4ME4-23 - Production Practice Lab

Swami Keshvanand Institute of Technology, Management & Gramothan,
Ramnagaria, Jagatpura, Jaipur-302017, INDIA

Approved by AICTE, Ministry of HRD, Government of India
Recognized by UGC under Section 2(f) of the UGC Act, 1956
Department of Mechanical Engineering 4ME4-23 Production Practice Lab-I
SWAMI KESHVANAND INSTITUTE OF TECHNOLOGY,

MANAGEMENT & GRAMOTHAN
(Affiliated to RTU, KOTA & Approved by AICTE, New Delhi)
(NBA Accredited Institution)
Department of Mechanical Engineering
LAB MANUAL
4ME4-23 PRODUCTION PRACTICE LAB
B.Tech. IV Semester, Mechanical Engineering
1
4ME4-23 PRODUCTION PRACTICE LAB
[AS PER CHOICE BASED CREDIT SYSTEM (CBCS) SCHEME]
SEMESTER – IV
Subject Code: 4ME4-23 IA Marks: 45
Number of Lecture Hrs / Week: 00 Exam Marks: 30
No of Practical Hours / Week: 03 Exam Hours: 03
CREDITS: 1.5
2
Vision & Mission of Institute

Vision: “To promote higher learning in advanced technology and industrial research to make our
country a global player.”
Mission: “To promote quality education, training and research in the field of Engineering by
establishing effective interface with industry and to encourage faculty to undertake industry
sponsoredprojects for the students.”
Vision and Mission of Mechanical Engineering Department

Vision of the Department: To become a nationally visible mechanical engineering department with
excellence in teaching learning, research and development, entrepreneurship and industry outreach
activities.
Mission of Mechanical department:
M1. To provide facilities and environment conducive to high quality education and research and
development in the field of mechanical engineering.
M2. To inculcate the technical, professional and communication skills in students, staff and faculty
members.
M3. To instil innovative skills, critical thinking, leadership & teamwork in students through various
teaching-learning activities and industry- linkages.
M4. To inculcate strong ethical qualities in the students and faculty for realizing lifelong learning and
serving the society and nation at large. Departmental Quality Policy
Departmental Quality Policy:
Department would pursue quality in all its endeavors like:
 Teaching-learning processes,
 Examinations,
 Extra and co-curricular activities,
 Industry-institution interaction,
 Continuing education, and
 Consultancy
Departmental Core Values
 Professional integrity
 Hard-work Self-discipline Positive work culture
 Empathy towards others.
 Departmental Safety Policy

 Department is committed to create safety culture in Students, Staff and faculty.
3
RTU Syllabus –IV Semester. B.Tech. Mech. Engg.
4
Program Educational Objectives (PEOs) as applicable for course
B.Tech. Mechanical Engineering Program at SKIT will produce graduates who will:
PEO I. Suitable for employment, venturing own business enterprise or pursuing higher studies.
PEO II. Capable mechanical engineers with the requisite knowledge, skills and attitudes.
Applicable POs for the course:
PO1 Engineering knowledge
PO2 Problem analysis
PO4 Conduct Investigations of Complex problems
PO6 The engineer and society
PO9 Individual and team work: An ability to function effectively as an individual, and as a
member or leader in diverse teams, and also in multidisciplinary settings.
PO10 Communication
PSO2 Life-long learning
5
Programme: B.Tech. (Mechanical Engineering)

Semester: IV
Course Name (Course Code): 4ME4-23 PRODUCTION PRACTICE LAB
Course Outcomes
After completion of this course, students will be able to –
C4ME4-23.1 Exhibit understanding of the constructional features, working principle and

operations performed on lathe, shaper, milling and grinding machinetool.
C4ME4-23.2 Select appropriate cutting tools, suitable work & tool holding devices,
optimum cutting parameters and safe working procedures on various
machine tools.
C4ME4-23.3 Produce the part as per given drawing on lathe, shaper, milling and
grinding machine tool and perform its error analysis.
C4ME4-23.4 Measure various sand properties by performing sand moulding tests

and prepare a green sand mould from a given split pattern.
C4ME4-23.5 Perform the welding operation as per given drawing using TIG, MIG
and SPOT welding techniques and exhibit use of safe working
procedures and appropriate welding equipment.
6
COURSE: PRODUCTION PRACTICE (4ME4-23)
Bloom's PSO
CO Course Outcomes PO Indicators
Level Indicators
1.1.1, 1.4.1,
Exhibit understanding of the
2.1.1, 2.1.2, 2.1.3
constructional features, working
9.1.1 9.1.2, 9.2.1, 9.2.2, 9.2.3, 14.1.1,
principle and operation L3
C4ME4-23.1 9.3.1
performed on lathe, shaper, 14.1.2
10.1.1, 10.1.2, 10.1.3, 10.2.1,
milling and grinding machine
10.2.2, 10.3.1, 10.3.2
tool.
Select appropriate cutting tools, 1.1.1, 1.4.1,
suitable work & tool holding 2.1.1, 2.1.2, 2.1.3
devices, optimum cutting 4.1.1, 4.1.2, 4.1.3, 4.1.4, 4.3.1, 14.1.1,
C4ME4-23.2 L4 9.1.1 9.1.2, 9.2.1, 9.2.2, 9.2.3,
parameters and safe working 14.1.2
9.3.1
procedures on various machine 10.1.1, 10.1.2, 10.1.3, 10.2.1,
tools. 10.2.2, 10.3.1, 10.3.2
1.1.1, 1.4.1,
Produce the part as per given 2.1.1, 2.1.2, 2.1.3
drawing on lathe, shaper, 4.1.1, 4.1.2, 4.1.3, 4.1.4, 4.3.1,
4.3.2, 6.1.1, 6.2.1 14.1.1,
C4ME4-23.3 milling and grinding machine L4
9.1.1 9.1.2, 9.2.1, 9.2.2, 9.2.3, 14.1.2
tool and perform its error 9.3.1
analysis. 10.1.1, 10.1.2, 10.1.3, 10.2.1,
10.2.2, 10.3.1, 10.3.2
1.1.1, 1.4.1,
Measure various sand properties 2.1.1, 2.1.2, 2.1.3
by performing sand moulding 4.1.1, 4.1.2, 4.1.3, 4.1.4, 4.3.1,
4.3.2 , 6.1.1, 6.2.1 14.1.1,
C4ME4-23.4 tests and prepare a green sand L4
9.1.1 9.1.2, 9.2.1, 9.2.2, 9.2.3, 14.1.2
mould from a given split 9.3.1
pattern. 10.1.1, 10.1.2, 10.1.3, 10.2.1,
10.2.2, 10.3.1, 10.3.2
Perform the welding operation
as per given drawing using TIG, 1.1.1, 1.4.1,
MIG and SPOT welding 2.1.1 2.1.2 2.1.3 6.1.1, 6.2.1
9.1.1 9.1.2, 9.2.1, 9.2.2, 9.2.3, 14.1.1,
C4ME4-23.5 techniques and exhibit use of L3
9.3.1 10.1.1, 10.1.2, 10.1.3, 14.1.2
safe working procedures and 10.2.1, 10.2.2, 10.3.1, 10.3.2
appropriate welding
equipments.
7
CO-PO/PSO Mapping: Formulation and Justification
The CO-PO/PSO mapping is based on the correlation of course outcome (CO) with Program Outcome
Indicators. These indicators are the breakup statements of broad Program Outcome statement.
The correlation is calculated as number of correlated indicators of a PO/PSO mapped with CO divided
by total indicators of a PO/PSO. The calculated value represents the correlation level between a CO &
PO/PSO. Detailed formulation and mathematical representation can be seen below in equation 1:
Input:
COi: The ith course outcome of the course
POj: The jth Program Outcome
Ijk: The kth indicator of the jth Program Outcome
: Degree of correlation
 (Ijk, COi): level of CO-PO mapping
= 1, if, 0< <0.33
= 2, if, 0.33≥<0.66
= 3, if, 0.66 ≥< 1
𝐶𝑂𝑖) = 𝛼 (𝐼𝑗𝑘, 𝑐𝑜𝑢𝑛𝑡( 𝜆(𝐼𝑗𝑘, 𝐶𝑂𝑖))
𝑐𝑜𝑢𝑛𝑡 (𝐼𝑘, 𝑃𝑂𝑗)
8
CO-PO/PSO Mapping
Programme: B.Tech. (Mechanical Engineering)
Semester: IV
Course Name (Course Code): PRODUCTION PRATICE LAB (4ME4-23)
PSO PSO
COs PO PO PO PO PO PO PO PO PO PO PO PO
1 2
1 2 3 4 5 6 7 8 9 10 11 12
C5ME4-23.1 2 1 - - - - - - 3 3 - - - 3
C5ME4-23.2 2 1 - 2 - - - - 3 3 - - - 3
C5ME4-23.3 2 1 - 2 - 3 - - 3 3 - - - 3
C5ME4-23.4 2 1 - 2 - - - - 3 3 - - - 3
C5ME4-23.5 2 1 - - - 3 - - 3 3 - - - 3
9
2nd Year - IV Semester: B.Tech. : Mechanical Engineering (Session 2020-21)
LIST OF EXPERIMENTS
Exp TITLE OF EXPERIMENT

No.
(a) To understand and write objectives of laboratory.
OL (b) To write and follow safety precautions in production practice laboratory.
(c) To draw layout of production engineering laboratory.
Machine Shop
(a) To study lathe machine construction and various parts including attachments, lathe tools cutting
speed, feed and depth of cut.
1. (b) To perform step turning, taper turning, knurling, chamfering and cut multi-start square / metric
threads on centre lathe machine as per given job drawing.
2. To perform boring operation using a boring bar on a centre lathe machine and cut BSW/ Metric internal
threads on it as per given job drawing.
3. Demonstration for job by eccentric turning on lathe machine using four jaw chuck.
4. (a) To study the milling machine, milling cutters, indexing heads and indexing methods.
(b) To prepare a spur gear on universal milling machine as per drawing.
5. To machine hexagonal nut using indexing head on universal milling machine.
6.
Demonstration on milling machine for generation of plane surfaces and use of end milling cutters.
7. (a) To study of single point cutting tool geometry and to grind the single point cutting tool model as per
given tool geometry.
(b) Demonstration of grinding of drilling tool bits.
8. (a) To study shaper machine, its mechanism and calculate quick return ratio.
(b) To prepare a job on shaper from given mild steel rod as per drawing.
9. To demonstrate cylindrical grinding using grinding attachment in a centre lathe.
10. To study of capstan lathe and its tooling and prepare a tool layout as per given drawing.
Foundry Shop
11. To prepare mould of a given pattern requiring core and to cast it in Aluminium .
(a) To perform moisture content test of moulding sand.
12.
(b) To perform clay content test of moulding sand.
(a) To perform permeability test of moulding sand.
13. (b) To perform Strength Test (compressive, shear, transverse and tensile) in green and dry conditions) and
Hardness Test (Mould and Core).
14. To perform A.F.S sieve test of moulding sand.
Welding Shop
To study of Spot welding process and join to metal sheets using spot welding.
15.
Beyond Curriculum: (any two)
16.
(a) Study and demonstration of TIG welding. (b) Study and demonstration of MIG welding.
10
GENERAL INSTRUCTIONS
1. Every student should obtain a set of instruction sheets entitled Production Practice
Laboratory.
2. For reasons of safety, every student must come to the laboratory in shoes. It is unsafe for
the students to come to the laboratory wearing garments with parts that that hang about
loosely. Students should preferably use half-sleeve shirts. The Students should also ensure
that floor around the machine is clear and dry (not oily) to avoid slipping.
3. An apron, safety goggles will be issued to each student. Students not wearing an apron,
goggles will not be permitted to the work in the laboratory.
4. Instruments and tools will be issued from the tool room. Every student must produce his
identity card for the purpose. Tools, etc. must be returned to the tool room on the same day.
5. The student should take the permission of the Lab Staff / Tutor before handling any
machine.
6. The student should not lean on the machine when it is working.
7. Power to the machines will be put off 10 minutes before the end of laboratory session to
allow the students to return the tools and clean work area..
8. Students are required to clear off the chips from the machine and lubricate the guides etc.
at the end of the session.
9. Laboratory reports should be submitted on A4 size sheets.
10. Reports will not be returned to the students. Students may see the graded reports in the
laboratory.
11. Use of mobile phones is strictly prohibited in laboratory.
12. Tiffin and edible items are not allowed in laboratory.
11
OBJECTIVES OF LABORATORY WORK IN M.E. DEPARTMENT
Students will be able to:

1. Show an attitude of enquiry.
2. Show confidence while working.
3. Work in the team and also as member of the team.
4. Show an attitude of safety consciousness.
5. Select appropriate equipment, instruments and material.
6. Set/handle and manipulate different types of equipment including modern engineering tools.
7. Observe and measure various types of physical phenomena and quantities.
8. Assess various types of errors and minimize these.
9. Solve an engineering problem by designing and performing an experiment.
10. Follow standard test procedures.
11. Present observations, other data and results appropriately in tabular and graphical form.
12. Analyze experiment data and draw conclusions.
13. Draw appropriate sketches and drawings etc.
14. Write reports of various studies and tests.
15. Understand concepts, principles and relationships related with the experiences.
12
SAFETY PRECAUTIONS TO BE TAKEN CARE OF
1. Ensure that you know to stop the machine before you set it in motion.
2. Maintain your concentration while the machine is in motion.
3. Take care not to distract or startle other machine operator.
4. Never clean the machine while it is in motion always isolate it from the power supply first.
5. Never leave your machine unattended while it is in motion.
6. Never use compressed airs to clean the machine it may blow in your face or someone else’s and cause
an eye injury.
7. Never clean away scarf with your bare hands, always use a suitable rake, which should be provided.
8. Keep hair short or under a cap-it can become tangled in drill or rotating shafts.
9. Avoid loose clothing wear a sung fitting boiler suit, done up, and ensure that any neck wear is tucked
in and secure.
10. Do not allow upgraded bar to protrude beyond the end of the machine, e.g. in center and capstan
lathes.
11. Always ensure that guards are correctly fitted and in position remember, guards are fitted on machine
to protect you from accidentally coming connect with dangerous moving parts.
12. Do NOT use mobiles or any such electronic gadgets in the laboratory.
13. Do NOT consume any kind of eatables during laboratory working.
13
EXPERIMENT WRITEUPS / MANUALS RULES

