The cylindrical grinder is a type of grinding machine used to

shape the outside of an object. The cylindrical grinder can work on a variety of shapes,
however the object must have a central axis of rotation. This includes but is not limited to such
shapes as a cylinder, an ellipse, a cam, or a crankshaft.
HYDRAULIC CYLINDRICAL GRINDER
Make: HMT, Ajmer

Type/Model:K130U
Specifications:
Height of Centers: 130 mm
Swing over Table: 260 mm
Max Grinding Length: 340 mm
Distance between Centers: 340 mm
Table- Max Travel: 310 mm
Max Swivel: 200
Size of Grinding Wheel: 300X 240 X 40 mm3
Speed of Grinding Wheel: 1910-2120 rpm
No. of Work Speed: 08
Range of Speed: 56-630 rpm
Power- Motor: 4 kW
Oil pump motor:1.1 kW

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-GG
SURFACE GRINDING MACHINE
SURFACE GRINDERS: Surface grinding machines are machines that are employed to finish
plane or flat surfaces. But they are also capable of grinding irregular, curved, tapered, convex,
and concave surfaces
HYDRAULIC SURFACE GRINDING MACHINE
Make: Alex machine tools, Bombay

Type: H-208
Specifications:
Work table size: 500x 200 mm2
Max longitudinal travel of table: 550 mm
Max Cross traverse of the table: 225 mm
Max Vertical traverse of table: 275 mm
Cross feed per stroke: 0.15-0.30 mm
Size of Grinding wheel: 200x20x50 mm3
Spindle speed: 2500 rpm
Power- Spindle motor: 1.5 kW
Hydraulic pump motor: 0.75 kW

Aim: Study of Cutting Tools, work holding devices and Machine Tools 4-HH

Aim: To Perform Facing, Centering and counter sinking operation 5-A
FACING OPERATION
CENTERING & COUNTERSINKING OPERATION
160

Aim: To Perform Facing, Centering and counter sinking operation 5-B
Tools required: Spanner, Facing Tool bit or Single point cutting Tool, 3-Jaw chuck, Steel scale,
Centre drill & Drill chuck
Theory: Work pieces to be machined are generally cut a little longer than required and then
end-faced to the proper length. Facing is an operation of machining the ends of a work piece
square with its axis. The purpose of facing are (i) To provide a true, flat surface, square with
the axis of the work piece (ii) To provide an accurate surface from which to take measurements
(iii) To cut the work piece to the required length
Work piece to be turned between the centers on a lathe must have a hole drilled in
each end so that the work piece may be supported by the lathe centers. Centering consists of
Drilling of the centre hole with a twist Drill. An additional countersinking or chamfering is
done to protect the center bore against damage with a countersunk bit with countersinking
angle of 600. In practice, a combination Drill and Countersink, more commonly called a Center
Drill is used for this operation.
Procedure:
To Face Work piece held in a chuck
1. Hold the work piece in a three-jaw chuck having at least an amount equal to the diameter
of the work piece projecting from the chuck jaws
2. Set up the facing Tool bit or Single point turning tool to the height of the Dead Center and
pointing slightly to the left
3. Swivel the compound rest 300 to the right if only one surface on the work piece must be
faced
4. Set up the facing Tool bit or Single point turning tool to the height of the Dead Center and
pointing slightly to the left
5. Lock the carriage in position
6. Set the depth of cut by using the graduated collar on the compound rest screw
7. Set the lathe to the correct speed & start
8. Feed the cutting tool by turning the cross feed handle and cut towards the center of the
work piece
9. Stop the lathe. Remove the work piece from the chuck & bring the other end of the work
piece for facing
10. Face the work piece to required length
Centering and Countersinking Operation:

1. If the work piece is held in the chuck of the lathe, the marking of the center and center-
punching is not necessary
2. With draw the Single point turning tool from the work zone and hold Center Drill on a
Drill chuck and mount it on the Tail stock spindle
3. Bring the body of the Tail stock near the work piece and tighten properly to the lathe bed
4. Start the Lathe and run the work piece at a relatively lower speed
5. Give the feed to the tool by rotating the Tailstock hand wheel
6. After the required depth is reached, with draw the tool & stop the lathe
7. Remove the work piece from the chuck. Do the Centering & Countersinking to the other
end of the work piece.

