Ex. No.

DATE

1
STUDY OF LATHE

Aim
To study about Lathe Machine
Lathe:
The lathe is a machine tool used principally for shaping articles of metal (and
sometimes wood or other materials) by causing the workpiece to be held and rotated by the
lathe while a tool bit is advanced into the work causing the cutting action. Lathes have
allowed man to reshape, machine and manufacture many precision cylindrical components
made of various types of metal, wood, plastics, and other materials. The basic lathe that was
designed to cut cylindrical metal stock has been developed further to produce screw threads,
tapered work, Drilled holes, knurled surfaces.
Lathe Specifications
A lathe is generally specified by;
i. The maximum diameter of the workpiece swing over the bed
ii. The maximum diameter of the workpiece swing over the cross-slide
iii. The maximum distance between the headstock and tailstock centres.
iv. The length of the bed.
v. Centre height (distance between lathe bed and imaginary axis between head tock
and tail stock)
Types of Lathe:
Lathes can be conveniently classified as engine lathes, turret lathes, and special
purpose lathes. All engine lathes and most turret and special purpose lathes have horizontal
spindles and, for that reason, are sometimes referred to as horizontal lathes.
1. Center lathe/ Engine lathe / Bench lathe
2. Tool room lathe
3. Turret lathe and Capstan lathe
4. Gang-tool lathe
5. Multi-spindle lathe
6. CNC lathe
7. Swish-style lathe
8. Combination lathe (3 in 1 machine)

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2|Page
Lathe Components:
1. Headstock:
2. Tailstock:
3. Carriage
4. Compound Rest
5. Bed

6. Feed Rod and Lead Screw

Work holding devices:

Many different devices, such as chucks, collets, faceplates, drive plates, mandrels, and
lathe centers, are used to hold and drive the work while it is being machined on a lathe. The
size and type of work to be machined and the particular operation that needs to be done will
determine which work holding device is best for any particular job.
1. Chuck
2. Independent chuck
3. Universal chuck
4. Collet chuck
5. Drill chuck
6. Faceplate
7. Lathe centres
8. Dog carrier

Cutting tools:
The most common tool bit is the general all-purpose bit made of high-speed steel.
These tool bits are generally inexpensive, easy to grind on a bench or pedestal grinder, take
lots of abuse and wear, and are strong enough for all-around repair and fabrication. HSS tool
bits can handle the high heat that is generated during cutting and are not changed after
cooling. These tool bits are used for turning, facing, boring and other lathe operations. Tool
bits made from special materials such as carbides, ceramics, diamonds, cast alloys are able to
machine workpieces at very high speeds but are brittle and expensive for normal lathe work.
High-speed steel tool bits are available in many shapes and sizes to accommodate any lathe
operation.
Single point cutting tool:
Single point tool bits can be one end of a high-speed steel tool bit or one edge of a
carbide or ceramic cutting tool or insert. Basically, a single point cutter bit is a tool that has

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only one cutting action proceeding at a time.

CARRIAGE

INDEPENDENT CHUCK

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Lathe Operations:
1. Plain Turning
2. Step Turning
3. Taper Turning
4. Facing
5. Drilling
6. Boring:
7. Threading
8. Knurling
9. Parting

Safety Precautions:
 Correct dress is important, remove rings and watches, roll sleeves above elbows.
 Always stop the lathe before making adjustments.
 Dont change spindle speeds until the lathe comes to a complete stop.
 Handle sharp cutters, centers, and drills with care.
 Remove chuck keys and wrenches before operating
 Always wear protective eye protection.
 Handle heavy chucks with care and protect the lathe ways with a block of wood when
installing a chuck.
 Know where the emergency stop is before operating the lathe.
 Use pliers or a brush to remove chips and swarf, never your hands.
 Never lean on the lathe.
 Never lay tools directly on the lathe ways. If a separate table is not available, use a
wide board with a cleat on each side to lay on the ways
 Keep tools overhang as short as possible
 Never attempt to measure work while it is turning
 Never file lathe work unless the file has a handle

Result:
Thus details of lathe and its allied subjects learned and understood.

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UNIVERSAL SCROLL CHUCK

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TAILSTOCK

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 TAPER TURNING BY COMPOUND REST METHOD

Material Supplied : Mild steel of size ф25mm x 75mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø24

2 Ø20

3 Ø13

4 Length 25/ 25/ 25

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 Ex. No. TAPER TURNING DATE

BY
2
COMPOUND REST METHOD

Aim:
Machine the cylindrical work piece to the required dimension of taper through taper
tuning operation by compound rest method
Material supplied:
Mild Steel rod of size Ø25mm x 75mm
Tools required:
1. Chuck key
2. Surface gauge
3. HSS Single point cutting tool
4. Tool holder
5. Allen key
6. Double end spanner (14-15) & (10-11)
Procedure:
1. Hold the work piece in the chuck and set it in concentric with the chuck by surface
gauge
2. Ensure its trueness in concentricity visually by makes it to revolve
3. The end of the work piece machined by facing operation
4. Machining the peripheral surface to the diameter of 20mm for the length of 50 mm by
turning operation
5. Unfasten the compound rest screw by the spanner which enables to swivel it
6. Set the compound rest to the angle what has arrived through calculation
7. Tighten the compound rest screws
8. Loosen the zip adjusting screw and adjust it to the point where the compound rest
will not wobble
9. Turn the work piece to the diameter of 13mm through several depth of cuts
10. Loose the compound rest screw and swivel it to zero degree position.
11. Release the work piece from the chuck and turnover to machine the other side
12. Turn the work piece to the diameter of 24mm for the remaining length
13. Face the work piece to the required finish length

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 CALCULATION:

α = tan-1 [(D – d) / 2l]

Where,
α = Half of the taper angle
D = Larger diameter at the taper end
d = Smaller diameter at the taper end
l = Tapered length

TAPER TURNING - COMPOUND REST METHOD

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Information on Taper turning:
When the diameter of a piece changes uniformly from one end to the other, the piece
is said to be tapered. Taper turning as a machining operation is the gradual reduction in
diameter from one part of a cylindrical workpiece to another part, Tapers can be either
external or internal. If a workpiece is tapered on the outside, it has an external taper; if it is
tapered on the inside, it has an internal taper. There are three basic methods of turning tapers
with a lathe. Depending on the degree, length, location of the taper (internal or external), and
the number of pieces to be done, the operator will either use the compound rest, offset the
tailstock, or use the taper attachment. With any of these methods the cutting edge of the tool
bit must be set exactly on center with the axis of the workpiece or the work will not be truly
conical and the rate of taper will vary with each cut.
Advantage of the method:
Short and sharp taper can be turn
Disadvantage of the method:
Long taper cannot be turn
Application of tapered component:
Mating parts of a component easily engage and disengage at the centerline

Result:
Thus the given work piece machined to the required shape and dimension and the
tapered portion machined through compound rest method.

