TABLE OF CONTENTS

Ex. No.

1
2
3
4
5
6
7
8

DATE

Name of the Experiment

Page No.

Remarks

Staff
Signature

Ex. No : 1
Date :
STUDY OF BASIC MACHINING LATHE
SAFETY PRECAUTIONS FOR MACHINING WORK

Job should be tightly held in the chuck.

If the job is held in between the centres, then apply grease on the nose of dead centre,
otherwise it will burnt out due to excess heat.

Do not measure the job while the work piece is rotating.

Do not leave the chuck key in the chuck.

Do not try to stop the lathe chuck or job with hands.

Do not handle metal chips by hand.

Do not give more depth of cut while the job is rotating at high speed.

Tighten the tool in the tool post.

Do not stand close to the rotating work piece and do not bring your face close it.

Do not reduce or increase the speed when the lathe operation is going on.

PRINCIPLE OF LATHE
In lathe the work piece is held in the chuck, a work holding device. The cutting tool is
mounted in the tool post. The chuck is rotated by means of electric power. When the chuck
rotates the work piece also rotates. The tool is moved against the rotating work piece by
giving small amount of depth of cut. Here the material is removed in form of chips.
Lathe machine has the following parts as shown in figure:

Bed

Compound rest

Head stock

Tool post

Carriage

Apron

Saddle

Lead screw

Cross slide

Tailstock

BED
It is the base of the machine on its left side the head stock is mounted. A movable casing
called tail stock is mounted on the right side.

HEAD STOCK
It consists of a spindle, gears and speed change levers. It is used to transmit the motion of
the job.
CARRIAGE
Carriage is used to carry a tool to bring it in contact with the rotating work piece or to
with draw from such a contact.
SADDLE
It is H shaped part fitted on the lathe bed. There is a hand wheel to move it on the bed
way. Cross slide, compound rest and tool post are fitted on this saddle.
CROSS SLIDE
It is on the upper side of saddle in the form of dove tail. A band wheel is provided to drive
the cross slide.
COMPOUND REST
It is fitted over the cross slide on a turn table. It permits both parallel and angular
movements to the cutting tool.
TOOL POST
It is fitted on the top most part of compound rest. Tool is mounted on this tool post.
Cutting tool is fixed in it with the help of screw.
APRON
It is the hanging part in front of the carriage. It accommodates the mechanism of hand and
power feed to the cutting tool for carrying out different operations.
HEAD SCREW
It is a long screw with ACME threads. It is used for transmitting power for automatic
feed or feed for thread cutting operating.
TAIL STOCK
It is located at the right end of the lathe bed and it can be positioned anywhere in the bed.
It is used for supporting lengthy jobs and also carries tool to carry out operations such as
tapping, drilling and reaming.

LATHE OPERATIONS
Simple Turning
It is operation for reducing the diameter of the work piece. The turning tool is used for
this operation. More feed of tool is given for rough turning. Then, less feed is given for
finishing.
In this operation, work is held in chuck and tool is set to the centre height of the work
piece.
Taper Turning
Taper is defined as the uniform change in the diameter of a work piece measured along its
length.
Calculation for taper turning
Taper = (D d) / 2L
Where,
D = larger diameter
d = smaller diameter
L = length of taper
Taper turning operation shown in figure.
This can be done by the following methods:
1. Compound rest method
2. Tail stock set over method
3. Using form tool
4. Taper attachment method.
Drilling
Drilling is the operation of making a hole on the work piece. Here the job is held in the
tail stock sleeve. Feed is given by rotating the hand wheel in the tail stocks which pushes
the tailstock sleeve
Facing
It is done for getting fine finish on the face of the job. Facing tool is set at an angle to the
work piece. In this operation the tool is fed from the centre of work piece towards the
outer surface against the rotating work piece. Depth of cut is low for the facing operation.
Step turning

It is similar to the process of turning but in this case different diameter in step of various
sizes are taken on the work piece roughing tool i.e. used for rough turning and the knife
tool is used for finishing cut.
Boring
It is the process of enlarging a drilled hole. A special type of boring tool is used for this
purpose.

