MACHINIST

NSQF LEVEL - 5

2nd Year (Volume - I of II)

TRADE PRACTICAL

SECTOR: Capital Goods and Manufacturing

DIRECTORATE GENERAL OF TRAINING

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
GOVERNMENT OF INDIA

NATIONAL INSTRUCTIONAL
MEDIA INSTITUTE, CHENNAI
Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032
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Sector : Capital Goods and Manufacturing
Duration : 2 Years
Trade : Machinist - 2nd year (Volume I of II) Trade practical - NSQF (Level -5)

Developed & Published by

National Instructional Media Institute

Post Box No.3142
Guindy, Chennai - 600032
INDIA
Email: [email protected]
Website: www.nimi.gov.in

Printed by
National Instructional Media Institute
Chennai - 600032

First Edition : March: 2020 Copies : 500

Rs. 155/-

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 FOREWORD
The Government of India has set an ambitious target of imparting skills to 30 crores people, one out of every
four Indians, by 2020 to help them secure jobs as part of the National Skills Development Policy. Industrial
Training Institutes (ITIs) play a vital role in this process especially in terms of providing skilled manpower.
Keeping this in mind, and for providing the current industry relevant skill training to Trainees, ITI syllabus
has been recently updated with the help of Mentor Councils comprising various stakeholders viz. Industries,
Entrepreneurs, Academicians and representatives from ITIs.

The National Instructional Media Institute (NIMI), Chennai, has now come up with instructional material to
suit the revised curriculum for Machinist , 2nd Year (Vol I of II) Trade practical - NSQF Level - 5 in
Capital goods & Manufacturing Sector under yearly Pattern required for ITIs and related institutions
imparting skill development. The NSQF Level - 5 will help the trainees to get an international equivalency
standard where their skill proficiency and competency will be duly recognized across the globe and this will
also increase the scope of recognition of prior learning. NSQF Level - 5 trainees will also get the opportunities
to promote life long learning and skill development. I have no doubt that with NSQF Level - 5 the trainers
and trainees of ITIs, and all stake holders will derive maximum benefits from these Instructional Media
Packages IMPs and that NIMI's effort will go a long way in improving the quality of Vocational training in the
country.

The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation
for their contribution in bringing out this publication.

Jai Hind

Director General
Directorate General of Training
Ministry of Skill Development & Entrepreneurship,
Government of India.

New Delhi - 110 001

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 PREFACE
The National Instructional Media Institute (NIMI) was established in 1986 at Chennai by then Directorate
General of Employment and Training (D.G.E & T), Ministry of Labour and Employment, (now under Directorate
General of Training, Ministry of Skill Development and Entrepreneurship) Government of India, with technical
assistance from the Govt. of Federal Republic of Germany. The prime objective of this Institute is to develop
and provide instructional materials for various trades as per the prescribed syllabus under the Craftsman
and Apprenticeship Training Schemes.

The instructional materials are created keeping in mind, the main objective of Vocational Training under
NCVT/NAC in India, which is to help an individual to master skills to do a job. The instructional materials are
generated in the form of Instructional Media Packages (IMPs). An IMP consists of Theory book, Practical
book, Test and Assignment book, Instructor Guide, Audio Visual Aid (Wall charts and Transparencies) and
other support materials.

The trade practical book consists of series of exercises to be completed by the trainees in the workshop.
These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The trade
theory book provides related theoretical knowledge required to enable the trainee to do a job. The test and
assignments will enable the instructor to give assignments for the evaluation of the performance of a trainee.
The wall charts and video clips are unique, as they not only help the instructor to effectively present a topic
but also help him to assess the trainee's understanding. The instructor guide enables the instructor to plan
his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations.

IMPs also deals with the complex skills required to be developed for effective team work. Necessary care
has also been taken to include important skill areas of allied trades as prescribed in the syllabus.

The availability of a complete Instructional Media Package in an institute helps both the trainer and
management to impart effective training.

The IMPs are the outcome of collective efforts of the staff members of NIMI and the members of the Media
Development Committees specially drawn from Public and Private sector industries, various training institutes
under the Directorate General of Training (DGT), Government and Private ITIs.