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 TAPER TURNING BY TAILSTOCK SETOVER METHOD

Material Supplied: Mild steel of size ф25mm x 75mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø24

2 Ø20

3 LENGTH 50

4 LENGTH 20

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 Ex. No. TAPER TURNING DATE

BY
3
TAILSTOCK SETOVER METHOD

Aim:
Machine the cylindrical workpiece to the required dimension of taper through taper
tuning operation by tailstock set over method
Material supplied:
Mild Steel rod of size Ø25mm x 75mm
Tools required:
1. Chuck key
2. Surface gauge
3. HSS Single point cutting tool
4. Drill chuck with key
5. Center drill
6. Live center
7. Dead center
8. Double end spanner
9. Dog carrier
10. Allen key
11. Dial test indicator
Procedure:
1. Hold the workpiece in the chuck and set it in concentric with the chuck by surface
gauge
2. Ensure its trueness in concentricity visually by makes it to revolve
3. The end of the workpiece machined by facing operation
4. Center drill held in the drill chuck and fitted in the tailstock
5. Make center drilling on the machined end
6. Release the workpiece from the chuck
7. Face the other end of the workpiece to the required length
8. Make the center drilling on the other end
9. Set the live center and dead center at the headstock and tailstock respectively

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CALCULATION:
Offset distance = [ L * (D – d) ] / 2l
Where,
D = Larger diameter at the taper end
d = Smaller diameter at the taper end
l = Tapered length
L = Total length of workpiece

TAPER TURNING – TAILSTOCK SETOVER METHOD

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 10. Hold the workpiece between centers and makes it to revolve by dog carrier
11. Turn the diameter to the dimension of 25mm for the length of 25mm
12. Loosen the tailstock adjusting screw
13. Offset the tailstock center out-of-line with the headstock center by the distance, what
had arrived through calculation
14. Check the set-over distance by dial test indicator
15. Release the workpiece from the centers and turnover to the next side and also set the
carrier in the position where it will not disturb the taper turning operation.
16. Turn the workpiece to the diameter of 20mm
17. Loosen the tailstock adjusting screw and moved it to the centerline of headstock

Result:
The given workpiece machined to the required shape and dimension and the tapered
portion machined through tailstock set over method.

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 TAPER TURNING BY ATTACHMENT METHOD

Material Supplied: Mild steel of size ф 25mm x 100 mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø24

2 5O

3 60

4 40

5 X

CALCULATION

tan α =( D−d
l )
We know α, D , l
Therefore found the value, d= D−( l tan α )

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 Ex. No. TAPER TURNING DATE

BY
4
ATTACHMENT METHOD

Aim:
Machine the cylindrical workpiece to the required dimension of taper through taper
tuning attachment method
Material supplied:
Mild Steel rod of size Ø25mm x 100mm
Tools required:
1. Chuck key
2. Surface gauge
3. HSS Single point cutting tool
4. Double end spanner (21 – 23) & (12 – 13)
5. Dial test indicator
Procedure:
1. Hold the work piece in the chuck and set it in concentric with the chuck by surface
gauge.
2. Ensure its trueness in concentricity visually by makes it to revolve.
3. The end of the work piece machined by facing operation.
4. Release the work piece from the chuck.
5. Face the other end of the workpiece to the required length.
6. Turn the diameter to the dimension of 25mm for the length of 100mm.
7. Loosen the guide block bolt and tilt the taper guide block at 5°.
8. Simultaneously adjust the depth of cut by using compound rest and carriage upto 60
mm long.
9. Release the workpiece from the chuck.

Result:
The given workpiece machined to the required shape and dimension and the tapered
portion machined through attachment method.

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 KNURLING

Material Supplied: Mild steel of size ф25mm x 75mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø24

2 Ø22

3 50

4 25

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 Ex. No. DATE
KNURLING OPERATION USING LATHE
5

Aim:
To machine the knurling operation on given cylindrical work piece as per given drawing
Material Supplied:
Mild Steel rod of size Ø25mm x 75mm
Tools Required:
1. Chuck key
2. Surface gauge
3. HSS Single point cutting tool
4. Tool post key
5. Knurling cutter
Procedure:
1. Hold the workpiece in the chuck and set it in concentric with the chuck by surface
gauge
2. Ensure its trueness in concentricity visually by makes it to revolve
3. The end of the workpiece machined by facing operation
4. Reduce the diameter to 22mm for 50mm length
5. Reset the workpiece to the other side
6. Maintain the total length by facing operation
7. Reduce the diameter to 24mm for 25mm length
8. Fit the knurling tool in the tool post
9. Knurl the surface of 24mm diameter by knurling tool
10. Release the workpiece from the chuck.

