manufacturing technology - i mechcnical

8/10/2019 Manufacturing Technology - I Mechcnical

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JANSONS INSTITUTE OF TECHNOLOGY

KARUMATHAMPATTI, COIMBATORE641 659

Department of Mechanical Engineering

LABORATORY RECORD

Name : ______________________________

Register No. : ______________________________

Branch : ______________________________

Semester : ______________________________

Academic Year : ______________________________


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JANSONS INSTITUTE OF TECHNOLOGYKARUMATHAMPATTI, COIMBATORE - 641 659

DEPARTMENT OF

Certified to be the Record of Laboratory work done by

Mr. / Ms. ..

Register Number: .. in the

. Laboratory

during the academic year ..

Faculty In-charge Head of the Department

Submitted for Anna University Practical Examination

held on...

.............

Internal Examiner External Examiner


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General Lab Procedures and Safety Procedures

All students should

1. Provide and wear eye protection at all times.

2. Wear appropriate clothing to prevent injuries or burns.3. Wear shoes adequate to protect feet against dropped objects or hot metal. No

sandals.

4. Avoid loose clothing that might get caught in a machine.

5. Protect long hair with a hair net or barrette, not caps.

6. Never operate a machine until given permission by the teacher.

7. Concentrate on class activities and behave in a mature manner.

8. Know the procedure to follow in case of an emergency, such as fire.

9. Handle tools and materials carefully and skilfully.

10. Make sure all tools and machines are used with safeguards.

11. Report any broken tool or machine to the instructor.

12. Avoid making excessive dust, and use the dust collection system where it is

provided.

13. Refrain from sitting on bench tops and leaning back on stools.

14. Prevent waste of all materials.

15. Report any injury to the instructor immediately.

16. Assist with clean-up at the end of each class.

17. Clear the floor of large scraps and excessive waste.

18. Store personal materials in appropriate lockers.

19. Avoid touching switches when cleaning off machines.

20.Clean all bench tops with a dust cloth.


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SYLLABUS

ME6311 MANUFACTURING TECHNOLOGY LABI L T P C

(Only for Mechanical) 0 0 3 2

OBJECTIVE

To study and practice the various operations that can be performed in lathe, shaper,

drilling, milling machines etc., and to equip with the practical knowledge required in the

core industries

LIST OF EXPERIMENTS

Machining and Machining time estimations for :

1. Taper Turning

2. External Thread cutting

3. Internal Thread Cutting

4. Eccentric Turning

5. Knurling

6. Square Head Shaping

7. Hexagonal Head Shaping


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INDEX

EX.NO DATE NAME OF EXPERIMENT MARK SIGNATURE


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Study of LATHE

INTRODUCTION:

Lathe is the father of all machine tool. It is a basic machine tool probably the

most important one of all, lathe was actually the first machine tool.

Lathe is a particular type of machine tool in which the work is held and rotated

against a suitable cutting tool for the purpose of producing surface of revolution in

any material.

LATHE SPECIFICATIONS:

In order to specify a lathe, a number of parameters could be used on the

specific applications. However, the major elements used for specifications should

invariably be based on the components that would be manufactured in the lathe.

The sum of lathe specifications is,

L=Distance between centers.

A=Swing diameter over bed.

B=Swing diameter over carriage.

R=Radius.

H=Height of center from bed

Distance between Centers (L):

This would be specifying the maximum length of the job that can be turned in

the lathe.

Swing Diameter over Bed (A):

This specifies the maximum diameter of the job that can be turned in the lathe

machine generally restricted to small length jobs.

Swing Diameter over Carriage (B):

This specifies the maximum diameter of job that can be turned in the lathe

machines with the job across the cross slide.


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Other factors should also be specified to fully describe the lathe machine.

1. Horse power of the motor

2. Feed range

3.Accuracy achieved

4. Cutting speed range

5. Screw cutting capacity6. Spindle nose diameter

PARTS OF ENGINE LATHE OR CENTER LATHE:

The principal parts of an engine lathe are,

1. Bed,

2. Head stock,

3. Tail stock,

4. Carriage,

4.1. Saddle,

4.2. Cross slide,4.3. Compound rest,

4.4. Tool post,

4.5. Apron.

5. Feed Mechanism,

6. Thread cutting mechanism.

Carriers and Catch Plates:

Carriers and catch plates are used to drive a work piece when it is held betweentwo centers. Carriers or driving dogs are attached to the end of the work piece by asetscrew, and catch plates are either screwed or bolted to the nose of the headstockspindle.

