Lab: 01

Title: Introduction & layout of manufacturing processes lab

Introduction
Manufacturing processes lab is all about machining operations. It has a wide variety of
experiments in which we cover about 8 to 10 different machining operations. Advance machine
shop in workshop is used for this lab. It provides a wide overview of different machines used for
performing different machining operations. Following are the experiments we will cover in this
lab:
Layout of advance machine shop

Figure 1 Layout Advance machine shop

Lab: 02
Title: taper turning by compound rest method
Objectives
 To know about taper turning
 To perform taper turning by compound rest method

Introduction
Compound rest method
This method is used to produce short and steep taper. The compound rest is swiveled to the
required angle and clamped in position, it can be moved up to 45° on both sides. This method
uses the principle of turning taper by rotating the work piece on the lathe axis and feeding the
tool at an angle to the axis of rotation of the work piece. The tool is mounted on the compound
rest which is attached to a circular base, graduated in degrees. The compound rest can easily be
swiveled or rotated and clamped at any desired angle.
The compound rest can be swiveled at 45° on either side of the lathe axis enabling it to turn a
steep taper. The movement of the single point cutting tool in this method is being purely
controlled by hand. Thus it provides a low production capacity and poor surface finish. The
positioning or setting of the compound rest is accomplished by swiveling the rest at the half taper
angle, if this is already known. If the diameter of the small and large end and length of taper are
known, the half taper angle can be calculated

Figure 2 Schematic of compound rest method

Tools required
 Single point cutting tool
 Lathe
 Vernier caliper
 Try square
 Chuck key

Procedure
1. First loosen the jaw in the chuck key to position the work piece, and then
tighten the jaws.
2. Fix the cutting tool in the tool post.
3. Switch on the lathe and move the carriage near to the work piece. Give it a
small cross feed, and then move carriage longitudinally to the required length
slowly.
4. Bring the carriage to the original position, give a small cross feed and
move carriage longitudinally. Repeat this step until required diameter is
obtained.
5. To get smooth surface give a very small feed when the diameter is
nearing the required value.
6. To face the end surface of the work piece, move the carriage to make the
tool touch the end surface of the work piece.
7. Then the taper turning operation is done on the work piece according to
the taper angle calculated. The compound rest base is swirled and set a
calculated taper angle, for this the tool is moved by 45o to the lathe axis.
8. The work piece is removed from the chuck and the dimensions of
work piece are checked for the requirement

Conclusion
So in this lab we have learned about compound rest method, also we have performed experiment
of taper turning using compound rest method.

Lab: 03
Title: To perform taper turning by Tail stock offset method
Objective
 To know about different parts and tools of lathe machine.
 To study taper turning by tail stock method.

Introduction
Taper turning
This is a process in which a conical surface is produced from a cylindrical work piece by gradual
reduction in its diameter.
Offset
It can be found with the help of the following formula
Entire length+Conicity
S=
2
D l−D s
Conicity=
l
Dl = Large diameter

Ds = Small diameter

l = Total length
Apparatus
 Lathe machine
 Work piece

Tools

 Chuck key, High speed steel (HSS) cutting tool bit, Outside calipers, tool holder with
key, spanner.

Procedure
1. In this method we shift the axis of rotation of the work piece, at an angle to the lathe axis,
and feeding the tool parallel to the lathe axis. Figure 1 shows the rotation of axis.

Figure 3 Rotation of axis

 2. The angle at which the axis of rotation of axis is shifted is equal to half of the angle of the
taper.
3. The body of the tailstock is made to slide on its base towards or away from the operator
by a set over screw.
4. The amount of set over being limited, this method is suitable for turning small taper on
long jobs.
5. Moreover, the lathe carrier being set at an angle, the angular velocity of the work is not
constant.

Precautions
1. The work piece should be fixed tight in a jaw.
2. Power supply must be switched off before measuring the diameters.

Conclusion
So in this lab we have performed the taper turning operation by using tail stock method.

Lab: 04
Title: Taper turning using taper attachment method
Objective
 to study taper turning using taper attachment method.
 To compare this method with other taper turning methods and conclude that this method
is better or accurate than the others.