Result:

The given workpiece machined to the dimension and knurled at the required portion

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 ECCENTRIC TURNING

Material Supplied : Aluminium rod of size ф30mm x 75mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø14

2 Ø32

3 25

4 20

5 25

6 Offset – 9

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 Ex. No. DATE
ECCENTRIC TURNING OPERATION USING
6 LATHE
Aim:
To machine the eccentric turning on given cylindrical work piece as per given drawing
Material Supplied:
Aluminium rod of size Ø32mm x 75mm long
Tools Required:
1.
2. 4-jaw chuck with chuck key 9. Marking plate
3. Surface gauge 10. V – block
4. HSS Single point cutting tool 11. U – clamp
5. Vernier caliper 12. Vernier height gauge
6. Steel rule 13. Dot Punch
7. Scriber 14. Hammer
8. Double end spanner
Procedure:
1. Hold the workpiece with the help of eccentric attachment
2. Hold the workpiece with 4-jaw chuck and set it to the eccentric marking line by using
surface gauge
3. Mark the eccentric distance from the center point by using Vernier height gauge.
4. Punch the centre of the offset mark by using dot punch.
5. Turn the diameter to 14mm for 25mm long
6. Machine a chamfer at the end for 1x45
7. Release the workpiece from the chuck
8. Mark the eccentric distance from the center point at the second side
9. Set the second side in the 4-jaw chuck for machining.
10. Ensure its concentricity with the chuck by surface gauge
11. Turn the diameter to 14mm for 25mm length
12. Machine a chamfer at the end for 1x45
13. Release the workpiece from the chuck

Result:

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 The given workpiece machined to the required dimension and eccentrically turned at
the required portions
EXTERNAL THREADING

Material Supplied : Mild steel of size ф25mm x 75mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø25

2 Ø22

3 30

4 15

5 30

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 Ex. No. DATE
EXTERNAL THREADING USING LATHE
7

Aim:
Generate thread on the external peripheral surface of the cylindrical workpiece for the
given dimension
Material Supplied:
Mild Steel rod of size Ø25mm x 75mm
Tools Required:
1. Chuck key
2. Surface gauge
3. HSS Single point cutting tool
4. Grooving tool
5. Threading tool
6. Center gauge
7. Screw pitch gauge
8. Tool holder
9. Allen key
10. Double end spanner
Procedure:
1. Hold the workpiece in the chuck and set it in concentric with the chuck by surface
gauge
2. Ensure its trueness in concentricity visually by makes it to revolve
3. By turning operation reduce the diameter to 24mm for the length more than 25mm
4. Turnover the workpiece and set it by surface gauge
5. The workpiece end machined to the required finish length by facing operation
6. For the length of 45mm, the diameter reduced to 20mm by turning operation
7. Set grooving tool in the tool holder
8. Make a step circumferentially to the diameter of 17mm for 5mm length by grooving
tool
9. Set threading tool in the tool holder
10. Its perpendicularity with the workpiece center verified with center gauge

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 11. Set the gears as per the calculation

CALCULATION:

Driver Number of threads to be cut on the workpiece

=
Driven Number of threads in the lead screw

THREAD NOMENCLATURE

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 12. Engage tumbler gear with spindle gear
13. Gets half-nut engage with lead screw
14. Thread cutting performed to the required length
15. After first pass, ensure its pitch by screw pitch gauge
16. Proceed the thread generation till the major diameter has reached through several
depth of cuts
17. After threading disengage then half-nut lever
18. Make a chamfer at the threaded end
19. Release the workpiece from the chuck and check the thread with screw pitch gauge
Core Application of threading:
Mate the components temporarily
Study on Threads:
Screw threads are cut with the lathe for accuracy and for versatility. Both inch and
metric screw threads can be cut using the lathe. A thread is a uniform helical groove cut
inside of a cylindrical workpiece, or on the outside of a tube or shaft. Cutting threads by
using the lathe requires a thorough knowledge of the different principles of threads and
procedures of cutting. Hand coordination, lathe mechanisms, and cutting tool angles are all
interrelated during the thread cutting process.
Thread-cutting tool bits are ground to cut the type and style of threads desired. Side and front
clearances must be ground, plus the special point shape for the type of thread desired. Thread-cutting
tool bits can be ground for standard 60° thread forms or for square, Acme, or special threads.
Before attempting to cut threads on the lathe a machine operator must have a
thorough knowledge of the principles, terminology and uses of threads.

Thread Nomenclature:
1. Pitch
2. Lead
3. Crest
4. Root
5. Flank
6. Angle of thread
7. Depth
8. Nominal diameter

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 9. Major diameter
10. Minor diameter

BRITISH STANDARD WHITWORTH THREAD BRITISH ASSOCIATION THREAD

(B.S.W THREADS) (B.A THREADS)

SELLERS THREAD UNIFIED SCREW THREAD

SQUARE THREAD ACME THREAD

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Forms of Threads:
British Standard Whitworth (B.S.W.) thread:
It is a symmetrical ‘V’–thread in which the angle between flanks is 55°. These
threads are generally used on bolts, nuts and studs etc.
British Association (B.A.) thread:
It is a symmetrical ‘V’—thread in which angle between flanks is 47½°. These
threads are used on screws for precision work

Sellers thread:
This thread is also called as American national thread. It is also a ‘V’— thread in
which angle between flanks is 60°. These are used for general purpose as on bolts, nuts, studs
and screws etc.
Metric thread:
These are the threads based on metric system and the Bureau of Indian Standard has
recommended to adopt the unified threads on metric system
Square threads:
The sides of the flanks of square threads are normal to the axis and hence parallel to
each other. The pitch of the threads is often taken as twice that of B.S.W. threads of the same
diameter. These are used for power transmission
Acme threads:
These are modified form of square threads and are much stronger than square
threads. The threads angle is 29°. These are used for the process of engagement and
disengagement of threads e.g., lead screw of lathe, cocks and bench vives etc.
Knuckle threads:
Knuckle threads are the modified form of square threads. These are semicircular at
the crest and root. The radius of the semicircle is 0.25 P and working depth is 0.5 P. These
threads are used in electric bulb and bottles etc.
Buttress threads:
These threads are combined form of square and V–threads. One side of the thread is
perpendicular to the axis of the thread and other is inclined at 45°. These are used for power
transmission