Aim: To Perform Facing, Centering and counter sinking operation 5-C
Work Sheet:

Aim: To perform Plain turning and marking operation 6-A
PLAIN TURNING
25
O
160
25 10 30 10 40 10 35
23
O

Aim: To perform Plain turning and marking operation 6-B
Tools required: Spanner, single point cutting tool, Steel scale or Vernier Caliper, outside caliper,
Lathe Dog.
Theory: Plain turning in a Lathe is to remove excess material from the work piece to produce a
Cylindrical shape. The work piece is turned straight when it is made to rotate about the
Lathe axis. The Tool is fed parallel to the Lathe axis. There are two kinds of cuts.
(i)Rough cut or Rough turning: Rough turning removes as much metal as possible in
The shortest length of time. Accuracy and Surface -
Finish are not important in this operation
(ii)Finish cut or Finish turning: Finish turning, which follows rough turning, produces
A smooth surface finish and cuts the work to an
Accurate size
Procedure:
1) Set the lathe to the correct speed and set the tool bit height to Lathe center
2) Mount the work piece between the centers using Lathe dog attached to the work piece. The
Straight-tail dog is driven by a stud in the drive plate and in case of Bent-tail dog, tail of the
dog fits into a slot on the driver plate.
3) Do rough turning by applying high rate of feed and heavy depth of cut using cross feed
Micrometer. Give one or more number of passes to the tool depending on the removal of the
metal and check diameter of work piece after each pass by outside caliper
4) Do Finish turning applying High cutting sped, giving small feeds and depth of cut
5) Check the final dimension of work piece
6) By taking the measurement from the scale by outside caliper or vernier, transfer the dimension
to the work piece and Mark by giving a light cut from the tool.
7) Graduated Micrometer is mounted on the compound rest and cross feed. The Micrometer
collars on Hi-Tech Lathe uses Metric system of measurement and by turning the collar of cross
feed screw by one graduation line, the tool will advance by 0.05mm and diameter will be
reduced by 0.1mm.
Hi-Tech Kirloskar Madras

Lathe Harihara Machine
Lathe Tools
Least Count on
Cross Feed 0.05 mm 0.05 mm 0.025 mm
Micrometer

Aim: To perform Plain turning and marking operation 6-C
Work Sheet:

Aim: To perform Knurling operation 7-A
25 10 30 10 40 10 35
23
O

Aim: To perform Knurling operation 7-B
Tools Required: Three-Jaw chuck or Lathe Dog & Face Plate, Knurling Tool, Spanner
Theory: Knurling is a process of impressing a definite shaped pattern into the surface of the
Work piece to improve its appearance or to provide a better gripping surface. Straight
Knurling is often used to increase the work piece diameter when a press fit is required.
The Knurling tool is a tool post-type tool holder on which a single or one set
Or more set of Hardened-Steel rolls are mounted. These rolls may be obtained in Diamond
And Straight-line patterns and in coarse, medium, and fine pitches
Procedure:
1) Mount the Marked work piece between the centers using Lathe Dog. If the work piece is held in
a chuck for knurling, the right end of the work piece should be supported with a revolving Tail
stock centre
2) Set the Lathe to run at one-quarter the speed required for turning
3) Set the center of the floating head of the knurling tool even with the dead-center point
4) Set the knurling tool at right angles to the work piece and tighten it securely in this position
5) Press the knurling tool against the work piece and start the Lathe or start the lathe and press the
knurling tool against the work piece until the knurling depth is reached
6) Examine the pattern. Once the pattern is correct ,Knurl to the proper length. Feed is generally
3mm/min
7) If the knurling patterns is not to a point after the length has been knurled, reverse the Lathe
feed and take another pass across the work piece
8) Plenty of oil is Poured on the tool and work piece during the operation
Note: Since the Tool exerts lot of pressure during knurling, may cause buckling of the work piece
and hence knurling operation is performed first after marking.

Aim: To perform Knurling operation 7-C
Work Sheet:

Aim: To perform Step turning operation 8-A
STEP TURNING
TYPES OF SHOULDERS
25 10 30 10 40 10 35
O
23
18
18
18

Aim: To perform Step turning operation 8-B
Tools Required: V-Tool, End-Facing Tool or Parting Tool, External Caliper and Vernier-
Caliper, Lathe Dog, Spanner
Theory: When turning more than one diameter on a piece of work, the change in diameters,
Or step, is known as a Shoulder and turning this part of the work piece is called
Shoulder turning. There are three common types of shoulders
(i) Square shoulder (ii) Filleted shoulder (iii) Bevelled or Angular shoulder
Procedure:
1) The marked work piece is mounted between the centers using Lathe dog
2) The Marked length is first turned using the V-tool
3) Rough and Finish –turn is performed within 0.5 to 1mm of the shoulder mark
4) For square shoulder an End-Facing tool or Parting tool is used to finish up to the Shoulder
mark

Aim: To perform Step turning operation 8-C
Work Sheet:

Aim: To perform Taper turning operation by Swiveling the Compound rest 9-A
Taper turning by swiveling compound rest
Calculation:

Aim: To perform Taper turning operation by Swiveling the Compound rest 9-B
Given: D=23mm, d=18mm, L=40mm
Setting angle
 Dd
tan( ) 
2 2L
 23  18
tan( )   0.0625
2 2  40

