AMPT (3140204) LAB MANUAL 2022 LNJ

AUTOMOBILE_AMPT_3140204_LAB MANUAL 2022
GOVERNMENT ENGINEERING
COLLEGE
MODASA
Automobile Engineering Department
LABORATORY MANUAL
&
HANDBOOK
COURSE: 3140204
Automotive Manufacturing Processes

&
Technology
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GUJARAT TECHNOLOGICAL UNIVERSITY
GOVERNMENT ENGINEERING COLLEGE, MODASA
Certificate
This is to certify that
Mr. / Ms. …………………………………………………………………………………
Enrollment No. …............................................. of Semester …………………… Degree
Course in ……………………………………… has Satisfactorily completed his / her term
work in subject ………………………………… within four walls of the Laboratory /
Tutorial room / Drawing Hall of this College during the academic year …………
Place:
Date:
Subject Teacher: Head of the Department:
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INDEX FOR LAB MANUAL

Expt. Page Date Faculty Grade
Title
No. No. Sign
1 Job making on Lathe machine
2 Job making on Milling machine
3 Job making on Shaper machine
4 Job making on Planer machine
5 Job making by using press tool
6 Job making on Drilling machine
To study the pattern allowances and to make the

7 drawing of pattern of given automotive part.
To study the investment and centrifugal casting

8 and casting defects.
To study the resistance welding and TIG

welding and its applications in automotive
9
industry.
To study the non conventional machining and its

10 applications in automotive industry.
To make the strip layout of given sheet metal

11
part of an automotive.
To calculate the punch and die size of given
12 part.
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EXPERIMENT :- 1
AIM: Job making on Lathe machine
Introduction:
The Lathe was invented by Jacques de Vaucanson around 1751.

The Lathe Machine is an ancient tool. At the very early stage this machine was developed around
1300 BC at that time there was not developed so many parts expect headstock and Tailstock. But during
the industrial revolution Metalworking lathe evolved into heavier machines with thicker, more rigid parts.
Between 19 and 20 century the electric motor is replaced line shafting as a power source. Then in 1950,
the servomechanism is applied to control lathe and other machine tools by numeric, direct numerical
control machine.
The Lathe is the most versatile machine tool among all standard of the machine tool. Nowadays the
manually controlled machine exists like a CNC machine and even does with the help of feed mechanism
the lathe machine operates manually.
Function:
A lathe machine is a machine tool that is used to remove metals from a work piece to give a desired
shape and size.Lathe Machines are used in metalworking, woodturning, metal spinning, thermal spraying,
glass working, and parts reclamation.
The function of Lathe is to remove the metal in the form of chips from a piece of work by mounting
the same rigidly on a machine spindle and revolving at the required speed and the cutting tool is fed
against the work either longitudinally or crosswise to make the work to the required shape and size.
Parts of the Lathe Machine and their functions:

A lathe machine tool consists of several parts like:
(1) Headstock (2) Bed (3) Tailstock (4) Carriage (5) Saddle (6) Cross-slide (7) Compound rest
(8) Tool post (9) Apron (10) Lead Screw (11) Feed rod (12) Chuck (13) Main spindle (14) Leg
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Head Stock:
Head Stock is situated at the left side of the lathe bed and it is the house of the driving mechanism
and electrical mechanism of a Lathe machine tool.It holds the job on its spindle nose having external screw
threads and internally Morse taper for holding lathe center. And it is rotating at a different speed by cone
pulley or all geared drive. There is a hole throughout spindle for handling long bar work.
Head Stock transmits power from the spindle to the feed rod, lead screw and thread cutting
mechanism.
Accessories mounted on headstock spindle:
(1)Three jaw chuck (2) Four jaw chuck (3) Lathe center and lathe dog (4) Collect chuck
(5) Faceplate (6) Magnetic chuck
A separate speed change gearbox is placed below headstock to reduce the speed in order to have different
feed rates for threading and automatic lateral movement of the carriage. The feed rod is used for most
turning operation and the lead screw is used for thread cutting operation.
Bed:
It is the base of the lathe machine. It is made of single piece casting of Semi-steel (Chilled Cast Iron). The
bed consists of two heavy metal slides running lengthwise, with ways or ‘V’ formed upon them and rigidly
supported with cross girths.
• It is sufficiently rigid and good damping capacity to absorb vibration.
• It prevents the deflection produced by the cutting forces.
• It supports the headstock, tailstock, carriage and other components of the lathe machine.
Tail Stock:
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Tail Stock is situated on the right side above the lathe bed.
It is used for:
• Support the long end of the job for holding and minimizes its sagging.
• It holds the tool for performing different operations like drilling, reaming, tapping, etc.
• And it is also used for a small amount of taper for a long job by offsetting the tailstock.
Carriage:
The carriage is used for support, guide and feed the tool against the job when the machining is done.
• It holds moves and controls the cutting tool.
• It gives rigid supports to the tool during operations.
• It transfers power from feed rod to cutting tool through apron mechanism for longitudinal cross-
feeding.
• It simplifies the thread cutting operation with the help of lead screw and half nut mechanism.
It is consists of:
• Saddle
• Cross-slide
• Compound rest
• Tool post
• Apron
• It provides three movements to the tool:

• Longitudinal feed-through carriage movement
• Cross feed-through cross slide movement
• Angular feed-through top slide movement
Saddle: Generally, it is made up of ‘H’ shaped casting and it has a ‘V’ guide and a flat guide for mounting it
on the lathe bed guide ways.
Cross-slide: It is assembled on the top of the saddle. The top surface of the cross-slide is provided with T-
slot.
Compound rest: It supports the tool post and cutting tool in its various positions. It can be swiveled at any
desired position in the horizontal plane. It is necessary for turning angles and boring short tapers.
Tool post:
• It is the topmost portion of the carriage and it is used to hold various cutting tools or tool holders.
• There are three types of tool post commonly used and those are:
• Ring and rocker tool post
• Square head tool post
• Quick change tool post
Apron: An apron is a house of the feed mechanism. It is fastened to the saddle and hangover in front of the bed.
Lead screw: A lead screw is also known as a power screw or a translation screw. It converts rotational motion to
linear motion. Lead Screw is used for Thread Cutting operation in a lathe machine tool.
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Feed Rod: Feed rod is used to move the carriage from the left side to the right side and also from the right side to
the left side.
Chuck:
• Chuck is used to holding the work piece securely.
• There are generally 2 types of chucks:
• 3 jaw self-centering chuck
• 4 jaw independent chuck
Main Spindle:
• The spindle is a hollow cylindrical shaft in which long jobs can pass through it.
• It is designed so well that the thrust of the cutting tool does not deflect the spindle.
Leg: Legs are carrying an entire load of a lathe machine tool and transfer to the ground. The legs are firmly secured
to the floor by the foundation bolt.
Types of Lathe Machine:

Lathe machine has been categorized into the following types:
• Center or Engine Lathe
• Speed Lathe
• Capstan and Turret Lathe
• Tool Room Lathe
• Bench Lathe
• Automatic Lathe
• Special Purpose and
• CNC Lathe Machine
Center or Engine Lathe Machine:
Center or Engine Lathe Machine is the most widely used lathe machine and still, it is, in every workshop, this
machine is present.
The operation like Turning, facing, grooving, Knurling, threading and more, such operations are
performed on this type of machine.Engine lathe machine has all the parts such as bed, Saddle, headstock,
and tailstock, etc. The headstock of an engine lathe is rigid and tailstock is moveable which is further used
to support an operation like knurling.
• It can easily feed the cutting tool in both directions i.e. longitudinal and lateral directions with the
help of feed mechanisms.
• Center Lathe machines are driven by the gear mechanism or pulley mechanism.
• It has three types of driven mechanisms, and those are Belt-driven, Motor-driven, Gearhead type.
Speed Lathe:
Speed lathe is also called as Wood Lathe.
As the name indicates “Speed” the machine works with high speed. The headstock spindle is rotating
at a very high speed. The parts having like headstock, tailstock, but it’s not having feed mechanism like
center or engine lathe having. The feed we provide is manually operated.
• The speed ranges of this machine operated between 1200 to 3600 RPM.
• Speed lathe is used for spinning, centering, polishing and machining of wood.
Capstan and Turret Lathe:
This is an advanced technology of the manufacturing industry.
The capstan and turret lathe machine used for Mass production (large Quantity) and it is a modified
version of the engine lathe machine. This machine is used where their sequence of operation is performed
on the work piece, there is no alternative operation performed on this machine.These machines provided
by hexagonal turret head instead of the tailstock in which multiple operations (Turning, facing, boring,
reaming) performed in a sequence without changing its tool manually, after each operation the turret
rotated.
It also consists of three tool post. It requires more floor space than other lathe machines.
Capstan and turret lathe is using for only large jobs.
The main advantage of using capstan and turret lathe is even less skilled operators can do a job.
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Tool Room Lathe:
The tool room lathe machine operates to speed up to 2500 rpm.
The parts are almost the same similar to engine lathe machine but the parts are built very accurately
and should be arranged in proper sequence because this lathe is used for highly precious work with very
fewer tolerances.It is mainly used in grindings, working on the tool, dies gauges and in machining work
where accuracy is needed.
Bench Lathe:
Bench lathe machines are mounted on the bench.This type of lathe machine is small in size and use
for very small precision work. It has all the similar parts of engine lathe and speed lathe.
Automatic Lathe:
As the name indicates “Automatic lathe” performs work automatically.Standard lathes have some
drawbacks i.e. they are not used for mass production. But automatic lathes are used for mass production.
Some mechanisms are responsible for the automation in it.Here there is no need to change the tool
manually because it changes automatically.
Having this machine the main advantage is that a single operator can handle machines more than 4 to
5 machine at a time.These types of lathes are high speed and heavy-duty.
Special Purpose Lathe:
As the name indicates “special purpose lathe” the machine performs the special types of operation
which can not be performed on standard and other machines.It is known for the heavy-duty production of
identical parts.
Some examples of special lathes include Vertical lathes, Wheel lathes, T-lathe, Multi Spindle lathes,
Production lathes, Duplicate or tracer lathes, etc.
Wheel lathe is used for machining of journals and rail rods. It is also used for turning the threads on
locomotive wheels.
The “T -lathe” is used for machining rotors for jet engines. The axis of the lathe bed is at right angles
to the axis of the headstock spindle in the form of a T.
CNC Machine:Lathe
CNC stands for Computerized numerically controlled.
This is widely used as a lathe in the present time because of its fast and accurate working. It is one of
the most advanced types.
It uses computer programs to control the machine tool. Once the program is fed into the computer as per
the program it starts operation with very high speed and accuracy.
• Even do preplanned programmed machine is there in which once code is set for the various
operations it can starts operation without changing code in the next time.
• A semi-skilled worker can easily operate this after the initial setup is done.
• These types of lathes are also used for mass production like capstan and turret but there is no
programmed fed system.
• The components manufactured by these lathes are very accurate in dimensional tolerances.
LATHE OPERATIONS:
Here is the comprehensive list of lathe operations. Although as any operation performs in lathe
machine tool but these are some of the general operation we are doing in a lathe.
(1) Centering (2) Facing (3) Turning (4) Chamfering (5) Knurling (6) Thread cutting
(7) Drilling (8) Boring (9) Reaming (10) Spinning (11) Tapping (12) Parting off
Before continuing any operation in lathe we have to load the job and center it on the head-stock
spindle. In lathe operations, the headstock spindle holds the job and it rotates with the same speed as the
spindle. The carriage holding the tool on the tool post, also the carriage gives the tool post moves
longitudinally or crosswise direction to give the desired feed on the job.
These two motions (longitudinally and crosswise) helps to remove the chips of the metal and giving the
proper shape of the job.
The Lathe is such a versatile machine that it can produce another lathe.
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Centering operation in the lathe:
We use this operation for producing a conical hole in the face of the job to make the bearing support
of the lathe center when the job is to hold between two centers. (Head-stock and Tail-stock).
Facing operation in the lathe:
Facing operation is for making the ends of the job to produce a smooth flat surface with the axis of
operation or a certain length of a job.
In this operation,
• Hold the job on Head-stock spindle using Three or four-jaw chuck.
• Start the machine on desire RPM to rotate the job.
• Give a desirable feed on the perpendicular direction of the axis of the job.
Turning operation in the lathe:
The operation by which we remove the excess material from the workpiece to produce a cone-
shaped or a cylindrical surface.
There are several types of turning operations, those are:
• Straight turning
• Shoulder turning
• Rough turning
• Finish turning
• Taper turning
• Eccentric turning
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Straight turning:
This operation is done to produce a cylindrical surface by removing excess material from the
workpiece.
It is done in the following ways:
• Mount the job by suitable job holding device and check the trueness of the job axis with the lathe
axis.
• Hold the cutting tool on the tool post and set the cutting edge at the job axis or slightly above it.
• Set the spindle as per the desired feed.
• Give depth of cut as per finish or rough cut.
• Start the machining.
• Engage automatic feed to move the carriage with the tool to the desired length, then disengage the
feed and carriage is brought back to its starting.
• The process is repeated until the job finished.
Shoulder turning:
A shoulder turning is called which has a different diameter to form a step from one diameter to another.
There are four kinds of shoulder.
• Square
• Beveled
• Radius
• Undercut
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Rough turning:
It is a process of removal of excess material from the workpiece in minimum time by applying a high
rate of feed and heavy depth of cut.
the depth of cut is around 2 to 5mm and the rate of feed is 0.3 to 1.5mm/revolution.
Finish turning:
The finish turning operation needs high cutting speed, minimum feed and a very small depth of cut
to generate the smooth surface.
In finish turning the depth of cut is around 0.5 to 1mm and the rate of feed is 0.1 to 0.3 mm/revolution.
Taper turning:
A taper is defined as a uniform decrease or increase in the diameter of a workpiece along with its
length. The operation by which a conical surface of the gradual reduction in diameter from a cylindrical
work piece is produced is called taper turning.
Taper turning methods:
• A tapering form may be done by anyone of the following methods.
• Taper turning by form tool
• By swiveling the compound rest
• Tail-stock set over method
• By taper turning attachment
• Let me discuss them in brief.
• Taper turning by form tool:
It is used to form a short length of taper by using a form tool or broad nose tool.
Any increase in the length of taper will require the use of a wider cutting edge which may destroy the
work piece due to the vibration and spoil the work piece.In this operation, the tool angle must be half of
the taper angle.
• Taper turning by swiveling the compound rest:
• This method is used for turning step and short tapers.
It is done as follows:
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• Set the compound rest by swiveling it from the centerline of the lathe center through an angle equal
to a half taper angle.
• Clamp the carriage in place.
• After adjusting and setting the tool, feed is applied by the compound rest’s feed handle to complete
the taper.
Tail-stock set over method:
• Set over of tail-stock from its center-line is done equal to half taper.
• Job is held between the centers. The length of the workpiece will be long enough. An only a small
taper on a long job is done by this process.
• It is used for external taper only.
By taper turning attachment:
• It is done in the following ways:
• The cross slide is first made free from lead screw by hinder screw.
• The rear end of the cross slide is then tightened with a guide block by a belt.
• Set the guide bar at an angle to the lathe axis. (Half taper angle)
• The required depth of cut is given by the compound slide is at a right angle to the lathe axis.
Chamfering operation:
Chamfering is used for beveling the end of a job to remove burrs, to look better, to make a passage
of the nut into the bolt.
This operation is done after thread cutting, knurling, rough turning.
Knurling operation:
It is the process of producing a rough surface on the workpiece to provide effective gripping.
Knurling tool is held rigidly on the tool post and pressed against the rotating job so that leaving the exact
facsimile of the tool on the surface of the job.
Thread cutting operation :

It is the operation that is used to produce a helical groove on a cylindrical or conical surface by
feeding the tool longitudinally when the job revolved between the two centers.
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Tool setting for thread cutting operation:
• The tool should be set exactly to the height of the centerline of the job and at 90 degrees to the job.
• Tool setting gauge is used for this purpose.
• Feeding during thread cutting operation:
It is done in two ways.
The tool may be feed exactly at 90 degrees to the job axis but it does not have good cutting action
because only the front end of the tool does cutting.
The tool may be feed at an angle from 27-30 degrees at which the compound rest may be set so that
the complete side of the tool is used for cutting action which gives a better polish on the threads.
The job speed will be 1/3 to 1/4 th of the job speed in turning operation.
Drilling operation:
Drilling is an operation by which we can make holes in a job.