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METRIC THREAD

KNUCKLE THREAD

BUTTRESS THREAD

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Important Terminologies:
External thread:
The threads on the outside surface of the bolt, stud and screw etc., are called
external threads
Internal Thread:
The threads on the inside surface of the hole or a nut are called internal threads
Right and Left hand thread:
A thread is called a right-hand thread if a nut when turned in clockwise direction
screws on a bolt. Similarly if the nut screws off the bolt when turned in the clockwise
direction, then thread is called left-hand thread
Thread cutting operation setting:

In cutting threads on a lathe, the pitch of the thread or number of threads per inch
obtained is determined by the speed ratio of the headstock spindle and the lead screw which
drives the carriage. Lathes equipped for thread cutting have gear arrangements for varying the
speed of the lead screw. Modern lathes have a quick-change gearbox for varying the lead
screw to spindle ratio so that the operator need only follow the instructions on the direction
plates of the lathe to set the proper feed to produce the desired number of threads per inch.
Once set to a specific number of threads per inch, the spindle speed can be varied depending
upon the material being cut and the size of the workpiece without affecting the threads per
inch.
The carriage is connected to the lead screw of the lathe for threading operations by
engaging the half nut on the carriage apron with the lead screw. A control is available to
reverse the direction of the lead screw for left or right-hand threading as desired. Be sure the
lead screw turns in the proper direction. Feed the cutter bit from right to left to produce a
right-hand thread. Feed the cutter bit from left to right to produce a left-hand thread.

Result:

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 The given workpiece machined in the lathe for the required dimension and external
threading performed as per the dimension

INTERNAL THREADING

Material Supplied : Cast Aluminium cylindrical block of size ф50mm x 25mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø50

2 Ø28

3 20

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 Ex. No. DATE
INTERNAL THREADING USING LATHE
8

Aim:
Generate thread on the internal peripheral surface of the cylindrical workpiece for the
given dimension
Material Supplied:
Cast Aluminium hollow cylindrical block of size Ø50mm x Ø28 x 20mm long
Tools Required:
1. Chuck key 6. Internal threading tool
2. Surface gauge 7. Center gauge
3. Tool holder 8. Screw pitch gauge
4. HSS Single point cutting tool 9. Double end spanner
5. Allen key
Procedure:
1. Hold the workpiece in the chuck and set it in concentric with the chuck by surface
gauge
2. Ensure its trueness in concentricity visually by makes it to revolve
3. Engage the tumbler gear with spindle gear
4. Gets half nut engaged with lead screw
5. Threading operation performed for the whole length
6. After first pass, ensure its pitch by screw pitch gauge
7. Proceed the thread generation till the major diameter has reached through several
depth of cuts
8. After threading disengage then half-nut lever
9. Release the gear and remove the workpiece from the chuck
10. Face the second side of the workpiece to the finish length. Machine chamfer at the
faced end
11. Release the workpiece from the chuck and check the pitch by screw pitch gauge

Core Application:
1. Nut
2. Gages

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Result:
The given workpiece machined in the lathe for the required dimension and internal
performed as per the dimension

SQUARE HEAD SHAPING

Material Supplied: Aluminium rod of size ф32mm x 45mm long

S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 22sq

2 Ø18

3 20

4 20

5 Diagonal 31.10

CALCULATION:
Diameter of the workpiece (after pre-machining) = 30mm
The distance across corners in a square can be expressed as

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 D = √2 d

D = diagonal of the square

d= square side length

Ex. No. DATE

SQUARE HEAD SHAPING
9

Aim:
To generate square head on the cylindrical workpiece in the shaping machine
Material Supplied:
Aluminium rod of size Ø32mm x 45mm long
Tools Required:
1. HSS Single point cutting tool 5. Vise adjusting lever
2. Surface gauge 6. Parallel block
3. Vernier caliper 7. Try square
4. Machine vise
Procedure:
1. The given workpiece is measured for its initial dimensions
2. Hold the workpiece in the machine vise and parallel block.
3. After fixing the workpiece the shaping tool, allow the ram to reciprocate.
4. Start to plan the shaping process, once touch the top place of the workpiece stop the
machine.
5. Set the table height division at zero, then move the table away from the tool head.
6. Set the table height 1 division depth of cut
7. Switch on the machine to reciprocate the ram to cut the workpiece
8. Move the table using ratchet pawl mechanism of slow feed
9. One side of the workpiece head machined and similarly done for the four sides for the
square head bolt.
10. Remove the workpiece from the machine vise.
11. Turnover the workpiece and rest the machined surface on the parallel block and
clamped. Machine the second side by adjusting the table for the depth of 6 mm
12. Set the workpiece in the vise for the third side machining by try square
13. Set the workpiece in the vise for the fourth side machining
14. Release the workpiece from the vise and check its squareness by try square and
Vernier caliper

Core Application:
1. Square head bolt
2. Machine vise screwing rod

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STUDY OF SHAPING MACHINE:
The shaper is a machine tool used primarily for:
1. Producing a flat or plane surface which may be in a horizontal, a vertical or an
angular plane.

TOOL HEAD

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 CRANK AND SLOTTED LEVER MECHANISM
2. Making slots, grooves and keyways
3. Producing contour of concave/convex or a combination of these
A shaper is a machine tool which holds and locates a workpiece on a table and machines or
cuts the workpiece by feeding it against a reciprocating cutting tool. In other words, the ram
of the shaper moves a single point cutting tool back-and-forth, and on each forward stroke,
the tool removes a chip of metal from the workpiece. When horizontal surfaces are being
machined, the table automatically feeds the work to the cutting tool on each return stroke of
the ram. When vertical cuts are being made, the work is fed to the cutting tool on each return
stroke of the ram either manually or automatically. The cutting tool on a shaper can be set to
cut horizontally, on an angle, or vertically.