Material
 Mild steel rod of 60 mm diameter and 350 mm long.

Apparatus
 Center lathe machine
 Adjustable spanner
 Spanner
 Chuck
 Chuck key
 L spanner
 Vernier caliper
 T handle tap wren
 Tapper attachment
 Point tool
 Figure 5 Center lathe machine Figure 4 Adjustable spanner

Figure 6 Spanner Figure 7 Chuck

Figure 8 Chuck Key Figure 9 L Spanner

Figure 10 Vernier caliper Figure 11 T handle tap wren

Introduction
Taper turning attachment
Taper Turning Attachment is very much popular and fits on all lathe machine. In ordinary
straight turning, the cutting tool moves along a line parallel to the axis of the work, causing the
finished job to be the same diameter throughout.
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 work piece to another part. Tapers can be either external or internal.
External taper: A work piece is tapered on the outside.
Internal taper: A work piece is tapered on the inside; it has an internal taper.
D−d
Taper angle: The angle is calculated using the formula, tanα=
2l

Advantages
i. Fast and consistent accuracy up to 300 mm Taper Turning job.
ii. It’s useful in threading on work piece inside as well as outside.
iii. Any length of work piece can be tuned.
iv. At set position accessory can be left. 
v. With taper turning we can easily do narrow boring.

Procedure
1. The work piece is fixed in a 3 jaws chuck with sufficient overhang losing and tightening
using chuck key
2. Adjust the machine to run the job to required cutting speed.
3. Fix the cutting tool (point tool) in the tool post using tool post key and centering
operation is performed so that the axis of the job coincides with the lathe axis.
4. Facing is performed by giving longitudinal depth of cut and cross feed.
5. Performing the turning operation until the diameter of work piece become 32 mm by
using Vernier caliper
6. Then facing operation perform until the length of the work piece become 300mm by
using Vernier caliper
7. Now set the taper angle 1.33 degree using taper attachment having calibrating scale
8. Once we set the angle tight the nut of taper attachment by spanner so that it does not
move during operation
9. After that we disengaged the compound slide wheel so that the compound slide does not
move during and do not disturb the taper angle
10. Now we adjust the tool so that it touches the work piece by using cross slide wheel of
interest depth
11. Now again start the lathe machine of required cutting speed
 12. Move the carriage gradually by carriage wheel so the tool cut the work piece
13. The process performs until the small diameter become 25mm by using Vernier caliper
14. So we get our required taper shape of work piece

Calculation of taper angle

d=25mm
L=300mm
D=32mm

tan ( α2 )= D−d
2l

α 35−25
tan ( )=
2 2(300)
α =1.33 °

Result
So we have obtained the taper shape of the given work piece according to the calculation of
angle.

Conclusion
So in this lab we have studied about taper turning using taper attachment method. We have also
compared it with other taper turning methods.

Lab: 06
Title: To study various parts of Capstan Lathe machine
Objectives

 To learn various components of capstan lathe machine

 Difference between central and capstan lathe machine

Introduction
Capstan lathe machine
It is lathe used to manufacture large number of identical parts in minimum time. It is used for
mass production.
Main parts of capstan lathe machine
Head Stock: It is a large casting located at the left hand side of the bed in which gears are
arranged in a required manner to control spindle speed.
Bed: It is a long box like casting with accurate guide ways upon which carriage and turret saddle
are mounted. Its strength is high.
Spindle Chuck: In heavy duty Turret Lathes for mass production normally air operated chucks
(pneumatic) are used. The chuck grips the work quickly and powerfully.
Cross Slide and Saddle: In small Capstan Lathes hand operated cross slide and saddle are used.
Turret: It is a hexagonal shape tool holder intended for holding six or more tools. It is mounted
on the auxiliary side i.e., directly mounted on the top of saddle.
Tools
For different purposes use different types of tools on lathe.
(1) Right hand tool
(2) Left hand tool
(3) Boring tool
(4) Grooving tool
(5) Parting off tool
(6) Forming tool
(7) Turning tool
(8) External thread cutting
(9) Internal thread cutting

Figure 14 Capstan Lathe Machine

Advantages
• In Capstan Lathe headstock with wider range of speeds is present and is of heavier in
construction and requires more power to drive the spindles.
• In Capstan four-way tool post to hold four tools at 900 is present, also a rear tool post for
holding another tool is present. A total of 11 tools can be attached.
• In Capstan Lathe the tail stock is replaced by turret which is a six sided block each side of
which may carry one or more tools.
• Two or more tools may be mounted on the same face on the turret making it possible to
machine more than one surface at a time. This feature reduces operational time.
• Labor cost is reduced in Capstan Lathe.