RESULT

Ex. No: 2
Date:
FACING, PLAIN TURNING AND STEP TURNING
AIM:
To obtain the required shape and size of the given work piece by facing, plain
turning and step turning.
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOLS REQUIRED:

Single point cutting tool

Vernier calliper

Steel rule

Outside Calliper

Marking Gauge

Chuck Key

Tool post Key

SEQUENCE OF OPERATIONS:

Facing

Turning

Step Turning

PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece, and then
tighter the jaws
3. Check the center of the job using marking gauge. If the center of the job is not in the
lathe axis readjust the chuck and fix the job in the lathe axis

4. Fix the single point cutting tool in the tool post

5. Select the corresponding spindle speed and feed the before starting the operation
6. Switch ON the lathe and do the facing operation on the one side of the job
7. Move the carriage near the work piece. Give it small cross feed and then move the
carriage
8. Then stop the machine, release the chuck, mark the length, invert the job and refax in
the chuck
9. Do the facing operation on the other side of the job.
10. Then the plain turning is done to reduce the diameter of the work piece
11. Finally, the dimensions of work piece are again checked

RESULT:
Thus the required size and shape of the given work piece is obtained using facing,
plain turning and step turning.
Ex. No: 3
Date:
TAPER TURNING AND KNURLING
AIM:
To obtain the required shape and size of the given work piece by taper turning and
knurling.
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOL REQUIRED:

Single point cutting Tool.

Vernier Calliper

Steel rule

Outside Calliper

Marking Gauge

Knurling Tool

Chuck Key

Tool post Key

SEQUENCE OF OPERATIONS:

Taper Turning

Knurling

CALCULATION:
Taper turning:
The angle is determined by using the formula,
Tan = (Dd)/2L

Where
D=Larger diameter of the work piece
d=smaller dia of the work piece
L=taper length of the work piece
PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece.
3. Check the center of the job using marking gauge.
4. Fix the single point cutting tool in the tool post.
5. Select the corresponding spindle speed and feed the before starting the operation.
6. Work the taper length on the job.
7. Calculate the taper angle and then the compound rest is rotated to the required
angle.
8. The taper turning operation is done on the workpiece according to the taper angle
calculated. The compound rest base is swirled and set at the calculated angle, for
this the tool is moved by 45o to the lathe axis.
9. Now the turning tool is replaced by knurling tool.
10. The Knurling tool is pressed against the rotating job.
11. Then the tool is fed parallel to the lathe axis and the diamond shaped impression is
produced on the cylindrical surface of the workpiece.
12. Finally, the dimensions of work piece are again checked

RESULT:
Thus the required shape and size is obtained using taper turning and knurling.
Ex. No: 3
Date:
THREAD CUTTING
AIM:
To obtain the required shape and size of the given work piece by thread cutting.
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOL REQUIRED:

Single point cutting Tool.

Vernier Calliper

Steel rule

Outside Calliper

Marking Gauge

Thread cutting tool

Thread pitch gauge

Chuck Key

Tool post Key

SEQUENCE OF OPERATIONS:

Internal Thread Cutting

CALCULATION:
Thread Cutting:
(Driver teeth)/ (Driven teeth) = (Pitch of the work)/ (Pitch of the lead screw)
PROCEDURE:

1. The given workpiece is held in the lathe and it is rotated about the lathe axis.
2. The facing and plain turning operations are carried out to the required dimensions.
3. The turning tool is replaced by thread cutting tool.
4. The gear ratio is calculated and the suitable size gears are fitted in the change
train.
5. The V tool is moved till the tool touches the Job.
6. The tool is moved away from the job end. After giving suitable depth of cut, the
half nut is engaged.
7. The tool is moved towards the headstock in helical path and the thread is
produced.
8. At the end of each cut the tool is withdrawn. Then the spindle of the machine is
reversed and the tool is moved towards tail stock.
9. The required depth of cut is given and the cycle is repeated to obtain the required
depth.