Shaper Specification:
1. Maximum ram stroke (mm)
2. Work table surface (W*L)
3. No. of stroke per min (st/min)
4. Motor power (KW)

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Construction:
Base:
Body (Pillar, Frame, and Column):
Cross rail:
Ram:
Tool head:
Machine table

Work Holding Devices:

Vise:
Hold-downs:
Parallel block:
Angle plate:

Result:
The given cylindrical workpiece machined in the lathe and the square head
generated in the shaping machine at the required portion
HEXAGONAL HEAD MILLING

Material Supplied: Aluminium rod of size ф32mm x 45mm long

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S.NO DRAWING DIMENSIONS ACTUAL DIMENSIONS ERROR

1 Ø25.4

2 Ø12

3 22

4 15

Ex. No. DATE

HEXAGONAL HEAD MILLING
10

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Aim:
Generate hexagonal head on the cylindrical workpiece in the vertical milling machine
Material Supplied:
Aluminium rod of size Ø24.5mm x 15mm long
Tools Required:
1. Vernier caliper
2. Dividing head with 3 jaw chuck
3. Chuck key
4. Collet
5. End mill cutter
6. Collet locking lever
Procedure:
1. Hold the workpiece in the chuck and set it in concentric with the chuck by surface
gauge
2. Ensure its trueness in concentricity visually by makes it to revolve
3. Hold the workpiece in the indexing head 3-jaw chuck
4. Touch the end mill cutter on the top of the workpiece and give depth of cut to the
depth of 2.5mm for the first side
5. Index the work piece as per the calculation to the second side machining
6. Repeat the operation for the remaining 4sides
7. Release the workpiece from the indexing head
Application:
1. Hexagonal head bolt
2. Hexagonal nut

Result:
The given cylindrical workpiece machined in the lathe and the hexagonal head
generated in the vertical milling machine at the required portion.

INDEXING CALCULATION:

Index number = 40 / N

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 = 40 / 6

= 6 4/6

= 6 2/3

Both the numerator and denominator by 7,

Index number = 6 14/21

Move the index crank by 6 complete turn and 14 holes in the 21 hole circle in the index
plate for every face

INDEXING MECHANISM

CALCULATION:
The distance across corners in a hexagon can be expressed as

Distance between across corner D= (2 / 3)* √3 * d

d= distance between across flat

Ex. No. DATE

11
STUDY OF SHEET METAL WORK

INTRODUCTION

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 Sheet metal work deals with working on the metal of 16-30 gauge, with hand tools
and simple machines. It is one of the major applications in engineering industry. It has its
own significance as useful trade in engineering work. Sheet works such as making a tray,
box, funnel, chimney, air duct, fabricate boiler shells and pipe joints from thin or thick plates,
etc. are few examples of its application. For successful working in the trade, one should have
a thorough knowledge of projective geometry and development of surfaces.

SHEET METAL TOOLS

Steel rule: It is used to measure and mark dimensions. It is graduated on both sides in
millimeters and centimeters or inches.
Divider: Divider is used in sheet metal jobs for circle making. With the divider we can also
do marking the parts of the job.
Steel Square: It is used for checking the right angle of the jobs.
Trammel: It is used to draw large circles and arcs. This is also a marking tool.
Wire Gauge: The thickness of sheet metal is referred in numbers known as Standard Wire
Gauge (SWG). The gaps in the circumference of the gauge are used to check the gauge
number.
Bench Shear: Sheet metal may be cut shearing action. In this, the force is applied through a
compound leave, making it possible to cut sheet metal upto 4mm thick.
Snips: This tool is used for cutting thin metal sheets, before or after marking, according to
the jobs, is called snips. The straight snip is used for cutting along outside curves and straight
lines and curved snip or bend snip is for trimming along inside curves.
Hammers: Light weight hammers and mallets are used in sheet metal work. Ball-peen
hammer has a cylindrical, slightly curved face and a ball head. It is a general purpose
hammer, used to mostly for riveting in sheet metal work. The cross-peen hammer and straight
peen hammers are used for folding the sheet and to work in the corners of the project.
Mallet: Mallet is used for bending and folding work. It is called as soft hammer. Generally, it
is made of wood.
Stakes: Stakes are nothing but anvils, which are used as supporting tools and to form seam,
bend or rivet, sheet metal objects. They are made from wrought iron, faced with steel.
Scriber: This tool is used for marking sheet metal jobs.
Punch: Punch is used in sheet metal jobs for punching or deep marking.

40 | P a g e
SHEET METAL OPERATIONS

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 1. Marking: Before making a job, lines and points are drawn on the sheet according to
the drawing so that the sheet is cut as per the required size. These lines and points are
known as marking.
2. Cutting: After making on the steels, they are cut according to the drawing with the
help of proper cutting tools. This act is known as cutting.
3. Swaging: In order to provide strength to the sheet metal jobs, slots are cut in them.
This operation is essential particularly for the thin sheets.
4. Hollowing: The act of hollowing a sheet metal for making a sheet job is called
hollowing.
5. Wiring: In order to provide strength to edge of sheet metal jobs, its edges are turned
and a wire is placed in the groove so prepared. This act is known as wiring.
Besides this, in sheet metal jobs shearing, blanking, piercing, punching and seaming etc. is
done with the help of machines.

Shearing: Cutting sheet metal into pieces with machines or by hands called shearing.

Blanking: Cutting a sheet according to the job from a flat sheet is called blanking.

Piercing: To make a round, square or any other kind of hole in a sheet, with the help of
machine is called piercing.

Punching: The making of a hole through sheets by means of a piercing machine is called
punching.

Seaming: A sheet metal joint in which the edge of piece is folded or turned over the edge of
another is called seaming operation.

SAFETY PRECAUTIONS FOR SHEET METAL WORK

1. Loose clothing should be avoided

2. Tools should always be kept in good working condition
3. Use hand leather gloves while handling heavy sheets.
4. Avoid feeling the cut portion by hand while cutting with snip.
5. Do not let sheet metal slip through your hands. Most cuts from sheet metal result from
allowing it to slide through the hands.

Result

Thus the various sheet metal operations, safety precautions sheet metal tools has been studied

42 | P a g e
43 | P a g e
 Ex. No. DATE

12
RECTANGULAR TRAY

Aim

To make a rectangular tray from the given sheet metal.

Material supplied

22 gauge Galvanished Iron (GI) sheet l.w = 160 x 130 mm.