NIMI would like to take this opportunity to convey sincere thanks to the Directors of Employment & Training
of various State Governments, Training Departments of Industries both in the Public and Private sectors,
Officers of DGT and DGT field institutes, proof readers, individual media developers and coordinators, but for
whose active support NIMI would not have been able to bring out this materials.

R. P. DHINGRA
Chennai - 600 032 EXECUTIVE DIRECTOR

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 ACKNOWLEDGEMENT
National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and contribution
extended by the following Media Developers and their sponsoring organisation to bring out this IMP (Trade Practical)
for the trade of Machinist under the Capital goods & Manufacturing Sector for ITIs.

MEDIA DEVELOPMENT COMMITTEE MEMBERS

Shri. N. Manoharan - Asst. Training Officer,

Govt.I.T.I. Chengalpattu.

Shri. R. Kumaresan - Asst. Training Officer,

Govt.I.T.I. North chennai.

Shri. M. Sambath - Training Officer

Govt.I.T.I. Guindy

Shri. G. Loganathan - Asst. Training Officer

Govt.I.T.I. Ambuttur

Shri. T. Janakiram - Asst. Director (Retd)

Govt.R.I.C. (Norht)

Shri. R. Kannan - DGM (Retd)

SIDCO

Shri. Subrath polley - I.T.I. Durga pur

Shri. Ashiskamilya - I.T.I. Howran homes

NIMI CO-ORDINATORS

Shri. Nirmalaya Nath - Deputy Director of Training

NIMI, Chennai - 32.

Shri. V. Gopalakrishnan - Assitant Manager,

Co-ordinator, NIMI, Chennai - 32

NIMI records its appreciation of the Data Entry, CAD, DTP Operators for their excellent and devoted services in
the process of development of this Instructional Material.
NIMI also acknowledges with thanks, the invaluable efforts rendered by all other staff who have contributed for the
development of this Instructional Material.
NIMI is grateful to all others who have directly or indirectly helped in developing this IMP.

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 INTRODUCTION
TRADE PRACTICAL
The trade practical manual is intented to be used in workshop . It consists of a series of practical exercises
to be completed by the trainees during the one year course of the Machinist trade supplemented and supported
by instructions/ informations to assist in performing the exercises. These exercises are designed to ensure that
all the skills in compliance with NSQF LEVEL - 5

The manual is divided into four modules. The distribution of time for the practical in the four modules are given
below.

The skill training in the shop floor is planned through a series of practical exercises centred around some
practical project. However, there are few instances where the individual exercise does not form a part of project.

While developing the practical manual a sincere effort was made to prepare each exercise which will be easy
to understand and carry out even by below average trainee. However the development team accept that there
is a scope for further improvement. NIMI, looks forward to the suggestions from the experienced training faculty
for improving the manual.
Module 1 - Tool and cutter grinding
Module 2 - Advance Milling
Module 3 - Electrical & Electronics
Module 4 - CNC Turning
The material is not the purpose of self learning and should be considered as supplementary to class room
instruction
TRADE THEORY
The manual of trade theory consists of theoretical information for the Year of the Machinist Trade. The contents
are sequenced according to the practical exercise contained in the manual on Trade practical. Attempt has
been made to relate the theortical aspects with the skill covered in each exercise to the extent possible. This
co-relation is maintained to help the trainees to develop the perceptional capabilities for performing the skills.

The Trade theory has to be taught and learnt along with the corresponding exercise contained in the manual
on trade practical. The indicating about the corresponding practical exercise are given in every sheet of this
manual.

It will be preferable to teach/learn the trade theory connected to each exercise atleast one class before
performing the related skills in the shop floor. The trade theory is to be treated as an integrated part of each
exercise.

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 CONTENTS

Exercise No. Title of the Exercise Learning Page No.

