Manufacturing Processes Lab

(MEL 203)
L-T-P: 0-0-2
Course Credit: 1
B.Tech. (3rd Sem) Autumn 2021
Department of Mechanical Engineering
NIT Srinagar

Course In-charge
Dr. Noor Zaman Khan
 List of Experiments
1. To study the construction details and working principle of Lathe Machine.
2. To perform taper turning operation on Lathe Machine
3. To perform step turning operation on Lathe Machine
4. To study the tool geometry of a single point cutting tool.
5. To perform drilling operation on a given work piece using Drilling Machine
6. To perform shaping operation on a given work piece using Shaper Machine
7. To perform external thread cutting operation on Lathe Machine
8. To investigate the effect of turning process parameters on the surface roughness
of machined component
 Course Outcomes

CO1: Describe the geometry of single point cutting tool

CO2: Apply knowledge of metal cutting to perform various machining operations

CO3: Explain the working and use of various components of conventional machine tools

CO4: Investigate the effect of machining process parameters on surface roughness

Safety Guidelines
1. Do not wear watches, bracelets, or loose turn clothing of any kind during
machine operation.
2. Must wear shoes and apron before coming to the lab for performing experiments.
3. Must be familiar with the location of emergency stop button to turn off all
electrical power for emergency.

4. Do not leave experiments running unattended.

5. Do not touch the workpiece or tool during experimentation

6. Eating, drinking, smoking, and handling contact lenses are prohibited in the lab
7. Maintain proper distance from moving parts or operating machines.
Important points
• Attached practical file is just for reference.
• Be careful about the Exp number and dimensions while writing the
practical file.
• Exp number may differ from the attached file.
• Figure number may also change.
• The conclusion is you cannot copy the attached file as it is.
• For Exp 4: tool geometry exp, take help from theory class notes and
this pdf file. Don’t copy the attached file and don’t follow the wrong
terminology in figures of attached file.
To study the construction details and working principle of Lathe Machine.
• AIM: To study the construction details and working principle of lathe machine.

• INTRODUCTION: Machining is the process of converting the given work piece into the required shape and
size with the help of a machine tool. The most widely used machine tool is lathe. In simple words machining
is the process of removing certain material from the work piece.

• LATHE: Lathe is the machine tool which is used to perform several operations on the work piece. Lathe is
useful in making several parts which is further assembled to make new machine. Hence lathe is known as
“mother of machines”.

• BASIC WORKING PRINCIPLE OF LATHE: In lathe, the work piece is held in the chuck, a work
holding device. The cutting tool is mounted in the tool post. The chuck is rotated by means of power. When
the chuck rotates, the work piece also rotates. The tool is moved against the rotating work piece by giving
small amount of depth of cut. The material is removed in the form of chips. Continuous feed and depth of cut
is given until the required dimensions are obtained in the work piece.
TYPES OF LATHE MACHINES
• There are different types of lathe machines, they are

• 1. Centre lathe

• 2. Tool room lathe

• 3. Bench lathe

• 4. Capstan and Turret lathe

• 5. Automatic lathe
DESCRIPTION OF LATHE
• Lathe is a machine which has several parts in it. They are

• Bed:

• Head stock:

• Carriage:

• Saddle:

• a) Cross slide:

• b) Compound rest:

• c) Tool post:

• Apron:

• Lead screw:

• Tail stock:

• Figure number as per the number of exp.

TOOL MATERIALS
1. The single point cutting tools are made of high-speed steel (HSS) and/or Tungsten carbide.

2. The main alloying elements in 18 – 4 – 1 HSS tools are 18 % tungsten, 4% chromium and 1 %
Vanadium. 5 to 10 % cobalt is also added to improve the heat resisting properties of the tool.

3. General purpose hand cutting tools are usually made from carbon steel or tool steel.

4. Carbide tipped tools fixed in tool holders, are mostly used in production shops
LATHE OPERATIONS
• Facing

• Plain Turning

• Step Turning

• Taper Turning

• Knurling

• Drilling
 Taper turning (Exp Number 2)
• AIM: To perform taper turning operation on a given workpiece using Lathe machine.