1. Before performing lab experiment a student/group has to read the experiment principle, procedure
and safety precautions given in manual thoroughly.
2. Each group will be allotted a single copy of manual on production of their I-cards.
3. Before performing the lab experiment student will have to submit Pre Experiment Viva sheet to the
lab instructor.
4. Do not fold the experiment write-ups / lab manuals.
5. After taking the reading, student will show it to instructor and then make calculations.
6. Compare your calculations with sample calculations available with instructor.
14
EXPERIMENT No. 00
Objectives:
(a) To write Vision and Mission of Institute and Vision, Mission, Quality Policy, Core Values and Safety
Policy of Mechanical Engineering Department.
(b) To write and understand Program Outcomes (POs) and Course Outcomes (COs) of Production Practice
Laboratory Course.
(c) To write and understand objectives of laboratory work.
(d) To write, understand and follow religiously safety precautions in production practice laboratory.
(e) To draw layout of production engineering laboratory.
15
EXPERIMENT No. 01(a)
1. TITLE OF THE EXPERIMENT

To study lathe machine construction and various parts including attachments, lathe tools cutting speed, feed and depth
of cut.
2. INPUTS REQUIRED
A lathe machine and its accessories, cutting tools of different types, learning charts etc.
3. THEORY
LATHE AND ITS WORKING PRINCIPLE

The lathe is a machine tool which holds the revolving work between two rigid and strong supports and a cutting tool,
supported in a tool post, is fed against it. While the work revolves about its own axis the tool is made to move either
parallel to or at an inclination with this axis to cut the desired material.
Figure1. Centre Lathe

TYPES OF LATHES
According to their construction and design lathe can be classified as follows:
1. Bench Lathe
2. Engine Lathe or Centre Lathe (placed in our workshop)
3. Speed Lathe
4. Tool Room Lathe
5. Capstan and Turret Lathe
6. Automatic Lathe
7. Special Purpose Lathe
16
SPECIFICATIONS OF LATHE: ( Fill this table for Lathe No. 5)

S.No. Particulars Specifications
1 Type of Lathe
2 Make & Model No.
3 Length of Bed
4 Width of Bed
5 Type of bed
6 Length between centre’s
7 Height of centre over bed
8 Maximum swing diameter over bed
9 Maximum swing diameter over carriage
10 Spindle bore and taper of bore
11 Number of spindle speeds
12 Number of feeds
13 Pitch value of lead screw
14 Horse power of motor
15 Type of gear box
16 Floor space required
17 Weight of machine
PARTS & ACCESSORIES OF A CENTRE LATHE

S.No. Parts Description
1. Head stock Head stock is one type of gear box & it is the heart of the machine which gives
various speed by means of gear arrangement. It houses necessary transmission
mechanism with speed changing levers to obtain different speeds. Chuck is
mounted on the spindle in head stock.
2. Spindle It is a hollow shaft in head stock which receives rotation from drive gears / pulleys.
Chuck plate and chuck is mounted on the spindle. It is made hollow to accommodate
long work pieces.
3. Carriage It serves the purpose of supporting, guiding and feeding the tool during the lathe
operations. It is fitted on the bed and slides along the bed guide ways and can be locked
on the bed at any desired position by tightening the carriage lock screw. It can be
moved manually or with power feed.
It consists of following five main parts:
1.Saddle 2.Cross Slide 3. Compound rest 4. Tool post 5. Apron
4. Cross Slide & Cross slide is mounted on the saddle. Cross slide give transverse motion whereas saddle
Saddle gives longitudinal motion to tool.
5. Compound Slide This slide may be swiveled to any angle and is necessary in turning short tapers, angles,
boring short tapers and forms.
6. Tool Post It is an assembly to hold the cutting tools firmly and rigidly during cutting
operations. Generally, a square tool post is used which can hold four tools at a time.
7. Apron Apron is a gear box which gives automatic feed to the carriage.
17
8. Tailstock It slides along the bed guide ways and can be locked on the bed at any desired position by
tightening the nut provided beneath the tail stock. It is used for two purposes:
(i) to support the end of the work when being machined, and
(ii) to hold a tool for performing operation like drilling, reaming, tapping, etc.
Bed It is made up of cast iron with straight V guide ways over it. It supports tailstock and
9. carriage. Tail stock and carriage moves along the guide ways over
bed to perform turning operation.
10. Lead screw Lead screw is used for threading operation. It engages the carriage through half nut
11. Feed Shaft Feed shaft is used for auto feeding of tool into work during turning.
12. Norton gear box Norton gear box is used to obtained metric as well as BSW thread in various pitch for
threading operation.
13. Tray Tray is provided to collect the cutting fluid & chip when machine is in running condition.
14. Side cover and Side cover is provided in the back side of the machine for protection of
guards gear train & for safety purpose.
15. Face plate It is a plate of large diameter, used for turning operations. Certain types of work that
cannot be held in chucks are held on the face plate with the help of various
accessories.
16. Taper Turning This attachment is used to turn long tapers. It is mounted on the carriage and can be set
Attachment at desired angle.
17. Mandrel The lathe mandrel is a hardened, grounded and straight cylindrical bar with centre hole at
each end. It is used to hold hollow work pieces to machine their external surfaces. The
work revolves with the mandrel which is mounted between centers
of lathe.
OPERATIONS ON LATHE MACHINE

1. Turning: It is the process in which the material is removed from a rotating workpeice to reduce the diameter
of a workpiece. There may be plain turning (with uniform diameter) or step turning in which variation in
diameters is made in the job.
2. Facing: It is the process in which the material is removed from a rotating to reduce the length of a workpiece.
3. Chamfering: It is the process in which the edges of a workpiece are beveled by a small angle to facilitate
handling or further assembly.
4. Parting: It is the process of making groove and cutting off parts. It is performed by a ‘parting tool.
5. Drilling: It is an operation of making a hole in the workpiece with the help of a drill. The workpiece is held
in a chuck and the drill is held in the tailstock. The drill is fed manually into the rotating workpiece, by
rotating the tailstock hand wheel.
6. Boring: Boring is an operation to enlarged a drilled hole with a single point cutting tool. In this, boring tool is
held in the tool post and is fed into the work similarly as in plain turning.
18
7. Taper Turning: It is an operation of producing an external conical surface on a workpiece. There are different
methods of taper turning:
i. Compound rest swiveling method (used in lab)
ii. Tailstock set over method
iii. Taper turning attachment method
8. Knurling: It is a process of producing indentations are called knurls and the operation performed for
producing knurls is known as knurling.
9. Thread Cutting: Thread cutting in a lathe is performed by traversing the cutting tool at definite rate, in
proportion to the rate at which the work revolves. Both external and internal threads can be cut on lathe.
Figure of Various operations on centre lathe machine
Facing and Turing
Parting Drilling
19
Boring
Thread Cutting
LATHE TOOLS
To generate different type of surfaces we use different tools. Some of these are mentioned below:
a) Turning Tool
b) Parting Tool (or square grooving tool)
c) Thread Cutting Tool
d) Boring Tool
e) Knurling Tool
f) Form Tool
Fig. Different types of tools used in lathe

20
CUTTING SPEED: It is the speed at which the metal is removed by the tool from the work piece.
It is given as: V= πdN/1000 mm/min.
Here, d is work diameter in mm and N is number of rotations of work per Minute.
FEED: In a lathe, feed is the distance the tool advances for each revolution of the work. It is generally
expressed as mm/rev or mm/min.
DEPTH OF CUT: The depth of cut it is the perpendicular distance measured from the machined
surface to the uncut surface of the work piece.
POST EXPERIMENT VIVA-VOCE QUESTIONS
a. Why lathe machine is called mother of all machines?

b. What specifications you will put in your purchase order if you are asked to buy another lathe machine like the
one you worked with?
c. Name the important operations performed on lathe.
d. Define feed, depth of cut and cutting speed for lathe.
e. Name the part used to hold work piece on lathe. Which accessory is used to hold long hollow part while
turning?
f. What is chamfering and why chamfers are provided? At what angle the tool is set for chamfering operations?
g. Give the functions of tail stock & Head stock?
h. What is the function of lead Screw?
i. Why lathe spindles are made hollow?
j. Which type of chuck is used to hold non-cylindrical jobs?
k. Draw the tool is used in turning and grooving operation in lathe.
l. On which part is drill bit mounted for drilling operations? How is feed given to drill bit when performing
drilling operation on lathe?
m. What is dead centre and live centre? Draw the sketch of dead centre.
n. Why lathe chucks have concentric circles on it?
o. What are the functions of compound slide?
p. Why centering of tool is necessary before machining operations on lathe?
q. How is centering of work piece done on lathe?
r. What is lathe steady rest and when it is used?
s. Name the standard tapers available.
t. How is taper specified in metric system? Name the methods used for taper turning.
u. What is the function of half nut?
v. What is a change gear?
w. How is the carriage locked during taper turning by compound rest offset method?
21
Jaipur
4ME4-23 Production Practice Lab-I
EXPERIMENT No. 01(b)

To perform step-turning, taper-turning, knurling, chamfering and cut multi-start square/ metric and square threads on a
centre lathe machine as per given job drawing.
2. INPUTS REQUIRED
A Center lathe machine with its accessories, cutting tools (side tool, parting tool, ‘V’ tool, knurling tool, center drill,
outside spring caliper, engineering scale, marking pencil, thread gauge, lubricant oil etc.
Job Drawing
3. PROCESS SEQUENCE
i. First check the length of the given workpiece which must be slightly greater than the drawing length.
ii. Mount the work into chuck nearly halfway out and start the spindle in anticlockwise direction (viewing from
tailstock end).
iii. Perform the facing operation on the work using a RH( right-hand) side tool. During facing, the working angle
between cutting edge of tool and job axis should be (nearly) 45°.
iv. Now adjust the cutting edge of tool to 90° (w.r.t. workpiece axis) and turn the workpiece diameter to maximum
diameter in drawing. Chamfer the job from its end.
v. Unclamp the job and clamp it again from other side. Perform the facing, turning and chamfering operations (as
in step 3 & 4).
22
Jaipur
vi. Mark the job at 55 mm from face end and turn its diameter upto 23 mm.
vii. Again mark the job at 20 mm from face end and turn its diameter upto 16 mm.
viii. Using parting tool, make a square groove of 5 mm length and 12 mm diameter as per given drawing.
ix. Turn the compound rest by the half taper angle calculated as α=tan-1[(D-d)/2l].
x. Perform taper turning operation using a ‘V’ tool by giving feed from compound slide.
xi. Fix a centre drill in place of dead centre and perform drilling operation.
xii. Fix the dead centre again and support the job in the drilled hole.
xiii. Using diamond-pattern knurling tool perform knurling operation as per the given drawing.
xiv. Set the machine in back gear and using Norton gear box select required gear ratio as per the given pitch of the
thread to be cut.
xv. Cut metric ‘V’ threads in multiple passes using a ‘V’ tool.
xvi. Unclamp the work and clamp it again from the other side.
xvii. Turn the job to the diameter of 23 mm. Also perform the chamfering operation at its end.
xviii. Set the machine in back gear (as in step 14) and using Norton gear box select required gear ratio as per the
given pitch of the thread to be cut.
xix. Cut the metric thread of given pitch ( ……mm) using parting tool of width …… mm (i.e. w=p/2).
xx. Finish the thread grooves and other job areas using a smooth hand file.
xxi. Unclamp the work and confirm its various dimensions as per the given drawing.
xxii. Prepare an error matrix from the actual and measured dimensions of the job.
4. ERROR MATRIX
STANDARD MEASURED
% PRECAUTIONS TO AVOID
S.NO. OPERATION VALUES VALUES
ERROR ERRORS
(as per drawing) (in final job)
1. Square threads Pitch=…..mm  The parting tool must be of required
width.(p/2)
 Lead screw may have pitch errors in
itself which must be checked.
2. Metric threads Pitch=… ... mm  The V tool must be of required angle
and shape.
 Lead screw may have pitch errors in
itself which must be checked.
3. Taper angle α = …… Compound slide must be set at correct

angle.
4. Work length L= ……mm Facing operation must be done
carefully.
5. SAFETY PRECAUTIONS
i. Always wear a proper workshop uniform and leather shoe while performing operations.
ii. Before operating a machine, it must be ensured that work and tool are properly clamped in the fixtures.
iii. The machines should not be left in running position while going for an urgent call or chat with another person.
iv. The key should never be left in the chuck after clamping and unclamping of job.
v. The operator should not lean towards the machine.
vi. Wear safety goggles or face shield to protect eyes from the chips produced due to metal cutting.
vii. The machine should be quickly turned off in case of power failures.
23
Jaipur
viii. When power resumes, the direction of spindle rotation (which should be anticlockwise when viewed from tail
stock end) must be ensured to avoid tool breakage.
6. SOURCES OF ERROR
i. Improper metallographic structure (or hard steel) may be one of the cause of work piece nonconformity.
ii. Marking and readings should be properly ensured to prepare accurate job.
iii. Machine may itself have mechanical errors that may account for improper pitch & faulty dimensions in the
final job.
7. RESULT: The job has been prepared as per the given drawing. The error matrix has also been prepared showing
precautions to avoid errors.
Post Experiment Viva-Voce Questions
i. Name the three different methods of taper turning.