In this operation, the job is rotated at the turning speed on the lathe axis and the drilling tool fitted on
the tail-stock spindle. And the tail-stock is moved towards the job by hand feed.
Boring operation:
In this operation, we can enlarge the diameter of the existing hole on a job by turning inside with
some farm tool known as a boring tool.
The boring tool is also fitted on tail-stock.
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Reaming operation:
Reaming is the operation for sizing or finishing a drilled hole to the required size by a tool called
reamer.
This tool is fitted on tail-stock.
Spinning operation:
In this operation, the job of this sheet metal is held between the former and the tail-stock center
rotates at high speed with the former.
the long round nose forming tool rigidly fixed on special tool post presses the job on the periphery of the
former. So the job is taken exactly the shape of the former.
• This is a chip less machining process.
Tapping operation:
We use this operation for creating internal threads within a hole by means of a tool called tap.
Three taps are generally used in an internal thread.
• Taper Tap
• Second Tap
• Plug Tap
Parting-off operation:
It is the operation of cutting off a bar type job after complete the machining process.In this operation
a bar type job is held on a chuck, rotates at turning speed, a parting off tool is fed into the job slowly until
the tool reaches the center of the job.
Specification of a Lathe:
A Lathe is generally specified by:
• Swing- the largest work diameter that can be swung for the lathe bed.
• The distance between the headstock and tailstock center.
• Length of the bed in meter.
• The pitch of the lead screw.
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• Horsepower of the machine.
• Speed range and the number of speeds of HS spindle.
• The weight of the machine in ton
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PERFORMANCE OF LATHE OPERATIONS
Name of machine: All Geared Lathe Machine

Specifications of machine:
Height of center 175 mm

Maximum swing over bed 350 mm
Maximum swing over cross slide 190 mm
Width of bed 240 mm
Admit between center 900 m
Std. size of spindle nose Loop type
Hole through spindle 40 mm
Range of spindle speeds (approx.) 60-1025 rpm
Min. no of spindle speeds 8
Min. no of feeds 40
Min. feed range per revolution
Longitudinal 0.032 mm
Transverse 0.008 mm
Max. Motor requirement 2 HP
Name of operations: (a) Facing (b) Centering(c) Straight Turning (d) Taper Turning
(e) Grooving (f) Knurling (g) Boring (h) External Threading
Name of Tools: (a) Face tool(b) Center tool (c) Grooving tool(d) Boring tool (e) Knurling tool
(f) Drill Bit (g) V tool
QUESTIONS:-
1. What is the main function of a lathe? List various types of lathes.

2. State the operation which may perform on a lathe.
3. How a lathe is specified? Discuss.
4. What are the basic parts of an engine lathe? Discuss the function of head stock.
5. What is the function of a back gear?
6. Explain with schematic diagram the principle of thread cutting on a lathe. Find out the relation
between ratio of charge gears to the work pitch and lead screw pitch. The pitch of a lead screw is 6
mm and the pitch of the thread to be cut in 1.5 mm .Find the change gear.
7. What are the influences of cutting tool angles on machining? Briefly state the effect of rake angle
during cutting.
8. Define cutting tool signature of a turning tool.
9. Differentiate between a capstan, a turret and an engine lathe.
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PERFORMANCE OF INTERNAL THREADING OPERATION
Name of machine: Lathe Machine
Specification of machine:
Height of center 175 mm

Maximum swing over bed 350 mm
Maximum swing over cross slide 190 mm
Width of bed 240 mm
Admit between center 900 m
Std. size of spindle nose Loop type
Hole through spindle 40 mm
Range of spindle speeds(approx.) 60-1025 rpm
Min. no of spindle speeds 8
Min. no of feeds 40
Min. feed range per revolution
Longitudinal 0.032 mm
Transverse 0.008 mm
Max. motor requirement 2 HP
Name of operations: (a) Internal Threading
Name of Tools: (a) Boring ‘V’ Tool
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EXPERIMENT :-2
AIM : Job making on Milling machine
Introduction:
The milling machine is most widely used in manufacturing industries after the lathe
machine.
However, In the case of lathe machine tool, the tools used there single point cutting tools but
In the case of this machine, the tool used is multi-point cutting tools.The milling is a process of
metal-removing by feeding the work piece passes through the rotating multipoint cutter.
• This machine can hold one or more number of cutters at a time and rotates at high speed to
remove metal at a faster rate.
• The metal removal rate is faster as compared to a lathe machine.
• This machine is used to make gears like Spur gears, and also drill the workpiece bore, and
produce slots.
Milling Machine Parts:
A milling machine consists of the following parts:
(1) Base (2) Column (3) Knee (4) Saddle (5) Table (6) Overhanging Arm (7) Spindle
(8)Arbor (9) Arbor Support (10) Milling Head (11) Ram (12) Knee
Base:
• It is the foundation part of a machine and all other parts are joined on it.
• It carries the entire load so it should have high compressive strength and it is made up of cast iron.
Column:
• It is mounted vertically on the base.
• It supports the knee, table, etc. and work as housing for all the other driving member.
• The column is a hollow member which contains driving gears and sometimes motor for
the spindle and the table.
Knee:
• It is a casting that supports the saddle and table.
• All gearing mechanism is enclosed within the knee.
• It is fastened to the column by dovetail ways.
• The knee is supported and adjusted by a vertical positioning screw (elevating screw).
• The elevating screw is used to adjust the knee up and down by raising or lowering the lever either
with the help of hand or power feed.
Saddle:
• This is placed between the table and the knee, and work as an intermediate part between
them.
• This can moves transversally to the column face.
• This slides over the guideways provided situated on the knee which is perpendicular to the
column face.
• The main function is to provide motion in a horizontal direction to the workpiece.
• This is also made by cast iron.
Table:
• This is a rectangular casting which is present on the top of the saddle.
• The table is situated over the knee.
• It is the part of a machine that holds the workpiece while machining.
• This is made by cast iron and has T-slot cut over it.
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• This provides vertical motion by moving the knee up and down.
• It provides horizontal motion by the feed screw.
• This provides a horizontal (transverse) motion by moving the saddle.
Overhanging arm:
• The overarm is used to fastened arbor support.
• It may consist of one or two cylindrical bars that slide through the holes in the column.
• It is made by cast iron.
Spindle:
• The spindle is the main part of the machine which holds the tool in the right place.
• This spindle provides the drive for arbors, cutters, and attachments used on a milling machine.
Arbor:
• This is a mechanical part, which is used as an extension part of the spindle in a
horizontal milling machine.
• It is fitted on the spindle whenever it’s required.
• This holds the tool and moves it in the correct direction.
Arbor Supports:
There are generally two types of arbor supports used in the milling machine.
• The first one has a small diameter bearing hole, 1-inch in maximum diameter, and the other
one has a large diameter bearing hole, usually up to 23/4 inches.
• The arbor support has an oil reservoir that lubricates the bearing surfaces.
• It can be clamped anywhere on the overarm.
• The arbor support is used only in the horizontal types of milling machines.
Milling head:
• It is the upper section of a vertical milling machine.
• It consists of a spindle, driving motor and other controlling mechanisms.
Ram:
• One end of the arm is attached to the column and other ends to the milling head.
• The ram can be moved transversally ( in and out) on the column by a hand lever.
Milling Machine Types:
The types of milling machines are the following:
Column and Knee Type Milling:

It is a very common machine type. In this machine, a vertical column is attached to the bed which
consists of all gear drives which rotate the knee and saddle.
• A knee is situated on the base which provides vertical motion to the workpiece or
which moves up and down.
• A saddle is attached to the upper section of the knee which can move in the
transverse direction.
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Vertical Milling:
• The spindle of this machine is in a vertical position.
• No arbor is required in this machine.
• The cutter tool has the cylindrical shape and the cutting edges are situated at the
circumference of the cylindrical face.
Horizontal Milling:
As the name implies, the spindle is situated horizontally.
• The spindle rotates horizontally.
• An arbor is attached to the machine which holds the cylindrical disk shape cutter
which cuts the metal work piece.
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Universal milling:
The universal milling machine is the same as the horizontal milling machine, except there
is an arrangement of swing up the table to 45 degrees in either direction.
Fixed Bed Milling:

• In this type of machine, the bed of the machine is fixed to the machine.
• There is no arrangement of the knee and saddle which can move vertically and transversally.
• The worktable is directly situated at the fixed bed.
• The spindle of this machine is mounted on a movable spindle head.
• It can move in the vertical and horizontal direction and to perform the cutting operation.
Simplex Milling:
In the simplex machine, spindle head or the spindle travel only in one direction.
Mostly it travels in the vertical direction.
Duplex Milling:
In this machine, the spindle travels both vertical and horizontal directions.
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Triple Milling:
• In the triplex machine, the spindle can move in all three directions along X, Y, and
Z-axis.
• Planer Milling
• The planner milling machine is mostly used for facing operations in mass production.
• These machines are similar to the bed type milling machine, except it can be
mounted with various cutters and spindle heads to the machine.
• These cutters in the machines can perform the facing operations simultaneously
which is a great function.
Tracer Milling:
This machine performs all difficult operations like, die making the job by synchronizing the
tracing unit.
• This can develop any difficult shape.
• This is mostly used in the automobile and aerospace industries.
CNC Milling:
CNC is the most versatile milling machine which is control by a computer.
• It is an upgraded version of the bed type milling machine, in which the spindle can
move in all three directions and the table can rotate 360 degrees.
• These all movement is hydraulically controlled which is commanded by a computer.
• In this, any difficult geometry can make on it.
• A sketch of the work piece is loaded to the computer which is cut on the work
piece by the cutters automatically.
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Operations that can be performed in a Milling Machine:
There are several types of operation that can be performed in a milling machine, and those
are:
• Plain Milling Operation

• Face Milling Operation
• End Milling Operation
• For Milling Operation
• T-slot Milling Operation
• Side Milling Operation
• Gear Milling Operation
• Straddle Milling Operation
• Grooves Milling Operation
• Gang Milling Operation
Plain Milling Operation:
It is the operation on producing plain, flat, horizontal surface, parallel to the axis of rotation.
• This operation is also known as slab milling.
• This operation is very common and done in almost all jobs.
• This can be carried out on every milling machine.
Face milling Operation:

This machining operation is done on the surfaces which are perpendicular to the axis of the cutter.
The operation is performed by the face milling cutter mounted on stub arbor of the machine.
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End milling operation:
It is the process of producing flat surfaces which may be horizontal, vertical and at an angle taking
worktable as a reference.
Form milling Operation:

It is the process of machining special contour (outline) composed of curves, straight lines, or entirely
of curves, at a single cut.This operation is accomplished by using convex, concave and corner rounding
milling cutters.
T-slot milling Operation:

It is the operation of producing the T-slots on the workpiece by using the T-slots milling cutter.
Side milling Operation:

It is the operation on producing the flat vertical surface on the sides of the work piece by using a side
milling cutter.
You can read the Milling cutter complete.The cutter is having teeth on its face as well as it’s side.
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Gear cutting Operation:
It is the operation on producing gear tooth on the gear blank by using a form-relieved cutter in a
milling machine.The cutter profile is exactly matched with the tooth space of the gear.
Straddle milling Operation:
It is the operation on producing the flat vertical surface on both sides of the workpiece by using two
side milling cutter mounted on the same arbor.The distance between the two cutters is adjusted by using a
spacing collar.This is commonly used to produce a hexagonal or square surface.
Grooves milling Operation:
The work piece is fixed firmly on a milling machine and fixing the end milling cutter on an arbor, by
adjusting the depth of cut, the work is fed against the cutter to cut the groove on the work surface.
Gang milling Operation:
It is the machining process in which two or more milling cutters are used together to perform
different milling operations simultaneously.
In gang milling, the cutters are mounted on the arbor.
The advantages of the Milling machine:

In the milling machine there are following advantages, those are:
• Ideal for the production of individual pieces and small batches.
• Capable of producing complex shapes with the use of multitooth, as well as a single point, cutting
tools.
• Operation cost can be very modest given general-purpose equipment and cutters are used.
Milling Machine Disadvantages:

These are the following disadvantages of a milling machine:
• It is more costly than casting, cold forming, extrusion, etc. If these processes can provide the
flatness, surface finish and dimensional accuracy required for the part.
• For mass production, it becomes economically necessary to use special-purpose machines.
• They may cost millions of dollars but the cost is justifiable when handling labor which is virtually
eliminated and machining accuracy and repeatability is ensured.
The applications of Milling Machine:
• These are the following applications of the milling machine:

• The milling machine is used to making gears.
• Usually used to a machined flat surface but can also produce irregular surfaces.
• Used to produce the groove or slot.
• Modern milling machine cut super alloys, titanium, tensile steel to closer tolerance, a greater
accuracy, and faster rate.
• The milling machine is used to design of metal and other materials
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PERFORMANCE OF MILLING OPERATION (GEAR CUTTING OPERATION)
Name of machine: (a) All Geared Lathe Machine (b) Horizontal Universal Geared milling machine
Specification of Milling Machine:
Longitudinal movement of table 725 mm

Cross movement of table` 250 mm
Vertical movement of table 460 mm
Movement after mounting vertical
attachment 330 mm
Swivel of table 45 Degree
Spindle bore 22 mm
Inside taper iso 40
Arbor Dia. 25.4 mm
Dia. Of spindle in front bearing 55 mm
No. of spindle speeds 6
Range of spindle speeds 50-750 rpm
Name of operations: (a) Facing

(b) Centering
(c)Straight Turning
(d) Gear tooth cutting
Name of Tools: (a) Face tool