Outcome
Module 1 : Tool and cutter grinding
3.1.115 Demonstrate and practice of grinding of different single point tools 1
3.1.116 Demonstrate and practice of grinding of slab milling cutter 5
3.1.117 Re-sharpening side and face milling cutter 1 8
3.1.118 Demonstrate and practice of grinding of end mill cutter 11
3.1.119 Resharpening of shell end mill cutter 14

Module 2 : Advance Milling

3.2.120 Practice of facing on milling machine 16
3.2.121 Drill on P.C.D. on Milling Machine with accuracy ± 0.02 mm 19
3.2.122 Perform tapping and reaming operation using milling machine with
an accuracy ± 0.02 mm 21
3.2.123 Perform spot facing operation using milling machine with accuracy
± 0.02 mm 23
3.2.124 Make a slot on face of the Job using milling machine with an
accuracy ± 0.02 mm 25
3.2.125 Make Internal Grooving using Milling Machine with an accuracy
± 0.02 mm 28
3.2.126 Make straight teeth Rack using Milling Machine with an accuracy
0.05 mm 29
3.2.127 Make helical teeth rack using milling machine with an accuracy 2
0.05 mm 31
3.2.128 Measurement of teeth by vernier gear tooth caliper 34

3.2.129 Make spur gear using simple indexing with an accuracy 0.05 mm 36
3.2.130 Make spur gear using differential Indexing with an accuracy 0.05 mm 38
3.2.131 Perform boring operation on vertical milling machine with an accuracy
0.05mm 40
3.2.132 Make helical gear on milling machine with an accuracy 0.05 mm 42
3.2.133 Make straight flute milling on milling machine with an accuracy 0.05
mm 45
3.2.134 Make helical flute on milling machine with an accuracy 0.02 mm 47

Module 3 : Electrical & Electronics

3.3.135 Measure current, voltage and resistance using simple ohms law
circuits and familiarizing multi meter 56
3.3.136 Soldering Techniques, Solder copper conductor joints 59
3.3.137 Step up and step down transformers 61

3.3.138 Working with solenoids and relays 63

3.3.139 Working of motor & generators 65
3.3.140 Behaviour of proximity sensors 67
3.3.141 Behaviour of ultrasonic sensors 70

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Exercise No. Title of the Exercise Learning Page No.
Outcome
3.3.142 Logical Operation of Sensors 72
3.3.143 Limit & Level control using sensors 3 74
3.3.144 Interfacing of sensors with electrical actuators 75

Module 4 : CNC Turning

3.4.145 Personal and CNC machine safety, safe handling of tools safety
switches & material handling 76
3.4.146 Demonstration of CNC lathe machine its parts and function 78
3.4.147 Working of CNC machine parts by using multimedia based
simulator 80
3.4.148 Identify machine over travel limits and emergency stop on the
machine 81
3.4.149 Tool path for turning, facing, grooving, threading and drilling 82
3.4.150 Identification of safety switches and interlocking of DIH modes 84
3.4.151 Identify common tool holder and insert shapes by ISO
nomenclature 85
3.4.152 Select cutting tool holder and insert for each operation 89
3.4.153 Fix inserts on the tool holder 90
3.4.154 Cutting tool material for various applications 91
3.4.155 Cutting parameters from tool manufacturer’s catalogue, cutting
speed and feed 92
3.4.156 Linear interpolation and circular interpolation assignments and
simulation on software 93
3.4.157 Write simulate CNC part programming using simulator with 4
canned cycles 95
3.4.158 Avoiding collisions caused by program errors, by making
deliberate program errors and verification/simulation software 97
3.4.159 Conduct a preliminary check of readiness of the CNC turning
centre 99
3.4.160 Starting the machine, do homing on CNC simulator 100
3.4.161 Facing and turning program 102
3.4.162 Mounting Jaws to suit the part holding area on CNC machine 103
3.4.163 Mounting tools on the turret according to part & process required 104
3.4.164 Perform work and tool setting 105
3.4.165 CNC turning centre operation in various modes (EDIT, MDI, SBL
& AUTO Mode) 106
3.4.166 Entering the tool offset, tool nose radius and orientation for TNRC
in offset page on CNC simulator 108
3.4.167 Program checking in dry run single block mode 110
3.4.168 Absolute & incremental programming assignments by simulation 111
3.4.169 Checking finish size by over sizing through tool offset 113
3.4.170 Part programming for combined facing, turning and chamfering
(sinumeric) 114
3.4.171 Recovering from axes over travel, on CNC simulator 116
3.4.172 Part program preparation, for turning with chamfering & radius
turning with TNRC 117
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 Exercise No. Title of the Exercise Learning Page No.
Outcome
3.4.173 Part program writing and execute 119
3.4.174 Checking finish size by over sizing through tool offset 121
3.4.175 Machining parts on CNC lathe with parallel, taper, step, radius
turning, grooving and threading 122
3.4.176 Machining long part on CNC lathe held in chuck and tail stock -
between center 124
3.4.177 Starting from interruption due to power shut down 125

3.4.178 Changing wear offset to take into account tool wear 126
3.4.179 Part program preparation simulation & automatic mode execution
of CNC machine for the exercise on blue print programming
contours with TNRC 127
3.4.180 Carryout drilling / boring cycles in CNC turning 128

LEARNING OUTCOME

On completion of this book you shall be able to

SI.No. Learning Outcome Ref. Exercise No.