( )  tan 1 (0.0625)
2

( )  3.57   3.6
2
25 10 30 10 40 10 35
23
O
18
18
18

Aim: To perform Taper turning operation by Swiveling the Compound rest 9-C
Tools required: Spanner, Lathe Dog, Single point cutting tool
Theory: A Taper may be defined as a uniform change in the diameter of a work piece
Measured along its axis. Metric tapers are expressed as a ratio of 1mm per unit of
Length
In a Lathe, taper turning means to produce a conical surface by gradual
Reduction in diameter from a cylindrical work piece. A Taper may be turned by any
One of the following methods
(i) by a Broad nose form tool
(ii) by Off setting the tail stock center
(iii) by swiveling the compound rest
(iv) by using taper turning attachment
(v) by combining longitudinal and cross feed in a special lathe
By swiveling the compound rest: To produce short or steep tapers stated in degrees,
This method is used. The compound rest may be swiveled at 450 on either side of the
lathe axis enabling it to turn a steep taper. The tool is fed in by hand, using the
compound rest feed handle. The setting of the compound rest is done by swiveling the
rest at the half taper angle. If the diameter of the small and large end and length of
taper are known, the half taper angle can be calculated.
 Dd
( )  tan 1 ( )
2 2L
Procedure:
1) Calculate the compound rest setting angle
2) Loosen the compound rest lock screws
3) Swivel the compound rest as follows
(a) Where included angles are given on the drawing, swivel the compound rest to one-half
the angle.
(b) Where angles are given on one side only, swivel the compound rest to that angle
4) Tighten the compound rest lock screws
5) Set the cutting tool to center with the tool holder at right angles to the taper to be cut
6) Tighten the tool post securely
7) Back off the top slide of the compound rest so that there will be enough travel to machine
the length of the taper
8) Move the carriage to the position the cutting tool near the start of the taper and lock the
Carriage
9) Rough turn the taper by feeding the cutting tool using the compound rest feed handle
10) Finish- turn and check the taper
Note:
1) If the tool nose is inclined towards the tailstock, smaller diameter of the taper will be start
from the headstock end and vice-versa
2) Taper tuning must be started from the bigger end

Aim: To perform Taper turning operation by Swiveling the Compound rest 9-D
Work Sheet:

Aim: To perform External Thread Cutting operation 10-A
THREAD NOMENCULATURE RIGHT AND LEFT HAND THREAD CUTTING
TUMBLER GEAR MECHANISM

Aim: To perform External Thread Cutting operation 10-B
CHANGE GEARS
METRIC THREADS IN HI-TECH LATHE

Pitch in 0.5 0.75 1.0 1.25 1.5 1.75 2.0 2.25 2.5 2.75 3.0
mm
P 25 30 25 25 30 40 40 45 50 55 60
Gears Q 100 100 50 100 100 80 100 100 100 100 80
R 40 50 40 70
S 127 127 127 127 127 127 127 127 127 127 127
Pitch in 3.5 4.0 4.5 5.0 5.5 6.0 7.5

mm
P 70 80 90 50 55 60 75
Gears Q 80 50 50 40 40 40 40
R 80 80 80 80
S 127 127 127 127 127 127 127
CHANGE GEAR FURNISHED

25 30 35 40 45 50 55 60 65 70 75 80 90 95 100 105 110 127

Aim: To perform External Thread Cutting operation 10-C
Change Gear Calculations:
Work Piece: 2.5mm pitch

1
Lead screw on Hi-Tech lathe: 4 TPI (4 threads per 1’’) = pitch
4 ''
Teeth of driving Gear P Pitch of thread Pw
=
Teeth of driven Gear S Pitch of Lead screw PL
P Pw P 2.5mm
  
S Pl S 1 ''
4
P 2.5 P 2.5  4
  
S 25.4 S 25.4
4
P 10

S 25.4
Since there are no suitable gears, the fraction (10/25.4) has to be converted into two fractions and
each one multiplied with a suitable number
P R 1 10 P R 1 10 10
      ( ) 50  ( )
Q S 2 12  7 Q S 2 12  7
P R 50 100
  
Q S 100 127
Metric Thread: Thread Angle=600, M 23 x 2.5

Max. Depth=0.7035 x Pitch
Min. Depth= 0.6855 x Pitch
Depth of cut= 0.6855 x 2.5= 1.71375  1.7
1.7  100
No. of Division on Cross feed Micrometer for calculated depth of cut=  34 Division
5
25 10 30 10 40 10 35
3
O 2
18
18
18