(b) Center tool
(c)End mill cutter
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EXPERIMENT :-3
AIM: Job making on Shaper machine
Introduction:-
The Shaper is a reciprocating type of machine tool basically used to produce Horizontal, Vertical or
Inclined flat surfaces by means of straight-line reciprocating single-point cutting tools similar to those
which is used in lathe operation.
The flat surface produced may be horizontal, vertical or inclined at an angle
Working Principle of Shaper Machine:
A shaper machine is working on the following principle:
• A shaper machine holds the Single point cutting tool in ram and work piece is fixed over the
table.
• The ram holding the tool reciprocates over the work piece and metal is cut during the forward
stroke called a cutting stroke.
• No metal is cut during its return stroke is called an Idle stroke.
The feed is given at the end of the cutting stroke. Generally, the cutting stroke is carried out at
slow speed and the idle stroke is carried at high speed with the help of quick return mechanism.
In the shaper machine, there is another mechanism called Quick return Motion Mechanism. In
the forward stroke, the Slider moves fast and removing the material from the work piece.
Whereas in the return stroke, the Slider moves faster than the forward stroke that means Quick
return, it takes less time to return, called a return stroke.
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Types of Shaper Machine:
Based on the type of driving mechanism types of shaper machines.
• Crank type (Example: Quick return Motion Mechanism)
• Geared type shaper
• Hydraulic type
Based on ram travel types of shaper machines.
• Horizontal Shaper
• Vertical Shaper
Based on the type of driving mechanism types of shaper machines.
• Crank type (Example: Quick return Motion Mechanism)
• Geared type shaper
• Hydraulic type
Based on the table design types of shaper machines.
• Standard or Plain Shaper
• Universal shaper
Standard or Plain Shaper:
In this machine, the table has only two motion: crosswise in the horizontal plane and vertical
movement (up and down).
The table is not provided with a swiveling motion.
Universal shaper:
This machine is similar to plain shaper except that the table can be tilted at a various angle,
making it possible to inclined flat surfaces.
The table can be swiveled about 360 degrees about a central axis parallel to the cutting
stroke direction and also perpendicular to it, that is, around two horizontal axes.The table also
has a movement in the horizontal plane and vertical direction (up and down ) as in plain
shaper.
Based on cutting stroke types of shaper machines:

• Push type shaper machine
• Draw type shaper machine
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Operations Performed on Shaper Machine:
There are 4-types of operations performed in a shaper machine, and those are:
• Horizontal cutting
• Vertical cutting
• Inclined cutting
• Irregular cutting
Horizontal cutting:
Horizontal surfaces are machined by moving the work mounted on the machine table at a cross direction
with respect to the ram movement. The clapper box can be set vertical or slightly inclined towards the
uncut surface. This arrangement enables the tool to lift automatically during the return stroke. The tool will
not drag on the machined surface.
Vertical cutting:
A vertical cut is made while machining the end of a work piece, squaring up a block or
machining a shoulder. The feed is given to the tool by rotating the down feed screw of the vertical
slide. The table is not moved vertically for this purpose. The apron is swiveled away from the
vertical surface being machined.
Inclined cutting:
An angular cut is done at any angle other than a right angle to the horizontal or to the vertical
plane.The work is set on the table and the vertical slide of the tooth head is swiveled to the required
angle either towards the left or towards right from the vertical position.
Irregular cutting:
A round nose tool is used for this operation.For a shallow cut the apron may be set vertical but if
the curve is quite sharp, the apron in swiveled towards the right or left away from the surface to be cut.
Parts of a Shaper Machine with Function:
Base:
• The Base is designed to take the entire load of the machine tool and it is bolted to the floor of the shop.
• This is made of grey cast iron to resist vibration and to take the compressive load.
Column:
• The column is a Box like casting made up of cast iron and mounted on a base.
• It is provided with accurately machined guideways on the top on which the ram reciprocates.
• The guideways are also provided on the front vertical face for the movement of cross rail. The column
encloses the ram driving mechanism.
Cross rail:
• The cross rail is mounted on the ground vertical guideways of the column.
The table can be raised or lowered to accommodate different sizes of the job by rotating elevating screw
which causes the cross rail to slide up and down on the vertical face of the column.
Saddle:
It is mounted on the cross rail to hold the table firmly on its top.
The crosswise movement of the saddle causes the table to move crosswise direction by rotating the
crossfeed screw.
Table:
• It is mounted on the saddle.
• It can be moved crosswise by rotating the crossfeed rod and vertically by rotating the elevating screw.
• The table is a box-like casting with accurately machined top and side surfaces. These surfaces having t-
slots for clamping the work.
• In Universal shaper, the table may be swiveled on a horizontal axis and its upper part may be tilted up or
down.
• In heavy Shaper, the front face of the table is supported by adjustable table support to give more rigidity.
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Ram:
It is a reciprocating member of the shaper which holds the tool and the reciprocates on the guideways
on the top of the column by means of quick return motion mechanism.It houses the screwed shaft for
altering the position of the RAM with respect to the work. The RAM is in semi-cylindrical form and
heavily ribbed inside to make it more rigid.
Tool Head:
The tool head holds the cutting tool firmly and provides both vertical and angular movement to the tool
with the help of a down feed screw handle.
• The head allows the tool to have an automatic relief during the return stroke.
• The vertical slide of a tool head consists of a swivel base which is graduated in degrees. So, the vertical
slide can set at any angle with the work surface.
• The amount of feed or depth of cut may be adjusted by a micrometer dial on top of the down feed screw.
A tool head again consists of:
• Apron
• Clapper box and clapper block
Apron consisting of clapper box and tool post is clamped on the vertical slide by the screw.The
apron Can be swiveled upon the apron swivel pin towards left or right. The clapper box houses the
clapper block by means of a hinge pin. The tool post is mounted on the clapper block.
During forwarding cutting stroke the clapper block keeps the rigid support to the tool by
fitting securely into clapper box and while returning stroke the tools slide over the work by
lifting, the block out of clapper boxes shown in the above figure.
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Specification of Shaper Machine:

The specification of shaper machine depends upon the following:
• The maximum length of stroke ram.
• Types of the drive ( Crank, Gear and Hydraulic type)
• Power input of the machine
• Floor space required to establish the machine
• Weight of the machine in tonne.
• Feed
• Cutting to return stroke ratio.
• Angular movement of the table.
Advantages of Shaper Machine:
• The single point tool used which is inexpensive or we can say low tooling cost.
• The cutting stroke having a definite stopping point.
• The work can be held easily in the shaper machine.
• The set up is very quick and easy and also can be readily changed from one job to another job.
Disadvantages of Shaper Machine:
By nature, it is a slow machine because of its straight-line forward and returns strokes the single
point cutting tool requires Several strokes to complete a work. (They are slow)
The cutting speed is not usually very high speeds of reciprocating motion due to high inertia force developed
in the motion of the units and components of the machine.
Applications of Shaper Machine:
• To generate straight and flat surfaces.
• Smooth rough surfaces.
• Make internal splines.
• Make gear teeth.
• To make dovetail slides.
• Make key ways in pullies or gears.
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• Machining of die, punches, straight and curved slots.
• Hydraulic Shaper Mechanism in Shaper Machine:
In hydraulic shaper machine, a constant speed motor drives a hydraulic pump which delivers oil at a
constant pressure to the line.A regulating valve admits oil under pressure to each end on the piston
alternately.At the same time allowing oil from the opposite end of the piston to return to the reservoir.The
piston is pushed by the oil and being connected to ram by piston rod, pushes the ram carrying the tool.The
admission of oil to each end of the piston, alternately, is accomplished with the help of trip dogs and pilot
valves.As the ram moves and complete its stroke (Forward and Return) a trip dog will trip the pilot valve
which operates the regulating valve.The regulating valve will admit the oil to the other side of the piston and
the motion of the ram will get reversed.
It is clear that the length of the ram stroke will depend upon the position of trip dogs.The length of the
ram stroke can be changed by unclamping and moving the trip dogs to the desired position.
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SHAPER PLANER
PLANER
These are lighter, smaller and cheaper. Work is mounted

These on alarger
are heavier, table which reciprocates
and costlier.
The tool is held on a ram which reciprocates while the tool is held on the machine frame
and the work mounted on the table remains and fed into the work.
stationary and gives the feed.
It is intended for small jobs. It is intended for large jobs.
Low machining accuracy. High machining accuracy.
Simple in construction. It is a robust one or robust in construction.
Not possible to make deep cuts and Possible to make deep cuts and heavy feeds.
heavy feeds.
A low rate of power consumption. A Multiple

high rate of
tooling
power consumption.
permits machining of
Usually, only one tool is used on a more than one surface at a time.
shaper.
Cutting and return speeds are Cutting and return speeds vary throughout the
uniform throughout the strokes. strokes.
Work setting requires less skill and less time. Work setting requires more skill and more time.
Tools used are lighter and smaller. Tools used are heavier, stronger and larger.
Limited cutting and return speeds A wide range of cutting and return
are available. speeds are available.
It requires less floor space. It requires a large floor space.
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PERFORMANCE OF SHAPING OPERATION
Name of machine: Shaper Machine
Specifications of machine:
Length of stroke 381 mm
Length of ram bearing in column 838 mm
Ram bearing width 203 mm
Length of ram without tool slide 622 mm
Length of cross slide 584 mm
Width of cross slide 203 mm
Length & depth of table 280 mm
Cross feed power or by hand 406 mm
Vertical travel of table 280 mm
Feed length of tool slide 89 mm
Maximum distance from table to bottom
of ram 317 mm
Minimum distance from table to bottom of
ram 8
No of speeds of ram 4
Motor 1 HP
Name of operations: (a) Facing

(b) Straight Turning
(c) Punching
Name of Tools: (a) Face tool

(b) V tool
(c) Punch
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EXPERIMENT :- 4
AIM: Job making on Planer machine
Introduction:
A planer is a machine tool primarily designed to produce planes and flat surfaces by a single-
point cutting tool.
A planer machine is just like a shaper machine but, it is very large and massive and it is capable
of machining heavy jobs which can’t be done by the shaper.
The main difference between planer and shaper is that In a planer, the work is loaded over the
table and reciprocates past the stationary cutting tool and the feed is given by the lateral movement of
the tool but In shaper, the ram holding the tool reciprocates over the stationary work loaded over the
table and feed is given by the crosswise movement of the table.
Planer Machine Main Parts:
A planer machine consists of the following parts:
• BED
• Table or Planten
• Housing or Column
• Cross rail
• Tool head
• Driving and
• Feed Mechanism
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Bed:
• It is a box-like a cast iron casting with cross ribs.
• It is very large and heavy in weight.
• The bed supports the column and all the moving parts of the machine.
• The length of the bed is twice the length of the table, so that table maybe slide on it. The bed is
provided with accurately machined v-type or flat type guideways for smooth sliding of the
table.
• The bed houses the driving mechanism for the table.
Table:
The table is a rectangular cast iron casting having accurately machined top surface to locate the
work accurately- slots are provided on the entire length of the table to hold the work properly and
holes are drilled on its surface in regular intervals for supporting the puppets and stop pins.
At each end of the table, a hallowed space is provided to collect the chips and a groove is cut on its
side for clamping planer reversing dogs at different positions.
The planer may have a single table or two separate tables mounted on guide ways and reciprocates
separately or together. Hydraulic bumpers are fitted at the end of the bed to stop the table from
overrunning and giving cushioning effect.
Housing or Column:
Housing is a rigid box-like vertical structure fastened on each side of the bed. They are also
called as uprights.These are heavily ribbed to take heavy load during cutting action. The front face of
each housing is provided with precision ways for sliding the cross rail up and down and also having
two side tool heads slide upon it.The column houses the cross rail elevating screw, vertical and cross
feed screws for tool heads.These screws may be operated by power or hand.
Cross Rail:
It is a rigid cast-iron box-like casting that connects the two housings.
It provides additional rigidity to the machine. The cross rail may be moved up and down on the
face of the housing by means of elevating screw and can be clamped at any position and it is parallel
to the top surface to the table.The front face of the cross rail provided with accurately machined
guideways for cross-feeding the tool head saddle by means of a screw.
Tool Head:
The planner tool head is similar to that of the shaper in construction and operation.
Tool heads are mounted on a cross rail by a saddle, which moves crosswise to give crossfeed. The swivel
base is pivoted on the saddles and it is graduated to 60 degrees on each side, so that which can be tilted at any
desired angle for machining angular surfaces by rotating down feed screw.The apron is fixed on the face of the
vertical slide which may be swiveled up to 20 degrees on each side for giving the tool clearance while machining
vertical surfaces.
The clipper block is hinged to the clipper box to hold the tool post in which cutting tool is held firmly.The
clipper block lifts the tool head upward during return stroke to prevent the cutting edge of the tool from dragging
on the work. The tool heads can be moved up and down by moving the cross rail up and down.
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Working of Planer:
Initially, the tool head of the machine is in a stationary position and the worktable can be move.The tool
single point cutting tool is fixed in the tool head and the workpiece is fixed on the work table.Now we switch on
the machine that means power supply to the machine and the worktable moves forward hence it cuts the material
and it is called cutting stroke.The worktable moves downward there is no cutting of material so this is called the
return stroke.The process will be continued unless you change the power supply or others.
Planer Machine Mechanism:

There is two important planer mechanism:
1. Table drive mechanism
2. Feeding mechanism
The different table drive mechanisms are:
1. Open and cross belt drive
2. Reversible motor drive (move to 37 slides)
3. Hydraulic drive
Open and Crossbelt Drive Mechanism:

This mechanism is used in a small size planer.
The countershaft mounted on housing is driven by the motor on which fast and lose pulleys are fixed.
By shifting the belt from loose to fast pulley the machine is started or by shifting the belt from fast to loose
pulley the machine can be stopped. The small diameter pulley drivers the crossed belt and large diameter
pulley drivers the open belt.
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The crossed belt further connects to the larger diameter pulleys 3(loose pulley)and 4(fast pulley) which
are keyed to the main shaft of the table and the open belt connects the smaller diameter pulleys 1 (loose
pulley) and 2(fast pulley) on the main shaft.
When the counter shaft rotates the motion will be transmitted to the main shaft of the table through
fast pulleys of the cross or open belt and no motion will be transmitted when the belt is on loose pulley.
The motion of the main shaft is transmitted through gear 5, 6 and 7 to the bull gear 8. The bull gear meshes
with a rack at the underside of the table, which converts the rotary motion to linear motion thereby table
starts reciprocating.
The crossed belt is used for driving the table during a cutting stroke, which gives greater power and less
speed by having the greater power and the speed is reduced as the belt connects smaller pulley on the
countershaft to the larger pulley 3 on the main shaft of the table.
At the end of the forward cutting stroke. The trip dog mounted on the side of the planer table
operates a belt shifter through a lever arrangement, thereby shifting the crossed belt from fast pulley 1
to loose pulley 2.
The motion is now transmitted from the larger pulley on the countershaft to the fast pulley on
the main shaft and no motion is transmitted by crossed belt to the main shaft.
When the shaft receives the motion from an open belt, the direction of rotation of the shaft reversed
and table starts moving to perform return stroke with a high speed as the open belt connects the larger
diameter pulley on the countershaft with the smaller diameter pulley on the main shaft and thus
obtaining the quick return motion.
At the end of the return stroke, second trip dog will hit against the belt shifter lever causing the
cross belt to shift from loose pulley (4) lever causing the cross belt to shift from loose pulley (4) to
fast pulley (3) and open belt to shift from fast pulley (2) to loose pulley (1) to repeat the cycle of
cutting stroke and return stroke. The length and position of the stroke may be adjusted by shifting the
dog position.
Planer Machine Operation:
The common operation that can be performed in the planer machine are:
• Planing Flat horizontal surfaces
• Planing Flat vertical surfaces
• Planing angular surfaces and machining dovetails
• Planing curved surfaces
• Planing slots and grooves
Planer Machine Types:
Following are the different types of planers machines generally used:
• Double housing Planer Machine
• Open side Planer Machine
• Pit Planer Machine
• Edge or Plate Planer machine
• Divided table Planer Machine
Double Housing Planer Machine:
This planer is widely used in most of the workshops. It consists of a long heavy base with accurately
machined guide ways on which a table reciprocates. The bed length is slightly greater than twice the length of the
table. Near the middle of the bed, two vertical housings are mounted. One on each side and these are connected at
the top by a cross member as shown in the figure below:
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These tool heads are moved by hand or power in the crosswise or vertical direction to give the
feed.In addition to these, there are two other tool heads mounted on the vertical face of the housing, which
can be moved in a vertical and horizontal direction to give the feed. Mechanical or hydraulic devices may be
used to drive the planer table.
Open side Planer Machine:

It has only one housing on one side of the base on which a cross rail on a table as shown in the figure.
39 | P a g e
Three tool heads can be mounted on the machine. In this machine, a single housing has to take up
the entire load, Therefor it should be rigid and robust to resist the forces.
The cross rail can slide vertically along the guideways of the housing and it carries to tool heads which
can be moved horizontally and vertically another tool head is fitted on the housing and it can also be
moved horizontally and vertically.
Pit Planer Machine:
It has a massive construction in which the table is kept in a pit and it is stationary. The
column carrying the cross rail reciprocates on a horizontal rail mounted on both sides of the table as
you can see in the figure.The table of the planer is made a level with the floor, so that very heavy
work can be loaded very easily. The cross rail carries two tool heads and these can be moved
horizontally and vertically to give the cut.The driving screw is used for driving the column by
means of a motor.
Edge Planer Machine:

This planer is also known as plate planer and it is used for squaring and bevelling the edges of
steel plates used for different pressure vessels and in ship buildings works.
The table carries the work that remains stationary. The work can be clamped by air-operated
clamps. The tool-head mounted on a carriage moves along two horizontal guide ways on a base front
end as shown in the figure.
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Divided table Planer Machine:

A simple divide table planer as shown in the figure.
It consists of two tables on the bed that can reciprocate separately or together. This design saves the idle time
while setting work.This planer is mainly suitable for mass production work where identical machining is to be
done, by loading the work on one of the tables, while the other reciprocates past the cutting tool for finishing the
work.After finishing the work the table is stopped and the finished job is removed by shifting the table to the end
and reloading the work on this table while the first table holding the job now reciprocates past the tool.For heavy
and large jobs, both the tables are clamped together and are given the reciprocating movement under the tool for
machining.
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Planer Machine Specification:
A Planer may be specified by the following dimensions:
• Distance between two housings
• Height from top of the table to the cross rail in its upmost position.
• The maximum length of table travel
• The open size planer is specified by the largest job that can be machined on its table.
• In addition to these basic dimensions, other particulars are:
• Number of feeds available
• Length of bed
• Length of table
• Power input
• Floor space required
• Method of a driving table, geared or hydraulic
• Number of speeds available
• Net weight of the machine
Advantages of Planer Machine:
There are some advantages of Planer Machine and those are:
• Greater accuracy
• Good surface finish
• The major advantages are at a time more than one tool can perform on the workpiece Low maintenance
requires comparatively other machine tools
Disadvantages of Planer Machine:
These are some disadvantages of Planer Machine:
• The machine price is high
• The power consumption is quite more
• Skilled worker required
• Only tool single point is used. We can not use other than a single-point cutting tool
Application of Planer Machine:
These are the applications of Planer Machine:
Planer machine used for providing flat surfaces on the work piece It is also used for cutting angular surface.
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EXPERIMENT :- 5
AIM: Job making by using a Press Tool
Introduction:
The Hydraulic press is a machine press that works is to generate compressive force by the use
of a Hydraulic cylinder.
The hydraulic press machine is a device which is used for lifting the heavyweight by the
application of much smaller force.
This is based on Pascal’s law.Pascal’s law state that the intensity of pressure in a static fluid is
transmitted equally in all the direction.
A hydraulic press machine consists of following parts:
(1) Safety Door (2) Limit switch (3) Manual control valve (4) Electrical control box (5) Relief valve
(6)Pressure gauge (7) Hydraulic cylinder (8) Motor (9) Oil tank (10) Pressing Plate (11) Bailing
Compartment
Safety Door: Safety door is just like the correction gate when any accessories get damage than from
this door we can fix this.
Limit switch: It is a switch that prevents the travel of an object in a mechanism past some
predetermined point, mechanically operated by the motion of the object itself.
Manual control Valve: The operation is controlled manually with the help of the valve.
Relief valve: When pressure is high exceeds the limit this valve is used to release or control the
pressure
Pressure gauge: It is fixed thereto measure the pressure.
Hydraulic cylinder: This is a mechanical actuator which is used to give a unidirectional force
through a unidirectional stroke
Oil tank: Here hydraulic oil is stored and supply.
Pressing Plate: The main works of pressing plates are to provide pressure to the object and this plate
having high strength.
Bailing Compartment: Here the work piece and placed and press according to the required shape
and size.
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Hydraulic Press Machine Working Principle:

A hydraulic press machine work in the following steps:
1. This is based on Pascal’s law, Pascal’s law state that the intensity of pressure in a static fluid is
transmitted equally in all the direction.
2. The hydraulic press consists of two cylinders of different diameters. One of the cylinders is of large
diameter and contains a Ram, while the other cylinder is the small diameter and contains the plunger as
shown in the below figure.
3. The two cylinders are connected by a pipe.
4. The cylinders and pipe contain a liquid through which pressure is transmitted.
5. When a small force f is applied on the plunger in the downward direction, a pressure is produced on
the liquid in contact with the plunger.
6. This pressure is transmitted equally in all directions and acts on the RAM in the upward direction as
shown in the figure.
7. The heavier weight placed on the ram is then lifted up.
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Types of Hydraulic Press Machine:

The hydraulic press machine is categorized into 5-types and those are:
• Four-column hydraulic press
• Single column hydraulic press (also known as C-type)
• Vertical hydraulic Press
• Horizontal hydraulic press
• Universal hydraulic Press
Four-column hydraulic press:

This machine can be used for any kind of material and eligible for various pressing technology like bending,
punching, etc.
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Vertical hydraulic Press:
This type of hydraulic machine has 2 columns and an overarm connected with the columns. And the pressure
applies vertically.
Horizontal hydraulic press:

In a horizontal hydraulic pressing machine, the workpiece remains between the two verticle plate and the
pressure applies horizontally or parallels to the axis of the machine.
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Universal hydraulic Press:

This type of pressing machine is used for many types of pressing processes like forging, punching, etc without any
external attachment.
A hydraulic press machine can be specified in terms of these following points:
• Types of hydraulic press, is it vertical or down stroking?
• The type of frame used in the machine.
• Maximum load of pressing.
• Return capacity of the machine.
• Stroke of the ram.
• The number of the cylinder inside in the machine.
• Type of cylinder, is it single or double-acting?
• The speed of the ram in mm/sec.
• The electrical power consumed by the machine in KW.
• Types of operation need (Automatic or Semi-automatic).
Hydraulic Press Machine Advantages:
The advantages of hydraulic press machine are:
• High tonnage capacity
• The hydraulic press is quieter because it’s having less number of moving parts.
• It generates a high amount of pressure.
• Greater Versatility (Ability to adapt).
And it also works for:
1. Powered metal forming
2. Straightening
3. Bonding
4. Transfer molding
5. Shell reductions
6. Press fits and more
• It takes less floor space or Floor space required is less.
Here do not worry about overloading or weight damage because at some point the pressure is set and when the
pressure gets more the relief valve opens.
• It having low tool cost as compared to mechanical counterparts.
• Smooth Pressing.
• Simple Design.
• A skilled operator not required even semi-skilled operators can work.
• The tool life will be longer.
• Improve the rigidity and strength of the workpiece.
Hydraulic Press Machine Disadvantages:
The disadvantages of hydraulic press machine are:
• The pressure is set for some limit can not exceed more than that.
• Maintenance requires is more.
• There is a carbon footprint.
• Applications of Hydraulic Press Machine:
• These are the following applications of hydraulic press machine:
• The hydraulic pressing machine is used to convert any metal block to a sheet.
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Although hydraulic press machine is used for:
• Forging
• Blanking
• Clinching
• Molding
• Deep drawing
• Metal forming operations and Punching,
Some more application of hydraulic press machine are:
• Thermoplastics
• Composites
• RTM (Resin Transfer Molding)
• SMC (Sheet Molded Composites)
• Carbon Fiber Molding, and
• GMT (Glass Mat Transfer)
Difference between Hydraulic Press Machine and Mechanical Press Machine:
Hydraulic Press Mechanical Press
The motion is uniform. The motion is not uniform.
Stroke length is more. As compared to hydraulic press having less.
Inertial loss is low. Here it’s more.
Range of speed is high. Speed range is low.
The motor needed is bing. The motor needed here is small.

Used for heavy-duty operation. Used for light-duty operation.
The flywheel is not there so here a

big motor is required. Flywheel (stored energy) is there.
The max pressure we get here at
any point In mechanical press at the bottom stroke max
between the stroke. pressure we get.
A deep drawing operation is
possible here. Not possible here.
High maintenance cost. Low maintenance cost.
The initial cost is high. The initial cost is low.
It works on oil pressure system. Here we use crack gear mechanism.
Less floor space is required. More floor space is required.
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EXPERIMENT :- 6
AIM: Job making on Drilling machine
Introduction:
A drilling machine is one of the important machine tools in the workshop.
A drilling machine is used to form a hole of different sizes on a job, drilling is a metal removing
process, by a drilling machine you can do drilling operation, reaming operation and boring operation.
Drilling is a material-removing or cutting process in which the tool uses a drill bit to cut a hole of
circular cross-section in solid materials.This is the most common machining process, one estimate is that
75% of all metal cutting material removed comes from the drilling operation.
Drilling Machine Main Parts:
A drilling machine consists of the following parts:
(1)Base (2) Column or Pillar (3) Arm (4) Worktable (5) Drill head (6) Feed Mechanism (7) Spindle
(9) Drill jigs (10) Chuck (11) Electric Motor
Pully or gears
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Parts of drilling machine
These are the main parts of the drill machine
Base:
It is one of the main parts of a drilling machine, it carries the entire weight of the machine, and
transfer the weight to the ground. The base of a drilling machine is generally made of cast iron or steel,
and it is very rigid. At the top of the base, there are some slots provided to support the big jobs. And on
one side of the base, a radial column or a pillar is situated.
The base is generally bolted with the ground or in some case the base is supported by two or four
legs.
Column or pillar:
The column or pillar is situated on one side of the base. In general, we use a radial column so that
the movement of the arm is possible in a clockwise or anti-clockwise direction. The column is also made
of cast iron or steel and is also very rigid so that it can carry the load of the arm as well as a drill head. A
sliding table is mounted on the column so that the table can have up and down motion according to the
need.
Upper arm:
At the top of the column, there is an upper arm, which carries the drill head and also the house of the
driving mechanism. The upper arm is also made of the same material as the base. To make the structure
rigid. In some drilling machine, a guide way is provided so that the drill head can slide over this.
Work table:
The work table is generally made of cast iron and it is mounted on the column. T-slots are provided
at the top surface of the table may be in some table there is a vice which also helps to hold the job.
The table can move up and down as also right or left according to the job and tool arrangement. The up
and down motion of the table can be given by hand as well as by some electrical mechanism. We use a
rack and pinion mechanism for a vertical moment of the table. The shape of the table can be rectangular or
also circular.
Drill head:
One side of the arm a drill head is mounted, a drill head is consist of various feed and driving
mechanism.
A drill chuck is mounted over it. A drill head can slide up and down as per the requirement of
the job. A V-types belt is provided to transfer the power from the motor to the pulley and from
pulley, the mechanical power is transferred to the drill head.
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Feed Mechanism:
In a drill machine, we use an electric motor, V-belt, and pulley to transfer the power from the
motor to the spindle.For the up and down motion of the drill head, we use hand and as well as
automatic feed by an electrical motor. Here also a rack and pinion are used to convert the rotational
movement from electrical motor or by hand to the straight-line movement.
Spindle:
It is a circular taper shaft which helps to hold the drill chuck. It is made of high carbon chromium
steel or stainless steel or steel alloys.It transfers the rotary motion from drill head to drill jigs.There is a
keyhole provided on the spindle to change the drill chuck.The spindle also can move up and down with the
help of rack and pinion mechanism.
Chuck:
The chuck is mounted on the lower end of the spindle, it holds the drill jig. Here also a keyhole is
provided to change the drill jigs.Drill chucks are generally self-centering. In a drill machine, we use
three-jaw chuck. And it is made of special alloy steel.
Electric Motor:
In a drilling machine, we use a single-phase ac motor. Which can run at an rpm of 600-5000, or
maybe more for high duty drilling machine?
Pully or gears:
Pully or gears is used to transmit power and also for getting different speed. In a drilling machine,
we use bevel gear to transmit power at an angle of 90 degrees.So now we are going to learn how power
transferred in a Drilling machine. The power transmission in the drilling machine used to transmit power
for its working. This power is supplied from the electric motor.
The process of transmission takes place with the help of the v-bolt and the pair of pulley stacks
opposite to each other.The speed of the spindle is fixed or controlled with the help of the pulley
stacks.
Drilling Machine Types:
In the market there are various types of Drilling machine available, here I mention some of the popular
types of drilling machines.
Sensitive Drilling Machine

Vertical or Pillar
Radial Arm
Gang Type
Multi-Spindle
Numerically control
Special Purpose Drilling Machine
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Sensitive Drilling Minache:
The sensitive drilling machine has only a hand-feed mechanism for feeding the tool into the
workpiece. This enables the operator to feel how the drill is cutting and accordingly he can control
the down feed pressure.
Vertical or Pillar Drilling Machine:
Vertical or Pillar Drilling Machine is free standing and is of a far heavier construction able to take
larger drills.It has a heavy frame to support a wider range of work.The table height is adjustable and
power speed and feeds are available.The larger drills normally have a taper shank located within taper
bore in the spindle end. These tapers are standardized as Morse tapers.
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Radial Arm Drilling Machine:

The radial drill machine is free-standing and the work piece is clamped in the position on the base. It
is used for heavy large and heavy work. The arm is power-driven for the height location. The drill head is
positioned using motorized drives and it transverse the swinging arm. The work piece remains stationary o
the machine base or worktable. The machine spindle is moved to the location required.
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Gang Type Drilling Machine:
In the Gang type Drilling Machine, several spindles/ or stations are mounted on one long table as
shown in the figure.
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Multi-spindle Drilling Machine:
In the Multi-spindle drilling machine, there are many spindles mounted on one head to allow
many holes to be drilled simultaneously.
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Numerical Control Drilling Machine:
Numerical control drilling machine can automatically change tooling with a turret or
automatic tool changer.Speeds, feeds, and table position is controlled using a computer program.
Twist drill nomenclature:
It is designed with cones like internal structure, narrow at the top of the web with a
gradually increasing thickness to the shank.It is a multi-point cutting tool. I also wrote an article
on the single-point cutting tool you can check that too.
Axis: The imaginary straight line which forms the longitudinal centerline of the drill.
Back taper: A slight decrease in diameter from front to back in the body of the drill.
Body: The portion of the drill extending from the sank or next to the outer corners of the cutting lips.
Body Diameter clearance: That portion of the land that has been cut away so it will not rub against the wall of
the hole.
Chisel Edge: The edge at the end of the web that connects the cutting lips.
Chisel Edge Angle: The angle included between the chisel angle and the cutting lips as viewed from the end of
the drill.
Clearance Diameter: The diameter over the cutaway portion of the drill lands.
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Drill Diameter: The diameter over the margins of the drill measured at the point.
Flutes: Helical or Street grooves cut or formed in the body of the drill to provide cutting lips, to permit removal of
chips and to allow cutting Fluids to reach the cutting lips.
Flute Length: The length from the outer corners of the cutting lips to the extreme back and of the flutes; it
includes the sweep of the tool used to generate the flutes and, therefore does not indicate the usable length of the
flutes.
Helix Angle: The angle made by the leading edge of the land with a plane containing the axis of the drill.
Land: The peripheral portion of the body between adjacent flutes.
Land Width: The distance between the leading edge and the hill of the land measured at the right angle to the
leading edge.
Lead: The axial advance of the leading edge of the land in one turn around the circumference.
Lips: The cutting edge of a two-flute drill extending from the chisel edge to the periphery.
Lip Relief: The axial relief on the drill point.
Lip Relief Angle: The axial relief angle at the outer corner of the lip; it is measured by projection onto a plane
tangent to the Periphery at the outer corner of the lip.
Margin: The cylindrical portion of the land which is not cut away to provide clearance.
Neck: The section of reduced diameter between the body and the shank of a drill.
Overall length: The length from the extreme end of the shank to the outer corners of the cutting lips; it does not
include the conical shank end often used on a straight shank drill, nor does it include the conical cutting point used
on both straight and taper shank drills.
Point: The cutting end of the drill made up of the end of the lands and the web; inform it resembles a cone, but
departs from a true cone to furnish clearance behind the cutting lips.
Point angle: The angle included between the cutting lips projected upon a plane parallel to the drill axis and
parallel to the two cutting lips.
Shank: The part of the drill by which it is held and driven.
Tang: The flattened end of a tapered shank intended to fit into a driving slot in a socket.
Tang drive: Two opposite parallel driving flats on the extreme end of a straight Shank.
Web: The central portion of the body that joins the land; the extreme end of the web forms the chisel edge is on a
two-flute drill.
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Drilling Machine Operation:
These are the following operations that can be performed in the Drilling machine.
Plane drilling operation

Core drilling operation
Step drilling operation
Boring operation
Counter boring operation
Reaming operation
Countersinking operation
Spot facing operation
Tapping operation
Trepanning operation
Drilling operation:
When we need a circular hole in a workpiece of any size there, we can use drilling operation, by a
drilling operation you can form any size of holes in a workpiece. Although you can use a lathe for drilling
operation too, drill machine is an appropriate machine to do holes in a work piece.
The cutting tool we used for this type of operation is drill bit. A drill bit is a multipoint rotary cutting tool which
helps to remove material from a work piece.
Core Drilling:
When sand castings are made, cores are used to displace the metal where holes are desired. When cast the molten
metal flows around the core. After the metal solidifies the casting is removed from the mold and the core
disintegrates leaving the desired holes. the holes are usually quite rough and require heavy body drill to clean up
the sidewall of the whole.
Step Drilling:
More than one diameter can be ground on the drill body which saves an extra operation.
The cutting tool we used for this type of operation is drill bit. A drill bit is a multipoint rotary cutting tool
which helps to remove material from a workpiece.
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Boring:
When you need to enlarge the diameter of the existing hole you need to perform the boring operation, but the
accuracy is not greater than reaming operation. The boring tool is generally a single-point cutting tool.
Reaming:
It is an operation of finishing a drilled hole.
A finished hole has the specified diameter size, is perfectly round, the diameter is the same size from end to end,
and it has a smoothly finished surface.
A drill hole is seldom accurate enough in size or sufficiently smooth to be called a precision hole.
The end of the tool known as the pilot keeps the counterbore concentric with the original hole.
Pilots are interchangeable with others of different sizes to fit the various size of holes.
Counter Sinking:
When greater accuracy is required the whole must be drilled undersize by a certain amount and finished by the
reaming. In short, When we need to enlarge the size of an existing hole with great accuracy in a work piece we
have to performed reaming operation. In this type of operation, we need a reamer to perform the operation.
A reamer is a rotary cutting tool that removes the material from the existing hole which has several parallel
and helical cutting edge throughout its cylindrical body.
Counter Boring:
It is the operation of boring a second hole, a larger diameter than the first but concentric with it. When this
operation is done on a drilling machine a tool known as counter bore is used. It is the operation of producing an
angular surface at the end of a hole. A countersink is used. The countersink is made in many diameters size and
several angles.
The angle size depends upon the reason for counter sinking. Flathead screws require a countersink with an
82 included angle, where is a Centre hole must be 60.Various types of rivet heads have included angles of from 90
to 145 degree.
Spot Facing:
It is the operation of machining a flat, circular surface around a whole to provide a seat for a Bolt head, nut
or washer. It is usually performed on casting. A Counter bore may be used for spot facing. The Surface machined
should be a square with the hole.
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Tapping:
Holes that are to be tapped(threaded) are first are drilled to a specified size. In order to tap holes on a
standard drilling machine, a tapping attachment must be used. This attachment is held in the spindle of the drill
press by a tapered Arbor, who drives the friction type mechanism. The tap holding chuck accurately centers the tap
on the round part of the shank and floating jaws hold the tap on its square end in a firm, rigid grip, which prevents
the tap from pulling out of the chuck when reversing.
Trepanning:
It is a hole making operation where an annular groove is produced leaving a solid cylindrical core in the
center. In Trepanning a cutter consisting of One or more cutting edges placed along the circumference of a circle is
used to produce the annular groove. Trepanning is feasible if the hole has a diameter of more than 50 mm. Hole
depth of 160 times the diameter can be obtained in Trepanning.
Drilling Machine Advantages:
• This machine is needed to mark on the end of components of dresses especially for setting pocket, dart &
so on.
• It can make the hole permanently for a long.
• Drilling Machine Dis-advantages:
• The use of a machine is limited.
• Drilling Machine Application:
• It is used to make a hole in the fabric for button attaching and to make a reference mark for attaching
different small components on the garments.
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PERFORMANCE OF DRILLING OPERATION
Name of machine: Radial Drill Machine
Specifications of the machine:
Drilling capacity 38 mm (MS)

Spindle nose MT-4
Spindle travel 220 mm
No 0f spindle speeds 8
range of spindle speeds 62-1980 rpm
0.08- 0.04
Range of power/manual feeds mm/rev
No. of power/manual feeds 2
Main motor 1.5 HP
Arm elevated motor 0.5 HP
Swivel of arm L/R side 90 Deg.
Maximum drill head travel 450 mm
Max./min.distance from spindle to base
plate 930/230 mm
Max./min.distance from spindle to column 810/360 mm
Dia of column 165 mm
Drilling radius (Max/Min) 895/440 mm
Name of operations: (a) Drilling

(b) Reaming
Name of Tools: (a) Twist Drill

(b) Reamer
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EXPERIMENT :- 7
AIM : To study the pattern allowances and to make the drawing of pattern of given
automotive part.
Introduction :
Casting is the one of the oldest manufacturing process and even today is the first step in manufacturing of
most products. In this process the material is first liquefied by properly heating it in a suitable furnace. Then the
liquid is poured into a previously prepared mould cavity, where it is allowed to solidify subsequently, the product
is taken out of the mould cavity trimaned and cleaned to shape.
It is clear from the definition of process that a successful casting operation needs a knowledge in the following
areas :
1. Preparation of moulds and patterns (Use to make the mould)
2. Melting and pouring of liquefied metal.
3. Solidification and further cooling room temperature.
4. Defects and inspection.
There are various of casting process depending among on the material, the type of patterns, mould and
pouring techniques. Before going into the details of the process we shall discuss the basic common features among
the various casting processes in the context of four area, we have just maintained.
The suitability of the casting operation for a given material depend upon :
1. The melting temperature of the job and the mould materials.
2. The solubility and chemical reaction between the job and the mould materials.
3. The solubility of the atmosphere in the material at different temperature to be encounted in the casting operation.
4. The thermal properties such as conductivity and coefficient of linear expansion of both the, mould and job
material.
Importance:
Costing have several properties that clearly defines their sale modern equipment used for mass production
communications, power agriculture, construction and in industry. Cast metal are required in various shapes and
seizes and large quantities of making machine and tool which in turn work to provide all the necessities and
comforts for life other metal shaping are of course necessarily to full fill a tremendous range of needs. However
certain advantage interested casting design and metallurgical advantages and the casting processes itself make them
superior over other metals.
Pattern Making :
Patterns are required to make moulds. The mould is made by packing suitable moulding material such as
moulding sand around the pattern. When the pattern is withdrawn the imprint provides the mould cavity which is
immediately filled with molten metal to become casting.
A pattern may be defined as a full size model of the desired period. Casting which when packed or
embedded in a suitable moulding material produces a cavity called mould. This mould when filled molten metal
from the desired casting after solidification of the molten metal. The pattern very closely confirm to the shape and
size of the desired casting except that it carries pattern allowances to compensate metal shrinkage provides
sufficient metal for mechanical surface and facilities moulding. The process of making a pattern is known as
pattern making.
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Types of pattern:
The type pattern selected for particular casting depends upon the following condition:
1. The shape and size of casting.
2. The number of casting required
3. The method of moulding employed.
The common type of pattern are discussed below :

Solid or single piece patterns:
A solid or single piece pattern has a compact form. It has no joints parting or loose piece in its construct. It
has usually one broad surface that serves as a parting surface in the mould. This type of pattern is used for a
limited number of casting because most of moulding operations like parting surface formation, calling of gating
system withdrawal of pattern etc. is done by hand.
Split Patterns:
The most of the patterns are not made in a single piece because of the difficulties encounted in moulding
them in order to eliminate this difficulty. Some more patterns are made in two or more pieces. A pattern consisting
of two pieces is called a two piece split pattern as shown in figure. One half of the pattern rests in the lower part of
the moulding box, known as drag and the other half in the upper part of the moulding box known as cope. The line
of separation of the parts is called casting line or parting surface. Sometimes a pattern for complex casting is made
in three parts. Such a pattern is called as a multi-piece pattern. A three piece pattern requires a moulding box with
three parts the middle one being called as check.
Applications:
The split patterns are commonly used for casting spindles cylinders steam valve bodies water stop. Cocks
and taps bearings small pulley and wheels.
Match Plate Pattern :

The match plate patterns are used on machines for quantity production of casting. A simple pattern or
number of pattern may be mould on a match plate. It consist of a flat metal or wooden plate to which patterns
runners gates are permanently fastened.These plates are provided with holes on either end of fit in a standard flask.
When the match plate is lifted of the mould the pattern are withdrawn and the gates and runners are completed in
one operation.
Loose piece pattern :

Some the pattern has to made with projection or over hanging parts. There projection makes the removal of
the pattern difficult. Therefore such projections are made in loose piece and are fastened loosely to the main
pattern by means of wooden or wire dowel pins/ These pins taken out during the moulding operations. After
moulding the main pattern is withdrawn first and the loose piece is removed with the help of lift.
Cope and drag Pattern:

When very large casting are to made the complete mould becomes to heavy to be handled by a single
operator. In order to this problem the cope and drag pattern is used. It is nothing but two piece pattern split on
convenient joint line one part is moulded in a cope and the other part in a drag of the moulding box.
The Gated Pattern:

The gated pattern is used for limited production of small casting. It eliminates hand cutting of gates and
thus makes the moulding easy. If the group of pattern is to be placed in one mould the gate pattern has a further
function of holding the pattern in proper positions with respect to each other.
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Sweep Pattern:
A sweep pattern is used for symmetrical moulding. It is not considered as true pattern when compared with
other. A sweep is template of wood or other material which has counter corresponding to the shaped and size of
casting. It is related about a central spindle. Figure shows curved sweep which may be used from part of the mould
for a large cast iron kettle. The Principle advantage of this pattern is that it eliminates expensive pattern
consumption.
Skelton Pattern :-
When a few and large sized casting are required it is not available to use a large solid pattern of that size .
In such cases a Skelton pattern in the hallow form consisting of a wooden frame and strips. The strips shown in
figure are used to form the outside and inside of the frame when it is filled with sand. In mounting the frame is set
on a level sand bed with the flange down and is filled with sand. The pattern is formed by smoking off the outside
with strikes. A half flask is placed over it and the surface of the sand pattern is dusted with parting sand. The flask
is then ran med up and lifted away after which the surface of sand pattern is scraped away and stricks are used to
form the inside of core before the frame is removed.
Shell Pattern :-
The shell pattern is used largely for drainage fitting and pipe work. This type of pattern is usually made of
metal and pasted along the centre line. The two sections being accurately doweled together . the short bend are
usually moulded and cast impairs. The shell pattern is a hallow construction like a shell. The out side shape is used
as a pattern to make the mould while the inside the core box for making cores.
Segmental Pattern :-
These patterns are used for prepare moulds of large circular casting, Avoiding the use of solid pattern of
the exact size. In Principle they work like a sweep but the difference is that a sweep is given a continuous
revolving motion.
Follow Board Pattern :-
A follow board is used for solid pattern having an irregular parting line. It may be used either single or
multiple gated patterns. The pattern requiring the follow boards are usually somewhat difficult to make as split
pattern. The board is gated out so that the pattern rests in it upon the parting line and this board then act as a
moulding board for the first mould operation.
Lagged –Up – Pattern :-

When a pattern or core box is so large or of such a form that it cannot be made economically form a solid
piece or when such a method would result in a pattern of the little strength or excessive weight. It is necessary use
a lagged or sand pattern.
Left and Right Hand Pattern :-

Some patterns are required to be in pairs and when their form is such that they cannot be reversed and have
the centres of hubs, boxes etc. opposite and in line then they must be made right and left hand pattern is required
on legs for wood turning lathe.
Example : Hangers for over head shafting, Legs for bench, legs of paddle type sewing machine, brackets
for luggage racks in the railway carriages etc.
PATTERN MATERIALS :-
The common materials of which the pattern are made are follows :
1. wood
2. Metals
3. Plaster
4. Plastics
5. waxes
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Factors affecting the selection of pattern material :
1. No. of casting to be made. 2.
2. Method of moulding to be used, i.e. hand moulding or machine moulding
3. Type of casting method to be used
4. Degree of accuracy in dimensions and the quality of surface finish required on the castings.
5. Design of casting.
PATTERN ALLOWANCES:-
A pattern is always made larger than the required size of the casting for several reasons such as shrinkage,
machining, distortion and rapping etc.
The following allowances are provided on a pattern:
Shrinkage allowance:
Most of the metal used in casting work contract during cooling from pouring temp. to room temp.
This contraction takes place in three forms. Viz. Liquid contraction, Solid contraction, solidifying
contraction. The first two are compensated by gates and risers and the last one by providing adequate
allowances in the pattern. The amount of contraction varies with different metals and therefore their
corresponding allowances also differ.
The prominent factors which influences the metal contraction are the following.
(i) Pouring temp. of the molten metal.