Lubrication
• Proper lubrication is very important. The accuracy of the lathe depends on the proper and
regular lubrication. Lubrication instructions are displayed in a lubrication chart.
• If the lubrication is neglected then the bearing surfaces may damage, impairing the
accuracy and shortening the life of the machine.
• Before putting the machine in operation, all the Oil cups, Apron, Norton Gear Box &
Head stock should be checked and filled with oil until the oil reaches the “Red Line” in
the oil sight glass.

Precautions
 Keep aware of the electrical hazards.
 Don’t wear loose dresses.
 Keep your eyes protected by wearing the goggles.

Conclusion
So in this lab we have studied about the milling machine and learned about its different parts.

Lab: 07
Title: to make a threaded bolt using Capstan Lathe machine
Objectives
 To learn different operations on capstan lathe machine
  To make a threaded bolt on Capstan Lathe Machine.

Parts used for making threads

1. Chasers
2. Self-opening die heads
3. Single point tools
4. Solid taps/collapsible taps

Procedure
1. Fix all the tools used for making hexagonal threaded bolt in turret.
2. Hold the work piece in spindle chuck to grip it properly.
3. Now set the turret stops according to the length of the work piece.
4. Now start the operation and at the end of each operation rotate the turnstile to change the
operation.
5. When the operations are completed then by using parting off tool cut the bolt from the
rod.

Turret

Work piece
(threaded bolt)

Figure 15 Thread bolt on Capstan Lathe

Precautions
  Keep aware of the electrical hazards.
 Don’t wear loose dresses.
 Keep your eyes protected by wearing the goggles.

Conclusion
So in this lab we have studied about different operations on milling machine and also we learned
the process of making threaded bolt using capstan lathe machine.

Lab: 08
Title: To study the parts of milling machine
Objective
• To learn basics about milling
• To learn Basic components of milling

Introduction
Milling
Milling is a metal removal process in which a work piece is fed against multiple cutters. Milling
is the process of machining using rotary cutters to remove material by advancing a cutter into a
work piece. This may be done varying direction on one or several axes, cutter head speed, and
pressure. In milling machine, the work piece is stationery and the cutting tools moves.

Types of milling
Depending upon the direction of feeding of work piece, milling can be divided into two
categories.
a. Up milling
b. Down milling

Up milling
When the work piece is fed against the direction of the cutter then the milling is known as up
milling. Cutting force in this case in minimum at first and maximum at last.
Disadvantages
  Jerking effect is produced due to lifting up of cutter as more material comes in contact
with cutter gradually.
 Splashing of coolant occurs as the cutter moves in opposite direction

Down milling
In this case work piece is fed in the direction of cutter. Cutting force is maximum at start and
minimum at the end. Down milling is always the preferred method wherever the machine tool,
fixture and work piece will allow. In peripheral down milling, the chip thickness will decrease
from the start of cut, gradually reaching zero at the end of cut.

Parts of milling machine

a. Base
The base of milling machine is mounted on its upper and lower surfaces. it holds all other parts
of milling machine. On one side of it is column and on the other side guide way, which helps
movement in upward and down ward direction. The base also serves as a reservoir of coolant
used in different processes.

b. Column
Column is the main supporting frame in vertical direction. It has all driving mechanisms for
spindle and table feed. The front face of column also supports the knee. The top is used to
support the over arm that extends outward at the front of the machine.

c. Knee
Knee slides up and down on the vertical ways of column face. This movement is adjusted by an
elevating screw mounted on the base which also supports the knee. The knee has the driving
mechanism for feed and different controls to operate it.