Aim: To perform External Thread Cutting operation 10-D
Tools required: Spanner, Thread tool bit (600 thread), Lathe Dog, Pitch Gauge, Thread center-
Gauge
Theory: Thread cutting on a Lathe is a process that produces a helical ridge of uniform section on
A work piece by feeding the tool longitudinally when the job is revolved between centers
Or by a chuck. The thread tool bit must be of the same shape as the thread form required.
The longitudinal feed should be equal to the pitch of the thread to be cut per revolution of
the work piece. The lead screw of the lathe, through which the saddle receives its traversing
motion has a definite pitch. A definite ratio between the longitudinal feed and rotation of the
head stock spindle should therefore be found out so that the relative speeds of rotation of the
work piece and the lead screw will result in the cutting of a screw of the desired pitch. This
is effected by change gears arranged between the spindle and lead screw.
Tumbler Gear Mechanism: Tumbler gears are used to give the desired direction of
movement to the lathe carriage, via Lead screw or feed shaft. The Tumbler gearing
comprises of two pinions mounted on a bracket. There are three position for bracket:
Forward, Neutral, and Reverse
Thread Terminology
 A screw thread is a helical ridge of uniform section formed on the inside or outside of a
cylinder or cone
An external thread is cut on an external surface or cone
An internal thread is produced on the inside of a cylinder or cone
The major diameter is the largest diameter of an external or internal thread
The minor diameter is the smallest diameter of an external or internal thread
The pitch diameter is the diameter of an imaginary cylinder that passes through the thread at
a point where the groove and thread widths are equal
The number of threads per inch is the number of crests or roots per inch of threaded section.
This term is not applied to metric thread
The pitch is the distance from a point on one thread to a corresponding point on the next
thread, measured parallel to the axis. Pitch is expressed in millimeter for Metric threads
The lead is the distance a screw thread advances axially in one revolution
The root is the bottom surface joining the sides of two adjacent threads
The crest is the top surface joining two sides of a thread
The depth of thread is the distance between the crest and root measured perpendicular to the
axis
The angle of thread is the included angle between the sides of a thread measured in an axial
plane
A right-hand thread is a helical ridge of uniform cross section onto which a nut is threaded in
a clockwise direction
A left-hand thread is a helical ridge of uniform cross-section onto which a nut is threaded in a
counterclockwise direction

Aim: To perform External Thread Cutting operation 10-E
Change Gear calculations
In general,
Teeth of driving gear Pitch of thread Pw
=
Teeth of driven gear Pitch of lead screw PL
Or
Specifically
When lead screw with inch pitch and work piece with millimeter pitch
Teeth of driving gear 5Pn


Teeth of driven gear 127
Where P= pitch of the thread to be cut

n= number of threads per inch on the lead screw
Procedure:
1) Calculate the change gears, depth of cut and No. of division on cross feed micrometer for depth
of cut
2) Mount the change gears and set them properly to mesh with each other
3) Tumbler gears are engaged depending on the type of thread to be cut i.e. right hand or left hand
thread
4) Set the lathe speed to about one-quarter the speed used for turning
5) Mount the work piece between the centers using lathe dog
6) Set the cutting tool to the height of the lathe center point
7) Set the tool bit at right angles to the work, using a thread center gauge
8) For a right hand thread, tool traverses from tail stock end to head stock end and for the left-hand
thread it is vice- versa
9) Move the carriage until the point of the threading tool is near start of the thread on the work
piece
10) Turn the cross feed handle until the threading tool is close to the diameter and holding the cross
feed handle in that position set the graduated collar to zero
11) Engage the lead screw
12) By counting the division on cross feed handle, give small depth of cut and start the lathe
13) After the end of one cut move away the tool and bring back the tool to the starting position by
reversing the machine
14) Apply lubricant fluid and take successive cuts by setting the depth of cut using cross feed handle
15) Finally, check the thread using pitch gauge for required pitch

Aim: To perform External Thread Cutting operation 10-F
II Case: Change Gear Calculation
Work Piece: 1.75mm pitch

1
Lead screw on Hi-Tech lathe: 4 TPI (4 threads per 1’’) = pitch
4 ''
Teeth of driving Gear P Pitch of thread Pw
=
Teeth of driven Gear S Pitch of Lead screw PL
P Pw P 1.75mm
  
S Pl S 1 ''
4
P 1.75 P 1.75  4
  
S 25.4 S 25.4
4
P 7

S 25.4
Since there are no suitable gears, the fraction (07/25.4) has to be converted into two fractions and
each one multiplied with a suitable number
P R 1 7 P R 1 7 10
      ( ) 40  ( )
Q S 2 12  7 Q S 2 12  7
P R 40 70
  
Q S 80 127
Metric Thread: Thread Angle=600, M 23 x 1.75

Max. Depth=0.7035 x Pitch
Min. Depth= 0.6855 x Pitch
Depth of cut= 0.6855 x 1.75= 1.1996  1.2
1.2  100
No. of Division on Cross feed Micrometer for calculated depth of cut=  24 Division
5

Aim: To perform External Thread Cutting operation 10-G
Space for Calculation:

Aim: To Perform Spur Gear Cutting Operation 11-A
GEAR NOMENCLATURE
MILLING OPERATION
Machine Shop/ Automobile Engineering/ Malnad College of Engineering

Aim: To Perform Spur Gear Cutting Operation 11-B

Aim: To Perform Spur Gear Cutting Operation 11-C
25 10 30 10 40 10 35
23
O
18
18
18
Spur Gear Calculations:
1
Involute Gear cutter Pressure angle= 14( ) 0
2
Cutter selection:-Available in our Machine Shop cutters of size 6DP, 8DP, 10DP, 12DP, 14DP, 16DP,
18DP, 20DP. In each DP there are sets of 8 cutters according to Involute curve which varies from size to
Rack.
Cutter No-1 135-Rack
Cutter No-2 55-134
Cutter No-3 35-54
Cutter No-4 26-34
Cutter No-5 21-25
Cutter No-6 17-20
Cutter No-7 14-16
Cutter No-8 12-13
Indexing Plate Chart (Brown and Sharpe):
Plate No-1= 15, 16, 17, 18, 19, 20.
Plate No-2= 21, 23, 27, 29, 31, 33.
Plate No-3= 37, 39, 41, 43, 47, 49.

