Department of Industrial & Production

Engineering
Faculty of Engineering
American International University-Bangladesh

IPE-2214: Machine Tools Lab

Midterm
Experiment-1: Study on Different Parts of Surface Grinding Machine.
Experiment-2: Study on Various Operations of Surface Grinding Machine.
Experiment-3: Study on Different Parts of Radial Drill Machine.
Experiment-4: Study on Various Operations of Radial Drill Machine.
Experiment-5: Study of Gear Indexing and Manufacturing of a Spur Gear on a Knee Type
Milling Machine.

Final term
Experiment-6: Deep Drawing Operation by Manual Hydraulic Press Machine.
Experiment-7: Bending Operation by Manual Hydraulic Press Machine.
Experiment-8: Sheet Metal Bending by Rolling Machine.
Experiment-9: Study of Different Parts of Plastic Injection Molding Machine.
Experiment-10: Class Assignment/OEL on Various Topics of Machine Tools Laboratory.
Experiment-1: Study on Different Parts of Surface Grinding Machine.
Objectives: To study the constructional features of the Surface grinding machines
through drawing.

Surface Grinding Machine: The grinding process consists of removing material from the
workpiece using a rotating wheel that has a surface composed of abrasive grains. Grinding is
considered to be the most accurate of the existing machining processes, grinding processes are
used when high accuracies, close dimensional tolerances, and a fine surface finish are
required. Grinding processes also allow for high production rates. This allows for a lowered
cost of production. Hard materials can also be machined.

Surface grinding is most common of the grinding operations. A rotating wheel is used in the
grinding of flat surfaces. Types of surface grinding are vertical spindle and rotary tables.
Internal grinding is used to grind the inside diameter of the workpiece. Tapered holes can be
ground with the use of int
Cylindrical grinding is also called center-type grinding and is used in the removing the
cylindrical surfaces and shoulders of the workpiece. Both the tool and the workpiece are rotated
by separate motors and at different speeds. The axes of rotation tool can be adjusted to produce a
variety if shapes.
Common Grinding Wheels: A grinding wheel is made of abrasive grains held together by a
bond. These grains cut like teeth when the wheel is revolved at high speed and is brought to bear
against a work piece. The properties of a wheel that determine how it acts are the kind and size
of abrasive how closely the grains are packed together and amount if the bonding material.

THEORY: Surface grinding machines are employed to finish plain or flat surfaces. They are
also capable of grinding irregular, curved, convex and concave surfaces. There are basically
four types of machines depending upon spindle direction and the table motion.

(a) Horizontal spindle and rotating table.

(b) Vertical spindle and rotating table.
(c) Horizontal spindle and reciprocating table.
(d) Vertical spindle and reciprocating table.

The majority of surface grinders are of horizontal table type. In the horizontal type of Machine
grinding is done on the periphery of wheel. The area of contact is small, and speed is
uniform over the grinding surface. In the vertical type of surface grinders apply the face or
side of wheel and cupped, cylindrical wheels are used.
Principle Parts of Surface Grinding

1. Base: the base has a column at the back for supporting wheel head. The base also as
the drive mechanism.

2. Table: the table is fitted to the saddle on carefully machined ways. It reciprocates along
ways to provide the longitudinal feed. T-slots are provided in the table surface for clamping
work pieces directly on table or for clamping grinding fixtures or magnetic chuck.

3. Wheel head: the wheel head is mounted on the column. It has ways for vertical slide
can be raised or lowered with the grinding wheel only manually by rotating a hand wheel to
accommodate workpieces of different heights.

Size of Surface Grinder

Size of surface grinders arc specified by the size of rectangular table, maximum
distance from grinding wheel spindle to the table surface, grinding wheel diameter and
speed, automatic cross feed rate and vertical feed rate, longitudinal feed of table, grinding
wheel drive motor power and overall dimensions of machine.
Experiment-2: Study on Various Operations of Surface Grinding Machine.
Objectives: Become familiar with basic lathe operations.
Apparatus Required: Surface Grinding Machine, Grinding wheel.
Material Required: Work piece, Vice.
Theory: Surface grinding is basically an abrasive machining process. Abrasive machining is the
basic process in which chips are formed by very small cutting edges that is the integral part of
the abrasive particles. The results that can be obtained from abrasive machining like grinding
range from the finest and smoothest surfaces produced by any machining processes, in which
very little material is removed, to rough, coarse surfaces and accompany high material removal
rate(MRR). The abrasive particles may be (1) Free, (2) Mounted in resin on a belt, or (3) Close
packed into wheels or stones, with abrasives held together by bonding material called bonded
product. The metal removal process is basically the same in all three cases but with important
differences due to spacing of active grains and degree of fixation of grains. Different types of
abrasive machining includes:
 Grinding: It uses wheels as machining tool and provides accurate sizing, finishing and
low MRR.
 Abrasive Machining:Its MRR is high and used to obtain desired shapes and approximate
sizes.
 Snagging: High MRR, rough rapid technique to clean up castings, forgings.
 Honing: “Stones” containing fine abrasives are uses as tool, primarily a hole finishing
process.
 Lapping: Fine particles embedded in soft metal or cloth; primarily a surface-finishing
process.