ii. Highlight the differences between metric and square threads in terms of geometry and applications.
iii. Give the nomenclature details of a metric thread having specification M 20 x 3.0
iv. What is the function of leadscrew in a lathe machine? What TPI it had in the machine you used?
v. Name the materials of tool and work piece in the above experiment.
vi. Explain how you will set the gear train for the threading operation?
24
Jaipur
Experiment 1 Pre Experiment Assignment

1) Name the parts of lathe machine.
2) Write the personnel protective equipment required to perform work on lathe machine.
3) What is the proper method to start the lathe machine?
4) What is the proper method to stop the lathe machine?
5) What is the difference between “Feed” and “depth of cut”?
6) Why coolant is used during turning operation on lathe?
7) By viewing the part drawing, write the names of the operations and tools required for the given job
on lathe machine?
8) Calculate the taper angle to perform taper turning on lathe machine.
25
Jaipur
Experiment No. 02
1.0 TITLE OF EXPERIMENT
To perform boring operation using a boring bar on a centre lathe machine and cut BSW/Metric internal
threads on it as per given job drawing.
2.0 INPUTS REQUIRED: Lathe Machine, boring tool, centre drill, work piece.
3.0 LEARNING OBJECTIVES

(i.) To understand the boring operation and configuration of a boring tool.
(ii.) To develop hands-on-experience on cutting internal threads by the use of a boring tool on a lathe
machine
4.0 THEORY
Boring is the process of enlarging and truing of a hole by removing material from internal surfaces
with a single-point cutter bit usually known as a ‘boring tool bar’. On a centre lathe, boring is generally
accomplished by either of these two methods:
(i.) Mounting the holder and boring tool bar with cutter bit on the tool post and revolving the workpiece.
(ii.) Mounting the workpiece in a fixed position to the carriage and revolving the boring tool bar and cutter
bit in a chuck attached to the headstock spindle.
The former method is widely used in most of the machine shopsand will be undertaken in this experiment.
Schematic illustration of boring operation
STEPWISE PROCEDURE
a) Mount the work in a chuck, face, spot and drill the hole approximately 1.5mm undersize.
b) Select a boring bar as large as possible and having diameter under the hole size. Extens it beyond
c) the holder only enough to clear the depth of the hole to be bored.
d) Mount the boring bar tool holder in the tool post on the left-hand side of the compound rest.
e) Set the boring cutting tool to center.
f) Set the lathe to proper speed and select medium feed.
g) Start the lathe and bring the tool into contact with the inside diameter of hole.
h) Take a light trial cut (0.12mm) until a true diameter is produced 10mm long at right side of the
26
Jaipur
i) work piece.
j) Stop & Determine the amount of material / depth of cut to be taken to generate final hole.
k) Start boring operation to make hole.
l) Keep approximately 0.25mm to 0.5mm for finish cut.
m) Stop the lathe and bring out the boring bar out of hole. Now set the tool for finish cut with fine
n) feed.
o) Chamfer all the external and internal edges across diameters.
p) For internal threading operation set a new boring tool bit having 60 degree thread angle.
q) Mount the boring tool, center it and cut a recess equal to major diameter of thread at the start and
r) end of the thread.
s) Select the gear train as per pitch of thread from chart.
t) Now start threading operations as done for external threads by engaging half nut.
u) Cut the thread to the depth. Check the fit by using plug gauge or with screw.
a) Define boring process.

b) Which hole has better accuracy drill or bored hole?
c) How is boring tool set before cutting operation?
d) What is the purpose of reaming a hole?
e) Give examples of internal threading.
f) How is the tool set for internal threading?
27
Jaipur
Experiment 2: Pre Experiment Assignment
1) Define Boring, Drilling, and Reaming operation.
2) Write the personnel protective equipments required to perform work on lathe machine.
3) How you will hold and set boring tool?
4) By viewing the part drawing, write the names of the operations and tools required for the given job on lathe
machine?
5) How is “feed” and “depth of cut” given in boring operation?
6) Which tool is required to drill-mark a centre hole on work piece before boring?
7) How you will check the bored hole?
28
Jaipur
EXPERIMENT NO. 3
Demonstration of eccentric turning on lathe machine using four jaw chuck.
2. INPUTS REQUIRED
A Centre lathe machine, a four-jaw chuck, chuck key, tool post spanner, side tool, vernier caliper, drill bit 10mm,
centre drill, outside spring calliper, engineering scale, marking pencil etc.
Materials Supplied: Mild Steel Rod Ø25x 102mm
Tool Material: High Speed Steel (H.S.S)
3. THEORY
If the cylindrical work piece has two separate axis of rotation, one being out of the centre to the other, the work piece is
eccentric and turning of different surfaces of the work piece is known as eccentric turning. Most turning jobs processed
on a lathe machine are concentric in nature and a three jaw chuck is generally used to hold the work piece. The 3 jaw
chuck moves all 3 jaws in unison when the chuck is adjusted. To do eccentric turning a four jaw chuck is used which
has independently motion of jaws that allows parts to be moved off centre.
Eccentric work is work that is turned off centre, or not on the normal centre axis. An engine crankshaft is a good
example of an eccentric work piece. Crankshafts normally have a main centre axis, called a main journal, and offset
axes, which produce the throw and the eccentric diameters of the mechanism.
4. PROCESS SEQUENCE
a) The given work piece is held firmly in a 4-jaw lathe chuck.
b) The cutting tool is set in a tool post such that the point of the cutting tool coincides with the lathe axis.
c) The machine is switched on to revolve the work piece at the selected speed.
d) By giving Cross feed and longitudinal feed to the cutting tool, the facing and turning operations are done
respectively.
e) The speed of the work piece is reduced.
f) The four jaw chuck is manually adjusted for the offset purpose to make the eccentricity.
g) The work piece is removed from the chuck and all the dimensions are measured and checked.
5. RESULT
A job has been prepared as per the given drawing having eccentric turning operation.
29
Jaipur
6. POST EXPERIMENT VIVA-VOCE QUESTIONS

i. Highlight the difference between turning, step turning and eccentric turning.
ii. List the domestic and industrial applications of eccentric turning.
iii. What is eccentric turning attachment?
******
30
Jaipur
Experiment 3 Pre Experiment Assignment
Title: Demonstration for job by eccentric turning on lathe machine using four jaw chuck.
1) What is eccentricity? Measure the eccentricity of the given job drawing.
2) By viewing the part drawing, write the names of the operations and tools required for the given job on lathe
machine?
4) Which types of chuck is used in eccentric turning?
5) How will you make alignment and clamping of work piece on chuck?
6) Write the precautions for eccentric turning on lathe to minimize error.
31
Jaipur
Jaipur
Experiment No. 04(a)

To study the milling machine, milling cutters, milling operations, indexing heads and indexing methods.

 To understand the classification of milling machines.
 To understand the construction features and working principle of column
and knee type milling machines.
 To identify the various milling cutters and the corresponding milling
operations.
 To understand the indexing mechanism and its applications.
3.0 THEORY INTRODUCTION

‘Milling’ is the machining process in which the removal of metal takes place due to the cutting action of a
revolving cutter when the work is fed past it. This revolving cutter is held on a spindle or arbor and rotates
at a high speed and because of the multiple cutting edges it removes metal at a very fast rate. The machine
can hold one or more number of cutters at a time.
4.0 CLASSIFICATION OF MILLING MACHINES
1. Column and knee type

(a) Hand milling machine
(b) Plain or Horizontal milling machine
(c) Universal milling machine
(d) Ornniversal milling machine
(e) Vertical milling machine
2. Manufacturing or fixed bed type

(a) Simplex milling machine
(b) Duplex milling machine
(c) Triplex milling machine
3. Special type
(a) Rotary table milling machine
(b) Drum milling machine
(c) Planetary milling machine
(d) Pantograph, profiling & tracer controlled milling machine
32
Jaipur
5.0 PRINCIPAL PARTS OF COLUMN AND KNEE TYPE MILLING MACHINE
(i) Base: The base of the machine is a grey iron casting accurately machined on its top and bottom surface
and serves as a foundation member for all other parts which rest upon it.
(ii) Column: The column is the main supporting frame mounted vertically on the base. The column is box
shaped, heavily ribbed inside and houses all the driving mechanisms for the spindle and table feed.
(iii) Knee: The knee is a rigid grey iron casting that slides up and down on the vertical ways of the column
face. The adjustment of height is effected by an elevating screw mounted on the base that also supports the
knee. The knee houses the feed mechanism of the table, and different controls to operate it. The top face of
the knee forms a slideway for the saddle to provide cross travel of the table.
(iv) Table: The table rests on ways on the saddle and travels longitudinally. The top of the table is accurately
finished and T-slots are provided for clamping the work and other fixtures Oil it. A leadscrew under the table
engages a nut on the saddle to move the table horizontally by hand or power.
(v) Overhanging arm: The overhanging arm that is mounted on the top of the column extends beyond the
column face and serves as a bearing support for the other end of the arbor. The arm is adjustable so that the
bearing support may be provided nearest to the cutter. More than one bearing support may be provided for
the arbor.
(vii) Spindle: The spindle of the machine is located in the upper part of the column and receives power from
the motor through belts, gears, clutches and transmits it to the arbor.
(viii) Arbor: An arbor may be considered an extension of the machine spindle on which milling cutters are
securely mounted and rotated. The arbors are made with taper shanks for proper alignment with the machine
spindles having taper holes at their nose.
FIG. A column and knee type (horizontal) milling machine
33
Jaipur
6.0 MILLING MACHINE OPERATIONS
The following are the different operations performed on milling machines:

(i.) Plain milling: The plain milling is the operation of production of a plain, flat, horizontal surface
parallel to the axis of rotation of a plain milling cutter. The operation is also called slab milling.
(ii.) Face milling: The face milling operation is performed by a face milling cutter rotated about an axis
perpendicular to the work surface.
(iii.) Side milling: The side milling is the operation of production of a flat vertical surface on the side of a
workpiece- by using side milling cutter. The depth of cut is adjusted by rotating the vertical feed screw
of the table.
(iv.) Angular milling: The angular milling is the operation of production of an angular surface on. a
workpiece other than at right angles to the axis of the milling machine spindle. The angular groove
may be single or double angle and may be of varying included angle according to the type and shape of
the angular cutter used. One simple example of angular milling is the production of V-blocks.
(v.) Form milling: The form milling is the operation of production irregular contours by using form
cutter. The irregular contour may be convex, concave, or of any other shape. After machining, the
formed surface is checked by a template gauge.
(vi.) End milling: The end milling is the operation of production of a flat surface which may be vertical,
horizontal or at an angle in reference to the table surface. The cutter used is an end mill. The end
milling cutters are also used for production of slots, grooves or' keyways. A vertical milling machine is
most suitable for end milling operation.
(vii.) Milling keyways, grooves and slots: The operation of production of keyways, grooves and slots of
varying shapes and sizes can be performed in a milling machine by using a plain milling cutter, a metal
slitting saw, an end mill or by a side milling cutter. The open slots can be cut by a plain milling cutter,
a metal slitting saw, or by a side milling cutter. The closed slots are produced by using end mills. A
dovetail slot or a T-slot is manufactured by using special type of cutters designed to give the required
shape on the workpiece.
Plain milling Face milling Side milling
Angular milling Form milling End milling

34
Jaipur
Milling keyways, grooves and slot
7.0 Milling Cutters

Milling cutters can be classified as below:
(1) Plain milling cutter.
(2) Side milling cutter
(3) Metal slitting saw
(4) Angle milling cutter
(5) End mill
(6) T-slot milling cutter
(7) Formed cutter.
(a) Convex milling cutter
(b) Concave milling cutter
(c) Gear cutter
Plain milling cutter Side milling cutter Metal slitting saw
35
Jaipur
Angle milling cutter End milling cutter T-slot cutter
Convex milling cutter Concave milling cutter Gear cutter
Formed cutters
8.0 INDEXING
It is the division of the job periphery into a desired number of equal divisions. It is accomplished by a
controlled movement of the crank such that the job rotates through a definite angle after each cut is over. The
device commonly employed for indexing operations is known as ‘Dividing head or Indexing Head’. The two
common types of indexing heads are:
(i) Plain dividing head
It is the simplest of all the dividing heads and is used in direct and simple indexing. The index plate
carries 12 or 24 equispaced slots on its periphery. The job is held between two centres, one on the dividing
head spindle and the other on the tailstock. The hand lever is used for locking the spindle in position. By
means of this dividing head 2, 3, 4, 6, 8, 12 and 24 divisions can be obtained when 24 slots plate is used and
2, 3, 4, 6 and 12 divisions when a 12 slots plate is used.
(ii) Universal dividing head

It is the most common type of indexing arrangement widely used in workshops. As the name implies,
this type of index head can be used to execute all forms of indexing. A universal dividing head is used for the
following purposes:
1. For setting the work in vertical, horizontal or in inclined positions, relative to the table surface.
2. For turning the workpiece periodically through a given angle to impart indexing movement.
3. For imparting a continuous rotary motion to the workpiece for milling helical grooves.
36
Jaipur
The important parts of a universal dividing head are the worm and worm gear, index plate, sector arm,
change gears and the spindle.
9.0 METHODS OF INDEXING

There are different indexing methods in popularity. These are :
(a) Direct indexing
(b) Simple indexing
(c) Compound indexing
(a) Direct Indexing