• MATERIALS REQUIRED: Mild steel round rod - f 32 X 100 mm

• TOOLS and EQUIPMENT REQUIRED: Lathe machine, Steel Rule, Vernier Calliper, Power hacksaw, Single point cutting tool

• FORMULA

• The taper angle is calculated using the following formula:

𝐷−𝑑
• 𝑇𝑎𝑝𝑒𝑟 𝑎𝑛𝑔𝑙𝑒 (𝛼) = 𝑡𝑎𝑛−1
2𝑙

• Where

• D = large diameter of taper in mm (30 mm), d = small diameter of taper in mm (15 mm)

• l = length of tapered part in mm, 𝛼 = angle of taper

• Taper length = 60 – Enrol number (For Enrol upto 40)
• Taper length = Enrol number (For Enrol between 41 to 80)
• Taper length = Enrol number - 60 (For Enrol above 81)
Procedure
1. Cut the 110 mm work piece rod from the given rod with the help of hand/power hacksaw.
2. Hold the given work piece firmly in a lathe chuck.
3. Set the cutting tool in a tool post.
4. Switch ON the machine to rotate the work piece at the selected speed.
5. By giving Cross feed to the cutting tool, the facing operation is done on both sides to make the workpiece of 100 in length.
6. By giving longitudinal feed to the cutting tool, the turning operation is done to reduce the diameter of workpiece from 32 mm to 30 mm
upto the length of 60 mm.
7. Hold the workpiece from other side to reduce the diameter of workpiece from 32 mm to 30 mm for remaining length of the workpiece.
8. The compound rest is swivelled for the calculated taper angle.
9. By giving angular feed to the cutting tool through the compound slide the taper turning operation is done for the required length.
10. The machine is switched OFF.
11. The work piece is removed from the chuck and all the dimensions are measured and checked.

Precautions:
Step turning (Exp Number 3)
• AIM: To perform step turning operation on a given workpiece using Lathe machine

• MATERIALS REQUIRED: Mild steel round rod - f 32 X 100 mm

• TOOLS and EQUIPMENTS REQUIRED: Lathe machine, Steel Rule, Cutting tool, Vernier Calliper,
Power hacksaw, Single point cutting tool

• THEORY: The main function of a lathe is to remove metal from the workpiece to give it the required shape
and size. This is accomplished by holding the work securely and rigidly on machine and then turning it
against a cutting tool which will remove metal from the work in the form of chips
Procedure
1. Cut the 110 mm work piece rod from the given rod with the help of hand/power hacksaw.
2. Hold the given work piece firmly in a lathe chuck.
3. Set the cutting tool in a tool post.
4. Switch ON the machine to rotate the work piece at the selected speed.
5. By giving Cross feed to the cutting tool, the facing operation is done on both sides to make the workpiece of 100 in length.
6. By giving longitudinal feed to the cutting tool, the turning operation is done to reduce the diameter of workpiece from 32 mm to 30 mm
upto the length of 60 mm.
7. Hold the workpiece from other side to reduce the diameter of workpiece from 32 mm to 30 mm for remaining length of the workpiece.
8. Perform turning operation to reduce the diameter of workpiece from 30 mm to 25 mm upto the length of 60 mm.
9. Perform turning operation to make the step by reducing the diameter of workpiece from 25 mm to 20 mm from the start upto the length of
40 mm.
10. Perform turning operation to make another step by reducing the diameter of workpiece from 20 mm to 15 mm from the start upto the length
of 20 mm.
11. The machine is switched OFF.
12. The work piece is removed from the chuck and all the dimensions are measured and checked.
 Tool Geometry (Experiment No. 4)
• Aim: To study the tool geometry of a single point cutting tool
• Tool used: Single point cutting tool, angle protector, radius gauge.
• https://www.youtube.com/watch?v=IMH_RQrEtqw
• Drawings: Isometric view of cutting tool, Three different views for determining six
angles.
• Tool Signature:
• 1. Back rake angle
• 2.Side Rake angle
• 3. End cutting edge angle
• 4. Side cutting edge angle
• 5. End relief angle
• 6. Side relief angle
• 7. Nose radius.
Single point cutting tool
•
Different views
Single point cutting tool
• Rake surface: The surface of the tool over which the chip flows
• Flank surface: The surface of the tool towards the machine
Rake angle
• Rake angle (Back rake angle, 𝜶𝒃 ): Angle of inclination of the rake face from the
base plane. It is imp in controlling the direction of chip flow and the strength of
the tool tip.
Relief Angle
• End relief Angle 𝝋𝒆 : It is the angle between end face of the flank and
tangent to the machined surface at the cutting edge
• Side rake angle, 𝜶𝒔 : Angle of inclination of the rake surface from the base plane
and measured in a plane perpendicular to the base of the tool and side cutting edge
(clockwise negative).