An abrasive is a hard and tough substance. It has many sharp edges. An abrasive cuts or wears
away materials that are softer than it. So in abrasive machining abrasives are used as cutting
tools or materials. The following figure shows an illustration of a typical grinding machine. The
main parts of the machine are
1. Base/Bed
2. Column
3. Saddle
4. Table
5. Wheel guard
6. Wheel head
Properties of Abrasives:
 Penetration Hardness: This property refers to tire ability of the scratch or cut a softer
material.
 Fracture Resistance: This property refers to the abilityof an abrasive material to resist
breaking or cracking under load.
 Wear Resistance: It refers to the ability of the abrasive grain to maintain sharpness.
Wear resistance is largely related to penetration hardness and tensile strength of the
abrasive.

Types of Abrasives:
 Natural Abrasives: Natural abrasives are obtained from nature. They are being replaced
by artificial ones, Except for diamond, the natural abrasives are relatively soft in
comparison to artificial abrasives. Some of the natural abrasives are:
1. Crocus: Reddish-brown oxide of iron and may be natural or synthetic.
2. Emery: Composed of corundrum (A1203) and 40% iron oxide and other
impurities.
3. Diamond: The hardest material known, is used in the form of grains bonded
together to form an abrasive stick or grinding wheel.

 Artificial Abrasives: They are harder and have greater impact toughness than any
natural abrasives except diamond. The commonly used artificial abrasives are Silicon
Carbide, Aluminum Oxide, Boron Carbide, Synthetic diamond etc.

Grinding Wheels and Their Selection:

A grinding wheel is made of abrasive grains held together by a bond. These grains cut like teeth
when the wheel is revolved at high speed and is brought to bear against a work piece. The
properties of a wheel that determine how it acts are the kind and size of abrasive, how closely the
grains are packed together and amount of the bonding material.

Figure: Common types of grinding wheels

Cutting Action of Grinding Wheel:
Each abrasive grain in a grinding wheel is a cutting tool. Each has sharp cutting edge which
cutoff tiny particles from the metal being ground. The following figure shows a schematic view
of cutting action by grinding wheel.

Figure: Cutting action of grinding wheels

Classification of Grinding Operations:
 Rough Machining Operations: On abrasive-machining operations, metal is removed
more rapidly than on finish-grinding operations. It involves depth of cut 1.5mm or more.
 Finish Grinding: On finish-grinding operations, grinding wheels remove metal relatively
slowly in comparison with other cutting tools. Finish grinding usually follows other
rough machining slowly in comparison with other cutting tools. It usually follows rough-
machining operations, and generally involves machining to very close tolerance. Three
types of precision grinding exists
 External cylindrical grinding
 Internal cylindrical grinding
 Surface grinding