Aim: To Perform Spur Gear Cutting Operation 11-D
For the Given DP=16 and the number of teeth N=12
N 12
Pitch Circle Diameter PD =   25.4  19.05mm
DP 16
PD 19.05
Module m =   1.58
N 12
N  2 12  2 14
Outside Diameter =    25.4  22.22  23mm
DP 16 16
1 1
Addendum =   25.4  1.587mm
DP 16
1.157 1.157
Dedendum =   25.4  1.836mm
DP 16
Whole Depth = Addendum+Dedendum=3.423mm
40 40 1
Simple Indexing = =  3 revolutions
N 12 3
A hole circle which can be divided by 3 of fraction is selected. If now 15 hole circle is selected from
1
Index Plate No.1, then 15  5 holes .The crank is turned 3 revolution plus the 5 holes on 15 hole
3
circle.

Aim: To Perform Spur Gear Cutting Operation 11-E
Tools Required: Gear Milling Cutter, Indexing Plate with Sector arms, Dividing Head, Chuck -key, Spanner
Theory: (1) Milling is a machining process which is performed with a rotary cutter with several cutting
edges arranged on the periphery of the cutter. It is a multiple point cutting tool which is used
in conjunction with a milling machine. This process is used to generate flat surfaces or curved
profile and many other intricate shapes with great accuracy and having very good surface
finish. Milling machines are one of the essential machines in any modern machine shop
(2) Based on the directions of movement of the milling cutter and the feeding direction of the
work piece, there are two possible types of milling (a) UP Milling [Conventional Milling] (b)
Down Milling [Climbing Milling]
The Up Milling is the Process of removing metal by a cutter which is rotated against the
direction of travel of the work piece. The thickness of the chip in Up- milling is minimum at the
beginning of the cut and reaches to the maximum when the cut terminates
The Down milling is the process of removing metal by a cutter which is rotated in the
same direction of travel of the work piece. The thickness of the chip is maximum when the
tooth begins its cut and it reduces to the minimum when the cut terminates
(3) The Indexing is the operation of dividing the periphery of a piece of work into any number of
equal parts. In Cutting Spur Gear, equal spacing of teeth on the Gear blank is performed by
Indexing
In Simple Indexing, the work piece is positioned by means of the crank, Index plate and
sector arms. The worm attached to the crank must be engaged with the Worm Wheel on the
dividing head spindle. Since there are 40 teeth on the worm wheel, one complete turn of the
Index crank will cause the spindle and the work piece to rotate one-fortieth of a turn. Similarly,
40 turns of the crank will rotate the spindle and work piece 1 turn. Thus, there is a ratio of 40:1
between the turns of the Index crank and the dividing Head spindle. Further Indexing is made
possible by having the Index plates with equi-spaced holes around various circles. This would
allow for indexing the periphery of the work piece to any convenient number of divisions.
Gear Terminology:
 Pitch Circle is the Imaginary Circle which by pure rolling action, would give the same motion as the
actual Gear
 Pitch Circle Diameter or Pitch Diameter (PD) is the diameter of the pitch circle. The size of the Gear is
N
usually specified by the pitch circle diameter. PD 
DP
 Pressure angle is the angle formed by a line through the point of contact of two mating teeth and
tangent to the two base circles and a line at right angles to the center line of the gears

Aim: To Perform Spur Gear Cutting Operation 11-F
 Addendum is the radial distance between the pitch circle and the outside diameter or the height of
1
the tooth above the pitch circle. Addendum=
DP
 The clearance is the radial distance between the top of one tooth and the bottom of the mating
tooth space
 Dedendum is the radial distance from the pitch circle to the bottom of the tooth space. The
1.157
dedendum is equal to addendum plus the clearance. Dedendum=
DP
 Circular Pitch (CP) is the distance from a point on one tooth to a corresponding point on the next
  PD
tooth measured on the pitch circle. CP=
N
 Diametral Pitch (DP) [Inch Gears] is the ratio of the number of teeth for each inch of pitch diameter
N 2
of the Gear. DP=
OD
 Outside diameter is the overall diameter of the Gear, which is the pitch circle plus two addendum.
N 2
OD=
DP
 Whole depth is the full depth of the tooth or the distance equal to the addendum plus the
dedendum
 Module (m) [Metric Gears] is the pitch diameter of a gear in millimeter divided by the number of
PD
teeth. m=
N
 Involute is the curved line produced by a point of a stretched string when it is unwrapped from a
given cylinder