(ii) Design and dimension of casting.
(iii) Moulding method. iv. Type mould material.
(iv) Mould resistance to shrinkage of metal.
(v)The metal of which the casting is to be made The contraction of metal is always volumetric but the
contraction allowances are always expressed as linear measures.
Machining Allowance:-
A casting may required machining all over or on certain specified portion, depending upon the assembly
conditions and the operation it has to perform. Such portions are marked duly in working drawings. The
corresponding portions or surfaces on the pattern are given adequate allowances, in addition to the shrinkage
allowance, by increasing the metal thickness there to compensate for the loss of metal due to machining on these
surfaces. The amount of these allowances depends upon the metal of casting used, size, shape of casting and the
degree of finish require on the machined portion. Ferrous metals need more allowance.
Draft Allowance:-
All patterns are given slight taper on all vertical surfaces, i.e. the surfaces parallel to the direction of their
withdrawal from the mould. This taper is known as draft or draft allowances. It can be expressed either in degree
or in terms of linear measures.
Rapping or Shake allowance:-

When pattern is to be withdrawn from the mould, it is first rapped or chucked by striking over it from side
to side, so that it surface may be free from the adjoining sand wall of the mould. As a result of this the size of
mould cavity increases a little and negative allowances is to be provided in the pattern to compensate the same.
Distortion Allowance:-
The tendency of distortion is not common in all the casting. Only casting which have an irregular shape
and some such design that the contraction is not uniform throughout will distort on cooling on account of the
setting up of thermal stresses in them. Such an effect can be easily seen in some dome shaped or U shaped casting,
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to eliminate this defect on opposite distortion is provided in the pattern so that the effect is neutralized and the
correct casting is obtained.
Pattern Colour Code:-

There is no universally accepted standard for the representation of different type of surfaces by different
colures. The practice varies with different countries and sometimes with different manufactures in the same
country.
The following practice will serve as useful guide both for pattern and core boxes.
1. Red: Surfaces to be machined.
2. Black: Surfaces to be un machined.
3. Yellow: Core prints
4. Red strips on yellow base – seats for loose pieces.
5. Black strips on yellow base – stop offs.
6. Clear or no colour – parting surfaces.
QUESTIONS:-
QUE-1: Write different steps in making a casting by expandable mould,” removable pattern sand mould
process.’
QUE-2: Explain the different types of Sand Moulds in detail.
QUE-3: Explain the different types of materials used in moulding.
QUE-4: Give the properties of Moulding Sand.
QUE-5: Give the applications of following:

(i) Core (ii) Chaplets (iii) Gates (iv) Riser (v) Runners (vi) Sprue (viI) Ladles
QUE-6: What is Pattern? Give the classification of pattern and explain with neat skatces:
(i) Gated Patterns (ii) Match Plate Pattern (iii)Sweep Pattern (iv) Skeleton Pattern
QUE-7: Why the Allowances are provided for making a Pattern?

Explain different types of pattern Allowances.
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EXPERIMENT :- 8
AIM : To study the investment and centrifugal casting and casting defects.
Introduction :
A large number developments have taken place in this field and various new moulding & casting methods
have been evolved to serve certain specific purpose. These new methods have helped in one way or other in
increasing production rate, effecting grater economy, improving quality of casting, eliminating or minimizing the
need of further machining, providing better surfaces finish & may other such aspects. These methods are termed
were as ‘special casting methods’ for the reason that economic consideration prohibit their common use in every
foundry.
Investment Casting :
Precision investment casting or the lost wax process, though known since long, come in practical during
world war – II. The process is consist of preparing wax, plastic or frozen mercury by pouring the same into a metal
mould or die.
Steps involved in making investment casting
(i) Die making
(ii) Making wax pattern
(iii) Assembling the wax pattern
(iv) Investing
(v) Removal of wax patterns
(vi) Pouring & casting
(vii) Cleaning & inspection
Centrifugal Casting :
This is process where the mould is rapidly about its central axis at metal is poured into it, because of
centrifugal force a continuous pressure will be acting on the metal as it solidifies. The slag oxide & others
inclusions being lighter get separated from the metal and segregates forward the centre.
The three main centrifugal casting are as follows :
(i) True Centrifugal Castings
(ii) Semi Centrifugal Castings
(iii) Centrifusing
True Centrifugal Casting :

This is normally used for the making of hallow pipes, tubes, hallow bushes etc. which are axis metric with
concentric holes. Since the mutual is always pushed outward because of the centrifugal force, no core needs to be
used for the making of concentric hole. The axis of rotation can be either horizontal, vertical or any angle in
between. Very long pipes are normally cast with horizontal axis where as short pieces in vertical axis. A normal
centrifugal machine used for making cast iron pipe in sand moulds as shown in fig. First moulding flask is
properly rammed with sand to confirm to the outer contour of the pipe to be made. Any end details, such as the
pipe to be made or flanged ends are obtained with the help of dry sand cores located in the ends. Then the flask is
dynamically balanced so as to reduce the occurrence of undesirable vibrations during the casting processes. The
finished flask is mounted in between the rollers and the mould is rotated slowly. Now the molten metal in requisite
quantity is poured in to the mould through movable pouring basine. The amount of metal poured determines the
thickness of the pipe to be cast. After the pouring is complete, the mould is rotated as its operational speed till it
solidifies, to form requisite tubing. Then the mould is replaced by a new mould machine and process continued.
Water jackets are provided around the mould for cooling.
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Semi Centrifugal Casting :
Semi Centrifugal casting is used for jobs which are use for made complicated than those possible in true
centrifugal casting, but are ax symmetric in nature. It is no necessary that these should have a central hole. Which
is to obtained with the help of a core. Which is to be obtained the moulds mode made of sand or metal are related
above a vertical axis and the metal enters the mould through the central pouring basin as shown in fig. For larger
production rules, The mould can be stocked one over the other, all feeding from the same central pouring basin.
The rotating speed used in this process are not as high as in case of centrifugal casting.
Centrifusing :
In order to obtain to higher metal pressure during solidification, when casting shape are not axisymmetrical
the centrifuging process is use. This is suitable for only small jobs of any shapes. A number of such small jobs are
joined together by means of radial runners with a central spray on a removing table as shown in fig. The jobs are
uniformly placed on table around the periphery. So that their masses are properly balanced. The process is similar
to semi-centrifugal casting. A comparison of the various casting processes discussed above are presented.
Shell Moulding :-
It is process in which the sand mix with a heated metallic pattern plate, so that a thin strong shell of mould
is formed around the pattern. Then the shell is removed from the pattern and the cope of drag are removed together
& kept in a flask with necessary back up material & the molten metal is poured into the mould.
Find and dry sand is used in shell moulding the grain size of the sand choosen is is depend on it is
essentially a thermosetting resin which get wardened irreversibly by heat. The resins most widely used, are the
phenol formaldehyde resins, combined, with sand they have high strength & resistance to heat.
Addetives may sometimes be added into the sand mixture to improve the surface finish & avoid thermal
cracking during pouring . Some of the additives used are coal dust, pulverized clay, magnese dixide calcium
carbonate.
The first step in preparing shell mould is the sand mixture in such away that each of the sand grain is
thoroughly coated with resin. To achieve this, first the sand, hexa & additives which all are very dry are mixed
inside a Muller for a period of 1 min. Then the liquid resin is added and mixing is continued for another 3 min. To
this cold or warm air is introduced into the Muller & mixing is continued till all liquid from the mixture and
casting and coating of grains is achieved for desired degree.
Since the sand resin mixture is to be use d at about 0 degree temperature preparing pattern is grey. C.I.
Mainly because of its easy availability & excellent stability of temp. involved in the process. But some times
additional rise ring provision is required as the cooling in shell mould slow.
CO2 Moulding :-
The process is basically hardening process for mould and cores. The sand mixture used in this process is
pure dry silica sand, free form clay and sodium silicate liquid base binder, the mould is prepared with a mixture of
sodium silicate and sand & then treated with carbon dioxide for two or three minutes such that a dry compressive
strength over1-4 mPa is arrived at. The carbon dioxide is expect to form a weak acid which hydrolyses the sodium
silicate resulting in amorphous silica which forms the bond. Because of high strength of band core need not to
better dimensional accuracy is achieved. But it is a little expensive process.
The shake out properties of CO2 are poor compared in normal moulding. Mould and covers get deferioted
from water pick up gf they kept stored for longer periods.
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The core sand should be completely free from clay moisture and any other impurities, otherwise the binder
consumption will increase.
The gassing of CO2 into the mould of core is done of number of ways depending essentially on the size of
the core of the mould. For smaller gastight hood is connected to CO2 source is placed directly in core box. For
very large mould which may be connected to a manifold getting the CO2 supply. The press should be maintained
around 0.14 to0.28 mpa depending largely on the thickness of section to be gassed.
There are four main types of die casting machines:-

1. Hot chamber die casting machine
2. Cold chamber die casting machine
3. Air blown or Goose-neck type machine
4. vacuum die casting machine.
Hot Chamber Die-Casting Machine :

The main part of the hot chamber is shown in fig. This is operated by hydraulic plunger act inside a
cylinder formed at one end of goose-neck type casting submerged in molten metal. A part is provided near the top
of cylinder to allow the entry of the molten metal in it. When the bottom of plunger is above the port the cylinder
is connected to the melting pot threw this part. Down stroke of plunger closes this port, cuts of metal, supplies and
applies the pressure on the molten metal present in goose-neck to force same into the die cavity threw injecting
nozzle. After the certain period of time the plunger is raised up, casting the remaining molten metal in nozzle &
channel to fall back into goose neck casting. Just before end of its up word stroke the plunger uncovers the port
through which more molten metal enters into cylinder. The dies are then opened & casting ejected. Zinc based low
melting point alloy are generally cast in these machines.
Cold Chamber Die-Casting Machine :-

The working principle of Cold Chamber Die-Casting Machine is illustrated in fig. The ward cold chamber
is used to denote the horizontal cylinder into which the injection plunger works. For these machines the meal is
melted separately in a furnace & transfer to these by means of small hand ladle. After closing the die the molten
metal is poured the horizontal chamber through metal inlet. The plunger is pushed forward hydraulically to force
the metal into die. After solidification die isopers of casting is ejected. The plunger is again drawn back & the
cycle is repeated as usual for next casting. These machines are widely used for casting a good number of
aluminum alloys & broses which can’t be cast in hot chamber machines as they require higher pouring
temperatures. Moreover the chances of iron pick up by aluminum are almost finished in these machines as it takes
place only at elevated temperatures & also become the molten alloy remains in contact with the steel chamber and
plunger for a very small period.
Defects In Casting :
Sand casting particularly are subjected to contain details which in a well designed casting are controllable
by proper foundry. Technique but are not wholly preventable casting defects are as follows.
1. Shifts:
This an external defects in a casting causes due to core misplacement or mismatching of top and bottom parts of
the casting usually at a parting line.
2. Warpage :
Warpage is unintentional & undesirable deformation in a casting that occurs during or after solidification. Due to
different rates of solidification in different sections of casting, stresses are setup in adjoining walls.
3. Fin :
A thin projection of method not intended as a part of the casting is called the fin. Fins are occurs usually at parting
of the mould.
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4. Swell :
A swell is an enlargement of mould cavity by metal pressure, resulting in localized or over all enlargement of the
casting. This is called by improper or defective ramming of mould.
5. Blow holes :
Blow holes are smooth, round holes appearing in the form of a cluster of a large number of small holes are caused
by excessive moisture in the sand or when permeability of sand is low, sand grains are to fine, sand is rammed too
ward or when venting is insufficient.
QUESTIONS:
QUE-1: Give the classification of casting process with advantages and applications of casting prcess.
QUE-2: Write a short note on Gating system with neat sketch.
QUE-3: Explain with neat sketch a Centrifugal Cating.
QUE-4: Write a short not on Die Casting.
QUE-4: Give the different Defects in Sand Casting.
QUE-5: Give the different Defects in Die Casting with it’s Causes and remedies.
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EXPERIMENT:- 9
AIM : To study the resistance welding and TIG welding and its applications in automotive
industry.
Introduction :
Resistance Welding:
Resistance welding is one of many methods of fastening two or more pieces of metal together. Some of
these methods are listed below in order to illustrate how resistance welding differs from the others.
1. Bolting 2. Riveting 3. Soldering 4. Arc Welding 5. Resistance Welding
Bolting, riveting, soldering and arc welding all require some additional material to be added to the metal
being fastened together. Additionally, bolting and riveting require holes to be made into the metal for the rivets or
bolts to fit. Resistance welding requires neither additional material or holes in the metal.
Resistance Welding is a method of joining metals. To join two metals by resistance welding, it is necessary
only to clamp them together under pressure and pass through them an electric current for a specific time. The heat
generated creates a plastic state and produces fusion at the interface surfaces.
Working principles:
The two pieces of metal to be joined are squeezed together by the electrodes on the welding machine so
they are in good electrical contact. Then electric current is passed through them, heating them until they begin to
melt at the spot where they are in contact. The molten metal from the two pieces flows together; then the current is
turned off and the molten metal solidifies, forming a solid metallic connection between the two pieces. The term
“Resistance Welding” comes from the fact that it is the electrical property of resistance of the metal being welded
that causes heat to be generated when current flows through it.
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A current of 10,000 amps is not readily available from any standard electrical outlet. 15 amps is the maximum
current available from common household and office outlets. Even in factories where large amounts of electrical
energy is used, 200 amps is typical of the current available from electrical distribution circuits. Therefore, to get
the 10,000 amps needed for resistance welding, some device must be used to step the current up from the
relatively low level available from the power line. Weld Current is the current in the welding circuit during the
making of a weld. The amount of weld current is controlled by two things: first, the setting of the transformer tap
switch determines the maximum amount of weld current available; second, the % current control determines the %
of the available current to be used for making the weld. Low % current settings are not normally recommended.
Adjust the tap switch so that proper welding current can be obtained with the % current set between 70 and 90%.
The only time the % current should be set below 70% is when the tap switch is on its lowest setting and 70%
current is still too high.
Squeeze Time :
The time interval between the initial application of the electrode force on the work and the first application
of current. Note that this is the process definition. The control definition is the time interval between sequence
initiation and beginning of weld current. Squeeze time is necessary to delay the weld current until electrode force
has built up to the desired level.
Weld Time:
The time during which welding current is applied to the work in making a weld. It is measured in cycles of
line voltage as are all timing functions. One cycle is 1/60 of a second in a 60 Hz power system.
Hold Time:
The time during which electrode force is maintained on the work after the last impulse of welding current
ceases. Hold time is necessary to allow the weld nugget to solidify before releasing the welded parts.
Off Time: The time during which the electrodes are off the work. The term is only applicable where the weld
cycle is repetitive (control set on “REPEAT”).
Classification of Resistance welding:
(a) Spot welding