Surface grinding: It is most common of the grinding operations. A rotating wheel is used in the
grinding of flat surfaces. Types of surface grinding are vertical spindle and rotary tables.
Cylindrical grinding: is also called center-type grinding and is used in the removing the
cylindrical surfaces and shoulders of the workpiece. Both the tool and the workpiece are rotated
by separate motors and at different speeds. The axes of rotation tool can be adjusted to produce a
variety of shapes.
Turing of Grinding Wheels: A grinding wheel should be trued each time it is put on the
spindle. It should be dressed whenever it becomes dull, loaded or grazed with use. Turing refers
to correcting an out of round condition of the wheel. A dressing tool is used to remove particles
of the abrasive from the high part of wheel. Turing also refers to remove particles of the abrasive
from the high part of the wheel. Turing also refers to forming the wheel to a particular shape,
such as concave or convex. To be in good condition, the wheel must be sharp and run true on
both the periphery and the sides.
Dressing produces a sharp grinding surface. A diamond tool is used to remove the dull or loaded
surface of the wheel. Dressing is necessary whenever the wheel cuts poorly, usually resulting in
burning the work.
Calculation of Grinding Ratio:
Where,
D=Grinding wheel diameter
d= Wheel depth of cut
V= Tangential velocity
v= Workpiece velocity
t= Undeformed thickness (grain depth of cut)
Grinding ratio, G=Volume of material removed/Volume of wheel wear
Experiment-3: Study on Different Parts of Radial Drill Machine.
Objectives: To know about the different parts of radial drill machine.
Radial Drilling Machine
• It is the largest and most versatile used for drilling medium to large and heavy work pieces.
• Radial drilling machine belongs to power feed type.
• The column and radial drilling machine support the radial arm, drill head and motor. Fig.3
shows the line sketch of rad ial drilling machine.

Figure: Radial Drill Machine

 Base: The main aim of the base is to support the whole weight of the machine. In
addition, the cutting fluid is contained here and the Box Table is installed on.
 Gear box: It is the core part for the radial drill for all procession is finished here, like
speed switch, auto feed, spindle,,, etc. They are inside of the gearbox.
 Arm: It is to support the gearbox and is connected with the column.
 Column: It is to support the gearbox and the arm. It connects the base.
  Top Cover: It is at the top end of the Column. 6. Box table Working with clamps, it
enables to reach the required accuracy.
 The ball screw transmit ion motor and clamping mechanism: The motor is to elevate the
gearbox. The clamping mechanism is to clamp both the Arm and the Column

Tool Holding Devices

Fig below shows the different work holding. The different methods used for holding drill in a
drill spindle are
• By directly fitting in the spindle hole.
• By using drill sleeve
• By using drill socket
• By using drill chuck

Figure: Tool Holding Devices

Experiment-4: Study on Various Operations of Radial Drill Machine.

Objectives: To learn about different types of operations of radial drill
machine.

Drilling Operations

Operations that can be performed in a drilling machine are

➢ Drilling

➢ Reaming

➢ Boring

➢ Counter boring

➢ Countersinking

➢ Tapping

Drilling: It is an operation by which holes are produced in solid metal by means of revolving tool
called ‘Drill’. Fig. shows the various operations on drilling machine.
Reaming: Reaming is accurate way of sizing and finishing the pre-existing hole. Multi tooth
cutting tool. Accuracy of 0.005mm can be achieved.
Boring: Boring is a process of enlarging an existing hole by a single point cutting tool. Boring
operation is often preferred because we can correct hole size, or alignment and can produce
smooth finish. Boring tool is held in the boring bar which has the shank. Accuracy of 0.005mm
can be achieved.

Figure: Different Operation by Radial Drill Machine

Counter Bore: This operation uses a pilot to guide the cutting action to accommodate the heads
of bolts. Fig. illustrates the counter boring, countersunk and spot facing processes.
Countersink: Special angled cone shaped enlargement at the end of the hole to accommodate the
screws. Cone angles of 60°, 82°, 90°, 100°, 110°, 120°.

Figure: Counter boring, countersunk and spot facing

Tapping: Tapping is the process by which internal threads are formed. It is performed either by
hand or by machine. Minor diameter of the thread is drilled and then tapping is done. Fig. 11
shows the tapping processes.

Figure: Hand taps and tapping process using tap wrench

Conclusion: Thus, the basic functioning and mechanism of was studied.
Experiment-5: Study of Gear Indexing and Manufacturing of a Spur Gear on
a Knee Type Milling Machine

Objective:

i. To study the indexing a spur gear.

ii. To manufacture a spur gear.
Theory:
Introduction:

Gear is a widely used mechanical component whose primary use is to transmit

power from one shaft to another. These gears are of many types namely spur gears,
helical gears, worm gears etc. gear drives are used to various kinds of machines
like automobiles, metal cutting tools, rolling mills, material handling equipments
etc. the friction and other losses in this type of power transmission equipment is
comparatively very low.
Gear Nomenclature:

Addendum: The addendum is the height by which a tooth of a gear projects beyond (outside for
external, or inside for internal) the standard pitch circle or pitch line; also, the radial distance
between the pitch circle and the addendum circle.

Dedendum is the depth of a tooth space below the pitch line. It is normally greater than the
addendum of the mating gear to provide clearance.