1 Resharpen different single & multipoint cutting tool.

[Different single point tools, slab milling cutter, side &
face milling cutter, end mill cutter and shell end mill cutter.] 3.1.115 to 3.1.119
2 Set different machining parameters and cutters to prepare
job by different milling machine operations. [Different
machining parameters - feed, speed, depth of cut, different
machining operation – facing, drilling, tapping, reaming,
counter boring,counter sinking, spot facing, and boring
slot cutting.] 3.2.120 to 3.2.125
3 Set the different machining parameters and cutters to prepare
components by performing different milling operation and
indexing. [ Different machining parameters – feed, speed and
depth of cut. Different components – Rack, Spur Gear,
External Spline, Steel Rule, Clutch, Helical Gear] 3.3.126 to 3.3.134
4 Identify and explain basic functioning of different electrical
equipment, sensors and apply such knowledge in industrial
application including basic maintenance work. [Different
electrical equipment- multi-meter, transformer, relays,
solenoids, motor & generator different sensors –proximity &
ultrasonic.] 3.4.135 to 3.4.144
5 Set (both job and tool) CNC turning centre and produce
components as per drawing by preparing part programme. 3.4.145 to 3.4.180
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 SYLLABUS
2st Year (Volume I of II) Duration: Six Month

Reference Professional Skills Professional Knowledge (Trade

Duration.
Learning Outcome (Trade Practical) Theory)
With Indicative Hours
Professional Re-sharpen different 115.Demonstrate and practice Tool & cutter grinder- Introduction,
single & multipoint of grinding of different single parts, construction, use and
Skill 75 Hrs;
cutting tool. [Different point tools. (25 hrs) specification, different types of tool
Professional single point tools, rest & their application.(09 hrs)
Knowledge slab milling cutter,
27 Hrs. side & face milling
cutter, end mill
cutter and shell end
mill cutter.]
116. Demonstrate and practice Various methods of cutter grinding.
of grinding of slab milling (09 hrs)
cutter. (13 hrs)
117. Re-sharpening side and
face milling cutter. (12 hrs)
118. Demonstrate and practice Various cutter grinding attachments
of grinding of end mill cutter. and their uses. (09 hrs)
(10 hrs)
119.Resharpening of shell end
mill cutter. (15 hrs)
Professional Set different machining Geometrical tolerances, definition,
120. Practice of facing on milling
Skill 75 Hrs; parameters and cutters symbol and their application.
Machine. (10 hrs)
to prepare job by Depth Micrometer – Parts,
Professional 121.Drill on P.C.D on milling
different milling reading, uses and safety. (09 hrs)
Knowledge Machine with accuracy +/-
machine operations.
27 Hrs. [Different machining 0.02 mm. (15 hrs)
parameters - feed, 122. Perform Tapping and Reaming Different types of micrometers and
speed, depth of cut, operation using milling Machine their uses.
different machining
operation – facing, an accuracy +/- 0.02 mm ( 10 Inside Micrometer – its parts, reading
hrs) and uses.
drilling, tapping, Bore Dial Gauge – its parts, reading
reaming, counter 123. Perform spot facing operation (both in Metric and English system)
boring, counter using milling machine with anduses. Telescopic gauge. (09 hrs)
sinking, spot facing, accuracy +/-0.02 mm. (15 hrs)
and boring slot cutting.