RESULT:
Thus the required shape and size is obtained using thread cutting.
Ex. No: 5
Date:
BORING
AIM:
To obtain the required shape and size of the given work piece by boring.
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOL REQUIRED:

Single point cutting Tool.

Vernier Calliper

Steel rule

Outside Calliper

Marking Gauge

Boring Tool

Chuck Key

Tool post Key

SEQUENCE OF OPERATIONS:

Boring

PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece.
3. Check the center of the job using marking gauge.
4. Fix the single point cutting tool in the tool post.

5. Select the corresponding spindle speed and feed the before starting the operation
6. The drill is fitted in the tail stock spindle
7. The tail stock is moved over the bed and chambered near the work piece
8. When the job rotates, the drill bit is fed into work by turning tail stock hand wheel
upto required path
9. Then Boring tool is fitted on the tool post and fed parallel to the axis of lathe
10. Boar the work piece to required diameter.

RESULT:
Thus the required shape and size is obtained using Boring.
Ex. No: 6
Date:
MACHINING OF HEXAGON IN SHAPING MACHINE
AIM:
To machine a hexagon in the given workpiece to the dimensions as shown in the
figure using Shaping Machine.
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOL REQUIRED:

Shaping Machine

Scriber

Divider

Steel Rule

Chalk piece

Bevel Protractor.

SEQUENCE OF OPERATIONS:

Shaping

PROCEDURE:
1. The given workpiece is measured for its initial dimensions.
2.

With the help of scriber, mark the hexagon dimensions in the workpiece.

3.

Fix the workpiece in the vice of the shaping machine.

4. After fixing the workpiece and the shaping tool, allow the ram to reciprocate.
5. Start the shaping process by giving the required depth by lowering the tool.

6. Slowly increase the depth of cut and repeat the procedure to make the hexagon
shape.
7. The workpiece is now checked for final dimensions.

RESULT:
Thus, a hexagon is machined in the given workpiece to the dimensions as shown
in the figure using Shaping Machine.
Ex. No:7
Date:
SPUR GEAR MILLING
AIM:
To machine a spur gear to the given module and number of teeth in the given
workpiece.
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOL REQUIRED:

Milling machine

Vernier caliper

Mandrel.

SEQUENCE OF OPERATIONS:

Milling

PROCEDURE:
1. Calculate the gear tooth proportions.
Blank diameter = (Z + 2) m
Tooth depth
= 2.25 m
Tooth width
= 1.5708 m
Where,
Z = Number of teeth required
m = module
2. Indexing calculation
Index crank movement = 40 / Z
3. The dividing head and the tail stock are bolted on the machine table. Their axis must
be set parallel to the machine table.
4. The gear blank is held between the dividing head and tailstock using a mandrel. The
mandrel is connected with the spindle of dividing head by a carrier and catch plate.

5. The cutter is mounted on the arbor. The cutter is centred accurately with the gear
blank.
6. Set the speed and feed for machining.
7. For giving depth of cut, the table is raised till the periphery of the gear blank just
touches the cutter.
8. The micrometer dial of vertical feed screw is set to zero in this position.
9. Then the table is raised further to give the required depth of cut.
10. The machine is started and feed is given to the table to cut the first groove of the
blank.
11. After the cut, the table is brought back to the starting position.
12. Then the gear blank is indexed for the next tooth space.
13. This is continued till all the gear teeth are cut.
CALCULATION:
Z = No. of teeth
m = module

= 23
= 2 mm

Blank Diameter

= (Z + 2) m
= (23 + 2) 2
= 50 mm

Tooth Depth

= 2.25 m
= 2.25 * 2
= 4.5 mm

Indexing Calculation = 40 / Z
= 40 / 23
= 1 17/23

RESULT :

Thus the required gear is machined using the milling machine to the required number of
teeth.