Dividing Heads
A dividing head is a tool that is used to divide a circle into equal divisions. Dividing heads are
employed in operations on knee type milling machine for setting the work piece at the required
angle to the table of the machine, turning the work piece through a pre-determined angle, diving
circle into the required number of parts (indexing) and also for continuous rotation of the work
piece in milling helical grooves with a large lead.

Figure: Dividing Head

Types of dividing heads:

There are dividing heads for direct indexing (called plain dividing heads), optical
dividing heads and universal dividing heads. Universal dividing heads are classified as
heads with and without an index plate. Index plate dividing heads are more widely
used. Universal dividing heads are setup for:

i. Simple indexing: It consists in turning the spindle through the required angle
by rotating the index crank.
ii. Differential indexing: It is employed where simple indexing cannot be effected
i.e. where an index plate with the number of holes required for simple indexing
is not available.
iii. Cutting helical grooves: In milling helical grooves, a complex helical
movement is imparted to the work piece, which involves a straight movement
along the work piece axis and rotation of the work about the same axis.

Machine, Equipment and Work Material:

1. Milling machine
2. Work material (Gear Blank)
3. Cutting tool (Gear Cutter)
Procedure
Sr. Operation Tools / Equipment
No.
01 Mount and align the dividing head and tailstock on machine Dividing head, tail stock,
table. dial indicator.
02 Mount the gear-milling cutter on the arbor and test for Gear cutter.
concentricity.
03 Hold the work piece on the mandrel and adjust the mandrel Try square, slip
between centers. gauges
04 Adjust the work piece to the center of cutter.
05 Set the revolutions, and feed for milling.
06 In the beginning the cutter should shave slightly on the work
piece.

07 Withdraw the work piece out of range of the cutter and

lift the milling table by the height of the tooth depth.
08 Milling of first tooth space.
09 Withdraw the work piece from the cut and turn the indexing
handle by the tooth pitch & mill next tooth
space.
10 Repeat the procedure for next tooth.
Experiment-6: Deep Drawing Operation by Manual Hydraulic Press
Machine.
Objectives: To Determine the Blank Size, Drawing Force for Producing a symmetrical cup of
circular cross section using a Draw Tool and Perform Drawing Operation.
Material Required: Aluminium sheet of required size and MS round bar of 25mm diameter.
Equipment And Tools Required: Hydraulic Press, Draw tool and Inclinometer.
Theory:
Drawing: Drawing operation is the process of forming a flat piece of material into a hollow
shape by means of a punch which causes the blank to flow into the die cavity. The depth of draw
may be shallow, moderate or deep. If the depth of the formed cup is up to half of its diameter, the
process is called “Shallow drawing”. If the depth of the formed cup exceeds the diameter it is
termed as "Deep drawing". Parts of various geometries and sizes are made by drawing operation,
two extreme examples being bottle caps and automobile panels.