d. Saddle
Saddle is on the top of the knee which slides on the guide ways set exactly to the column face.
saddle can be moved horizontally to apply cross feed. This is done by a screw which is present
on knee and engages nut on the bottom of the saddle.

e. Table
The table rests on the ways on the saddle and travels longitudinally. Table can also be moved
horizontally by lead screw which engages a nut on the saddle. in universal machines table can be
swiveled horizontally.

f. Overhanging arm
The overhanging arm is present on the top of column which extends beyond the column face and
serves as a bearing support for the other end of the arbor.
 g. Spindle
The spindle is located on the upper part of the machine and receives power from the motor
through belts and pulleys, gears, clutches and transmit to the arbor.

h. Arbor
Arbor is an extension of the spindle on which milling cutters are securely mounted and rotated
the arbors are made with taper shanks for proper alignment with the machine. arbor consist of
i. Draw bolt
ii. Locknut
iii. Spindle
iv. Key block
v. Arbor
vi. Setscrew
vii. Spacing
viii. Cutters
ix. Bearing bush

Figure 16 Milling Machine

Conclusion
So in this lab we have studied about the milling machine and learned about its different parts.

Lab: 09
Title: to make a spur gear using milling machine
Objectives
 To learn about operations on milling machine.
 To make a spur gear on milling machine

Introduction
Spur gear
Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk
with teeth projecting radially.

Figure 17 Spur Gear

Indexing
The indexing head is the operation of dividing the periphery of a work piece into any number of
equal parts. While cutting the spur gear, an equal spacing of the teeth on the gear blank is
performed by indexing. The indexing can be achieved by using a special attachment known as
dividing head or index head.
Formula: 40/n, where n is the number of teeth. We have to write the answer of this formula into
the mix fraction form. Then from those values we will set the index head.

Outer diameter of Gear

( n+2 )∗Cp
It is calculated by using the formula: O.D =
π
Depth of the cut
It is calculated using: 0.86/TPI, TPI = threads per inch

Procedure
1. We first fix the disc shaped work piece in machine
2. Then we do indexing and set the index head.
3. Then we select the suitable cutting tool of the required depth.
4. Then we start the operation and make the spur gear.

Figure 18 Spur Gear using Milling

Conclusion
So in this lab we have learned about different concepts used in making spur gears and also we
have learned the operation of making spur gear using milling machine.

Lab: 10
Title: To study various parts of shaper machine
Objective
To study various parts of a shaper machine.

Introduction
Shaping
Shaping is the process of machining a flat surface which may be horizontal, vertical, inclined,
concave or convex. The machine used for shaping operation is called shaper machine. The work
piece performs transverse motion. Transverse motion of the work piece resulting in a flat surface
by gradual removal of excess material layer by layer.

Parts of Shaper machine

Following are the main parts of shaper machine
Base: It is a box type casting which provide support to all the components of a shaper.
Column: It is also a box type casting. It encloses all the mechanisms of a shaper machine such
as conversion of rotatory to reciprocator motion mechanism and stroke length adjustment
mechanism.
Cross Rail: It is used to move the rail up and down.
Table: Table is the most important component of a shaper machine. It provides support to the
work piece. Its top and sides are perfectly machined. There is a T-slot on the table to clamp the
work piece.
Ram: Ram is the reciprocating member of the shaper machine which converts the rotational
motion of motor into the reciprocator motion.
Tool head: Tool head provide the feed to the tool.

Figure 19 Shaper Machine

Types of Shaper machine

Based on mechanism
 1. Crank mechanism
2. Hydraulic mechanism
3. Geared mechanism

Based on design of table

1. Plane shaper
2. Heavy duty shaper
3. Standard shaper
4. Universal shaper
Based on position and travel of ram
1. Horizontal shaper
2. Vertical shaper

Precautions
1. Keep aware of the electric hazards.
2. Don’t wear loose dresses.
3. Keep your eyes protected by wearing the goggles

Conclusion
So in this lab we have learned about shaping process, shaper machine and different parts of
shaper machine.