Chuck:

A chuck is one of the most important devices for holding and rotating a piece ofwork in a lathe. Work piece of short length, and large diameter or irregular shapes,which cannot be conveniently mounted between centers, are held quickly and rigidly ina chuck.

Types of chucks:

1. Four jaw independent chuck

2. Three jaw universal chuck

3.Air or hydraulic operated chuck

4. Magnetic chuck

5. Collet chuck

6. Combination chuck


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Face Plate:

A faceplate consists of a circular disk bored out and threaded to fit the nose of

the lathe spindle. This has the radial, plain and T slots for holding work by bolts and

clamps.

Angle plate:

This is a cast iron plate having two faces machined to make them absolutely atright angles to each other. Holes and slots are provided on both faces so that it may be

clamped on a faceplate and can hold the work piece on the face by bolts and clamps.

Mandrels:

A mandrel is a device for holding and rotating a hollow piece of work that has

been previously drilled or bored. The work revolves with the mandrel which is mounted

between two centers.

Plain mandrel:

The plain mandrel this type of mandrel is most commonly used in shops andfinds wide application where a large number of identical pieces having standard size

holes are required to be mounted on it.

Step mandrel:

A step mandrel having steps of different diameters may be employed to drive

different work pieces having different sizes of holes without replacing the mandrel each

time. This type of mandrel is suitable for turning collars, washers and odd size jobs

used in repairing workshops.

Cooler mandrel:A cooler mandrel having solid coolers is used for turning work pieces having

holes of larger diameter, usually above 100 mm. This construction reduces weight and

fits better than a solid mandrel of equal size.

Screwed mandrel:

A screwed mandrel is threaded at one end with a collar. Work pieces having

internal threads are screwed on to it against the collar for machining.

Cone mandrel: A cone mandrel consists of a solid attached to the one end of the

body, and a sliding cone, which can be adjusted by turning a nut at a threaded end.


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Gang mandrel:

This has a fixed collar at one end and a movable collar at the threaded end,which may be adjusted, to this position by a nut. The mandrel is used to hole a set ofhollow work piece between two collars by tightening the nut.

Expansion mandrel:

There are different types of expansion mandrels. The mandrel consists oftapered pin, which is driven into a sleeve that is parallel outside and tapered inside thesleeve has three longitudinal slots, two of which are cut nearly through, and the thirdsplits it completely.

Rests:

A rest is a mechanical device which supports a long slender work piece, which isturned between centers or by a clutch, at some intermediate point to prevent bendingof the work piece due to its own weight and vibrations set up due to the cutting forcethat acts on it.

Steady rest:

A steady rest shown in Fig consists of a cast iron base, which may be made toslide on the loath bed ways and clamped at any desired position where a support isnecessary.

Follower rest:

A follower rest consists of a C like casting two adjustable jaws which supportthe work piece. The rest is bolted to the back end of the carriage and moves with it.TYPES OF LATHE:

1. Speed lathea. Woodworking

b. Centeringc. Polishingd. Spinning

2. Engine lathea. Belt driveb .Individual motor drivec. Gear head lathe

3. Bench lathe4. Tool room lathe5. Capstan and turret lathe6. Special purpose

a. Wheel latheb. T. Lathec. Gap. Bed lathed. Duplicating lathe

7. Automatic lathe


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The Engine Lathe or Center Lathe:

The term engine lathe is associated with the lathe owing to the fed that earlylathe was driven by steam engines It has all parts.

The Bench Lathe:

This is a small lathe usually mounted on bench it has similarly all the parts of an

engine lathe or speed lathe and it only difference is being in the size. This is used forsmall and precision work.

The Tool Room Lathe:

A tool room lathe having the features similar to an engine lathe is much moreaccurately built and has wide range of spindle speed ranging from a very few to quitehigh speed unto 2500 rpm. This lathe is mainly used for precision works on tools, dies,and gauges and in machinery work.