124. Make slot on face of the job Gauges – different types and their
using milling Machine with an uses, difference between Gauges and
accuracy +/- 0.02 mm. (10 hrs) Measuring Instruments.
Gear introduction, use and type.
125. Make Internal Grooving using
Elements of a spur gear. Gear tooth of
milling Machine with an
each forms types, merits and demerits
accuracy 0.02 mm. (15 hrs)
of each. (09 hrs)
Professional Set the different 126. Make Straight Teeth Rack
Skill 100Hrs; machining parameters using Milling Machine with an
Professional and cutters to prepare accuracy 0.05 mm. (8 hrs)
Knowledge components by 127.Make Helical Teeth Rack using
36Hrs. performing different Milling Machine with an
milling operation and accuracy 0.05 mm one straight
indexing. [Different rack (8 hrs)
machining parameters
– feed,speed and

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 depth of cut. Different 128. Measurement of teeth by Rack – types, uses and calculations.
components – Rack, VernierGear Tooth Caliper. Selection of gear cutter type and form
Spur Gear, External (05 hrs) & various methods of checking gear
Spline, Steel Rule, and its parts.
Clutch,Helical Gear] Vernier gear tooth caliper - its
construction and application in
checking gear tooth. 08 hrs)
129.Make spur gear using Spur gear calculations, curves and
Simpleindexing with an their uses.
accuracy 0.05 mm. (08 hrs) Use of radius gauges and template.
(07 hrs)
130.Make spur gear using
differential indexing with an
accuracy 0.05 mm. (12 hrs)
131. Perform Boring operation on Vertical Milling Machine- its parts.
Vertical Milling Machine with an Method of boring in Vertical milling.
accuracy 0.05 mm. (18 hrs) Difference between Horizontal and
Vertical Milling Machine. 07 hrs)

132. Make helical gear on milling Helix and Spiral introduction, types and
machine with an accuracy elements. Difference between helix &
0.05 mm. (20 hrs) spiral. Difference between R.H. and
L.H.helix. Helical gear- elements,
application.Calculations for cutting helical
gear. (07 hrs)

133. Make straight flute milling on Reamer – types, elements and uses.
Milling Machine with an Calculations for cutting Reamer.
accuracy 0.05 mm. (10 hrs) Twist drill-nomenclature, cutter
selection. Calculations for cutting twist
134. Make helical flute on Milling
drill.(07 hrs)
Machine with an accuracy 0.02
mm. (11 hrs)

Professional Identify and explain 135. MeasureCurrent, Voltage Study of basic Electricals- Voltage –
basicfunctioning of and Resistance using Simple Current etc.
Skill50 Hrs;
different Ohm`s Law Circuit And Working Of Solenoids, Inductors,
Professional electricaequipment, Familiarizing Multi-meter. Motors, Generator Based On
Knowledge sensors (05hrs) Electromagnetic Induction Principle
18Hrs. and apply such 136.Soldering Techniques (05hrs) Switches, Fuse And Circuit Breakers
knowledge in Introduction To Sensors- Fundamental
industrial 137.Step up and step down Of Sensor
application transformers. (05hrs) Proximity Sensors Classification And
including basic 138. Working with Solenoids and Operation-Proximity Sensor-Types Of
maintenance work. Relays. (05hrs) Proximity Sensor And Their Working-
[Different electrical Industrial Application Sensors For
equipment- 139.Working of Motor & Distance And Displacement -LVDT-Linear
multimeter, Generators. (05hrs) Potentiometer-Ultrasonic And Optical
transformer, 140.Behaviour of Proximity Sensors-Industrial Application.(18 hrs)
relays, solenoids, Sensors. (05hrs)
motor & generator; 141.Behaviour of ultrasonic
different sensors – sensors. (05hrs)
proximity &
ultrasonic.] 142. Logical Operation of
Sensors.(05hrs)
143. Limit & Level Control using
Sensors. (05hrs)
144.Interfacing of Sensors with
Electrical Actuators. (05hrs)