Figure: Deep Drawing Operation

As the drawing progress i.e. as the punch forces the blank into die cavity, the blank diameter
decreases and causes the blank to become thicker at its outer portions. This is due to the
circumferential compressive stress to which the material element in the outer portions is
subjected. If this stress becomes excessive the outer portions of the blank will have the tendency
to buckle or wrinkle. To avoid this, a pressure pad or blank holder is provided. The holding down
of pressure is obtained by means of springs, rubber pad, compressed air cylinder or the auxiliary
ram on a double action press. The portion of the blank between the die wall and punch is
subjected to nearly purely tension and tends to stretch and becomes thinner. The portion of the
formed cup which wraps around the punch radius is under tension in the presence of bending.
This part becomes the thinnest portion of the cup. This action is termed as 'necking' and in the
presence of unsatisfactory drawing operation, is usually the first place to fracture. The outer
portions of the blank and are become thicker during the operation.
A simple push through drawing die is shown. The drawing punch should be properly vented with
drilled passengers. Venting serves double purpose it eliminates suction which would hot the cup
on the punch and damage the cup when it is stripped from the punch. Secondly, venting provides
passages for lubricants. Many presses are used for the deep drawing operations are hydraulically
operated and these presses have an additional hydraulic cylinder and piston for the additional
slide.
Product applications of deep drawing process are: cups, shells, automotive bodies, gas tanks,
house hold hard ware etc.
Blank Size:
Blank size calculation is an important aspect of deep drawing calculations, as it determines the
amount of material required for the production of a specific part. The blank size is calculated
based on the dimensions of the finished part, the material properties, and the desired thickness of
the blank.
The basic formula for calculating the blank size is:
Blank Diameter (BD) = Finished Diameter (FD) + (2 x Depth of Draw (DOD))
where the depth of draw is the difference between the height of the blank before and after
forming.
Drawing Force:
Calculating the drawing force required for a deep drawing process involves several factors,
including the material properties, the blank size and shape, the punch and die dimensions, and
the friction between the material and the tooling.
One common equation used to calculate the drawing force is:
F = K * T * L * (S – L * R)
Where:
F = Drawing force (in pounds or newtons) K = Coefficient of drawing force (typically ranges
from 0.5 to 0.6) T = Tensile strength of the material (in psi or MPa) L = Blank diameter or length
(in inches or millimeters) S = Punch diameter or length (in inches or millimeters) R = Die radius
(in inches or millimeters)
Drawing Operation:
1. Fix the punch to the ram of the press.
2. Fix the die on the bed of the machine using clamps, bolts and nuts.
3. Calculate the required blank size and place the same between thepunch and die block. 4.
Apply the hydraulic pressure on the punch through ram so that the punch slowly descends on the
blank and forces it take the cup shape formed by the end of the punch, by the it reaches the
bottom of the die.
5. When the cup reaches the counter bored portion of the die, the top edge of the cup formed
around the punch expands slightly due to spring back.
6. Observe the reading of the pressure gauge which directly gives the force required to perform
the operation.
7. Calculate the drawing force required, to perform the operation using above relations.
8. Compare the two readings
9. Then move the punch in the return direction so that the cup will be stripped by counter bored
portion.
Precautions:
1. The die should be properly clamped to the bed of the machine and it is not disturbed during
the process.
2. The punch is properly fixed to the ram of the machine.
3. The load should be applied uniformly on the bar.
4. The bar should be held properly on the die block.
Experiment-7: Bending Operation by Manual Hydraulic Press Machine.
Objectives: To make rod/pipe bending using Hydraulic press(or) To perform Bending Operation.
Material Required: Mild Steel round bar of suitable (25mm) diameter. EQUIPMENT AND
Tools Required: Hydraulic Press.
Theory:
Bending: Bending is the metal working process by which a straight length is transformed in to
the curved length. It is a very common forming process for changing sheet and plate into
channels, drums, tanks etc. During the bending operation, the outer surface of the material is in
tension and the inside surface is in compression. The strain in the bent material increases with
decrease in the radius of curvature. The stretching of the bend causes the neutral axis of the
section towards the inner surface. In most cases the distance of the neutral axis to the inside of
the bend is 0.3t - 0.5t where t is the thickness of the part.

Bending Methods:
The two bending methods commonly used are v-bending and edge bending.
1. V- Bending:
In V bending, a wedge shaped punch forces a metal sheet or strip in to a wedge shaped die cavity
.The bend angle may be acute, 90o or obtuse. As the punch descends the contact forces at the die
corner produces a sufficiently large bending moment at punch corner to cause the necessary
deformation. To maintain the deformation to be plane - strain, the side creep of the part during its
bending is prevented or reduced by incorporating a spring loaded knurled pin in the die. The
friction between pin and the part will achieve this. Plane strain conditions will also be established
in the center of the sheet if its width is more than 10 time its thickness.
2. Edge Bending:
In edge bending , a flat punch forces the stock against the vertical force of the die. The bend axis
is parallel to the edge of the die and the stock, is subjected.
Bending Operation:
1. Fix the wedge shaped punch to the ram of the press.
2. Fix the wedge shaped die cavity on the bed of the press using clamps, bolts and nuts.
3. Place the MS round bar between the punch and die.
4. Apply pressure on the bar by moving the ram in downward direction through the punch.
5. As the punch descends, the contact forces at the die corner produce a sufficiently large
bending movement at the punch corner to cause the necessary deformation.
6. Then the bar will take the shape of die cavity.
Precautions:
1. The die should be properly clamped to the bed of the machine and it is not disturbed during
the process.
2. The punch is properly fixed to the ram of the machine.
3. The load should be applied uniformly on the bar.
4. The bar should be held properly on the die block.
Experiment-8: Sheet Metal Bending by Rolling Machine.
Objectives: To study and observe the plate rolling machine and fabricate a cylinder from a plate
of given length.