The Capstan and Turret Lathe:

These lathes are developed of the engine lathe and are used for product on

work. The distinguishing features of this type of lathe is that the tailstock of an enginelathe is replaced by a hexagonal turret on the face of which multiple tools may befitted and feed into the work in the proper sequence.

Special Purpose Lathe:

As the name implies they are used for special purpose and the jobs, whichcannot be accommodated or conveniently machined on a standard lathe. The wheellathe is made for finishing the journal and turning the traded on the railroad carriageand locomotive wheel. The gab bed lathe in which a section of the bed is adjacent tothe headstock of the bed is recoverable is used to sluing extra large diameter piece.The T lathe a new member of the lathe family is intended for machining of rotor for jet

engines.Automatic Lathe:

These are high speed heavy duty mass production lathe with complete automaticcontrols once the tools are set and the machine started it performs automatically all theoperation to finish the job.

TOOLS:

A cutting tool may be used either for cutting a part as with a knife or forremaining the chips parts are produced by removing the metal mostly in the form ofsmall ships removal in the metal cutting process may be performed wither by cuttingtools having distinct cutting edges or by abrasively sticks abrasive cloth etc,

All cutting tools can be divided into 2 groups

1. Single point cutting tool2. Multi point cutting tool


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Single Point Cutting Tools:

Single point cutting tool has a sharpened cutting part its point and shaft; the

point of the too bounded by the base. The side flank or major flank or end slank or

minor flank or and it base. The side cutting edges of a tool is form by the interaction of

the base and the side flank. The end cutting edge, a tool into form by the intersection

of the base and the flank, the chip and cut from the work piece by the side cuttingedges. The paint a where the end and side cutting edge met is called nose of tool.

LATHE OPERATIONS:

TURNING:

Turning is the further most generally used operation is the lathe. In ties the

work held in spindle is rotated which the tool is fed part the work piece in a direction

parallel in the axis of rotation. The surface generated is the cylindrical shape

FACING:

Facing is the operation of machining the ends of a piece of work to produce flat

Surface Square with the axis. The operation involves feeding the tool parallel to the

axis of rotation of the work piece.

TAPER TURNING:

Taper may be turned in a lathe by feeding the tool at an angle to the axis of the

work piece. Which taper is essential that the tool cuttings edge should be accurately on

the centre line of the work piece otherwise correct taper will not be obtained

i. By a broad nose form tool

ii. By setting over to the tailstock center

iii. By swiveling the compound rest

iv. By a taper turning attachment.

v. By combing longitudinal and cross feed in a lather.

THREAD CUTTING: Thread cutting is one of the most important

operations performed in a lathe. When the job is reduced between centers or by a

chuck. The longitudinal feed should be equal to the pitch of the thread to be cut per

revolution of the work piece.


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LATHE EXERCISES

FACING AND PLAIN TURNING

ECCENTRIC TURNING

ASSEMBLY

KNURLING

TAPER TURNING

o Tailstock set-over

method

o Compound rest

method

THREAD CUTTING

o Internal thread

cutting

o External thread

cutting


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FACING AND PLAIN TURNING

Ex. No: Date:

AIM:

To obtain the required shape and size of the work piece by turning and facing

operation.

MATERIALS SUPPLIED:

Cylindrical work piece of diameter _______mm and length_________ mm mild

steel rod.

TOOLS REQUIRED:

1. Lathe

2. Cutting tool

3.Vernier caliper

4. Try square

5. Scriber

6.Vernier height gauge

SEQUENCE OF OPERATIONS:

1. Checking

2. Work piece

3. Tool setting

4. Facing

5. Turning

6. Chamfering


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WORKING STEPS:

1. The given work piece is checked for its dimension.

2. The work piece is held in the chuck. Chuck key is used to tighten the job

firmly, ensuring centering of work piece.

3. The single point cutting tool is held in the tool post and tightens the nuts

using spanner.

4. Facing is done with cutting tool moving from the centre of work piece

towards outside. It is one until the required length of the job is obtained.

5. Turning is done to reduce the diameter of the job. Sufficient depth of cit is

given and it is done until the required diameter of the job is obtained.

6. Finally the dimension of work piece is again checked.

RESULT:

Thus the required size and shape of the given work piece is obtained.


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ECCENTRIC TURNING

Ex. No: Date:

AIM:


operation.