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Professional Set (both job 145. Know rules of personal and CNC Personal safety, safe material handling, and
Skill 200 andtool) machine safety, safe handling of safe machine operation on CNC turning
CNC turning tools, safety switches and centers.CNC technology basics, Comparison
Hrs.;
centre and material handling equipment between CNC and conventional lathes.
Professional produce using CNCdidactic/ simulation Concepts of positioning
Knowledge components software and equipment. (03 hrs) accuracy,repeatability.CNC lathe machine
72 Hrs. as per elements and their
146. Identify CNC lathe machine
drawing by functions - bed, chuck, tailstock, turret, ball
elements and their functions,
preparing screws, guide ways, LM guides coolant
on the machine. (07 hrs)
part system, hydraulic system, chip conveyor,
programme 147. Understand the working of parts steady rest, console, spindle
of CNC lathe, explained using motor and drive, axes motors, tail stock,
CNC didactic/ simulation encoders, control switches. Feedback, CNC
software. (09 hrs) interpolation, open and
close loop control systems.
148. Identify machine over travel
Machining operations and the tool path sin
limits and emergency stop, on
them – stock removal in turning and facing,
the machine. (01 hr)
grooving, face grooving,threading, drilling. (09
149. Decide tool path for turning, hrs)
facing, grooving, threading,
drilling. (04hrs)
150. Identification of safety switches
and interlocking of DIH modes.
(01 hr)
151. Identify common tool holder and
insert shapes by ISO
nomenclature. (05hrs)
152. Select cutting tool and insert for
each operation. (03hrs)
153. Fix inserts and tools in tool
holders. (02hrs)
154. Decide cutting tool material for
various applications. (03hrs)
155. Select cutting parameters from
tool manufacturer.s catalogue.
(02hrs)
156. Write CNC programs for simple
tool motions and parts using linear
and circular interpolation, check
on program verification/simulation
software. (10hrs)
157. Write CNC part programs using
canned cycles for stock removal,
grooving, threading operations,
with drilling and finish turning. Use
TNRC commands for finish
turning. Check simulation on
program verification/ simulation
software. (20 hrs)
158. Avoiding collisions caused by
program errors. Knowing causes
and effects of collisions due to
program errors, by making
deliberate program errors and
simulation on program
verification/ simulation software.
(05 hrs)

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159. Conduct a preliminary check of Program execution in differentmodes like MDI,
the readiness of the CNC lathe single block andauto.Process planning &
cleanliness of ,functioning of sequencing,tool layout& selection and cutting
lubrication, coolant level,correct parameters selection.Work and tool offsets.
working of subsys tems,on the Inputs value to the offset/geometry page into
machine. (05 hrs) machine.Turning in multiple setups, hard and soft
jaws, soft jaw boring, useof tailstock and steady
160. Starting the machine, do homing
rest.Length to diameter (L/D) ratio anddeciding
on CNC simulator. (02 hrs)
work holding based on it.Machine operation
161. Entering the CNC program in modes – Jog, MDI,MPG, Edit, Memory. Entering
EDIT mode for an exercise on and editing programs on machine console,
Simple turning & Facing (step entering offsets data in offsets page. Use of
turning) without using canned Emergency stop, Reset, Feed rate override,
cycles, on CNC simulator. spindle speed override, edit slock on/off buttons
(15 hrs) and keys. (18 hrs)
162. Mounting jaws to suit the part
holding area on CNC machine
(03 hrs)
163. Mounting tools on the turret
according to part and process
requirement, on CNC simulator
& on CNC machine. (08 hrs)
164. Perform Work and tool setting:
Job zero/work coordinate
system and tool setup and live
tool setup. (08 hrs)
165. Determining work and tool
offsets using JOG, MDI, MPG
modes, on CNC simulator.
(08 hrs)
166. Entering the tool offsets tool
nose radii and orientation for
TNRC in offsets page, on CNC
simulator.(05 hrs)
167. Program checking in dry run,
First part checking: Program checking in
single block modes, on CNC
single block and dry run modes – necessity
simulator & CNC machine. (01hr)
and method. Tool offsets adjustment on first
168. Absolute and incremental part for close tolerance dimensions, by over
programming assignments and sizing (for outside dimensions) or under sizing
simulation. (04 hrs) (for inside dimensions) the dimension to prevent
part rejection. Wear offset setting – necessity,
169. Checking finish size by over
relationship with tool wear, entering inoffsets
sizing through tool offsets, on
page. Process and tool selection related to
CNC simulator. (02hrs)
grooving, drilling, boring and threading.Axes
170. Prepare part program and cut the over travel, recovering from over travel.
part in auto mode in CNCmachine Collisions due to improper machine setup and
for the exercise on Simple turning operation – causes and effects.Recovering from
& Facing (step turning) (08 hrs) collisions. Find out alarm codes and meaning of
those codes. ( 27 hrs)
171. Recovering from axes over
travel,on CNC simulator (01 hr )
172. Part program writing, setup,
checking and Automatic Mode
Execution for exercise on Turning
with Radius/ chamfer with TNRC
on CNC machine (10hrs)