Tools required

1. Steel rule 6. Ball peen hammer

2. Divider 7. Protractor
3. Scriber 8. Stakes
4. Straight snip 9. Rivet set
5. Mallet

Sequence of operations

1. Checking 5. Bending
2. Levelling 6. Hemming
3. Marking 7. Riveting
4. Cutting

Procedure

1. The size of the given sheet is checked with the steel rule.
2. The layout of the tray is marked on the given sheet.
3. The layout of the tray is cut by using the straight snip.
4. Folding is done as per the given order using wallet and stake.
5. Bending is done as per the given dimensions using the stake and mallet.
6. Finally, the tray is riveted using the given rivets and hammer

Result

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Thus, the desired rectangular tray is made from the given sheet metal.

45 | P a g e
 Ex. No. DATE

13
FUNNEL MAKING

Aim
To make a funnel from the given sheet metal.
Material Supplied
22 Gauge Galvanished Iron (G.I) Sheet.
Tools required
1. Steel rule 5. White paper
2. Mallet 6. Ball peen hammer
3. Scriber 7. Groover
4. Straight snips 8. Solder
Sequence of operations
1. Checking 5. Cutting
2. Levelling 6. Folding
3. Marking on Paper 7. Hemming
4. Marking on sheet metal 8. Soldering
Procedure
1. The size of the given sheet metal is checked for its dimensions using a steel rule.
2. The required development of surface is being made on the white paper which is
overlapped on the sheet metal.
3. The marking is done on the sheet metal as per the development being done on the
paper.
4. Now using straight snips, unwanted materials are removed.
5. Now fold and bend the workpiece to make the funnel shape and joint is made on the
workpieces.
6. Then using a groover, a locked grooved joint is made for about 5 mm. Also, hemming
is done in the bottom of the funnel.
7. In between top face and bottom face, a butt joint is made using a solder.
8. Finally, trimming and finishing operations are carried out.

Result
Thus, the funnel of the required dimensions is made from the given sheet metal.

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METAL SPINNING OPERATION

47 | P a g e
 Ex. No. DATE

14
METAL SPINNING OF CUP
Aim

To make a rectangular tray from the given sheet metal.

Material supplied

22 gauge Galvanished Iron (GI) sheet l.w = 160 x 130 mm.

Tools required

1. Steel rule 6. Ball peen hammer

2. Divider 7. Protractor
3. Scriber 8. Stakes
4. Straight snip 9. Rivet set
5. Mallet

Sequence of operations

1. Checking 5. Bending
2. Levelling 6. Hemming
3. Marking 7. Riveting
4. Cutting

Procedure

1. The size of the given sheet is checked with the steel rule.
2. The layout of the tray is marked on the given sheet.
3. The layout of the tray is cut by using the straight snip.
4. Folding is done as per the given order using wallet and stake.
5. Bending is done as per the given dimensions using the stake and mallet.
6. Finally, the tray is riveted using the given rivets and hammer

Result

Thus, the desired rectangular tray is made from the given sheet metal.

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49 | P a g e
 Ex. No. DATE

15
STUDY OF WELDING

INTRODUCTION

Welding is the process of joining similar metals by the application of heat, with or without
application of pressure of filler metal, in such a way that the equivalent in composition and
characteristics of the metals joined.

The various welding processes are:

 Electric arc welding

 Gas welding
 Thermit welding
 Resistance welding
 Friction welding

However, only electric arc and gas welding are discussed here. In either process, the work
pieces are melted along a common edge, to their melting point and then a filler metal is
introduced to form the joint on solidification. The materials to be welded must be free from
rust, scale, oil or other impurities, so as to obtain a sound weld.

ARC WELDING

It is the process of joining tow metals by melting their edges by an electric arc using filler rod
without the application of pressure. This process is also called Electric Arc Welding. The
filler rod is called electrode, which has a flux coating. The filler rod (welding rod) melts on
the electric arc produced and welds the metals plates. Electric arc welding is widely used to
join metal plates using filler rod.

Arc welding procedure

[1] The surface to be welded is cleaned and the edges of the plates may be filled for
perfect joint and more strength.
[2] The welding rod is held in the electrode holder and the ground clamp is clamped to
the plate to be welded.
[3] The electric arc produced melts the welding rod and joins the two metal plates.
Maintain a gap of 3mm between the plate and the welding rod.
[4] Complete the welding process by removing slag using chipping hammer.

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Arc welding set up

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For the electric arc welding set up the following equipment’s are necessary.

[1] An AC transformer or a DC transformer

[2] Electrode or Filler rod
[3] Electrode Holder
[4] Welding cables
[5] Ground clamp
[6] Safety devices like face shield, hand gloves etc.
[7] Other devices like chipping hammer, wire brush, tongs etc.

GAS WELDING

Gas welding is a processing in which the required heat to melt the surfaces is supplied by a
high temperature flame obtained by a mixture of two gases. Usually the mixture of oxygen
and acetylene is used for welding purpose. The filler rod and parent metal plates are melted
by the heat of the flame produced using oxygen and acetylene gas mixture. Gas welding is
also widely used to join metal plates.

Gas welding procedure

1. The surface to be welded is cleaned.

2. Open the acetylene and oxygen cylinder valve slowly, then open the acetylene valve
in the torch keep the tip of the torch away from body and lgith it using lighter. Open
oxygen and acetylene valves in torch slowly to get the required flame for welding.
3. Maintain a gap of 3 mm between the plate to be welded and the inner cone of the
flame. The torch and filler rod are moved backwards along the line to be welded.

Gas welding setup

The different equipment’s present in the gas welding set up are

(i) Gas cylinders

(ii) Pressure regulators
(iii) Pressure gauges
(iv) Welding torch
(v) Hoses
(vi) Other accessories like goggles, welding rod, spark lighter, apron etc.

TYPES OF FLAMES

1. Neutral Flame: When oxygen and acetylene are supplied to the torch in nearly equal
volumes, a neutral flame is produced having a maximum temperature of 3200 oC. The
neutral flame is widely used for welding steel, stainless steel, cast iron, copper,
aluminium, etc.
2. Oxidizing Flame: Oxidizing flame with excess of oxygen is used for welding brass.