MATERIALS SUPPLIED:


steel rod.

TOOLS REQUIRED:

1. Lathe

2. Cutting tool

3.Vernier caliper

4. Try square

5. Scriber



1. Checking

2. Work piece

3. Tool setting

4. Facing

5. Turning

6. Chamfering


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WORKING STEPS:





using spanner.

4. Facing is done with cutting tool moving from the center of work piece


5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is



RESULT:



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MACHINE THE WORK PIECE TO THE GIVEN DIMENSION

Ex. No: Date:

AIM:


operation.

MATERIALS SUPPLIED:


steel rod.

TOOLS REQUIRED:

1. Lathe

2. Cutting tool

3.Vernier caliper

4. Try square

5. Scriber



1. Checking

2. Work piece

3. Tool setting

4. Facing

5. Turning

6. Chamfering


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WORKING STEPS:





using spanner.

4. Facing is done with cutting tool moving from the center of work piece


5. Turning is done to reduce the diameter of the job. Sufficient depth of cut is



RESULT:



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STEP TURNING AND KNURLING

Ex. No: Date:

AIM:

To obtain the required shape and size of the work piece by step turning and

knurling.

MATERIALS SUPPLIED:

Cylindrical work piece of diameter________ mm and length__________mm mild

steel rod.

TOOLS REQUIRED:

1. Lathe

2. Cutting tool

3.Vernier caliper

4. Try square

5. Scriber6.Vernier height gauge

7. Knurling tool


1. Checking

2. Work piece setting

3. Tool setting4. Facing

5. Turning

6. Knurling


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WORKING STEPS:





using spanner.





6. Fix the knurling tool in the tool post.

7. Move the carriage outward, and then move it longitudinally, and give a small

cross feed. Repeat this step until knurling of required length is done.


RESULT:



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TAPER TURNING USING COMPOUND REST METHOD

Ex. No: Date:

AIM:

To obtain the required shape and size of the work piece by taper turning

operation using compound method.

MATERIALS SUPPLIED:

Cylindrical work piece of diameter_________mm and length_________ mm mild

steel rod.

TOOLS REQUIRED:

1. Lathe

2. Cutting tool

3.Vernier caliper

4. Try square



1. Checking


3. Tool setting

4. Facing

5. Turning

6. Taper turning


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WORKING STEPS:

Taper turning:

The angle is determined by using the formula,

Tan = (D-d)/2L

Where,

D=Larger diameter of the work piece

d=smaller dia of the work piece

L=taper length of the work piece


2. The work piece is held in the chuck. Chuck key is used to tighten the job firmly,

ensuring centering of work piece.

3. The single point cutting tool is held in the tool post and tightens the nuts using Tool

post key.

4. Facing is done with cutting tool moving from the centre of work piece towards

outside. It is one until the required length of the job is obtained.

5. Turning is done to reduce the diameter of the job. Sufficient depth of cit is given

and it is done until the required diameter of the job is obtained.

6. Next step taper turning is done on the work piece, as per the taper angle already

calculated. Then the compound rest base is swiveled and set at half taper angle.

Cutting tool is moved at an angle to the lathe axis. Tool is moved by the compound

rest hand wheel.

7. For chamfering to be done at the end of the work piece, the tool is held at 45 0to

the lathe axis and is fed against the rotating work spice.


RESULT:



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EXTERNAL THREAD CUTTING

Ex. No: Date:

AIM:

To obtain the required shape and size of the work piece by turning and thread

cutting.

MATERIALS SUPPLIED:

Cylindrical work piece of diameter_________mm and length___________mm

mild steel rod.

TOOLS REQUIRED:

1. Lathe

2. Cutting tool

3.Vernier caliper

4. Try square

5. Scriber



1. Checking


3. Tool setting

4. Facing5. Turning

6. Chamfering

7. Thread cutting.


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WORKING STEPS:





using spanner.





6. For chamfering to be done at the end of the work piece, the tool is held at

450to the lathe axis and is fed against the rotating work spice.

7. The cutting tool in the tool post is taken out. Thread cutting tool is held in the

tool post and tightened the nuts.

8. For right hand thread the lead screw rotates in clock wise direction and for

left thread, it rotates in anti clock wise direction. The carriage is engaged to

lead screw and automatic feed is given.