Lab: 11
Title: To make a rectangular part on shaper machine
Objectives
To perform different operations and make a rectangular part on shaper machine.

Introduction
We can perform different operations using shaper machine. Some of them are:
Regular operations
Operations performed on flat horizontal surfaces, vertical surface, and inclined surfaces are
called regular operations.
Special operations
These operations include external and internal T-slots, rack gears etc.
Procedure
• Work piece is fitted on the machine table.
• Then point cutting tool is fitted in the tool post of a shaper machine.
• The height of table is adjusted by cross rail handle.
• Set the stroke length of the ram by using stroke adjustment screw.
• Then start the machine.
• The Ram will start reciprocating and the point cutting tool will start removing the extra
material.
• By using cross feed adjustment screw, feed is given to the work piece for better and
uniform surface finish.

Precautions
1. Keep aware of the electrical hazards.
2. Don’t wear loose dresses.
3. Keep your eyes protected by wearing the goggles.

Conclusion
So in this lab we have performed operation on shaper machine and we have made a rectangular
part.

Lab: 12
Title: To study parts of sensitive drilling machine
Objectives
To study various parts of sensitive drilling machine.

Introduction
Drilling
Drilling is an operation to make a new round hole in a work piece. It is performed using drilling
machine.

Types of drill machine

a. Portable drill machine.
b. Sensitive drill machine.
Portable drill machine
A magnetic drill is a portable machine for drilling holes in large and heavy work pieces which
are difficult to move.

Sensitive drill machine

It is a light weight, high speed machine designed for drilling small holes in light jobs. The
machine has only a hand feed mechanism for feeding the tool into the work piece. This enables
the operator to feel how the drill is cutting and accordingly he can control the down feed
pressure.

Parts of drilling machine

Drill chuck: Tool used for drilling operation.
Electric motor: Produce rotatory motion.
Belts: Transmitting rotatory motion of motor to drill bit chuck.
Pulley: Belt and electric motor attached through pulley and belt arrangement.
Guard: To protect sensitive parts of machines from surroundings.
Hond feed: For feeding drill bit.
Spindle clamp: for fixing spindle within place.
Spindle: Rotatory part to which Drill bit chuck is attached.
Regular work table: for supporting the job.
Base table: Support whole weight of the machine.
Table clamp: Fix the work table.
Column: The column is a vertical post that holds the worktable and the head containing the
driving mechanism. The column may be of round or box section.
Conclusion
So in this lab we have learned about drilling, drilling machine and types of drilling machine.
Also we have learned about different parts of drilling machine.

Lab: 13
Title: Practical regarding drilling operations such as counter boring,
counter sinking etc.
Objectives
To learn about different operations performed on drilling machines.

Apparatus
Sensitive drilling machine

Figure 21 Sensitive drilling machine

Principle
It works on the principle of rotation. Usually a drill bit is a tool which is used to make hole. Drill
bit is driven by an electric motor. Power is transmitted to drill bit (or spindle) with the help of
Belt and pulley. It is operated on various speeds depending upon the sizes of pulleys.

Counter boring
Counter boring: Counter boring is the operation of enlarging one end of an existing hole
concentric with the original hole with square bottom

Counter sinking
Counter sinking is the operation of making a cone shaped enlargement at the end of a hole to
provide recess for a flat head screw or a countersunk rivet.

Procedure
a. Fix the desired drill bit in the spindle.
b. Clamp the work-part on the holding table of machine.
c. Adjust the table so that the desired point on which hole is to be drilled, should be straight
beneath the drill bit.
d. Turn the drill machine ON.
e. Start drilling the hole & slowly feed the tool downward with the help of feed handle.
f. Unclamp the work-piece after drill is completed.

Safety precautions
a. Keep aware of the electrical hazards.
b. Don’t wear loose dresses.
c. Keep your eyes protected by wearing the goggles.