It is also named as rapid indexing. For this direct indexing plate is used which has 24 equally spaced holes in
a circle. It is possible to divide the surface of workpiece into any number of equal divisions out of 2, 3, 4, 56,
8, 12, 24 parts. These all numbers are the factors of 24. In this case fist of all worm and worm wheel is
disengaged. We find number of holes by which spring loaded pin is to be moved. If we want to divide the
surface into 6 parts than number of holes by which pin is to be moved for 6 parts. So number of holes holes
that is after completing one pair of milling whole surface of workpiece we have to move the pin by 4 holes
before next milling operation, that is to be done for 5 number of times for making hexagonal bolt.
(b) Simple Indexing
It is also named as plain indexing. It over comes the major limitation of direct indexing that is possibility of
dividing circumference of workpiece into some fixed number of divisions. In this case worm and worm gear
is first engaged. So one complete turn of indexing crank revolves the workpiece by 1/40 th revolution. Three
indexing plates are widely used by most of the machine tool manufacturers.These plates have concentric
circles of holes with their different numbers as described below:
Plate No. 1 15 16 17 18 19 20
Plate No. 2 21 23 27 29 31 33
Plate No. 3 37 39 41 43 47 49
(c) Compound Indexing

The word compound indexing is an indicative of compound movements of indexing crank and then plate
along with crank. In this case indexing plate is normally held stationary by a lock pin, first we rotate the
indexing crank through a required number of holes in a selected hole circle, then crank is fixed through pin. It
is followed by another movement by disengaging the rear lock pin, the indexing plate along with indexing
crank is rotated in forward or backward direction through predetermined holes in a selected hole circle, then
lock pin is reengaged.
10. RESULT
We have studied the milling machine, milling cutters, milling operations, indexing heads and indexing
methods.
******
37
Jaipur
POST EXPERIMNET VIVA-VOCE QUESTIONS
a) Classify Milling operations.

b) Name the different types of milling machines.
c) Give specifications of horizontal milling machines.
d) Give specifications of vertical milling machines.
e) What is use of indexing head?
f) Name the milling cutters used in vertical milling machines.
g) Name the milling cutters used in horizontal milling machines.
h) Which milling cutter is used for cutting T- slots?
i) Which milling cutter is used for cutting grooves?
j) Which milling cutter is used for cutting gear tooth?
k) Which milling cutter is used for planning operation?
l) What is gang milling?
m) Where is side and face cutter used?
n) Give specifications of a gear milling cutter.
o) Give principle of indexing.
p) Of what material is cutter made up of?
q) What is arbour? How milling cutters are mounted on it?
38
Jaipur
Experiment 4 - Pre Experiment Assignment
Title: To prepare a spur gear as per the given specifications using indexing head on a milling machine.
1) Name the parts of vertical Milling machine.
2) Write the personnel protective equipments required to perform work on milling machine.
3) By viewing the part drawing, write the names of the operations and tools required for the given job on milling
machine?
4) Write the required parameters of gear to cut on milling.
5) Write the principle of universal indexing head?
6) Write the specifications of horizontal milling machine.
7) Write the specification of gear cutter you will use.
39
Jaipur
Experiment No. 04 (b)

Title of Experiment
To prepare a spur gear as per the given specifications using indexing head on a milling
machine.
Learning Objectives
i. To know construction and function of plain machine vice and universal dividing head.
ii. To understand the indexing mechanism of the milling machine placed in the mechanical
workshop.
iii. To set the milling machine (placed in the mechanical workshop) for gear cutting operation
without theaid of an instructor.
iv. To cut the gear teeth of required number and profile on the given blank size.
Accessories required-
(a) Plain machine vice
(b) Universal indexing head
Material Required -
(a) Bright Al blank (Ø 30mm × 30mm long)
(b) Involute profile gear cutter [24 Dp (diametral pitch), 1/2″ bore dia. and 14½ pressure angle.]
Theory: Gear may be manufactured by casting, stamping, machining or by powder metallurgical

processes. Out of all these processes, the most common and accurate method of production of
gears is by machining. The different methods of production of gears by the machining operations
are described below:
1. Formed cutter method

(a) By a formed disc cutter in a milling machine.[will be used in this experiment]
(b) By a formed end mill in a milling machine.
2. Template process
3. Gear generating process
40
Jaipur
Schematic sketch of Experimental set-up
FIG. Job setup on milling table

Stepwise procedure:
1. On the basis of the number of teeth to be cut and given blank diameter, select the appropriate cutter.
We have, Blank diameter as …… mm.No.
of teeth to be cut= …….
So cutter chosen is Cutter No. 6 having an involute profile with 24 Dp (diametral pitch), 1/2″ bore dia.
and 14½⁰ as pressure angle.
2. Hold the given blank in a appropriate mandrel.
3. The mandrel is further held securely between chuck and foot stock.
4. Now as per simple indexing method, calculate the number of holes to be moved by the crank as per the
following formula;
No. of crank movement=40/N,
Where, N=No. of teeth to be cut (20 in this case) So
number of crank movement=40/20=2
5. The cutter is now positioned at the centre of the blank to accomplish the first cut.
6. The depth of cut has to be selected as per the following empirical formula,
Depth of cut=2.157/Dp (in inches)
= 2.157/Dp x 25.4 mm
= 2.157/24 x 25.4 mm ≈ 2.28 mm
7. After completing first cut, the index crank has to be moved by two rotations (CW) to start the second
cut. The process may be repeated subsequently after cutting each tooth.
8. After cutting the required number of teeth (20 in this case), the job may be externally finished by an
emery paper or hand file to remove minor burrs or other surface irregularities.
Result : A gear has been cut with following specifications;

(a) No. of teeth=……………
(b) Type of profile=…………
(c) Tooth thickness=…………..
(d) Tooth depth=………….
(e) Module=……..
41
Jaipur
1. Name the different methods of gear manufacturing.
2. Write down the relationships of the following in terms of module and number of teeth
for a 20⁰ gear tooth:
(a) Pitch circle=………………
(b) Addendum=………………
(c) Dedendum=………………
(d) Working depth=………….
(e) Tooth depth=……………..
(f) Outside diameter=…………
3. Write down the precautions and sources of error for the above experiment.
4. What is the main difference between hobbing and milling process for manufacture of gears?
5. Explain principle of indexing.
6. Name different indexing methods & which method you used?
*****
42
Jaipur
Experiment 4(b): Pre Experiment Assignment
Title: To prepare a spur gear as per the given specifications using indexing head on a milling machine.
1) Name the parts of vertical Milling machine.
2) Write the personnel protective equipment required to perform work on milling machine.
3) By viewing the part drawing, write the names of the operations and tools required for the given job on
milling machine?
4) Write the required parameters of gear to cut on milling.
5) Write the principle of universal indexing head?
6) Write the specifications of horizontal milling machine.
7) Write the specification of gear cutter you will use.
43
Jaipur
Experiment No. 05
Title: To machine hexagonal nut using indexing head on universal milling machine.
Learning Objectives
 To know construction and function of plain machine vice and universal dividing head.
 To understand the indexing mechanism of the milling machine placed in the mechanical workshop.
 To set the milling machine (placed in the mechanical workshop) for nut making operation without the
aid of an instructor.
 To cut the required number of nut faces and profile on the given blank size.
Accessories required-
i. Universal indexing head
ii. Horizontal milling machine
iii. Lathe machine (with drill chuck)
iv. Foot stock
v. Vernier Calliper
Material Required -
(a) Bright Al blank ( Ø 30mm × 20mm long)
(b) Side and face milling cutter (4″ x 1/2″ x 1″)( External diameter x width x bore size)
Job drawing
Isometric view Orthographic projected view
44
Jaipur
Stepwise procedure
i. Check the external diameter of given blank and turn it to 30 mm (if it is oversize).
ii. Chamfer it at an angle of 30 degrees from one of its faces.
iii. Drill a hole of 10.1 mm diameter in it.
iv. Now, on the basis of type of geometry of part to be made, an appropriate cutter has to be selected.
Since we are making a nut, a side and face milling cutter [with specifications 4″ x 1/2″ x 1″(
External diameter x width x bore size)] is chosen.
v. Hold the given blank (having 30 mm diameter) in the mandrel.
vi. The mandrel is further held securely between chuck and foot stock.
vii. Now as per simple indexing method, calculate the number of holes to be moved by the crank as per
the following formula;
 No. of crank movement=40/N , Where, N=No. of peripheral divisions to be made
 Since we are making a hexagonal nut
 We have, N=No. of faces to be cut=6
 So number of crank movement=40/6=6
viii. The cutter is now positioned at the centre of the blank to accomplish the first cut. The depth of cut has
to be selected as per the geometry of the job.
 Depth of cut= (d/2)-(√3/2) (d/2) , where d= blank diameter=30mm(in our case)
Putting value, Depth of cut ≈ 2 mm
ix. After completing first cut, the index crank has to be moved by six complete rotations and by 12 holes
in 16 holes circle of the index plate to start cutting second face. The process may be repeated
subsequently after cutting each face till sixth face is cut.
x. Now, by using 1/2″ tap set, internal threads are being made in the job.
xi. After completing the above steps, the job may finally be externally finished by an emery paper or
hand file to remove minor burrs or other surface irregularities.
Result
A hexagonal nut has been prepared with the following specifications;
(a) Pitch, p=……..
(a) Crest diameter, d′=………
(b) Height of nut, h=………
(c) Width across flats, w=…….
(d) Angle of chamfer , θ=…….
Error Analysis Matrix
S.No. Nut dimensions Empirical/Standard Standard Actual % Error

relations for the nut values in the values as [(a-b)/(a)]x100
prepared job measured in
prepared (a) the job
(b)
Size across
1.
corners
Width across
2.
flats(w)
45
Jaipur

1) Write the name of different cutters used in horizontal milling machine.
2) Write the personnel protective equipments required to perform work on lathe machine.
3) Write the formulae for indexing a hexagonal nut
4) By viewing the part drawing, write the names of the operations and tools required for the given job on
milling machine?
5) How is “feed” and “depth of cut” given in milling?
6) Calculate the all the required dimensions of hexagonal nut given in experiment.
Pitch = Height = width across flat= width across corners=
7) Write specifications of milling cutter used.
46
Jaipur
Experiment No. 06
Title of Experiment: Demonstration of milling machine for generation of plane surfaces using end milling
cutter.
Requirements: Vertical milling machine, milling vice, end mill cutter 10mm diameter.
Job drawing
(All dimensions in mm)
Stepwise procedure
1. Select an end mill of appropriate specifications as per given drawing.

Diameter of End Mill: ........................mm.
2. Mount the workpiece securely using machine vise fixed on the milling table.
3. Select suitable depth of cut ( approx.1mm) to start the cutting operation.
4. Provide feed to the workpiece in a direction parallel to the table and perpendicular to the tool axis.
5. Subsequently increase depth of cut to perform next cycle of cut.
Result: A job has been prepared as per given drawing using end mill on a vertical milling machine.
a) Give specifications of vertical milling machines.

b) Name the milling cutters used in vertical milling machines.
c) Which milling cutter is used for cutting T- slots?
d) Which milling cutter is used for cutting grooves?
e) Which milling cutter is used for cutting gear tooth?
f) Which milling cutter is used for planning operation?
g) Of what material is cutter made up of?
h) What is an Arbour? How milling cutters are mounted on it?
i) What is collet ? How milling cutters are mounted on it?
47
Jaipur
1) Write the name of different cutters used in vertical milling machine.
2) Write the operations that can be performed on vertical milling machine.
3) For what purpose end milling is done?
4) Write specifications of end milling cutter to be used in milling a slot.
5) Write specifications of Vertical milling machine.
48
Jaipur

Title: To study a single point cutting tool geometry and to grind the single point cutting tool from a
given M.S. blank.
LEARNING OBJECTIVES
i. To understand the geometry of a single point cutting tool widely used in lathe and shaper machines.
ii. To understand the significance tool signature.
iii. To develop skill of cutting a single point tool on a bench grinder.
INPUTS REQUIRED: model of single point tool, mild steel bar, pedestal grinder.
TOOL SIGNATURE: It is the system of designating the principal angles of a single point cutting tool. The signature
is the sequence of numbers listing the various angles, in degrees, and the size of the nose radius.
The system most commonly used is American Standard Association (ASA), which is: Bake rake angle, Side rake
angle, End relief angle, Side relief angle, End cutting Edge angle, Side cutting Edge angle and Nose radius.
For example a tool may be designated in the following sequence: 8-14-6-6-6-15-1.
In this particular tool, Bake rake angle is 8°; Side rake angle is 14°; End relief angle is 6°; Side relief angle is 6°;
End cutting Edge angle is 6°; Side cutting Edge angle is 15° and Nose radius is 1 mm.
Tool Angles are described below :
(i.) Side Rake angle: It is the angle by which the face of the tool inclined side-ways. It determines the tool thickness
behind the cutting edge. It is the angle between the tool face and a line parallel to its base and measured in a plane.
(ii.) Back Rake angle: It is the angle between the face of the tool and a line parallel to the base of the shank in a plane
parallel to the centre line of point, this angle affects the direction of the chip flow.
(iii.) End Relief angle: It is the angle between the surface of the flank immediately below the point and a line drawn
from the point perpendicular to the base.
(iv.) Side Relief angle: It is provided on the tool to provide clearance between its flange and the work-piece surface.
(v.) End Cutting Edge angle: It provides the clearance between the tool’s cutting edge and work-piece.
(vi.) Side Cutting Edge angle: It is responsible for turning the chip away from the finish surface. It is the angle
between the straight cuttingedge on the side of the tool and side of the tool shank.
(vii.) Nose angle (or Nose radius): It is the angle between the side cutting edge and the end cutting edge and is
provided to remove the fragilecorner of the tool. It increases the tool life and improves the surface finish.
(viii.) Clearance angle: It is the angle between the portion of the flank adjacent to the base and a plane free cutting
action. It minimizestool forces and decreases cutting temperature.
(ix.) Working angles: These angles do not depend upon the shape of the tool but depend upon the position of the tool
with respect tothe work-piece.
(x.) Tip angle: It is the angle between the tool face and the ground and surface of flank. It is usually between 60° to 80°.
49
Jaipur
Fig. Orthographic view of a single point cutting tool
Fig. Isometric View of a Single point cutting tool
RESULT: We have studied the geometry of a single point cutting tool and have ground a single point tool
comprising of sixangles and nose radius.
*****
50
Jaipur
a) Differentiate between single point and multipoint cutting tools.