9. Suitable depth is given and thread is cut on the work spice.

10.Finally the dimension of work piece and pitch of the thread are again

checked.

RESULT:



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INTERNAL THREAD CUTTING

Ex. No: Date:

AIM:

To obtain the required shape and size of the work piece by Facing, plain turning,

Boring and internal threading.

MATERIALS SUPPLIED:

Cylindrical work piece of diameter_______ mm and length_______ mm mild

steel rod.

TOOLS REQUIRED:

1. Lathe

2. Cutting tool

3.Vernier caliper

4. Try square


7. Boring tool and internal thread cutting tool.


1. Checking


3. Tool setting

4. Facing

5. Turning

6. Boring

7. Thread cutting.


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WORKING STEPS:





using spanner.





6. Fix the boring tool in the tail stock.

7. Slowly given the feed by rotating the wheel in the tailstock which moves the

tool longitudinally to producing a boring.

8. Fix the internal threading tool, to cut the internal thread.


RESULT:



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Study of shaper

INTRODUCTION:

The shaper is a reciprocating type of machine tool used to produce

flat surface. The surface may be horizontal, vertical or inclined. Modern shaper can

generate contoured surfaces also. The metal working shaper was developed in the year

1836 by James Nesmyth an English man.

Purposes of the shaping machines are as follows:

The main purpose of shaping machine is to machine plane horizontal surface.

It is possible to form vertical and angular surfaces also. With proper tools and

accessories even irregular surfaces can be formed.

Working Principle.

The job is rigidly fixed on the machine table. The single point cutting tool held properly

in the tool post is mounted on a reciprocating ram. The reciprocating motion of the ram

is obtained by a quick return motion mechanism. As the ram reciprocates, the tool cuts

the material during its forward stroke. During return, there is no cutting action and this

stroke is called the idle stroke. The forward and return strokes constitute one operating

cycle of the shaper.

Types of Shaper.

Shapers are classified as follows:

As Per Type of Motion.

Crank type

Geared type

Hydraulic type

As Per Position and Travel of Ram

Horizontal type

Vertical type

Travelling head type


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As Per Design of Table

Standard shaper

Universal shaper

As Per Cutting Stroke

Push type

Draw type

Major parts of shaper are

Base

Column

Cross rail

Table

Ram

Tool headBase:

It is made of cast iron to absorb vibration and it takes the entire load coming on the

machine.

Column:

It is made of cast iron. It has a hollow box construction. Quick return mechanism for

ram is placed inside the column. There is two guide ways at the top in which the ram

reciprocates horizontally. There are two guide ways at the front vertical face of columnin which cross rail can moves vertically.

Cross rail:

The cross rail has got two horizontal guide ways in the face. Horizontal cross feed screw

is fitted in the crossed side. For vertical movement of the slide elevating screw is

provided.

Table:

It is rectangular hollow cast iron block the table slide on horizontal guide ways of cross

rail. The surface has T-slots for clamping work. The table can be moved horizontally by

rotating cross feed screw. The front face of the table is supported by the adjustable

table support


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Ram:

Ram carries the tool head at its flank end. Ram reciprocates on the guide ways. It is

connected to the quick return mechanism; stroke of ram can be adjusted by hand

wheel at the top.

Tool head:

Vertical and angular feed can be given to the tool head, the slide can be moved

vertically by rotating down feed screw. There is swivel base for the tool head graduated

in degrees the tool can be swivelled to any required angle.Apron can be titled to the

right or left and clamped in that position. A tool block is hinged inside the box and is

rigidly placed inside the clapper box. During the return stroke the tool block lifts out of

clapper box. This prevents the rubbing of the tool on the job.


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SHAPER EXERCISES

SQUARE HEAD SHAPING


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SQUARE HEAD SHAPING

Ex. No: Date:

AIM:

To shape the given work piece to the given shape and dimension.

Machine:

Shaping machine (12" stroke)

Cutting Tools:

Single point cutting tool, Parting tool

Measuring and Marking tools:

Steel rule

Scriber

Divider

Spirit Level

Vernier caliper

Punch

Hammer

Work Piece:

Cast Iron Block

Work holding Device:

Machine vice, V- Block


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Working steps:

Measure the work piece for its initial dimension.