• Side relief Angle 𝝋𝒔 : It is the angle between side face of the flank and tangent to
the machined surface at the cutting edge
• End cutting edge angle 𝑪𝒆 : It is
the angle between the end cutting
edge of the tool and the line
perpendicular to the tool shank.

• Side cutting edge angle 𝑪𝒔 : It is

the angle between the side
cutting edge of the tool and the
line parallel to the tool shank
Tool Signature
•
Drilling (Experiment No. 5)
• Aim: To perform drilling operation on a given workpiece using
drilling machine
• Material Required: Mild Steel plate (100mm x 60mm x 10mm)
• Tools and equipment required: HSS drill bits of diameter 6mm,
8mm and 10mm, Drilling machine, steel rule, centre punch, hammer,
vernier calliper.
• Theory and Working Principle:
• Principle parts of drilling machine:
• Procedure:
• Precautions:
 If you write only numerical value for dimensioning,
Figure for Drilling then write a line at the bottom of the file page as
“All dimensions are in ‘mm’”
100 mm

φ 8mm φ 10mm 20 mm
φ 6mm

60 mm 20 mm
φ 8mm φ 10mm
φ 6mm

20 mm

20 mm 30 mm 30 mm 20 mm
Shaper (Experiment No. 6)
• Aim: To perform shaping operation on a given workpiece using shaper
machine
• Material Required: Cast iron block (70mm x 60mm x 40mm)
• Dimensions of Job: 70mm x 8mm x 3mm
• Tools and equipment required: Cutting tool, Shaper machine, steel
rule, vernier calliper.
• Theory and Working Principle:
• 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 Whitworth quick return motion mechanism.

• Principle parts of Shaper machine:

The principal parts of a shaper, as shown in Figure are as follows:
1. Base: It is a heavy structure of cast iron which supports other parts of a shaper.
2. Column: It is a box-like structure made up of cast iron and mounted upon the base. It contains the driving
mechanism and is provided with two machined guide ways on the top of it on which the ram reciprocates.
3. Ram: It is a reciprocating member which reciprocates on the guide ways provided above the column. It carries a
tool-slide on its head and a mechanism for adjusting the stroke length
4.Tool head: It is attached to the front portion of the ram with the help of a nut and a bolt. It is used to hold the tool
rigidly, it also provides the vertical and angular movements to the tool for cutting.
5. Cross-rail: It is attached to the front vertical portion of the column. It is used for the following two purposes:
(a) It helps in elevating the table over the column in the upward direction, and
(b) The table can be moved in a direction perpendicular to the axis of the ram over this cross rail.
6. Table: It is used for holding the work piece. It can be adjusted horizontally and vertically with the help of spindles.
• Procedure: Self
• Precautions: Self
Exp No. 8: To investigate the effect of turning process
parameters on the surface roughness of machined component

• Will be discussed in the class.