b) Give examples of single point and multipoint cutting tools.
c) Give name of some tool materials.
d) How is single point tool designated?
e) Why is back rake & side rake angle provided?
f) When will you provide positive rake, negative rake and zero rake angles of lathe tool?
g) What is role of nose radius? Give its approximate values?
h) Give approximate values of rake angle, cutting angle and all clearances angle for HSS tool – Mild Steel system.
i) What are tool inserts?
j) What is throw away bits?
k) Give composition of HSS material.
l) Name the type of tool wears.
51
Jaipur
Experiment 7(a) : Pre Experiment Assignment

Aim: To study a single point cutting tool geometry and to grind the single point cutting tool.
1) Give suitable materials used for making cutting tools.
2) Write the examples of single point cutting tool and multipoint cutting tools
3) Give the type of abrasive grinding wheels used for tool grinding.
4) Write specifications of tool-cutter grinding machine.
5) Write ASA tool signature of single point cutting tool.
52
Jaipur
EXPERIMENT No. 7(b)

1. TITLE: Demonstration of grinding of drilling tool bits.
2. GROUP NO.: ………………………; GROUP MEMBERS: ………………………………….
3. INPUTS REQUIRED: A dull or chipped drill bit, bench grinder or belt sander, a drill point gage or
protractor head on the combination square, learning charts.
4. OBJECTIVE: Drill bits used for making holes in metal, wood and masonry becomes dull with normal
use. Drill bits having worn cutting edges make hole making tasks more difficult and time-consuming and
can cause costly accidents. They produce incorrect hole in both size and shape.
5. OUTLINE OF PROCEDURE
i) Run the bench grinder machine at correct direction of motion. Check the trueness of the grinding
wheel face. Note particularly the features and hand motions, which control the geometrical form of
the drill tool. (Please do not remove guards).
ii) Learn the names of the major components of twist drill tool. Record these details.
iii) Record the specification of bench grinder.
iv) Pay attention to the drill point angle, chisel edge thickness and lip angle.
6. OBSERVATIONS:
(a) Draw a well labeled diagram of drill tool bit (figure 1).
(b) Observe and record the drill parts and their functions.
(c) Record the specifications of bench grinder machine in tabular form (Table 1).
(e) Observe and record the various steps involved in regrinding of drill bit.
FIGURE 1: GEOMETRY OF TWIST DRILL
53
Jaipur
7. STEPS FOR REGRINDING OF DRILL BITS:
a) Pre-check: Before sharpening a twist drill, the operator must check the condition of the drill for
chipped and cracked lips or edges that must be ground off during the sharpening process. The
operator must also check the references for the proper lip angle and lip clearance angle for the
material to be drilled.
b) Check whether both the roughing and finishing wheels are true. If not, move a wheel dresser across
them.
c) After setting up the bench grinder for drill sharpening, the operator should keep a comfortable
distance in front of the grinding wheel to sharpen the twist drill.
d) Take the drill bit into both hands. Hold the bit approximately horizontal with the cutting lip being at
ground level. The axis of the drill should be at a 59 OR 60 degree angle to the face of the grinding
wheel. Place the end of the landing so that it is directly against the wheel or belt.
e) Grind the lip angle first and then concentrate on grinding the lip clearance angle, which will then
determine the lip length. The usual lip angle is an included angle of 118° (59° x 2) which is the lip
angle of general purpose drills. Use the drill point gage frequently to check lip angle and lip length.
f) Shaping the Land: By rotating or rolling the drill bit counter clockwise, create a rounded landing that
gives more support to the lip.
g) Grinding Web: Ground the point thinner on a thin grinding wheel with a rounded face to fit into the
flute. An equal amount of metal should be ground from each flute. The web should not be ground too
thin as this may weaken the web and cause the drill to split in the middle.
h) Check both the cutting lips with the drill point gage.
i) Check for correct angle.
j) Check for equal lip length.
k) Check lip clearances visually. It should be 8 to 12 degrees.
l) If a drill becomes too hot during sharpening, air cool the drill.
8. PRECAUTIONS:
a) Wear protective goggles while grinding.
b) Do not remove protective guards from machine.
c) Before starting the grinder check the correct rotation of the wheels.
d) Do not touch the edges of the drill as it may cause burns and cuts.
54
Jaipur
e) When grinding, do not allow the drill to become overheated. Overheating will cause the drill edges to
become blue which is an indication that the drill's temper has been lost. The blue area must be ground
completely away to reestablish the drill's temper.
f) Do not quench the drill in water as it will induce cracks.
g) Check whether both the roughing and finishing wheels are true. If not, move a wheel dresser across
them.
h) The lip must be ground with equal angles & lengths otherwise the hole produced will be inaccurate.
VIVA-VOCE QUESTIONS:
a) Why it is necessary to regrind the drill?
b) Name the causes of wear of drill geometry.
c) Name the tool material of drill.
d) Name the parts of drill.
e) What is the function of flutes of drill?
f) Give the point angle of drill used for mild steel.
g) Give the point angle of drill used for wood & plastics.
h) Why lip should be ground with equal angles and length?
*****
55
Jaipur
Experiment 7(b) : Pre Experiment Assignment
Aim: Demonstration of grinding of drilling tool bits.
1) Give suitable materials used for making drilling tools.
2) Give value of point angle of drill bit.
3) Give the type of abrasive grinding wheels used for tool grinding.
4) How you will check the point angle of drill tool?
5) Read drill bit selection chart. Write the types of drills available in workshop.
56
Jaipur
EXPERIMENT NO. 8(a)

1. AIM: To study shaper machine, its mechanism and calculate quick-return mechanism of shaper machine.
2. GROUP NO. …………; GROUP MEMBERS: …………………………
3. INPUTS REQUIRED: Shaper machine with all accessories and tools, Charts etc.
4. OUTLINE OF PROCEDURE:
i) Run the shaper machine at low speed and observe the motions, which control the shapes of the surfaces
produced. Note particularly the features, which control the geometrical form of the surface.
ii) Learn the names of the major units and the components of each machine. Record these details. (Please
ensure that the main isolator switch is off and check that the machine cannot be inadvertently started. Do
not remove guards).
iii) Note down the special features of the speed and feed control on machine.
iv) Pay attention to the following:
a. Size specification of shaper machine tool.
b. Shaper machine tool structures and guide ways I slide ways.
c. Quick return mechanism of machine.
d. Drive mechanism for secondary (feed) motion.
5. OBSERVATIONS:
(a) Draw a well labelled diagram of shaper machine.
(b) Observe and record the shaper parts and their functions.
(c) Record the Specifications of shaper machine in tabular form.
(e) Observe and record the quick return motion perform by shaper machine.
f) Observe and draw various shaper tools.
6. PARTS OF SHAPER MACHINE:

a) Base – Base is a hollow casting upon which the other parts of the shaper are mounted. It is made up of
Grey Cast Iron.
b) Column – Frame is a large casting that rests upon the base. It houses the mechanism and supports the
ram and the table. The cross rail carrying the table and the drives to move the table up or down or cross
is also supported on column and slides by the front side of column. It is made up of cast iron.
57
Jaipur
c) Ram – Ram is the main moving part of the shaper. It holds and drives the single point cutting tool back
and forth across the work. It carries tool head. It gets its drive from the quick return mechanism which
makes it run faster while returning and slower while cutting.
d) Shaper Tool Head – The tool head is attached to the front of the ram. It may be swiveled to a required
angle to the left or right with respect to vertical slide of tool head and locked in place with the help of a
bolt or screw. The tool holder rests in a clapper block which is fitted on the clapper box which in turn is
fastened to the front of the shaper head slide.
e) Table – It is a metal box, which is attached to the frame of the shaper. It has “T” slots on the top and
sides, which are used for clamping work or a vice on the table.
f) Cross-Rail It is a heavy cast iron construction (like a box) over which the saddle slides horizontally. The
table cross feed screw and the rail vertical feed screw are housed inside it.
g) Table Support or Out Board Clamp – It gives an extra support to the table. It is fitted on the front side
of the machine to take up the cutting pressure as the tool cuts in forward motion.
h) Pointer or Stroke Indicator – It indicates the length of stroke.
i) Bull Gear – It is a big (generally helical) gear which carries the mechanism and is driven by a pinion.
On the face of this bull gear, there is a dovetail way in which the crank block is held.
j) Sliding Block – The block is made of wear resisting metal. It is generally made out of bronze and slides
in the slot of the rocker arm with up and down movement.
58
Jaipur
k) Elevating Screw – It is used for raising and lowering the table.
l) Stroke Adjustment Crank – Through this the stroke adjustment is done by offsetting the crank block
from the centre of the bull gear to the required distance.
m) Clapper Box – It is hinged on the swiveling slide of shaper head and carries the tool holder. It prevents
rubbing of tool edge against work piece during return stroke.
7. Quick Return Mechanism of Shaper:
Shaper drive mechanism is called slotted lever quick return mechanism. The tool does cutting only in the
forward stroke of the ram. It does not cut i.e.; it is idle during the return stroke of ram. Thus the return stroke
is faster than forward stroke. The ratio of time in forward stroke to return stroke is called quick return ratio.
It is evident that the angle B1LB2 made by the forward stroke or cutting stroke is greater than the angle
B1MB2 described by the return stroke. The angular velocity of the crank pin being constant, the return
stroke is therefore, completed within a shorter time for which it is known as ‘QUICK RETURN
MOTION’. The ratio between the cutting time and return time may be determined from the formula:
CUTTING TIME = angle B1LB2
RETURN TIME angle B1MB2
Figure 2(a,b) Mechanism of Shaper and angles
59
Jaipur
8. CUTTING TOOLS USED IN SHAPING:

a) Rough cut tool
b) Finishing tool
c) Keyway / groove cutting tool
d) Goose neck tool
e) Side cutting tool
9. Specification of a shaper as follows:
1. Make: ANOOP
2. Machining Size: 18” (450mm)
3. Max stroke: 20” (510mm)
4. Length of Ram: 36” (673mm)
5. Ram cycles per minute or strokes per minute: 15 to 90
6. Highest vertical travel of tool slide: 4” (100mm)
7. Min distance of table to ram: 2” (50mm)
8. Highest horizontal travel of table: 15” (450mm)
9. Dimension of table top: 18” x 12” (473mm x 330mm)
10. Floor space necessary: 1981mm x 1067mm
11. Length & width of table slide: 30” x 11”
12. Length of cross slide: 30”
13. Net weight: 1750kg
14. Power of the motor: 2 HP @1440rpm
10. Conclusions : the quick return ratio of shaper is ………….
60
Jaipur
a) Give three uses of shaper machine.
b) Name the mechanism used in shaper machine.
c) Which part reciprocates during motion in shaper?
d) Name important parts of shaper machine.
e) Name the operations performed on shaper machine.
f) What is function of clapper box?
g) How is feed and depth of cut adjusted in shaper?
h) Define quick return ratio. Give approximate value of quick return ratio of shaper.
i) Why quick return mechanism is required in shaper? Name some other machine tool which also
operates on quick return mechanism.
j) How is cutting stroke and is position of stroke adjusted in shaper machine?
k) What is the function of rat chat pawl mechanism in shaper?
l) How shaper is different from planner and slotter machine.
61
Jaipur

1.0 TITLE OF THE EXPERIMENT
To prepare a job on a shaper as per given drawing.
2.0 LEARNING OBJECTIVES:

 To set the given workpiece horizontally using spirit level on machine vise.
 To practice the manual feed motion on shaper.
 To regulate the feed so as to attain required surface finish.
 To prepare a step in the job as per given drawing.
3.0 INPUTS REQUIRED

A shaper machine, tooling, machine vise, try square, spirit level, safety goggles, apron,
brush etc.
4.0 PROCESS SEQUENCE

(i.) Place the given workpiece horizontally on the shaper table using spirit level and packing (if required).
(ii.) Set the required depth of cut using the tool head.
(iii.) Start giving uniform feed so as to produce a smooth flat surface.
(iv.) Align the workpiece from other face keeping in view of perpendicularity of faces.
(v.) Repeat the above steps to get the four faces finished with required perpendicularity.
(vi.) Process the job to achieve the required step as per given dimensions in drawing.
5.0 RESULT: The given workpiece has been produced as per given drawing.
******
62
Jaipur
Experiment 8(a,b): Pre Experiment Assignment
Aim: To study shaper machine, its mechanism and calculate quick-return mechanism of shaper machine.
1) Write the name of parts of shaper
2) Name the mechanism of shaper.
3) Define quick return ratio for shaper.
4) Name other machine tools which have similar mechanism like shaper.
5) Give industrial uses of Shaper machine.
6) Write specifications of Shaper machine.
63
Jaipur
EXPERIMENT NO. 09
1. TITLE: Demonstration of cylindrical grinding using grinding attachment in a centre lathe.
2. INPUTS REQUIRED
 Materials: Machined mild steel bar or lathe centre, grinding wheel of proper grade and size, lathe
centres, spanner set.
 Machine required: centre lathe machine and tool post grinder.
The tool post grinder is a portable grinding machine that can be mounted on the compound rest of a lathe in
place of the tool post. It can be used to machine work that is too hard to cut by ordinary means or to machine
work that requires a very fine finish. Figure 1 shows a typical tool post grinder. The grinding wheel takes the
place of a lathe cutting tool. It is used for external, internal & taper grinding of shafts, mandrels, sleeves and
centres.
Figure 1: Tool Post Grinding Attachment on Lathe
3. STEPS INVOLVED IN CYLINDRICAL GRINDING

i) Measure the size of work piece and determine the grinding depth to obtain final size after grinding.
ii) Mount the work piece on lathe chuck in head stock or between lathe centres powered with dogs.
iii) Mount the tool post grinder and adjust the centre of the grinding spindle to the centre height of the
lathe spindle.
iv) Mount the proper grinding wheel, trued and dressed accurately to profile required.
v) Set a slow spindle speed of the lathe.
vi) Start the lathe with spindle revolving in reverse direction to that of grinding wheel.
vii) Start the grinding wheel until it sparks lightly against the revolving work piece.
viii) Traverse the lathe table slowly and grind up the work piece. The traverse speed should be such that
the work travels one fourth of the width of grinding wheel for each rotation of work.
ix) Measure each end of work for size and taper. If taper exists adjust the wheel so that it grinds parallel.
x) After work is set parallel, set the cross feed graduated dial to ZERO.
xi) Feed the work into the grinding wheel approximately 0.02mm per pass until the work is within 0.02
mm of finished size. Feed the wheel until proper size is achieved.
64
Jaipur
4. OBSERVATIONS
Table: 1 Specifications of Lathe Tool Post Grinder
S.No. Particulars Size
1. Make & Type
2. Model No.
3. Size of Grinding Wheel
4. Motor HP, RPM Phase
5. External grinding wheel speed
6. Spindle diameter (mm)
7. Power Transfer
8. Max. tool post diameter capacity
Table2. Operational parameters