52 | P a g e
 3. Reducing Flame or Carburizing flame: Carburizing flame produced with an excess
of acetylene, is need for welding lead.

WELDING JOINTS

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They are Butt joint, Corner joint, Lap joint, and Edge joint. In this, welding is done on top. So
that gravity helps pull the molten metal into the joint.

SAFETY PRECAUTIONS FOR WELDING

GENERAL

 Always weld in a well ventilated place.

 Do not weld around combustible or inflammable materials, where sparks may cause a
fire.
 Never weld containers which have been used for storing gasoline, oil or similar
materials, without first having them thoroughly cleaned.

ARC WELDING

 Check the ground connection and insulation of all the wires.

 The arc should be observed one through a shield or goggles.
 Always wear the safety hand gloves, apron and leather shoes.
 Prevent welding cables from coming in contact with hot metal, water, oil or grease.
Avoid dragging the cables around sharp corners.
 Always turn-off the machine when leaving the work.
 Remove the slag by chipping hammer only.
 Apply eye drops after welding is over for the day, to relieve the strain on the eyes.

GAS WELDING

 Always wear welding googles while doing gas welding.

 Always use the spark lighter to light the torch, never use a match.
 Do not allow blow pipe to heat cylinders, hoses or any other equipment.
 Do not allow the hose to become excessively warm.
 Secure cylinders in use, against falling, which may knock – off the valve.
 Goggles, face shields and gloves must be used while welding.
 Any repairable parts of the welding equipment should be sent to the manufacturer for
necessary repairs.

54 | P a g e
55 | P a g e
 Ex. No. DATE

16
LAP JOINT

Aim

To make the lap joint using arc welding on the given workpieces.

Material supplied

Mild steel plate of size, l.b.t = 75 x 50 x 5 mm (two pieces).

Tools required

1. Welding transformer 6. Flat file

2. Welding rod 7. Chipping hammer
3. Electrode holder 8. Wire brush
4. Gloves and apron 9. Earthing clamps
5. Hand shield and googles

Sequence of operations

1. Edge preparation 5. Cooling

2. Positioning 6. Chipping
3. Tacking 7. Cleaning
4. Welding

Procedure

1. The given workpieces are thoroughly cleaned of rust, scale and other foreign material.
2. The electrode is fitted in the electrode holder and the welding current is set to a proper
value.
3. When current is passed, arc is produced between the electrode and workpiece. Here
the welding should be carried out on both sides.
4. As soon as the welding process is finished, switch off the current supply and allow the
workpiece to cool.
5. The slag formation on weld is removed by using a chipping hammer.
6. Finally, using wire brush, welded portion are cleaned.

Result:

Thus, the required lap joint is obtained by arc welding.

56 | P a g e
Ex. No. DATE

57 | P a g e
 17 STRUCTURAL WELDING

Aim

To make the lap joint using arc welding on the given workpieces.

Material supplied

Mild steel plate of size, l.b.t = 75 x 50 x 5 mm (two pieces).

Tools required

1. Welding transformer 6. Flat file

2. Welding rod 7. Chipping hammer
3. Electrode holder 8. Wire brush
4. Gloves and apron 9. Earthing clamps
5. Hand shield and googles

Sequence of operations

1. Edge preparation 5. Cooling

2. Positioning 6. Chipping
3. Tacking 7. Cleaning
4. Welding

Procedure

1. The given workpieces are thoroughly cleaned of rust, scale and other foreign material.
2. The electrode is fitted in the electrode holder and the welding current is set to a proper
value.
3. When current is passed, arc is produced between the electrode and workpiece. Here
the welding should be carried out on both sides.
4. As soon as the welding process is finished, switch off the current supply and allow the
workpiece to cool.
5. The slag formation on weld is removed by using a chipping hammer.
6. Finally, using wire brush, welded portion are cleaned.

Result:

Thus, the required lap joint is obtained by arc welding.

58 | P a g e
Ex. No. DATE

59 | P a g e
 18 STUDY OF FOUNDRY

INTRODUCTION

Foundry practice deals with the process of making castings in moulds, formed in
either sand or some other material. This is found to be the cheapest method of metal shaping.
Further, castings may be made to fairly close dimensional tolerances by choosing proper
moulding and casting process. The mould or cavity into which the material is poured is made
of some heat-resisting material.

FOUNDRY TOOLS AND EQUIPEMENTS

Moulding Boxes: Moulding boxes are used for making sand moulds. A moulding box is
normally a rectangular wooden/metal box with bottom and top surfaces open. The upper part
(cope) and the lower part (drag) are aligned properly.

Trowel: It is used to carry green sand, to quench the green sand and for smoothen the surface
of the mould. It consists of a metal blade with a wooden handle. The blade is usually
rectangular, square or triangular in shape.

Sprue Pin: It is tapered cylindrical wooden piece. It is used for making a sprue hole in the
mould to facilitate pouring of metal. The size of the sprue pin depends upon the size of the
mould.

Swap: Swap is a small brush. This is used for applying small amount of water around the
pattern before removing it from the mould.

Rammer: A rammer is used to press or ram the moulding sand uniformly into the moulding
box.

Draw spike: A draw spike is a steel spike with sharp pointed end. This is used to pick the
pattern from the mould after ramming.

Vent wire: This wire is used for making vent holes in the sand mould so that the molten
gases released during poring of molten metal, can easily escape from mould.

Strike Edge or Strike-off Bar: It is a piece of metal or wood with straight edge. It is used to
remove the excess sand from the mould after ramming, to provide a level surface.

Lifters: Lifters are made of thin sections of steel of various widths and lengths, with one end
bent at right angles. These are used for cleaning and finishing the bottom and sides of the
deep and narrow pockets of the mould.

Gate cutter: It is a semi-circular piece of thin sheet, used to cut gates in the mould. Gates are
meant for easy flow of molten metal into mould.

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Mallet: It is used to blow, pack the green sand and to temper the sand. The mallet is made up
of wood.