What is Plate Rolling Machine?

The plate rolling machine is a kind of equipment that uses work rolls to bend
sheet metal. It can form parts of different shapes, cylindrical and tapered. It is
essential processing equipment. The working principle of the plate bending
machine is to move the work roll through the action of hydraulic pressure,
mechanical force, and additional external parties to make the plate bend or
bend into shape. According to the rotation, movement, and position changes of
work rolls of different forms, the plate rolling machine can process parts such
as the oval, arc, and cylindrical elements.
The Principle of Plate Rolling Machine
The upper roller of the symmetrical plate rolling machine is at the
symmetrical position of the two lower rollers through the hydraulic oil in the
hydraulic cylinder to act on the piston for vertical lifting movement, and the
final gear of the main reducer drives the gears of the two lower rollers to mesh
for rotating motion, which is the rolling motion Provide torque. The flat
plastic metal plate of the plate rolling machine passes between the three
working rolls of the plate rolling machine. With the help of the pressing of the
upper roller and the rotation of the lower roller, the metal plate is
continuously bent through multiple passes, resulting in permanent plastic
deformation. Roll into the required cylinder, cone, or part of them. The
disadvantage of this hydraulic three-roller bending machine is that the end of
the plate needs to be pre-bent with the help of other equipment. This rolling
machine is suitable for large rolling machines with a thickness of more than
50mm. A row of fixed idlers is added under the two lower rollers to shorten
the span of the two lower rollers, thereby improving the precision of the rolled
workpiece and the overall performance of the machine.
This curves the metal workpiece into a cylindrical form, where it is welded
together to produce a cylinder. The support end of the top shaft can be opened
to allow removal of the finished work piece, especially a completed tube shape.

Below is a diagram showing how a plate is formed into a tube with a single
(initial) pinch plate rolling machine.

Single-pinch (initial-pinch) machines are the most common and may require
inserting the workpiece into the machine twice in order to prebend both ends
to eliminate flat spots when rolling a full tube shape and to ensure better
closure of the seam. To prebend the first end, the operator inserts the plate
into the machine, which clamps it and pinches it between the top roll and
bottom pinch roll. A rear bending roll, moving diagonally toward the top roll,
pushes against the metal to bend the radius. The operator then removes the
plate from the bender, rotates the plate 180 degrees to insert the second end
into the rolls, then rolls the cylinder to completion.
Double pinch pyramid machines with 3 rolls can prebend both ends of a plate
with a single insertion into the bending machine, for reduction in material
handling and time. But they cost more and cannot roll as tight a diameter. The
wide opening between the rolls allows heavy plate to be rolled. On double
pinch machines, the top roll position is fixed and the two lower rolls move in a
straight path or an arc toward the top roll.

Finally, 4 roll machines can accurately roll metal to tight diameters and can
do it in one pass through because the metal is always held in position by the
bottm pinch roll while the 3rd and 4th rolls take turns curving the metal. You
can make cylinder shapes, oval shapes, cone shapes, semi-curves, and shapes
with curves and straight sections. Below is a diagram of how to roll a plate
into a cylindrical shape on a 4 roll machine.

Forming a full tube shape should have little or no gap in the middle of the
seam due to the "crowning" of the rolls. Crowning is where the rolls are
slightly larger diameter in the middle which compensates for deflection under
load.

How Does a Metal Plate Bending/Rolling/Rolling Machine Work?

There are 4 crucial steps one must follow in order to achieve desired metal
plate shape through a metal Plate Bending/Rolling/rolling machine.
 Setting bending force according to the desired radius
 Placing the metal plate on the table to maintain uniform bending/rolling
 Pre-Pinching/Pre-Bending the tails of the metal plate
 Passing the metal plate through the Plate Bending/Rolling/rolling
machine

Step 1: Setting Bending Force on the Plate Bending/Rolling Machine

A bending operator will first assess the workload of the Plate
Bending/Rolling/rolling machine. Once they are through the assessment, they
decide on the bending force to be applied on the metal plate to bend/roll the
machine at desired ID or OD (Inside Diameter or Outside Diameter).

Step 2: Placing the Metal Plate on the Table to Restrict Unwanted Movement
When the operator puts the metal plate on the table, it limits the movement of
the plate in an unwanted direction. This is necessary since a moving metal
plate would be mis-bent during the process.