Lab: 14
Title: To study Universal Cylindrical Grinding Machine
Objectives
To know about universal grinding machine and its parts.
Introduction
Grinding
Grinding is generally known as the Abrasive machining. Abrasive machining is the surface
finish and material removal process from the work piece surface in the form of minute particles.
The removal of material takes place by the process of a typical shaped abrading particle.
Abrasive particles are used in bonds wheel, coated belts or simply loose particles. Grinding is the
material removal and a surface finish process in which the material is removed from the work
surface in the phase of small chips by process of tiny abrasive particles of grinding wheel.
Surface finishing process is generally the last operation performed to obtain the higher surface
finish.
Wear rate: Cylindrical grinding process parameters to measure the effects on Surface are wear
rate, Material Removal rate etc.

Surface finishing process

The various machining operations are performed on the work piece material to produce the
required shape and size of the product with high surface finish. When the work piece is subjected
to different manufacturing operations, intense mechanical stresses and localized heating get
involved in the process, thus create machining marks on the surface of the work piece. In
combination with the machine, the work piece and tool on which they mounted to create a
vibratory system responsible for random, forced or induced vibration. Because of the vibrations,
the machined component surfaces get damaged in terms of surface finish and surface integrity.
The degree of surface finish describes the geometry and micro structural quality of the machined
surface.

Grinding machine
A grinding machine, generally abbreviated to the grinder (surface or cylindrical), is any of power
apparatuses utilized for surface finishing. Rough wheel is employed for grinding as the cutting
tool. Each grain on the outer surface of wheel cuts a little chip from the work piece by shear
distortion.
Mechanism

Advantages of Grinding process

• Working principle and operation is simple.
• It does not require additional skills
• Surface finishing will be approximate 10 times better as compared to milling and turning
process of machining.
• Dimensional accuracy will be quite good. 
• Grinding process could be performed on hardened and unhardened work piece.

Conclusion
In this lab we have discussed grinding process, grinding machine and its advantages.
Lab: 15
Title: perform practical for finishing cylindrical surface
Objectives
• To study external cylindrical grinding on given work piece by using universal grinding
machine.
• To know how to operate universal grinding machine.

Material
Aluminum rod having diameter 2.1 in and length 12 in.

Apparatus
Universal Grinding machine

Figure 23 Universal Grinding Machine

Theory
Cutting speed
• It is the comparative peripheral angular velocity of the abrasive grinding wheel with
respect to the work material. The mathematical formula used to calculate the cutting
π .D. N
speed is: V = , where D = diameter of grinding wheel (mm), N = grinding wheel
100
revolution (rpm) V = Cutting velocity of wheel (mph).

Feed rate
It is the longitudinal apparent motion of the work material relative to the axis of abrasive wheel
rotation. It is measured in mm/revolution. The feed rate is used to compute and estimate the total
time taken for grinding. The total time taken for grinding process can be calculated by following
L× I
equation: T = ×K
S× N
where
T = time taken for grinding (min) L = longitudinal travel (mm). I = number of passes, S = feed
rate (mm/rev.).
N = Grinding wheel revolution (rpm) and
K = coefficient depends upon the designated degree of accuracy and level of surface finish
Values of coefficients generally taken for rough grinding, K = 1 to 1.2; and for finish grinding,
K = 1.3 to 1.5.

Depth of cut
It is the thickness of the work piece layer removed in individual exceed. It is generally measured
in mm. It is maintained ranging from 0.005 to 0.04 mm normally. For precision grinding, smaller
depths of cuts are set.

Procedure
1. The work piece is fixed in 3 jaws chuck with sufficient overhang losing and tightening
using chuck key.
2. Support the other end of work piece by tail stock.
3. Give angle to the wheel head having calibration by losing nut using spanner if needed,
here we won’t have needed.
4. Now switch on motor of head stock such that it rotates the work piece. 
 5. Then switch on the grinding wheel by pushing the (ON and OFF) button to the right-front
side of machine.
6. Now start the feeding by rotating wheel moment hand wheel slightly.
7. The process continues until we get 2 in. diameter of rod (work piece) measure by using
Vernier caliper.
8. Thus we get our required aluminum rod having better surface finish.

Result
We get our required aluminum rod having diameter 2 in. and length 12 in.

Precautions
a. The work piece must rotate.
b. The Abrasive wheel must revolve.
c. The work piece must pass the wheel.
d. The grinding wheel must pass the work