(b) Seam welding
(c) Projection welding:
(d) Resistance Butt welding
(e) Flash Butt welding
(f) Upset welding
Advantages:
The automotive and appliance industries choose resistance welding for manufacturing because of the great
advantages this process has to offer. The first advantage is speed. When over 5000 welds need to be made in a
typical car, a process where each weld takes less than a second is of great importance. The process is also adaptable
to robotic manipulation so the speed is extremely fast. It is excellent for the sheet metals used in automotive
construction, and because no filler metal is needed, the complex wire feed systems in many arc welding processes
are avoided.
• Higher speeds, <.1 seconds for automotive spot welding, short process time
• Excellent for sheet metal applications <1/4 inch
• No filler metals or consumables required
• Relatively safe due to low voltage requirements
• Environmentally friendly clean process
• Joint formed is reliable
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Applications:
Resistance welding and mechanical joining are the predominant joining technologies applied in automotive
industry for assembly of the car body, or the Body-in-White (BIW). Nearly all sheet metal components of steels
are assembled by spot welding, and most sheet metal components of aluminum are assembled by self-piercing-
riveting and clinching, whereas projection welding has often been used for fastening weld nuts to sheets.
TIG welding :
TIG welding Definition:

The designation TIG comes from USA and is an abbreviation of Tungsten Inert Gas. Tungsten - also called
wolfram - is a metal with a fusion point of more than 3300oC, which means more than double the fusion point of
the metals which are usually welded.
Inert Gas is the same thing as inactive gas, which means a type of gas that will not to combine with other
elements. In Germany this method is called WIG welding, the W meaning wolfram.
TIG welding is the international standardised designation for this welding method. According to DS/EN 24063
this welding process has number 141.
The Principle of TIG Welding:
TIG welding is an electric arc welding process in which the fusion energy is produced by an electric arc
burning between the workpiece and the tungsten electrode. During the welding process the electrode, the arc and
the weld pool are protected against the damaging effects of the atmospheric air by an inert shielding gas. By means
of a gas nozzle the shielding gas is lead to the welding zone where it replaces the atmospheric air. TIG welding
differs from the other arc welding processes by the fact that the electrode is not consumed like the electrodes in
other processes such as MIG/MAG and MMA. If it is necessary to use filler material, it is added either manually
or automatically as a bare wire.
The TIG Arc:

As mentioned before the fusion energy in TIG welding is produced in the arc burning between the tungsten
electrode and the workpiece. The wire feeding can be done manually or mechanically. In DC TIG welding the
tungsten electrode is usually connected to negative polarity and the workpiece to positive polarity. According to
the theory of electrons the negatively charged electrons and positively charged ions will migrate when the arc is
ignited. The electrons will migrate from the negative pole to the positive pole while the ions will travel in the
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opposite direction. In the arc there will therefore be a collision between the electron and the ions and this collision
produces heat energy.
Advantages:
The TIG welding process has a very large area of application due to its many advantages,
• It provides a concentrated heating of the workpiece.

• It provides an effective protection of the weld pool by an inert shielding gas.
• It can be independent of filler material.
• The filler materials do not need to be finely prepared if only the alloying is all right.
• There is no need for after treatment of the weld as no slag or spatter are produced.
• Places of difficult access can be welded.
Areas of application
TIG welding is often used for jobs that demand high quality welding such as for instance:
• The offshore industry
• Combined heat and power plants
• The petrochemical industry
• The food industry
• The chemical industry
• The nuclear industry
Materials for TIG welding:
• Welding of thin materials in stainless steels

• Aluminum
• Nickel
• Nickel alloys
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QUESTIONS:
QUE-1: Define the welding. Give the classification of welding with its merits, demerits and applications.
QUE-2: Write a short note on TIG welding with neat sketch.
QUE-3: What is resistance welding? Enlist the Resistance welding processes and Explain with neat sketch
(i) Spot welding (ii) Seam welding.
QUE-4: Explain Projection welding with neat sketch and write merits and demerits of it.
QUE-5: Enlist defects of weld and explain in brief of each.
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EXPERIMENT :- 10
AIM : To study the non conventional machining and its applications in

Automotive industry.
Introduction:
Manufacturing processes can be broadly divided into two groups:
(a) primary manufacturing processes : Provide basic shape and size
(b) secondary manufacturing processes : Provide final shape and size with tighter control on dimension,
surface characteristics
Material removal processes once again can be divided into two groups
1. Conventional Machining Processes
2. Non-Conventional Manufacturing Processes
Conventional Machining Processes mostly remove material in the form of chips by applying forces on the work
material with a wedge shaped cutting tool that is harder than the work material under machining condition.
The main reasons for choosing non-traditional machining processes are:

1. To machine high steel alloys.
2. To generate desired complex surfaces and
3. To achieve high accuracy and surface finish.
Characteristics of Non-Conventional Manufacturing Processes :

• Material removal may occur with chip formation or even no chip formation may take place. For example in
AJM, chips are of microscopic size and in case of Electrochemical machining material removal occurs due
to electrochemical dissolution at atomic level
• In NCM, there may not be a physical tool present. For example in laser jet machining, machining is carried
out by laser beam. However in Electrochemical Machining there is a physical tool that is very much
required for machining
• In NCM, the tool need not be harder than the work piece material. For example, in EDM, copper is used as
the tool material to machine hardened steels.
• Mostly NCM processes do not necessarily use mechanical energy to provide material removal. They use
different energy domains to provide machining. For example, in USM, AJM, WJM mechanical energy is
used to machine material, whereas in ECM electrochemical dissolution constitutes material removal
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Classification:
Classification of Non-conventional machining processes was mainly on the basis of the nature of energy
employed in machining process. They are:
1. Chemical Processes
1. Chemical Machining (CM)
2. Photochemical Machining (PCM)
2. Electrochemical Processes
1. Electro-Chemical Machining (ECM)
2. Electro Chemical Grinding (ECG)
3. Electro-Thermal Processes
1. Electrical Discharge Machining (EDM)
2. Electron Beam machining (EBM)
3. Plasma Arc Machining (PAM)
4. Laser Beam Machining (LBM)
4. Mechanical Processes
1. Ultrasonic Machining (USM)
2. Abrasive Jet Machining (AJM)
3. Water Jet Machining (WJM)
4. Abrasive Water jet Machining (AWJM)
General Characteristics of Advanced Machining Processes:
Process
parameters and
S.No Process Characteristics
MRR or cutting
speed
Shallow removal on
large flat or curved
surfaces; blanking of
0.0025-0.1
1 Chemical machining (CM) thin sheets; low tooling
mm/min.
and equipment cost;
suitable for low-
production runs.
Complex shapes with V: 5-25 DC; A:

deep cavities; highest 1.5-8 A/mm2; 2.5-
Electrochemical machining
2 rate of material removal 12 mm/min,
(ECM)
among other depending on
nontraditional processes; current density.
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expensive tooling and

equipment; high power
consumption; medium-
to-high production
quantity.
Cutting off and

sharpening hard
materials, such as A: 1-3 A/mm2;
Electrochemical grinding
3 tungsten-carbide tools; typically 25
(ECG) 3
also used as honing mm /s per 1000A.
process; higher removal
rate than grinding.
Shaping and cutting

complex parts made of
hard materials; some
V: 50-380; A: 0.1-
Electrical-discharge surface damage may
4 500; typically 300
machining (EDM) result; also used as a
mm3/min.
grinding and cutting
process; expensive
tooling and equipment.
Contour cutting of flat or Varies with

Wire electric discharge
5 curved surfaces; material and
machining
expensive equipment. thickness.
Cutting and hole making

on thin materials; very
Laser-beam machining small holes and slots;
6 0.50-7.5 mm/min.
(LBM) heat-affected zone;
requires a vacuum;
expensive equipment.
Cutting and hole making

on thin materials; very
Electro-beam machining small holes and slots;
7 1-2 mm3/min.
(EBM) heat-affected zone;
requires a vacuum;
expensive equipment.
Cutting all types of Varies

8 Water-jet machining(WJM) nonmetallic materials; considerably with
suitable for contour material.
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cutting of flexible
materials; no thermal
damage; noisy.
Single-layer or multi-
Abrasive water-jet layer cutting of metallic
9 Up to 7.5 m/min.
machining (AWJM) and nonmetallic
materials.
Cutting, slotting,
deburring, etching and
Varies
Abrasive-jet machining cleaning of metallic and
10 considerably with
(AJM) nonmetallic materials;
material.
tends to round off sharp
edges;
Ultrasonic Machining (USM):
Ultrasonic machining is a subtraction manufacturing process that removes material from the surface of a
part through high frequency, low amplitude vibrations of a tool against the material surface in the presence of fine
abrasive particles.
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Water-Jet Machining (WJM):
WJM is a form of micro erosion. It works by forcing a large volume of water through a small orifice in the
nozzle. The extreme pressure of the accelerated water particles contacts a small area of the workpiece and acts like
a saw and cuts a narrow groove in the material.
Applications:
Mostly used to cut lower strength materials such as wood, plastics, rubber, paper, leather,
composite, etc.
– Food preparation
– Good for materials that cannot withstand high temperatures of other methods for stress distortion or
metallurgical reasons.
Abrasive Water-Jet Machining (AWJM):
The water jet contains abrasive particles such as silicon carbide, thus increasing MRR. Metallic materials
can be cut. Particularly suitable for heat-sensitive materials.
A high-velocity jet of dry air, nitrogen, or carbon dioxide containing abrasive particles is aimed at the
workpiece surface under controlled conditions. The gas supply pressure is on the order of 850 kPa (125 psi) and
the jet velocity can be as high as 300 m/s and is controlled by a valve.
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AJM Applications & Limitations :
• Applications – Can cut traditionally hard to cut materials, e.g., composites, ceramics, glass
– Good for materials that cannot stand high temperatures
• Limitations – Expensive process

– Flaring can become large
– Not suitable for mass production because of high maintenance requirements
Chemical Machining (CM):
Chemical machining, basically an etching process, is the oldest nontraditional machining process. Material is
removed from a surface by chemical dissolution using chemical reagents, or etchants, such as acids and alkaline
solutions. The workpiece is immersed in a bath containing an etchant. The area that are not required to be etched
are masked with “cut and peel” tapes, paints, or polymeric materials. In chemical milling, shallow cavities are
produced on plates, sheets, forgings, and extrusions for overall reduction of weight (e.g., in aerospace industry).
Depths of removal can be as much as 12 mm.
Typical applications: – Chemical blanking: burr-free etching of printed-circuit boards (PCB), decorative panels,
thin sheet-metal stampings, and the production of complex or small shapes.
– Chemical milling: weight reduction of space launch vehicles.
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Electrochemical Machining (ECM):
In ECM, a dc voltage (10-25 v) is applied across the gap between a pre-shaped cathode tool and an anode
work piece. The work piece is dissolved by an electrochemical reaction to the shape of the tool. The electrolyte
flows at high speed (10-60 m/s) through the gap (0.1-0.6 mm) to dissipate heat and wash away the dissolved metal.
Advantages:
• high shape complexity possible
• high MRR possible
• high strength materials
• mirror surface finish possible.
Disadvantages:
• work piece must be electrically conductive
• very high tooling (dedicated) and equipment costs
• high power consumption.
Applications:
• complex cavities in high-strength materials, esp. in aerospace industry for mass production of turbine blades.
Electrical Discharge Machining (EDM):

EDM is a thermal erosion process whereby material is melted and vaporized from an electrically conducive
work piece immersed in a liquid dielectric with a series of spark discharges between the tool electrode and the
work piece created by a power supply.
The EDM system consists of a shaped tool or wire electrode, and the part. The part is connected to a power
supply to create a potential difference between the workpiece and the tool. When the potential difference is
sufficiently high, a transient spark discharges through the fluid, removing a very small amount of metal from the
work piece.
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The dielectric fluid (1) acts as an insulator until the potential is sufficiently high, (2) acts as a flushing
medium, and (3) provides a cooling medium.
Applications:
Widely used in aerospace, mold making, and die casting to produce die cavities, small deep holes, narrow
slots, turbine blades, and intricate shapes.
Limitations:
– A hard skin, or recast layer is produced which may be undesirable in some cases.
– Beneath the recast layer is a heat affected zone which may be softer than parent material.
– Finishing cuts are needed at low MRR. – Produces slightly tapered holes, specially if blind.
Laser-Beam Machining (LBM):

Laser beam machining (LBM) is a non-traditional subtractive manufacturing process, a form of machining,
in which a laseris directed towards the work piece for machining. This process uses thermal energy to remove
material from metallic or nonmetallic surfaces.
Advantages:
• More precise
• Useful with a variety of materials: metals, composites, plastics, and ceramics
• Smooth, clean cuts
• Faster process
• Decreased heataffected zone
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Applications:
– Multiple holes in very thin and thick materials

– Non-standard shaped holes and slots
– Prototype parts –
Trimming, scribing and engraving of hard materials
– Small diameter lubrication holes
Limitations:
– Localized thermal stresses, heat affected zones, recast layer and thermal distribution in thin parts
– Difficulty of material processing depends on how close materials boiling and melting points are
– Hole wall geometry can be irregular – The cutting of flammable materials is usually inert gas assisted
Electron-Beam Machining (EBM):
Electron-beam machining (EBM) is a process where high-velocity electrons concentrated into a narrow beam are
directed toward the work piece, creating heat and vaporizing the material. EBM can be used for very accurate cutting or
boring of a wide variety of metals. Surface finish is better and kerf width is narrower than those for other thermal cutting
processes
EBM Characteristics:
• Mechanics of material removal – melting, vaporization

• Medium – vacuum
• Tool – beam of electrons moving at very high velocity
• Maximum MRR = 10 mm3/min
• Specific power consumption = 450 W/mm3/min
• Critical parameters – accelerating voltage, beam diameter, work speed, melting temperature
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• Materials application – all materials
• Shape application – drilling fine holes, cutting contours in sheets, cutting narrow slots
• Limitations – very high specific energy consumption, necessity of vacuum, expensive machine
Plasma Arc Machining (PAM ):
Plasma arc machining is a nontraditional thermal process. Plasma is defined as a gas that has been heated to
a sufficiently high temperature to become partially ionized and therefore electrically conductive. The term plasma,
as employed in physics, means ionized particles. The temperature of plasma may reach as high as 28000 ° C.
Primary gasses, such as nitrogen, argon-hydrogen, or air, are forced through the nozzle and arc and become
heated and ionized. Secondary gases or water flow are often used to help clean the kerf of molten metal during
cutting.
The plasma arc produced by modern equipment is generated by a plasma torch that is constructed in such a
manner as to provide an electric arc between an electrode and workpiece,. A typical plasma torch consists of
an electrode holder, an electrode, a device to swirl the gas, and a water-cooled nozzle. The geometry of the torch
nozzle is such that the hot gases are constricted in a narrow column.
Applications:
The stream of ionized particles from the nozzle can be used to perform a variety of industrial jobs. The plasma arc,
as an industrial tool, is a most heavy employed in sheet and plate cutting operations as an alternative to more
conventional oxy-fuel torches or other cutting tools. Plasma arc is routinely used as an integral component of some
modern punching machines.
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Advantages of PAM :
(a) It gives faster production rate.
(b) Very hard and brittle metals can be machined.
(c) Small cavities can be machined with good dimensional accuracy.
Disadvantages of PAM Process:

(a) Its initial cost is very high.
(b) The process requires over safety precautions which further enhance the initial cost of the setup.
(c) Some of the workpiece materials are very much prone to metallurgical changes on excessive heating so
this fact imposes limitations to this process.
(d) It is uneconomical for bigger cavities to be machined.
QUESTIONS:
QUE-1: Write the inherent drawbacks of conventional machining processes.