S.No. Particulars Values
1. Spindle speed of Lathe
2. Grinding wheel RPM / cutting speed (mps)
3. Feed rate
Table3. Results
S.No. (mm)
1. Initial Diameter of work piece =
2. Final Diameter of work piece =
3. Grinding depth achieved =
5. PRECAUTIONS
i) Centre the tool post spindle before starting the grinding operation.
ii) Turn tool post grinder on and off alternately, until the abrasive wheel is brought up to top speed.
iii) Dress & true the grinding wheel before operation.
iv) Ensure that work piece rotates opposite to grinding wheel.
v) Do not allow the abrasive wheel to feed entirely off the centre.
vi) To produce a good finish, reduce the feed rate and the depth of cut to 0.0005 inch.

a) Why grinding is required sometimes on machined surfaces?
b) Give the machining tolerances achieved by grinding operations.
c) Give the value of surface finish achieved by grinding.
d) What do you mean by truing of grinding wheel?
e) Why dressing of grinding wheel is essential?
f) How is dressing of grinding wheel done?
g) Give the classification of grinding wheel.
h) Which type of grinding wheel is preferred for cylindrical grinding?
i) Explain the settings required to perform cylindrical grinding on lathe?
65
Jaipur
Experiment 9 : Pre Experiment Assignment
Aim: Demonstration of cylindrical grinding using grinding attachment in a centre lathe.
1) Write applications of tool post grinder.
2) Name the types of abrasive wheels used for grinding purpose.
3) Write specifications of tool post grinder.
4) What do you mean by dressing of grinding wheel and how it is done?
5) Write the specification / designation of grinding wheel used in your laboratory.
66
Jaipur
Experiment No. 10
Demonstration and study of a capstan lathe and its tooling.

i. To understand the construction features and working principle of capstan lathe.
ii. To differentiate between capstan lathe and a centre lathe.
3.0 CHARACTERISTICS OF SEMI-AUTOMATIC (CAPSTAN) LATHE

1. Some major auxiliary motions and handling operations like bar feeding, speed change, tool change
etc. are done quickly and consistently with lesser human involvement.
2. The operators need lesser skill and putting lesser effort and attention 9 Suitable for batch or small lot
production.
3. Costlier than centre lathes of same capacity.
Schematic of a Capstan Lathe
DIFFERENCE BETWEEN CAPSTAN LATHE & CENTRE LATHE

Capstan lathe, in contrast to centre lathe
1. Are semiautomatic.
2. Possess an axially movable indexable turret (mostly hexagonal) in place of tailstock.
3. Holds large number of cutting tools; upto four in indexable tool post on the front slide, one in the rear
slide and upto six in the turret (if hexagonal) as indicated in the schematic diagrams.
4. Are more productive for quick engagement and overlapped functioning of the tools in addition to
faster mounting and feeding of the job and rapid speed change.
5. Enable repetitive production of same job requiring less involvement, effort and attention of the
operator for pre-setting of work–speed and feed rate and length of travel of the cutting tools.
6. Are relatively costlier.
7. Are suitable and economically viable for batch production or small lot production
67
Jaipur
4.0 RESULT: We have studied constructional features and characteristics of a capstan (semi-automatic)
lathe.
4.1.1 How is capstan different from centre lathe machine?

4.1.2 Name the important parts of capstan lathe?
4.1.3 What is function of turret head?
4.1.4 For which type of jobs, is capstan lathe used for?
4.1.5 How is job bar hold in capstan lathe?
4.1.6 How is tool sequence and position adjusted in capstan lathe?
4.1.7 What are the benefits of using capstan lathe?
68
Jaipur
Aim: Demonstration and study of a capstan lathe and its tooling and preparation of a tool layout.
1) Give names of different types of lathes available in your laboratory.
2) Give three differences between centre lathe and capstan lathe.
3) How many tools can be mounted on centre lathe tool post?
4) How many tools can be mounted on capstan lathe tool turret?
5) Which type of chuck is used in Centre lathe & Capstan lathe.
6) Write specifications of Capstan lathe.
69
Jaipur
EXPERIMENT No. 11
1. TITLE OF THE EXPERIMENT:
To prepare mould of a given pattern requiring core and to cast it in Aluminium.
2. GROUP NO. GROUP MEMBERS:
3. INPUTS REQUIRED: A pattern, core box, moulding boxes, moulding sand, parting sand, facing sand, muffle
furnace, Al ingots, foundry tools and accessories.
Fig. 1 Schematic of job, pattern and mould
4. THEORY:
The two piece pattern is split into two parts so that one part is in drag and other in the cope. The split surface of
the pattern is the same as the parting plane of the mould. The two halves of the pattern are aligned properly by
making use of dowel pins, which are fitted in the cope half. A core is made up of sand material and is used for
making cavities and hollow projections which cannot be produced by pattern alone. The core prints are provided
on the pattern so that the cores are securely and correctly positioned in the mould cavity. The design of the core
print is such that it sustain the weight of core and upward metallostatic pressure of molten metal. The core print
should also ensure that the core is not shifted during entry of the molten metal into cavity.
5. OPERATING INSTRUCTIONS:
Steps used to prepare a casting are shown in Figure
a) Obtain the drawing of the pattern.
b) Place the drag flask upside down on the moulding board and put one half of the pattern in inverted position in the
board.
c) Sprinkle parting sand over the pattern and moulding board o facilitate easy removal of the pattern from the
mould.
d) Fill the drag with the moulding sand and ram it properly using peen and floor rammer.
e) Scrap off excess sand with a straight bar called strike-off-bar.
70
Jaipur
f) Turn the drag flask by 180o and place the other half of the split pattern on the part already in drag and ensure
proper alignment using dowel pins.
g) Mount the cope onto the drag and check their alignment using alignment pins.
h) Place sprue and riser pins approximately 25 mm on either side of the pattern.
i) Repeat steps from (b) to (d) and Cut the pouring basin adjacent to the sprue pin.
j) Use vent wires to do holes so that gases can escape through them and remove the sprue and riser pins carefully.
k) Lift the cope from the drag carefully and place it aside. And take out the pattern from the drag using draw spike
and mallet. Before drawing the pattern the sand around it is moistened with a swab so that edges of the mould
remain firm when the pattern is withdrawn.
l) Cut the gate and runner by using rubber cutter in the drag, connecting the mould and the sprue opening.
m) Prepare the core in core box and place it in the mould cavity to produce the hollow casting.
n) Assemble the mould by carefully placing the cope over the drag.
o) Melt sufficient quantity of Al in the muffle furnaces.
p) Pour the molten Al in the pouring basin carefully till it is seen coming out from the riser.
q) Allow the casting to solidify for few hours.
r) Remove the cope and get the solidified casting from the sand mould.
s) Clean the casting by removing sand dust and cutting riser, runner, sprue etc.
6. RESULT: A mould requiring core has been prepared and casted as per the given drawing.
7. PRECAUTIONS:
a) Care must be taken while using foundry tool especially rammer.
b) Location of sprue, riser and pattern in the mould must be decided at the first stage.
c) Avoid hard ramming.
d) Flask must be properly aligned.
e) Split pieces of pattern should be correctly aligned in the mould.
f) Drawing of pattern from the sand mould must be done cautiously
g) Molten metal should be handle carefully.
h) Avoid any contact of molten metal with water.

i. Draw the sketch of mould and label its parts.
ii. Explain function of riser?
iii. Why vent holes are provided in mould?
iv. Give composition of moulding sand.
v. Prepare the list of foundry tools.
vi. Define pattern? What are pattern materials?
vii. Name products made by casting.
71
Jaipur
viii. What is core? How it is prepared?
ix. Name the allowances used on pattern.
x. What is fettling?
72
Jaipur
Aim: To prepare mould of a given pattern requiring core and to cast it in Aluminium.
1. Write the names of primary manufacturing processes and secondary manufacturing processes used to obtain
shapes and features of a product.
2. Give examples of products made by casting process.
3. Give two principle advantages of casting process over forming, machining and joining processes.
4. Recall and write the name of tools used by you in foundry shop during first year.
5. Write the constituents of moulding sand .
6. Write names of different types of pattern used in foundry shop.
7. What is a parting line?
73
Jaipur

To conduct the moisture test in a given sand sample using Moisture Meter.
2. INPUTS REQUIRED
A moisture teller, sand specimen, powdered calcium carbide (CaC2) etc.
3. THEORY
There can be two methods to determine the moisture content in a given sand sample:
(i) Moisture content may be determined by the loss of weight, after evaporation. a sample of molding sand
weighing 50gms is dried at 110° to 115°, and then cooled to room temperature in desiccation and re-weighed.
The difference in weight before and after heating gives the moisture content in thesample.
% Moisture content=loss of weight in sample X 100/weight of sample

before heating
We can also use a “moisture teller” (dry-type) for this purpose. In this suspending the sample on a fine metallic
screen and allowing hot air to flow through the sample dry the sand. This method of drying is fast (takes few
minutes) as compared to previous method (which takes 2 hours to dry out the sand)
(ii) There can be another moisture teller (chemical-type) that uses CaC2 to measure the moisturecontent
CaC2+2H2OC2H2 + Ca(OH)2 ( acetylene raises pressure of vessel,

pressure gauge is used to measure it.)
4. OPERATING INSTRUCTIONS
(i) Transfer the sand sample (taken in appropriate amount) in the tester.
(ii) Take two spoons of absorbent compound (CaC2 in this experiment) and transfer into the body of the tester.
(iii) Hold the body horizontally and place the cap in position. Bring the clamp in position and tighten the cap
with screw.
(iv) Shake the instrument vigorously to ensure that the sand sample and CaC2 are intimatelymixed.
(v) Observe and note the reading of the pointer of the gauge (when it stabilizes).
(vi) The reading will give the percentage of moisture in the sample directly.
(vii) Unscrew the handle and take out the cap. Throw away the used material and clean the instrument for
subsequent test.
5. RESULT: Thee percentage of moisture in the given sand specimen was found to be ………percent.
74
Jaipur
CONCLUSIONS:
6. PRECAUTIONS
1. Clean the instrument before and after the use.
2. Do not expose sand sample in the atmosphere.
3. Do not keep the absorbent (CaC2) compound exposed to atmosphere.
4. Keep the entire instrument in the box and close the box after required tests.

a) How the of dry compression strength (in MPa) of sand varies with the amount moisture content.
b) Discuss how the moulding sand characteristics varies with the amount of moisturecontent:
(i)Permeability (ii) Compression Strength (iii) Density.
c) What will happen if moisture content of sand is high?
d) What defects may arise due to high moisture content of sand?
****
75
Jaipur
Experiment 12(a, b) : Pre Experiment Assignment
Aim: To conduct the moisture test & clay content test in a given sand sample using Moisture Meter.
1. Name the foundry sand which contains moisture……………………………………………
2. Give the moisture content of moulding sand. ……………………………………………………
3. The function of moisture in moulding sand is ……………………………………………………
…………………………………………………………………………………………………….
4. Give the clay content of moulding sand. …………………………………………………………
5. What function does clay perform in moulding sand? ………………………………………..…..
6. Give chemical formulae of clay. …………………………………………………………………
7. Which chemical is required to wash away clay from the silica sand? …………………………..
8. How moisture of moulding sand can be measured directly?
…………………………………………………………………………………………………….
9. How we can control the moisture of mould?
…………………………………………………………………………………………………………
……………………………………………………………………………………………………..…..
10. What is calcium carbide? What precautions one must take care while handling calcium carbide?
……………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………
……………………………………………………………………………………
76
Jaipur
1. TITLE To determine the clay content in a given moulding sand.
2. INPUTS REQUIRED Jar, electric motor, sand sample and a muffle furnace.
3. PROCESS SEQUENCE
(i) The clay content of moulding sand is determined by dissolving or washing it off the sand. To determine the
clay percentage a 50 gm sample is dried at 105⁰C to 110⁰C and the dried sample is taken in a one liter glass
flask and added with 475 ml of distilled water and 25 ml of a one per cent solution of caustic soda (NaOH
25gm per liter).
(ii) The testing apparatus is of shape of a jar which is securely covered and sealed, and stirred at 60 rpm by electric
motor for few minutes.
(iii) After it, the sand adhering to cover or sides is washed into jar. After thorough washing, residue is dried and
reweighed. Actually residue is obtained only after ensuring that it settles into water up to a depth of 25mm in
5min.
(iv) The material which is not able to settle through 25mm depth in 5min is clay and should be washed away from
the jar.
(v) Repeat the steps (iii) and (iv) till all the clay is washed out from the sample.
(vi) Dry the sample in the muffle furnace and weigh it after drying.
4. OBSERVATIONS
Weight of the sample taken (W1) =
Weight of the sand sample after drying (W2) =
% of clay in the sample = (W1 -W2 X 100
5. RESULT: The clay content in the given sample of sand is found to be ……………
6. CONCLUSION:
*****
77
Jaipur
a) What is the effect of clay content in the sand properties? Show the variation of Green compression strength (in
MPa) of sand with the amount clay content.
b) State the detriment caused to the mould properties if the moulding sand contains too much clay.
c) Give the chemical composition of clay.
d) Name some casting defects that may arise due to high clay content.
e) Give approximate value of clay content to be maintained in mould.
78
Jaipur
1. AIM: To determine the permeability of green moulding sand.
2. GROUP NO. GROUP MEMBERS:
3. INPUTS REQUIRED: Permeability Tester, Standard sand specimen, sand ramming

machine, beaker, furnace etc.
4. THEORY: Permeability is defined as that physical property of the molded mass of sand
mixture which allows gas to pass through it. It is determined by measuring the quantity of air
that passes through a given sample of sand in a prescribed time and under standard condition.
Permeability of molding sand depends on several factors including shape of sand grains,
fineness, degree of packing, moisture content and amount of binder present. Hence, coarse
grained sands are more permeable than finer ones.
Permeability No. is obtained by : PN = 50.128 / T(minutes)
5. CONSTRUCTION OF PERMEABILITY TESTER:
The apparatus used for determining permeability of sand shown is figure1. consists of the
following:
6. STANDRAD SAND SPECIMEN PREPARATION