Aim: To Perform Spur Gear Cutting Operation 11-G
Procedure:
1. For the given DP or OD and the number of teeth, calculate all the necessary Gear data
1
2. Calculate the Indexing. In this case for DP=16 and N=12, it is 3 revolutions
3
3. Mount 16 DP#8 cutter on the Arbor
4. Mount Index Plate No.1 on the Dividing Head
5. Loosen the Index Crank nut and set the Index Pin into a hole on the 15-hole circle (If 15-hole circle is
selected)
6. Tighten the Index Crank Nut and check to see that the Pin enters the hole easily
7. Loosen the set screw on the sector arm
8. Place the narrow edge of the left arm against the Index pin
9. Count 5 holes on the 15-hole circle. Do not include the hole in which the Index crank pin is engaged
10. Move the right sector arm slightly beyond the fifth hole and tighten the sector arm setscrew
11. Align the cutter with the work piece and move the table so that cutter clears the end of the work
12. Set the depth of cut and take the first cut
13. Now, stop the cutter & return the table to the original starting position
14.Withdraw the Index pin and turn the crank clock wise three full revolution plus the 5 holes indicated
by the right sector arm. Release the Index pin between the fourth and fifth holes, and gently tap it
until it drops into the fifth hole.
15. Turn the sector arm farthest from the pin clockwise until it is against the Index pin
16. Lock the dividing Head, then continue machining and indexing for the remaining teeth

Aim: To Perform Spur Gear Cutting Operation 11-H
Case II: Gear calculation
For the Given DP=18 and the number of teeth N=13
N 13
Pitch Circle Diameter PD =   25.4  18.35mm
DP 18
PD 18.35
Module m =   1.41
N 13
N  2 13  2 15
Outside Diameter =    25.4  21.16  21mm
DP 18 18
1 1
Addendum =   25.4  1.411mm
DP 18
1.157 1.157
Dedendum =   25.4  1.632mm
DP 18
Whole Depth = Addendum + Dedendum=3.043mm
40 40 1
Simple Indexing = =  3 revolutions
N 13 13
A hole circle which can be divided by 13 of fraction is selected. If now 39 hole circle is selected from
1
Index Plate No.3, then  39  3 holes .The crank is turned 3 revolution plus the 3 holes on 39 hole
13
circle.

Aim: To Perform Spur Gear Cutting Operation 11-I
Space for Calculation:

Aim: To perform Shaping operation 12-A
SHAPING OPERATION
CRANK AND SLOTTED LEVER QUICK RETURN MOTION MECHANISM

Aim: To perform Shaping operation 12-B
CUTTING ACTION AND FUNCTIONING OF CLAPPER BOX
25 10 30 10 40 10 35
O
23
18
18
18

Aim: To perform Shaping operation 12-C
Tools Required: Single Point Cutting Tool, Spanner
Theory: The Shaper (also called Shaping Machine) is a reciprocating type of Machine Tool used for
Producing small flat surfaces with the help of a Single point tool reciprocating over the
stationary work piece. The flat surface may be Horizontal, Inclined or Vertical. The
reciprocating motion of the tool is obtained either by the Crank and Slotted Lever Quick
Return Motion Mechanism or Whit worth Return Motion Mechanism
In Crank Shaper, the Length of Stroke is altered by varying the radius of the
crank pin and its block on the stroke wheel (Bull wheel). The Tool does useful work i.e.
cutting only in the Forward Stroke of the Ram. It does not cut i.e. it is Idle during the
Return Stroke of the Ram. The geometry of the Slotted Link Motion is such that Return
Stroke occupies a Shorter Time and so minimizes the Time wasted. In order that while
returning, the Tool may not rub and spoil the strip of the metal machined in the Forward
Stroke, a Special device called the “Clapper Box” is provided in the Tool post. It lifts the tip
of the Tool during the Return Stroke.
Procedure: (Machining Horizontal Surface)
1. Mount the work piece in the vise of shaping machine

2. Mount the Tool in tool post with minimum overhang
3. The Table is raised till there is a clearance of 25 to 30 mm between the Tool and the work
piece
4. Adjust the Length and Position of Stroke
5. Adjust the Depth of cut by rotating the down feed screw of the tool head
6. Position the Tool and work piece. Start the machine
7. First carry out rough cuts and then finish cuts.