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Bellow: Bellow is used to blow off loose and particles from mould. It blows air to move the
loose sand out.

Slick: It is a small double ended tool having a flat on one end and a spoon on the other. It is
used for mending and finishing small surfaces of the mould.

Shovel: It is used for mixing and tempering moulding sand and for transferring the sand into
the flask. It is made of steel blade with a wooden handle.

Riddle: It is used for cleaning the moulding sand. The riddles are specified by the diameter
of the frame and the mesh number.

PATTERNS

A patterns is the replica of the desired casting, which when packed in a suitable material
produces a cavity called the mould. This cavity when filled with molten metal, produces the
desired casting after solidification.

TYPES OF PATTERNS

1. Solid pattern or single piece pattern

2. Split pattern
3. Loose piece pattern
4. Shell pattern
5. Match plate pattern

PATTERN MATERIALS

Metal and Alloys: When large number of castings are required, the pattern is made of metal.
The metal patterns are more durable and produce moulds to a close dimensional accuracy.

Plaster: The plaster of Paris or gypsum cement is successfully used as a pattern material
because it can be easily casted into intricate shapes and can be easily worked.

Waxes: Wax patterns are excellent for investment casting process. It helps in imparting a
high degree of surface finish and dimensional accuracy to castings. The waxes commonly
chosen are paraffin wax, shellac wax, bee’s wax, ceresin wax and micro-crystalline wax.

Wood: It is the widely used material for pattern making. It is used when the number of
castings to be produced is relatively less. Pine, teak, kail and mahagony are the commonly
used woods for patterns. Metal pattern is produced by using a wooden pattern called Master
pattern. The most commonly used wood for master pattern is Mahagony.

Plastics: Thermo-setting plastics are becoming more popular now-a-days, for making
patterns. The commonly used plastics are: Polyester resin, epoxy resin and polystyrene.

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MOULDING SAND

The principal material used in making a mould is sand. The sand is defined as the granular
particles resulting from the breakdown of rocks. Quartz and other silica rocks are the source
of silica sand, which is commonly used for moulding. The silica sand is found in nature on
the bottoms and banks of rivers, larger bodies of water. The silica sand comprises from 90 to

63 | P a g e
95% of the total material in any moulding sand. A good moulding sand contains the
following ingredients:

SILICA SAND (SiO2) - 80.8%

ALUMINA (Al2O3) - 14.9%
IRON OXIDE (Fe2O3) - 1.3%
COMBINED WATER - 2.5%
OTHER INERT MATERIALS - 1.5%
PROPERTIES OF MOULDING SAND

For producing sand castings, moulding sand or mould should possess the following
properties:

1. Porosity or permeability
2. Plasticity
3. Cohesiveness
4. Adhesiveness
5. Refractoriness
6. Collapsibility

SAFETY PRECAUTIONS FOR FOUNDRY

 While melting the metal wear infrared goggles, face shield, long sleeve wool shirt,
insulated leggings, apron and gloves.
 Adequate exhaust ventilation should be provided to exhaust fumes and smokes.
 Proper lighting should be there to avoid accident.
 Worker should be trained in safety before giving work.
 Every work must be done under the guidance of lab in-charge.
 Do not let the sand too we. Water is an enemy of molten metals.
 Never stand near or look over the mould during the pouring or immediately after
pouring because the metal might spurt out of the hole.

64 | P a g e
DATE

65 | P a g e
 Ex. No.

21 MOULDING – GEAR PATTERN

Aim

To prepare mould for the gear pattern.

Materials Required

1. Moulding sand 2. Parting sand 3. Facing sand

Tools Required

1. Trowel 8. Vent wire

2. Lifter 9. Riddle
3. Gate Cutter 10. Moulding box
4. Swab 11. Strike off bar
5. Bellow 12. Riser
6. Rammer 13. Draw spike
7. Runner 14. Sprue pin

Procedure

1. The mould box, pattern, tools and thee table/floor are cleaned.
2. The drag is filled with green sand after positioning the gear pattern on the table.
3. The green sand is rammed carefully and the excess sand is struck off.
4. Tilt the drag upside down and sprinkle river sand on top of it.
5. The cope is positioned on top of the drag.
6. Position the sprue pin and riser pin, then fill the cope with sand and ramming is done
and the excess sand is struck off.
7. The sprue pin and riser pin is removed carefully.
8. Apply water on the edges of the pattern and remove it carefully using the draw spike.
Vent holes are made using vent wire.
9. A funnel-shaped opening and gate is made to pour the molten metal.

Result:

Thus, the mould for the given gear pattern is prepared.

66 | P a g e
Ex. No. DATE

67 | P a g e
 22 STEPPED CONE PULLEY

Aim

To prepare mould for the given stepped cone pulley.

Materials Required

1. Moulding sand 2. Parting sand 3. Facing sand

Tools Required

1. Trowel 6. Rammer 11. Strike off bar

2. Lifter 7. Runner 12. Riser
3. Gate Cutter 8. Vent wire 13. Draw spike
4. Swab 9. Riddle 14. Sprue pin
5. Bellow 10. Moulding box

Procedure

1. The mould box, pattern, tools and thee table/floor are cleaned.
2. A suitable box is prepared with the help of core box.
3. The drag box is placed above the moulding board. Now the pattern is kept at center of
the drag.
4. Now parting sand is sprinkled before we keep the pattern.
5. Facing sand is sprinkled over the pattern to a depth of 5mm. Then green sand filled
over it.
6. Proper ramming is done on the green sand to get a air tight packing. Excess sand is
removed by strike off bar.
7. The drag box is inverted upside down. The cope box is placed over the drag box and
locked.
8. The riser pin and sprue pin is placed at right position and green sand is filled over the
pattern.
9. Proper ramming is done on the green sand to get air tight packing, with strike off bar
levelling is done.
10. The pattern is removed by draw spike tool.
11. Gate is prepared using gate cutter and core is placed vertically inside the cavity.
12. The vent holes are made with vent wire on the cope.

Result:

Thus, the mould for the given stepped cone pulley pattern is developed.

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