The specimen be prepared by a laboratory sand rammer is used along with a specimen tube.
The measured amount of sand is filled in the specimen tube, and a fixed weight of 6.35 to
7.25Kg is allowed to fall on the sand three times from a height of 50.8 ±0.125 mm. The
specimen thus produced should have a height of 50.8± 0.8 mm. To produce this size of
specimen usually sand of 145 to 175 g would be required.
Jaipur
7. PROCEDURE FOR PERMEABILITY TEST:

To determine permeability, the AFS Standard sand specimen of 5.08 cm (2 inches) diameter
and 5.08 cm in height prepared by ramming the required quantity of sand is placed in the
mercury cup of the permeability meter. The air drum is raised to take 2000 cm3 of air in to
the air drum which will be indicated by the graduation on it. The whole air is then allowed to
escape through the sand specimen with a pressure of about 10 g /cm2 and the time(minute) is
recorded.
8. OBSERVATIONS:
 Orifice size: …………………..
 Condition of sand: green sand / dry sand
S.No. Manometer Time (min) Permeability Average

Reading (g/cm2) Number PN
PN
1.
2.
3.
9. RESULT: The average permeability number of sand is …………..

10. CONCLUSIONS
11. SOURCES OF ERROR
 Air and water leakage in the apparatus.

 Air leakage through specimen in mercury cup
 Choking of valve

12. VIVA-VOCE QUESTIONS
a) Define permeability. Why it is considered as important property for casting?
b) On what factors does permeability of sand depend?
c) Deduce the formula for permeability number.
d) What is the value of PN in medium size casting?
e) How you can control the permeability of sand?
f) What defects you expect due to poor permeability of sand?
Jaipur
Experiment 13(a, b) : Pre Experiment Assignment
Aim: To determine the permeability and green and dry strength of moulding sand.
1. Define permeability of moulding sand.
2. How is permeability of moulding sand measured?
3. Write formulae to calculate permeability.
4. Define green mould strength, dry mould strength, shear strength.
5. Give the permissible values for green mould strengths & dry mould strength.
Jaipur

To perform Strength Tests (compressive and shear) in green and dry conditions and conduct Hardness Test
of mould and core.
2.0 Inputs: Universal Sand Strength Tester, Ramming machine, mould hardness tester, sand sample.
THEORY
Basic Terminology
The strength of a mould in a foundry industry can be determined both for green and dry conditions.
Following are the key terms and terminologies used in this experiment:
a) Green compression strength: or simply green strength refers to the stress requiredto rupture the
sand specimen under compressive load. It generally ranges in 30 to160 kPa.
b) Green shear strength: It refers to the stress required to shear the sand specimen along the axis under
load. It generally ranges in 10 to 50 kPa.
c) Dry strength: the test similar to above carried on sand specimen dried between 105to 110 C for 2 hours.
Dry strengths are greater than green strength. Dry compressionstrength ranges from140 to 1500 kPa.
 Mould Hardness: Mould and core hardness can be found out by the Mould Hardness Tester. A steel
ball of 50 mm diameter weighing 237 gm is pressed on the mould surface. The depth of penetration of
steel ball will give the hardness of mould surface on the direct reading dial. This hardness test is useful
in finding out the mould uniformity. The following are the moulding hardness numbers for Moulding
sand (1 number = 1/100 mm):
 Soft rammed moulds = 100

Medium rammed moulds = 125
Hard rammed mould = 175
Jaipur
Universal Strength Machine: The measurement of strength of moulding sand can be carried out on a
Universal Sand Strength Testing Machine. The strength can be measured in tension, compression and shear.
The sands that could be tested are green sand, dry sand and core sand. A standard sand specimen is prepared
by using a sand rammer.
(a) Compression pads (b) Shear pads
4. PROCEDURE OF SAND STRENGTH TESTING
Preparing the standard sand sample (specimen)
i. Ensure that the presetting of the sand rammer has been done properly prior to its further use.
ii. Place the specimen tube in the pedestal cap. Take approximately 150 g of sand and transfer it in
the specimen tube. Lift the plunger by using lifting cam and place the specimen tube along with
the pedestal cap at the bottom and carefully insert the plunger of the rammer into it.
iii. Make sure that the boss on the pedestal cap is located in the hole on the rammer base. Lower the
plunger by operating the lifting cam and allow the plunger to move downward in the tube.
iv. Turn the ramming cam handle and allow the weight to fall on the sand in the specimen tube.
v. Repeat this for 3 times to get rammed sand specimen. The top of the plunger rod will level with
the center tolerance line ―0‖ on the scale when the height of the test specimen will be exactly 50
mm. (However, if the top of plunger rod lies between plus (+) and minus (-), it is still acceptable.)
vi. Lift the plunger by means of lifting cam. Take out the specimen tube with specimen.
vii. For removing the specimen from the tube, place the tube with the rammed sample inverted over
the stripping post and pull the tube slowly downwards. The sample will slide out of the tube and
Jaipur
rest on the stripper.
Procedure for Compressive strength
(i) Ensure that the presetting of the strength machine has been done prior to its further use.
(ii) Place the standard sand specimen of dia. 50 mm X 50 mm height.
(iii) Place the compression pads so that the plain surfaces of the specimen touch against
the pads.
(iv) Rotate the wheel clockwise until the load starts applying on specimen (this will be seen by
movement of the pressure gauge needle) and then uniformly at about 16 RPM till the specimen
collapses.
(v) Note the red pointer reading on the C.S. (compression scale)
(vi) Take minimum three readings from the sand sample by repeating steps (ii) and (v).
Procedure for Shear strength
i. Replace the compression pads with a pair of shear pads.

ii. The test is conducted in the same manner as compression test except that the shear strength of the
specimen is read on the shear scale (S.S.) of the gauge.
Procedure for mould hardness
(i.) Prepare moulding sand by mixing silica, clay, bentonite, molasses and water in required amount.
Mixing has to be done in muller or by hand tools.
(ii.) Prepare and green sand mould of a given pattern by using foundry tools. Do not create vent holes.
Hold the sand hardness tester vertically and press it on the mould and note the reading of the dial.
(iii.) Repeat the readings at number of location on the face of same mould.
(iv.) Take the average of the reading as mould hardness.
5. OBSERVATIONS
A. Green Compressive strength
S.No. Gauge reading on the Compressive Strength

Compression Scale (g/cm2)
1.
2.
Average
Jaipur
B. Green Shear strength
S.No. Gauge reading on the Shear Strength (g /cm2)

No. Shear Scale
1.
2.
Average
C. Mould Hardness
S.No. Hardness Number

1.
2.
3.
6. RESULT
 The compressive strength of sand sample = .......................................... g/ cm2.
 The shear strength of sand sample = ...................................................... g/ cm2.
 The mould Hardness value of sample = …………………………….
CONCLUSION:
7. PRECAUTIONS
i. Moulding sand ingredients must be mixed thoroughly before preparing mould.

ii. High moisture content can affect the hardness reading.
iii. Always try to prepare sand mould by uniform ramming at all sections of the mould.
iv. Check the zero errors in the hardness tester.
v. Keep the hardness tester vertical during testing.
vi. Do not repeat the test on the same point at mould.
vii. Ensure mould is kept on hard and flat surface during test.
Jaipur
a) Define the green mould tensile, compression strength and shear strength.
b) What is the effect of clay content in the sand strength and hardness? Show the variation
of green compression strength (in MPa) of sand with the amount clay content.
c) Show the variation of various strength of moulding sand with % moisture content.
d) Suggest methods to increase the strength of mould.
*******
Jaipur
EXPERIMENT No. 14

To perform the A.F.S. Sieve Analysis test of a given moulding sand.
2. EQUIPMENTS TO BE USED
(i) Set of sieves: 16, 22, 30, 44, 60, 100, 170, 200, 300, Pan (9 sieves and the Pan)
(ii) Sieve shaker machine.
(iii) Weighing balance to measure the mass of samples.
3. INTRODUCTION:
Sieve analysis or Grain-size analysis is conducted to determine the size distribution and fineness of
sand. It is a process in which the proportion of material of each grain size present in a given soil (grain-
size distribution) is determined.
AFS number = (Total of % weight retained x multiplier )/ 100
4. TECHNICAL SPECIFICATIONS:
(i) 9 sieves and a pan
(ii) Diameter of sieve (size of sieve) = 230 mm
(iii) Vibratory motor of 1400 rpm & 1/7 HP
(iv) Total height of apparatus = 1060 mm.
(v) Table for arrangement of sieves:
Sl. No.
(top to bottom) 1 2 3 4 5 6 7 8 9 pan
Sieve No. 16 22 30 44 60 100 170 200 300

Jaipur
5. PROCEDURE:
It is assumed that the sand has already been disaggregated and that the clay and mud, if present in
considerable amounts have been removed. Thus clay free and dry sand is used. The stepwise procedure
is as mentioned below:
a) Clean the screens of the sieves carefully by turning the sieve face down and striking the table
evenly with the rim.
b) Arrange the screens in order, coarsest at the top, pan on the bottom. (16, 22, 30, 44, 60, 100,
170, 200, 300, Pan)
c) Weigh the sample of 100 grams.
d) Pour the sample into the top sieve and shake gently by hand. Place the cover on the arrangement.
e) Shake the sieves for 15 minutes on the sieve shaking machine.
f) Make sure you weigh the packet and record its weight on your observation table.
6. OBSERVATIONS:
a) Weight of sand used= 100 grams

b) Required time for vibrate the apparatus = 15 minutes
S.No. Mesh no. Weight retained Percentage weight Multiplier Product

in the sieve retained in the sieve
(I) (II) (III) (IV) (V) (VI) = (IV) x (V)
1. 16
2. 22
3. 30
4. 44
5. 60
6. 100
7. 170
8. 200
9. 300
10. Pan
Total Ʃ= Ʃ= Ʃ=
Percentage weight retained in the sieve = Weight (in grams) retained in a sieve x 100
Weight (in grams) of total sample
Grain Fineness Number = Total Product
Total sum of percentage sand retained by different sieves
7. RESULT: Grain Fineness Number of the given sand sample is =

Jaipur
8. CONCLUSION
9. PRECAUTIONS:
(i) Ensure to use clay free and dry sand for experiment.
(ii) The cleaning process of the screen on the sieves should be done carefully in order to remove all grain
sands.
(iii) Avoid contact the sieves screen with the fingers.
(iv) The stack of sieves on the Sieve Shaker must be locked tightly to avoid them from moving away
during the shaking process.
(v) Make sure the left over sand in each sieve is transferred to the container for use in weighing process.
(vi) Carefully measure the sand. Avoid any loss of sand during handling.
10. VIVA-VOCE QUESTIONS
a) Activity: Plot the Grain Distribution Chart with respect to Mesh No. on graph paper.
b) Give the value of GFN of sands which is generally used by most of the foundries.
c) What do you mean by grain size and grain size distribution?
d) Name the properties which are affected by grain size and its distribution.
e) Four samples of sand having GFN no as a) 41.00; b) 67.50; c) 105.34; d) 150.9. Give the typical use
of these sands in foundries.

Jaipur
Aim: To perform the A.F.S. Sieve Analysis test of a given moulding sand.
1. Define grain fineness number for moulding sand.
2. What does sieve number means?
3. Write formulae to calculate AFS number.
4. Write all the sieve numbers in order with their multipliers
5. Name the BIS standard followed for the experiment.