Aim: To perform Shaping operation 12-D
Work Sheet:

Aim: To Perform Eccentric Turning Operation 13-A
Laying out the Centers of an Eccentric
O 25
75
23
15 40 15
O
3,5
O 12
2

Aim: To Perform Eccentric Turning Operation 13-B
Tools required: Surface plate, V-block with C-clamp, dot punch, scriber, combination set, height-
Gauge, Ball pean hammer
Theory: An Eccentric is a shaft that may have two or more turned diameters parallel to each
Other but not concentric with the normal axis of the work. Eccentrics are used in locking
devices, in the feed mechanism on some machines and in the crank shaft of Automobiles,
where it is necessary to convert rotary motion into reciprocating motion or vice versa
The amount of Eccentricity or Throw, of an Eccentric is the distance that a set of

center holes has been off set from the normal work axis
Procedure:
1. Place the 25mm diameter work piece in a chuck and face it to length
2. Place the work piece in a V-block on a surface plate and apply lay out dye (or Wet chalk)
to both ends of the work piece
3. Set a Vernier height gauge to the top of the work and note the Vernier reading
4. Subtract half the work diameter from the reading and set the gauge to this dimension
5. Scribe a centerline on both ends of the work piece
6. Rotate the work piece 900 and scribe another centerline on both ends at the same height-
gauge setting
7. Now from the top edge of the work piece lower the height-gauge setting by 9mm and scribe
the lines for the off set center on one end
8. Similarly scribe the lines for the off-set centers on other end from the top edge of the work
piece opposite end to earlier
9. Carefully center-punch the four scribed centers
10. Mount the work piece in four jaw chuck and true the work piece for true centers
11. Turn the work piece for 23mm diameter with the true centers
12. Set the work piece on the off set centers for one end with required length of work over
hanging and turn the Eccentric to the required diameter and length
13. Set the work piece on the off set centers for other end and similarly turn the Eccentric

Aim: To Perform Eccentric Turning Operation 13-C
Work Sheet:

VIVA Questions 14-A
1. What is the function of Outside Calipers and Inside Calipers

2. What is use of combination set
3. What are the basic differences between a Metric and an Inch Micrometer
4. Define Least count of a Micrometer
5. State the two main applications of the Vernier Height Gauge
6. What is the function of surface Gauge
7. State the purpose of Single-cut files and Double-cut files
8. Define Machinability
9. Explain types of chips produced during Machining operations
10. Which is the most desirable type of chip? Give reasons
11. How does high temperature affect a Machining operation
12. Why is it important that friction between the chip and tool be kept to a minimum
13. What are the various costs associated with Machining operation
14. What common factors determine Surface finish
15. Why are surface treatments used on Metals
16. Explain Cutting-Tool Nomenclature
17. What properties should a cutting tool possess
18. How does Negative Rake on a cutting tool affect the cutting process
19. What are three factors that influence cutting tool life
20. Which factor increase causes the greatest reduction in cutting-tool life
21. How is metal-removal rate measured
22. How do you define Tool life
23. What are the various forms of wear found in cutting tools
24. Explain Orthogonal cutting and Oblique cutting
25. Show schematically Merchant’s force circle in Orthogonal cutting
26. Generally what are materials used for lathe Tool bit
27. What elements are found in High-speed steel tool bits
28. State four reasons Cemented-Carbide tools have been widely accepted by Industry
29. List four main advantages of Diamond cutting tools
30. Name four important applications for Ceramic tools
31. What advantages do polycrystalline Cubic Boron Nitride (PCBN) tools offer in Industry
32. What is the function of a cutting fluid
33. Define Broaching
34. State three reasons for Lapping
35. What is the purpose of Honing
36. Explain the Nomenclature of Drill
37. Define Drilling, Boring ,Reaming, Countersinking, Counter-boring, Tapping
38. Compare a Sensitive Drill Press with an Upwright Drilling machine
39. What are the advantages of a Radial Drilling machine
40. What is the purpose of a Drill Chuck
41. Name three materials used to manufacture Drills
42. Give the classification of Drilling machine
43. How is Drilling machine specified
44. Define cutting speed, feed and machining time for Drilling
45. Sketch a twist drill and name its different parts
46. Can tapping be done on a drilling machine
47. What is the purpose of reamer
48. Explain the Nomenclature of Single point cutting tool
VIVA Questions 14-B
49. Differentiate between Machine and Machine Tool