Set the work piece on machine vice with V- block

Fix the cutting tool on tool holder.

Move cutting tool to the work piece to set the initial zero of the feed.

Take the work piece out of the machine vice and mark the dimension on the

work piece to the appropriate dimensions using proper measuring tools.

Fix the parting tool according to the marking.

Give the feed in smaller graduation until the entire groove is made.

Result

Thus the given work piece is shaped to the given dimensions is made.


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Study of Milling Machine

Introduction:

Milling is the cutting operation that removes metal by feeding the work against a

rotating, cutter having single or multiple cutting edges. Flat or curved surfaces of many

shapes can be machined by milling with good finish and accuracy. A milling machine

may also be used for drilling, slotting, making a circular profile and gear cutting by

having suitable attachments.

The milling machine is classified as follows:

I. Column and knee type:-

1. Plain milling machine

2. Universal milling machine

3. Omuniversal milling machine

4. Vertical milling machine

II. Planomiller

III. Fixed bed type milling machine

IV. Special type:

1. Rotary table milling machine,

2. Drum type milling machine,

3. Planetary milling machine,

4. Pantograph milling machine.

Milling Machine Construction:

The main part of machine is base, Column, Knee, Saddle, Table, Overarm, Arbor

Support and Elevating Screw.

Base: It gives support and rigidity to the machine and also acts as a reservoir for the

cutting fluids.


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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.

Knee: The knee is a rigid casting mounted on the front face of the column. The knee

moves vertically along the guide ways and this movement enables to adjust the

distance between the cutter and the job mounted on the table. The adjustment is

obtained manually or automatically by operating the elevating screw provided below the

knee.

Saddle: The saddle rests on the knee and constitutes the intermediate part between

the knee and the table. The saddle moves transversely, i.e., crosswise (in or out) on

guide ways provided on the knee.

Table: The table rests on guide ways in the saddle and provides support to the work.

The table is made of cast iron, its top surface is accurately machined and carriers T-

slots which accommodate the clamping bolt for fixing the work. The worktable and

hence the job fitted on it is given motions in three directions:

a). Vertical (up and down) movement provided by raising or lowering the knee.

b). Cross (in or out) or transverse motion provided by moving the saddle in

relation to knee.

c). Longitudinal (back and forth) motion provided by hand wheel fitted on the

side of feed screw.

In addition to the above motions, the table of a universal milling machine can be

swiveled 45 to either side of the centre line and thus fed at an angle to the spindle.

Overarm:The Overarm is mounted at the top of the column and is guided in perfect

alignment by the machined surfaces. The Overarm is the support for the arbor.

Arbor support: The arbor support is fitted to the Overarm and can be clamped at any

location on the Overarm. Its function is to align and support various arbors. The arbor

is a machined shaft that holds and drives the cutters.

Elevating screw: The upward and downward movement to the knee and the table is

given by the elevating screw that is operated by hand or an automatic feed.


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MILLING EXERCISES

HEXAGONAL HEAD SHAPING


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MILLING A HEXAGONAL SURFACE

Ex. No: Date:

AIM:

To machine the hexagonal surface on the given block using horizontal milling

machine.

Machine:

Horizontal milling machine

Cutting tools:

Milling Cutter

Measuring and Marking tools:

Steel rule

Scriber

Divider

Verniercaliper

Punch

Hammer

Work Piece:

CI Round block (100, thickness35mm)

Work Holding Device:

Machine vice

Tool Holding Device:

Indexing Chuck


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Procedure:

The given workpieceis checked for its initial dimensions.

The width across the flat is first determined (Across flat = 1.5 S + 3 mm)

A universal dividing head is mounted on the table with its spindle swivelled to

the horizontal position.

The workpiece is mounted at the nose of the dividing head spindle by the help

of a suitable chuck.

The workpiece is centered below the cutter and the first cut is taken.

The workpiece is rotated through one sixth of a revolution by using the

indexing mechanism and then the second cut is taken. It is to be repeated for

six numbers of times to finish six faces of the work piece.

Calculation:

Diameter, D = 2 x S

Distance across the Flat = (1.5 x S) + 3mm

Depth of cut =

Indexing calculation:For Hexagonal surface,

The number of faces, Z = 6.

Simple Indexing =

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