Jaipur
EXPERIMENT NO. 15
1. TITLE OF EXPERIMENT: To study Spot welding process and join the two metal sheets
using it.
2. INPUTS REQUIRED
1. Tongs
2. Welding Goggles
3. Welding Apron & gloves.
4. M.S. Sheet
5. SPOT welding machine - rocker arm type.
3. THEORY
Spot welding is a resistance welding process in which work pieces are welded due to a
combination of a pressure applied and localized heat generated by a high electric current flowing
through the contact area of the weld.
The heat generated is given by : H (Heat) = I2(Current) x R( Ohmic resistance) x t (Energized time)
Fig.: Principle of Spot welding

4. SPECIFICATIONS OF SPOT WELDING MACHINE
Type: Mechanical powered Rocker Arm type
Supply 415± 10% V; 3 phase; 50Hz
Load 10 KVA
Throat Depth 280 ~ 330 mm
Throat Clearance 190 mm
Output Current 3000 A
Clamping Force 128 kgf
Weight 230 kg
Jaipur
Fig. : Schematic sketch of a spot welding machine
5. JOB DRAWING
6. PROCEDURE OF SPOT WELDING

i. Prepare the work pieces as per drawing. The two work pieces to be joined are cleaned to
remove dirt, grease and other oxides either chemically or mechanically to obtain a sound
weld.
ii. Typically the sheets are to be in the 0.5 to 3 mm thickness range. Mark the position of
spot on sheet using scriber and marking punch.
iii. The work pieces are then overlapped and placed firmly between two water cooled
cylindrically shaped copper alloy electrodes, which in turn are connected to a secondary.
iv. Check the position of work piece between electrodes. In operation, the welding current is
switched ON. As the current passes through the electrodes, to the work piece, heat is
generated in the air gap at the point of contact of the two work pieces. The heat at this contact
point is maximum with temperature varying from 815-930° celcius, and as a result melts the
work pieces locally at the contact point to form a spot weld.
v. In order to obtain a strong bond, external pressure is applied to the work piece, through the
electrode, by means of a piston-cylinder/ mechanical pressing arrangement. The current is
switched OFF.
vi. In some cases, external pressure is not required and the holding pressure of the two electrodes
Jaipur
is just sufficient to create a good joint.
vii. Heat dissipates throughout the work piece which cools the spot weld causing the metal to
solidify. The pressure is released and the work piece is moved to the next location to make
another spot weld.
7. RESULT: We have studied the construction and working of a spot welding machine. The
work pieces of G.I. sheet of thickness SWG 20 are joined by spot welding.
8. SAFETY PRECAUTIONS
i. Spray of molten metal droplets (sparks) may be ejected from the area of the weld during
theprocess. So wear leather apron and gloves while working with spot welding machine.
ii. Spot welding generate spark and intensive light so eye protection is required. Welding
goggles with a 5.0 shade are recommended.
iii. Forcing a large current through the spot for longer duration will melt the metal and form
cavity in the sheets. It will also damage the electrodes.
iv. Proper cooling of electrode is required during operation.
v. Applying too little energy will not melt the metal or will make a poor weld. Applying too
much energy will melt too much metal, eject molten material, and make a hole rather than a
weld.

a) Explain principle of spot welding.
b) Discuss the welding parameters of spot welding.
c) Give some examples of products where you are able to identify the spot welding.
d) Discuss the advantages and disadvantages of spot welding.
e) Name the metal of which electrodes of spot welding machine made up.
f) Why cooling of electrode necessary?
g) Why electrodes are conical tipped shape?
Jaipur
Jaipur

AimTo study Spot welding process and join the two metal sheetsusing it.
1. Name the different types of fusion welding process.
2. Explain the principle of resistance spot welding.
3. What is nugget?
4. Which metals can be easily joined by spot welding?
5. Name the material of electrodes of spot welding machine?
6. Why coolant is required in spot welding machines?
7. How you will select the current settings in spot welding?

Jaipur
EXPERIMENT No. 16(a)(Beyond curriculum)

1. TITLE OF THE EXPERIMENT: Study and demonstration of tungsten inert gas welding (TIG).
2. INPUTS REQUIRED
i. MS flat 30 x 60 X 3 (mm) ------- 2 Nos.
ii. Tungsten Electrode diameter ..................................... (1.6, 2.4, 3.2 mm)
iii. Mild steel filler rod diameter ................................. ( 2.4mm, 3,2mm 4.6mm)
iv. Tongs, Chipping hammer
v. Welding Screen, Welding Apron & gloves.
vi. TIG WELDING SET & TIG torch
vii. Argon gas cylinder
viii. Regulator, Flow meter and pressure gauges
3. INTRODUCTION: Tungsten inert gas (TIG) welding, also known as Gas tungsten arc
welding (GTAW), is an arc welding process that uses a non-consumable tungsten electrode to
produce the weld. TIG welding process uses an electric power source, a shielding gas and a
TIG hand torch. The power is fed out of the current power source, to the TIG hand torch and is
delivered to a tungsten electrode which is fitted into the torch. An electric arc is then created
between the tungsten electrode and the work piece. The tungsten and the welding zone is
protected from the surrounding air by an inert gas(Argon or Helium) shielding which is
delivered from gas cylinder through the torch. A filler metal is normally used, though some
welds, known as autogenous welds, do not require it. The electric arc can produce
temperatures of up to 7000°C to 15000°C. The weld pool can be used to join the base metal
with or without filler material. The TIG welding process can be used for the joining of a
number of materials though the most common ones are Aluminum, Magnesium and Stainless
Steel.
Figure 1: TIG Welding Set-up

Jaipur
4. PROCEDURAL STEPS:
i. Prepare the edges of the work pieces to be joined to the required V shape.
ii. Finish the edges using emery paper.
iii. Place the work pieces on the work table in the required position.
iv. Set the current of the machine to 80 TO 100 A.
v. Fix the tungsten electrode to the electrode holder.
vi. Required size of the nozzle is selected and it is fixed to the torch.
vii. Adjust the inert gas flow rate to the required rate.
viii. Select the filler rod (same as base metals) of required diameter.
ix. Touch the electrode to the work, so that current flow will be established and then separated by a
small distance and the arc will be generate.
x. First tack weld is done on the work pieces.
xi. Move the electrode slowly along the length of the joint with the filler rod, so that the fillermetal
will be deposited in the joint.
xii. Repeat the operation for the second pass, so that required amount of filler metal will be deposited
on the work pieces.
5. RESULT: Thus we have studied the TIG welding process and prepared a butt joint using TIG
welding.
6. PRECAUTIONS
i. Never look at the arc with the naked eye. Always use a shield while welding.
ii. Always wear the safety hand gloves, apron and leather shoes.
iii. Ensure proper insulation of the cables and check for openings.
iv. Select the parameters of the machine properly based on the metals to be welded.
v. Set these parameters properly before performing the operation.
vi. Inflammable and combustible materials are removed from the vicinity of
welding operations.
7. POST EXPERINMENT VIVA-VOCE QUESTIONS
i. Differentiate between TIG, MIG and MAW.

ii. Give applications of TIG.
iii. Why nozzle is required in the TIG torch?
iv. How is Tungsten rod tip prepared?
v. Name the metals which can be joined by TIG.
vi. Give advantages of TIG over electric arc welding.
vii. Give disadvantages of TIG over MIG welding.
viii. Name the components of TIG torch.
ix. Give the sizes of tungsten electrodes available.
Jaipur
x. Name the gases used in shielding (i) Aluminum (ii) Stainless Steel (iii) Mild steel.
xi. How you will identify the TIG electrode type?
xii. How can we check the diameter of TIG electrode?
xiii. Give the temperature of TIG welding zone
Jaipur
EXPERIMENT No. 16(b) (Beyond curriculum)
1. TITLE OF THE EXPERIMENT: Study and demonstration of metal inert gas (MIG) welding.
2. INPUTS REQUIRED:
(i) MS flat 30 x 60 X 3 mm3 ( 2 Nos.)

(ii) Filler wire (mild steel)
(iii) Tongs, Chipping hammer
(iv) Welding Screen, Welding Apron & gloves.
(v) MIG WELDING MACHINE
(vi) Welding Tables with fixtures
3. THEORY
MIG welding, also referred as Gas Metal Arc Welding (GMAW), uses a consumable
electrode and is known for its high deposition rate characteristics. In MIG welding, an arc is
established between a continuous wire electrode (which is always being consumed i.e. filler)
and the base metal. A continuous electrode (thin wire filler) is fed by powered feed rolls (wire
feeder) into the weld pool. The filler material is usually the same composition (or alloy) as the
base metal. An electric arc is created between the tip of the wire and the weld pool. The wire
is progressively melted at the same speed at which it is being fed and forms part of the weld
pool. Commonly spray metal transfer is used in MIG. Since molten metal is sensitive to
oxygen in the air the arc and the weld pool are protected against atmospheric contamination
by a shield of inert (non-reactive) gas. Welding parameters include the voltage, travel speed,
arc (stick-out) length and wire feed rate. The arc voltage and wire feed rate will determine the
filler metal transfer method.
4. DESCRIPTION OF METAL INERT GAS WELDING SETUP

To perform gas metal arc welding, the basic necessary equipments required are:-
a) Welding gun
b) Wire feed unit
c) Welding power supply
d) Electrode wire
e) Shielding gas supply
Jaipur
5. PROCEDURE
i. Prepare the edges of the work pieces to be joined to the required V shape.
ii. Finish the edges using emery paper.
iii. Place the work pieces on the work table in the required position and clamp.
iv. Set the current of the machine to 50A TO 80 A.
v. The gun nozzle size and the shielding gas flow rate should be set according to the recommended
welding procedure for the material and joint design to be welded.
vi. Select the filler wire (same as base metals) of required diameter from chart.
vii. The electrode feed rate and welding voltage are set to the recommended values for the electrode
size and material.
viii. Touch the electrode to the work, so that current flow will be established and then separated by a
small distance and the arc will be generated. The position of the electrode with respect to the weld
joint is important in order to obtain the desired joint penetration, fusion, and weld bead geometry.
ix. A trial bead weld should be made to establish proper voltage (arc length) and feed rate values.
x. First tack weld is done on the work pieces.
xi. Move the electrode slowly along the length of the joint with the filler rod, so that the filler metal
will be deposited in the joint.
xii. Repeat the operation for the second pass, so that required amount of filler metal will be deposited
on the work pieces.
xiii. After completion switch off the equipment.
6. RESULT: Thus we have prepared a welded joint using TIG welding.
7. PRECAUTIONS
(i) Never look at the arc with the naked eye. Always use a shield while welding.
(ii) Always wear the safety hand gloves, apron and leather shoes.
(iii) Ensure proper insulation of the cables and check for openings.
(iv) Select the parameters of the machine properly based on the metals to be welded.
(v) Set these parameters properly before performing the operation.
Jaipur
(vi) Inflammable and combustible materials are removed from the vicinity of welding operations.
8. POST EXPRIMENT VIVA-VOCE QUESTIONS
(i) Give advantages & applications of MIG welding.
(ii) Explain metal transfers modes in MIG welding.
(iii) Discuss the various welding parameters in MIG welding.
(iv) How MIG is superior to TIG welding
(v) Name the equipments, tools and parameters required for MIG welding.
(vi) Discuss problems encountered in MIG welding.
(vii) How is feeding rate of wire adjusted?
(viii) What is the role of inert gas in MIG welding?
(ix) Which gas is generally used in MIG of steels?

4ME4-23 - Production Practice Lab

Uploaded by

Copyright:

Available Formats

4ME4-23 - Production Practice Lab

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4ME4-23 - Production Practice Lab

Uploaded by

Copyright:

Available Formats

Swami Keshvanand Institute of Technology, Management & Gramothan,

Ramnagaria, Jagatpura, Jaipur-302017, INDIA

SWAMI KESHVANAND INSTITUTE OF TECHNOLOGY,

Department of Mechanical Engineering

4ME4-23 PRODUCTION PRACTICE LAB

B.Tech. IV Semester, Mechanical Engineering

4ME4-23 PRODUCTION PRACTICE LAB

[AS PER CHOICE BASED CREDIT SYSTEM (CBCS) SCHEME]

Number of Lecture Hrs / Week: 00 Exam Marks: 30

No of Practical Hours / Week: 03 Exam Hours: 03

Vision & Mission of Institute

Vision and Mission of Mechanical Engineering Department

 Departmental Safety Policy

RTU Syllabus –IV Semester. B.Tech. Mech. Engg.

Program Educational Objectives (PEOs) as applicable for course

Applicable POs for the course:

PO1 Engineering knowledge

PO2 Problem analysis

PO4 Conduct Investigations of Complex problems

PO6 The engineer and society

PSO2 Life-long learning

Programme: B.Tech. (Mechanical Engineering)

After completion of this course, students will be able to –

C4ME4-23.1 Exhibit understanding of the constructional features, working principle and

C4ME4-23.4 Measure various sand properties by performing sand moulding tests

COURSE: PRODUCTION PRACTICE (4ME4-23)

CO-PO/PSO Mapping: Formulation and Justification

𝑐𝑜𝑢𝑛𝑡 (𝐼𝑘, 𝑃𝑂𝑗)

2nd Year - IV Semester: B.Tech. : Mechanical Engineering (Session 2020-21)

Exp TITLE OF EXPERIMENT

6. The student should not lean on the machine when it is working.

9. Laboratory reports should be submitted on A4 size sheets.

11. Use of mobile phones is strictly prohibited in laboratory.

12. Tiffin and edible items are not allowed in laboratory.

OBJECTIVES OF LABORATORY WORK IN M.E. DEPARTMENT

Students will be able to:

SAFETY PRECAUTIONS TO BE TAKEN CARE OF

EXPERIMENT WRITEUPS / MANUALS RULES

EXPERIMENT No. 01(a)

1. TITLE OF THE EXPERIMENT

LATHE AND ITS WORKING PRINCIPLE

Figure1. Centre Lathe

SPECIFICATIONS OF LATHE: ( Fill this table for Lathe No. 5)

PARTS & ACCESSORIES OF A CENTRE LATHE

OPERATIONS ON LATHE MACHINE

Figure of Various operations on centre lathe machine

Facing and Turing

Fig. Different types of tools used in lathe

POST EXPERIMENT VIVA-VOCE QUESTIONS

a. Why lathe machine is called mother of all machines?

EXPERIMENT No. 01(b)

1. TITLE OF THE EXPERIMENT

3. Taper angle α = …… Compound slide must be set at correct

stock end) must be ensured to avoid tool breakage.

Post Experiment Viva-Voce Questions

i. Name the three different methods of taper turning.

Experiment 1 Pre Experiment Assignment

3) What is the proper method to start the lathe machine?

4) What is the proper method to stop the lathe machine?