50. State the operations that can be performed on a Lathe
51. What are types of Lathes you are familiar with? Give their applications
52. Explain the parts of a Centre lathe
53. How is the size of a Lathe designated
54. How can you specify a Lathe
55. Differentiate between Turrent lathe and Capstan lathe
56. State the purpose of the following (a) Head stock spindle (b) lead screw and feed rod (c) Quick-
change Gear box (d) Split-nut lever (e) Feed change lever (f) Cross-slide (g) Compound rest (h)
Lathe –Bed
57. Name the types of Lathe centers and state the purpose of each
58. State the purpose of the following (a) Three-Jaw Universal chuck (b) Four-Jaw Independent
chuck (c) Collet Chuck (d) magnetic chuck
59. Explain the difference between three jaw chuck and four jaw chuck
60. What is the purpose of four jaw Independent chuck
61. Discuss merits and demerits of a Geared-head drive over cone –pulley drive
62. What is Bull gear and it’s function
63. List the accessories of a lathe
64. Name three types of Lathe Dogs
65. Define cutting speeds, machining time, lathe feed and depth of cut in lathe
66. What is (a) Roughing cut (b) Finishing cut
67. What is the value of one graduation on a metric graduated micrometer collar of Hi-tech lathe
68. State three purposes of facing a work piece
69. Define the process of knurling
70. What are the different patterns produced in knurling operations
71. What is the material knurling tool rolls made of
72. Why is it important not to disengage the fee during the knurling operation
73. define Taper
74. what are the various methods available for taper turning in a lathe
75. Define Thread
76. What are the main types of screw threads
77. List four purposes of thread
78. Define pitch diameter, pitch ,lead, root and crest of a thread
79. What is the purpose of the quick-change gear box
80. What is the purpose of Tumbler gear mechanism
81. What is the purpose of thread-chasing dial
82. State the purpose of a follower rest and steady rest
83. State the purpose of a Mandrel
84. Define an Eccentric and state its purpose
85. Why should a hole be bored before it is reamed
86. What is the purpose of reaming in a lathe
87. Explain the Nomenclature of Milling cutter
88. How is milling machine specified
89. What are the various types of milling cutters that are used in milling
90. Define the following terms used in milling operation (a) cutting speed (b) feed (c) depth of cut
(d) machining time
91. State three reasons a vertical milling machine is such a versatile machine tool
92. Name operations that can be performed on a vertical milling machine
VIVA Questions 14-C
93. Name operations that can be performed on Horizontal milling machine

94. Differentiate Horizontal and Vertical milling machine
95. What is the purpose of end milling and face milling
96. Name two common materials from which end mills are made
97. Describe Climb milling and Conventional milling
98. Differentiate between Up milling and Down milling
99. What is the purpose of an Arbor
100. What is Indexing
101. For what purpose is Direct indexing used
102. Explain how the ratio of 40:1 determined on a standard Dividing Head
103. Explain the principle of Angular Indexing
104. For what purpose is Differential Indexing used
105. What is simple Indexing
106. Find simple indexing for 40/12
107. What is the purpose of Indexing plates
108. What is the difference between Hobbing and Milling as Gear cutting processes
109. Define the following Gear terms (a) Pitch diameter (b) Diametral pitch (c) Addendum (d)
Dedendum (e) Clearance (f) Outside diameter (g) Module
110. Describe Thread milling
111. What are the advantages of Helical gears over Spur gears
112. How can a Key way be machined on a shaft
113. How can you classify the Shaper
114. How can you specify a Shaper
115. Explain the principle of Quick Return motion mechanism of a shaper. What is the need of
this mechanism
116. What is the normal ratio of Cutting Stroke and Return Stroke in a Shaper
117. Explain the function of Clapper block
118. Classify Planer
119. Differentiate between Shaper, Planer and Slotter
120. Why Quick Return motion is provided in shapers and Planers
121. What do you understand by grit, Grade, Bond and Structure of a Grinding wheel
122. Describe any four types of Bonds for Bonded Abrasives on a Grinding Wheel
123. What are the main difference between Cylindrical and Centre less grindings
124. What do you meant by Grinding
125. What are the factors to be considered for Grinding operation

VIVA Questions 14-D
Reference:
1. Google Images
2. Manufacturing Technology by P.N.Rao
3. All About Machine Tools by Heinrich Gerling

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MACHINE SHOP

1) Machine Shop Safety

“Think Safe, Work Safe and be Safe”

Machine Shop Rules

Safe Work Practices

Machine Shop / Automobile Engineering / Malnad college of Engineering

Machine Shop / Automobile Engineering / Malnad college of Engineering

DOUBLE END SPANNER

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VERNIER HEIGHT GAUGE

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MICROMETER: A micrometer sometimes known as a micrometer screw gauge is a device

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Machine Shop / Automobile Engineering / Malnad college of Engineering

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THREAD PITCH GAUGE

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CUTTING TOOLS AND WORK HOLDING DEVICES

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KNURLING TOOL: is a tool post-type toolholder on which pair of hardened-steel rolls is

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THREADING TOOL BIT

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PLAIN MILLING CUTTERS

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SIDE MILLING CUTTERS (STAGGERED-TOOTH)

FACE MILLING CUTTERS

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WOODRUFF KEYSEAT CUTTER

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SLOTTING TOOL: is single point cutting tool similar to shaping Tool

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A KEY-TYPE DRILL CHUCK

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THREE- JAW UNIVERSAL CHUCK WITH KEY

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FOUR-JAW INDEPENDENT CHUCK

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REVOLVING TAILSTOCK CENTERS

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LATHE SPECIFICATIONS LATHE SPECIFICATIONS

Make: Chaitanya Machine Tools Make: Kirloskar Ltd, Mysore

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CAPSTAN AND TURRET LATHES

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Shaping Machine Shaping Machine

Make: Sagar Engg Works Make: Cooper Engg Ltd

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Make: Sant Engg Works, Jallandar