Step 3: Pre-Pinching / Pre-Bending before Commencing the Bending Process

Pre-pinching or Pre-bending is the process of bending both the tails of the
metal plate at the initial stage to achieve the desired radius at tails during the
bending. It also helps the operator do minimal process post-bending.

Step 4: Bending the Workpiece through the Metal Plate Bending/Rolling

Machine

Types of Machines used for Performing Plate Bending/Rolling Operations

All around the world, several industries such as shipbuilding, metal
fabrication, wind energy, earth moving, metal structures, rocket shell making,
oil tanks, tubes and pipes, and thousands of others utilize metal Plate
Bending/Rolling machines to make varying sizes of equipment and metal
structures.

These are the types of Plate Bending/Rolling/rolling machines that these

industries use for performing their Plate Bending/Rolling/rolling operations:
Plate Rolling Machine
3 Roll Pyramid Type Mechanical Plate Bending Machine
The 3 Roll Pyramid Type Mechanical Plate bending are designed to cater the
basic requirements of bending & forming of metal plates. In this machine, the
bottom rolls are driven by electric motor & gear box. The upper roll is having
manual up & down adjustment to achieve desired bending radius. This is a
very simple & robust design machine suitable for light to medium jobs.
3 Roll Pyramid Type Hydro-Mechanical Plate Bending
The 3 Roll Pyramid Type Hydro Mechanical Plate Bending Machines are
designed with top roll UP & DOWN movement by hydraulic cylinder. This
saves time & labor to adjust top roll. This feature makes the machine more
productive and suitable for handling heavy jobs. Dropper end movement is
done by hydraulic cylinder. The bending of the plate on the plate
rolling machine is achieved by the pressure generated
when the upper roller moves downward. Their working
principle is as shown.

Schematic diagram of rounding machine

With three-roller bending machine, the two ends of the plate need to be pre-
bent, and the length of the pre-bend is 0.5L + (30 ~ 50) mm (L is the center
distance of the lower roller). The pre-bending can be pre-bending with press
molding or with a pallet in the rounding machine.

Schematic diagram of steel plate pre-bending

https://youtu.be/8npnNBHJRG4
https://youtu.be/TUeJO2agClo?si=4szaPlN_bMBXoyRD
Experiment-9: Study of Different Parts of Plastic Injection Molding Machine.
Objectives: To study the constructional features of the Plastic molding machines through
drawing.

Theory
Molding machines are used to give a definite shape to the compounds. These machines impart
various thermoplastic resins, thermoset polymers, or metal injection molding (MINI) compounds
into finished shapes. Current day molding machines are controlled by computer systems that act
upon information that is provided by the sensors. After receiving the information, the
automated system controls each action of the molding machine and ensures
consistency in the output and quality of the end product. This reduction of the
manual interference increases the chances of accuracy and also enhances the speed of
entire process.

Depending on the input material, molding machines can be:

 Plastic injection molding machines
 Metal injection molding machines

Plastic molding machines are used to manufacture different plastic parts of any product, parts
using the blow molding process. Depending on the requirement of the end product,
different molding processes can be used. During plastic molding process, force is applied
to the plastic material during and after it enters the mold. The product is released from the
mold, as soon as it hardens.

 An injection unit, which melts the plastic and injects the plastic into the mold
 The clamping unit which holds the mold. The injection molding unit clamps the mold in
a closed position during injection, opens the mold after cooling and ejects the finished
part. Plastic Injection molding is mainly used for producing complex shapes of various
sizes having very fine details. The parts produced by using this method have greater
 dimensional control and can produce the products in bulk.

Plastic Injection molding process's efficiency varies by the number of parts you plan to
produce. For a small quantity, such as 10 parts, it may be less expensive to simply
machine the desired part utilizing a CNC milling machine. On the other hand, if several
thousand parts have to be made, injection molding is ideal.
 Figure: Injection Molding Machine
Some of the materials that are best suited for producing parts using Plastic
Injection Molding are:
 High Density Polyethylene
 Polyvinyl chloride
 Acetyl Polyamide
 Low Density Polyethylene
 Polypropylene Filled and Blended Plastics
Plastic molding is widely used for many applications, such as:
 Aerospace
 Hydraulics and Pneumatics Packaging
 Architecture Appliances
 Fiber Optics
 Medical and Dental
 Power Tools
 Agriculture
 Measuring Instruments
Experiment-10: Class Assignment/OEL on Various Topics of Machine tools
Laboratory.