Give the classification of non conventional machining processes with neat.
QUE-2: Give the advantages and dis-advantages of Electro Chemical Machining ( ECM ).
QUE-3: Explain with neat sketch Electrical Discharge Machining ( EDM ) and write the merits and demerits of it.
QUE-4: Write a short note on ( i ) Abrasive Jet Machining ( ii ) Plasma Arc Machining
QUE-5: Explain the principle of Ultrasonic Machining ( USM )
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EXPERIMENT:- 11
AIM : To make the strip layout of given sheet metal part of an auto vehicle.
Introduction:
The strip layout design exercise is like a tailor’s job. Here the tailor maps the different parts of the shirt and
makes a layout as per the customer’s choice, efficient cloth utilization and fashion. Later the layout is used for
stitching shirts. Similarly strip layout involves laying out the material strip that is passed through the press in order
to produce stamping, exactly as it will appear after all operations have been performed on its parts (Ann & Kai,
1994). The strip layout design is an art by itself, wherein the experience and practice in the light of reality decides
the quality of the stamped sheet product. In early days, the strip layout was done manually. The trial and error
method followed resulted in maximum material.
Utilization and is still followed in many small and medium scale industries. Nowadays there are many
computer aided systems that takes care of the strip layout design even in complex parts. A knowledge based
system for strip layout design was presented by Ann and Kai (Ann & Kai, 1994), includes two important modules
viz., part orientation module and sequence of operation module. The part orientation module is meant for
providing recommendations about the appropriate ‘part orientation’ in the parent strip, while the sequence of
operation module is mainly to suggest the proper design in terms of strip layout in each of the four operations of
the progressive die – piercing, blanking, bending and trimming. The ‘part orientation module’ has few sub-
modules like customer’s specification, where the user can opt for any strip orientation; material optimization, in
which the KBS will decide the appropriate orientation, part-to-part and part-to-edge distances, space for pilot hole
and their locations; type of end product removal method, where the rules are meant for checking the type of end-
product removal methods employed to remove the final stamped part from the scrap strip; smooth strip movement
through the die, contains rules to check whether the strip is rigid enough to move through the die smoothly without
any obstruction due to collapsing of the strip.
87 | P a g e
In the design of blanking parts from strip material, the first step is to prepare blanking layout, that is, to
layout the position of the work pieces in the strip and their orientation with respect to one another. While doing so,
the major consideration is the economy of material.
Another important consideration in strip layout is the distance between the blanks and the strip edge and
distance between blank to blank. To prevent the scrap from twisting and wedging between the punch and the die.
The distance must increase with material thickness.
A general rule of thumb is to keep this distance equal to from 1 to 1.5times the material thickness. The following
figure are example of strip layouts.
A– Front scrap
B – Bridge thickness
(space between parts and strip edge, and part to parts)
C – the distance from a point on one part to the
corresponding point on the next part.
H – Part width
l - Length of part
W – Width of strip
Y – Scrap recovery at end
N – Number of blanks
t– Thickness of strip
L – Length of strip
B= 1.25t, when C is less than 2 inch

= 1.5t, when C is more than 2 inch
C=l+B
W = H + 2B
A = t + 0.015H
Y =L – Nc +B
N = L – B /C
88 | P a g e
PERCENTAGE OF UTILIZATION :
Strip layout is important to have economy of press tool operation. Scrap strip layout gives an idea on the
positioning of various punches, stops and pilots.It ensures the ideal location of blanks in the stock strip.
Several trial layouts have to be made to confirm themaximum percentage of utilization of stock strip. The
goal should be to have at least 75% utilization.
The percentage of stock used to calculated by theformula:
% of utilization = Area of one blank X 100 /Lead X Width
Where, Lead = Length of component + Bridge thickness

Width= Breadth of component + 2 X Bridge thickness
-----------------------------
EXAMPLE 1: FOR STRIP LAYOUT CALCULATION
Length of part = 20mm : Breadth of part = 10mm
Thickness of part =1.5mm
Bridge thickness = one times of sheet thickness taken

= 1.0 X 1.5 = 1.50mm
Width of strip W = H + 2B
= 20 + 2 X 1.5 =23mm
Front scrap “a” = t + 0.015H

= 1.5 + 0.015 X 20
= 1.8mm
C =l + B = 10+1.5 =11.5mm
89 | P a g e
Some Examples of Strip Layout
[1]
90 | P a g e
[2]
91 | P a g e
[3]
[4]
92 | P a g e
EXPERIMENT:-12
AIM : To calculate the punch and die size of given part.
Introduction:
Types of Press Working Operations:
All sheet metal operations can be grouped into two categories: cutting operations and forming operations.
Blanking: It is the operation of cutting a flat shape from sheet metal. The article punched out is
called the blank and is the required product of the operation. The hole and the material left behind
are discarded as waste. It is usually the first step of series of operations.
• Punching or Piercing: It is a cutting operation by which various shaped holes are made in sheet
metal. Punching is similar to blanking except that in punching the hole is the desired product, the
material punched out to form the hole being waste.
• Notching: This is cutting operation by which metal pieces are cut from the edge of a sheet, strip or
blank.
• Perforating: This is a process by which multiple holes which are very small and close together are
cut in flat workpiece material.
• Trimming: This operation consists of cutting unwanted excess material from the periphery of a
previously formed product.
• Shaving: The edges of a blanked part are generally rough, uneven and unsquare. Accurate
dimensions of the part are obtained by removing a thin strip of metal along the edges.
• Slitting: It refers to the operation of making incomplete holes in a workpiece.
• Lancing: This is a cutting operation in which a hole is partially cut and then one side is bent down
to form a sort of tab. Since no metal is actually removed, there will be no scrap.
• Nibbling: This operation is generally substituted for blanking in case of small quantities of
Components having complex shapes. The part is usually moved and guided by hand as the
Continuously operating punch cuts away at the edge of the desired contour.
• Bending: In this forming operation sheet metal is uniformly strained around a linear axis which
lies in the neutral plane and perpendicular to the length wise direction of the sheet.
• Drawing: This is a process of forming a flat workpiece into a hollow shape by means of punch
which causes the blank to flow into a die cavity.
• Squeezing: Under this operation the metal is caused to flow to all portions of a die cavity under
the action of compressive forces.
• Coining: It is a forming operation in which a slug is deformed such that the two sides of the slug
are having two different impressions.
• Embossing: It is also a forming operation in which a sheet is deformed such that an emboss is
formed on one side and a corresponding depression on the other side.
93 | P a g e
Principle of Blanking:
The appearance of the cut edge of the blank is shown schematically in figure 2.4.7. When the plastic deformation
starts, the material flows beneath the upper shear and would appears an edge radius as
Shown at A in the stock. Similar flow of metal at the lower shear would result in the edge radius
B in the slug. The metal pushed in by the upper Figure 2.4.7: Characteristics of cut in shearing
shear before the separation would burnish the metal and result in the cut band as shown in C in the stock by the
upper shear and D in the slug by the lower shear.
Clearance
The die opening must be sufficiently larger than the punch to permit a clean fracture of the metal.This
difference in dimensions between the mating members of a die set is called Clearance.
When correct clearances are used, a clean break would appear as a result of the extension of the upper and
lower fractures towards each other. With an insufficient clearance additional cut bands would appear before the
final separation. Ductile materials require smaller clearances (Otherwise soft material will be drawn into the gap)
and longer penetration of the punch compared to harder materials.
If the clearance is more than the optimum value, then

• Penetration is more;
• Work done is more;
• Burr forms.
If the clearance is less than the optimum value, then

• Peak load is more;
• Penetration is slightly more;
• Work done is more;
• The edge of the product is not smooth.
94 | P a g e
The clearance may also be determined with the help of following relation:
C = 0.0032 t { _s }0.5 mm
Where _s = shear strength of the work piece material in N / mm2 .
Calculations of Blanking – Punching:
Problem-1.:
A blanking die is to be designed to blank the part outline shown in the figure below. The
material is 4 mm thick stainless steel (the allowance for the stainless steel is a = 0.075).
Determine the dimensions of the blanking punch and the die opening.
Solution:
Since a = 0.075, the clearance is given by,

c = 0.075 (4) = 0.3 mm.
Blanking die dimensions: the same as for the part in the figure:
L = 85 mm w = 50 mm t = 25 mm s = 25 mm
Blanking punch
95 | P a g e
Solution:
c = 0.075 (4) = 0.3 mm.
Blanking die dimensions: the same as for the part in the figure:
L = 85 mm w = 50 mm t = 25 mm s = 25 mm
Blanking punch dimensions:

Length L = 85 - 2(0.3) = 84.4 mm
Width w = 50 - 2(0.3) = 49.4 mm
Top and bottom t widths = 25 - 2(0.3) = 24.4 mm
The s = 25 mm inset dimension remains the same.
Problem-2.:
A compound die will be used to blank and punch a large washer out of 6061ST aluminum alloy (the allowance is
a = 0.06). sheet stock 3.50 mm thick. The outside diameter of the washer is 50 mm and the inside diameter is
15 mm. Determine (a) the punch and die sizes for the blanking operation, and (b) the punch and die sizes for the
punching operation.
96 | P a g e
Solution:
c = 0.06 (3.5) = 0.21 mm
(a) Blanking punch diameter = Db- 2c = 50 - 2(0.21) = 49.58 mm

Blanking die diameter = Db= 50 mm
(b) Punching punch diameter = Dh= 15 mm

Punching die diameter = Dh+ 2c = 30 + 2(0.21) = 15.42 mm
97 | P a g e
Problem-3.:
A blanking operation is to be performed on 2 mm thick cold rolled steel. The part is circular
with diameter = 75 mm. Determine: a) the appropriate punch and die sizes for this operation if
the allowance for the cold rolled steel is a = 0.075. b) the blanking force required if the steel
has a shear strength = 325 MPa and the tensile strength is 450 MPa.
Solution:
(a) Since a = 0.075, the clearance is given by,
c = 0.075 (2) = 0.15 mm.
Thus the Punch diameter Dh is calculated as
Dh = Db- 2c = 75.0 - 2(0.15) = 74.70 mm.
and the Die diameter is Db = 75 mm.
(b) the blanking force is given by F = StL

The thick of the metal stock t is given by the problem as t = 2 mm
The length of cut edge is calculated as:
L = πD = 75π = 235.65 mm
Thus the blanking force is
F = 325 (2) (235.65) = 153,200 N
98 | P a g e
Problem-4.:
Deep drawing
A cup is to be drawn in a deep drawing operation. The height of the cup is 75 mm and its
inside diameter = 100 mm. The sheet metal thickness = 2 mm. If the blank diameter = 225mm, determine (a)
drawing ratio, (b) reduction, and (c) thickness-to-diameter ratio. (d) Does
the operation seem feasible?
Solution:
(a) Drawing ratio DR = Db/Dp= 225/100 = 2.25

(b) Reduction r = (Db- Dp)/Db= (225 - 100)/225 = 0.555 = 55.5%
(c) Thickness-to-diameter ratio t/Db= 2/225 = 0.0089 = 0.89%
(d) Feasibility? No!
DR is too large (greater than 2),
r is too large (greater than 50%),
and t/D is too small (less than 1%).
99 | P a g e
SAFETY PRECAUTIONS
1. Always wear apron, shoes and gloves for safety
2. Never operate any machines until you have been instructed properly
3. Always wear goggles to protect your eyes from flying chips.
4. Never hold the job when the machine runs.
5. Never give heavy feed on longer job
6.Never change the gear and belt when the machine is running
7.Always use the correct size spanner and tool for fitting and removing of
tool
8.Never try to clear the chips when the machine is running
9.To prevent accident, clean the spilled oil and grease immediately
10.Always clear the area around the machine and machine tool surface
11.Leather shoes or boots with steel toes are recommended.
12.No open toed shoes or sandals are allowed in the shop.
13.Do not wear loose clothing. Cotton clothes are best to wear.
14. Remove all jewelry and tie back long hair.
15.Do not operate any machine equipment unless you have been instructed
16. Improper use and the safety risks involved with the machining operation.
17. Do not leave any machinery or power tools running and unattended.
18. Clean up metal shavings, oil, etc. from machine tools after use; pick up
after yourself and return tools to their proper storage area.
100 | P a g e

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AUTOMOBILE_AMPT_3140204_LAB MANUAL 2022

Automotive Manufacturing Processes

GUJARAT TECHNOLOGICAL UNIVERSITY

GOVERNMENT ENGINEERING COLLEGE, MODASA

Mr. / Ms. …………………………………………………………………………………

Enrollment No. …............................................. of Semester …………………… Degree

Course in ……………………………………… has Satisfactorily completed his / her term

work in subject ………………………………… within four walls of the Laboratory /

Subject Teacher: Head of the Department:

INDEX FOR LAB MANUAL

1 Job making on Lathe machine

2 Job making on Milling machine

3 Job making on Shaper machine

4 Job making on Planer machine

5 Job making by using press tool

6 Job making on Drilling machine

To study the pattern allowances and to make the

To study the investment and centrifugal casting

To study the resistance welding and TIG

To study the non conventional machining and its

To make the strip layout of given sheet metal

AIM: Job making on Lathe machine

The Lathe was invented by Jacques de Vaucanson around 1751.

Parts of the Lathe Machine and their functions:

Accessories mounted on headstock spindle:

• It provides three movements to the tool:

Types of Lathe Machine:

Facing operation in the lathe:

Thread cutting operation :

Drilling is an operation by which we can make holes in a job.

Name of machine: All Geared Lathe Machine

Height of center 175 mm

1. What is the main function of a lathe? List various types of lathes.

Name of machine: Lathe Machine

Height of center 175 mm

Name of operations: (a) Internal Threading

Name of Tools: (a) Boring ‘V’ Tool

AIM : Job making on Milling machine

Column and Knee Type Milling:

Fixed Bed Milling:

• Plain Milling Operation

Face milling Operation:

Form milling Operation:

T-slot milling Operation:

Side milling Operation:

The advantages of the Milling machine:

Milling Machine Disadvantages:

• These are the following applications of the milling machine:

Specification of Milling Machine:

Longitudinal movement of table 725 mm

Name of operations: (a) Facing

Name of Tools: (a) Face tool

AIM: Job making on Shaper machine

Based on cutting stroke types of shaper machines:

Specification of Shaper Machine:

These are lighter, smaller and cheaper. Work is mounted

It is intended for small jobs. It is intended for large jobs.

Low machining accuracy. High machining accuracy.

Simple in construction. It is a robust one or robust in construction.