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174. Checking finish size by over sizing
through tool offsets, on the
machine. (02 hrs)
175. Machining parts on CNC lathe
with combination step, taper,
radius turning, grooving&threading,
with external and internal operations,
first and second operation, on the
machine.(10 hrs)
176. Machining long part on CNC
lathe held in chuck and tailstock
(between centers). (04 hrs)
177. Starting from interruption due to
power shutdown, tool breakage. (01hr)
178. Changing wear offsets to take
intoaccount tool wear. (02hrs)
179. Part program preparation,
Simulation & Automatic Mode
Execution of CNC Machine for
the exercise on Blue print
programming contours with
TNRC. (08 hrs)
180. Carryout Drilling/Boring cycles in CNC
Turning. (10 hrs)
(First 60% of the practice is on CNC
machine simulator, followed by 40%
on machine.)

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Capital Goods & Manufacturing Exercise 3.1.115
Machinist - Tool and cutter grinder

Demonstrate and practice of grinding of different single point tools

Objectives : At the end of this exercise you shall be able to
• operate a tool and cutter grinder
• mount and use cup wheel for tool grinding
• grind-single point cutting tools with the specified clearance, rake angles and cutting angle accurately
(within  30 min) using tool and cutter grinder.

Job Sequence
TASK 1: Sharpen a Straight Turning Tool (RH) on T&C Grinder

• Grind four sides square and to 19 mm on a surface

grinder.
• Rough grind the tool profile on a pedestal grinder.
• Use a simple protractor to check the clearance,
rake and cutting angles.
• Fix taper cup wheel on the spindle of the tool and
cutter grinder and dress its face.
• Fix universal vice on the work table and hold the
tool for grinding the side cutting edge.
• Set the vice to 30º in the horizontal plane and 8º
in the vertical plane and grind the side cutting
edge. (Fig 1)
• Set the vice to 60º in the horizontal plane and 8º
in the vertical plane and grind the end cutting
edge. (Fig 2).

1
• Mount the disc wheel 150 mm on the machine spindle
and dress the face with an abrasive stick.
• Set the vice to 30º in the horizontal plane, 14º in the
vertical plane. Hold the tool for 4º negative top rake
using a combination bevel protractor and spirit level.
• Grind the top rake (4º negative) and side rake (14º
positive) by traversing the table until the grinding wheel
face just touches the point ‘X’. (Fig 3).
• Remove the tool and hone the nose radius with a fine grit
abrasive stick without spoiling the cutting edges. • Deburr.

Job Sequence
TASK 2: Sharpen a straight turning tool (LH) on T & C grinder
• Grind four sides square and to 19mm on a surface
grinder.
• Rough grind the tool profile on a pedestal grinder.
• Use simple protractor to check the clearance, rake
and cutting angles.
• Fix taper cup wheel on the spindle of the tool and cut
ter grinder and dress its face.
• Fix universal vice on the work table and hold the tool
for grinding the side cutting edge.
• Set the vice to 30° in horizontal plane and 8° in the
vertical plane and grind the side cutting edge (Fig 1)

• Grind the top rake (4° negative) and side rake (14°
positive) by traversing the table until the grinding wheel
face just touches the point ‘X’ (Fig 3)

• Set the vice to 60° in the horizontal plane and 8° in the

vertical plane and grind the end cutting edge. (Fig 2)
Mount the disc wheel 150 mm on the machine spindle • Remove the tool and hone the nose radius with a fine
and dress the face with an abrasive stick. grit abrasive stick without spoiling the cutting edges.
• Set the vice to 30° in the horizontal plane, 14° in the • Deburr.
vertical plane. Hold the tool for 4° negative top rake • Check the angles using bevel protractor.
using a combination bevel protractor and spirit level.

Job Sequence
TASK 3: Sharpen a ‘V’ tool on T & C grinder

• Sharpen a v - Tool (Shaper) on tool and cutter grinder. • Dress the grinding wheel on the machine.
• Rough grinding the tool profile on a pedstal grinder or • Mount the universal vice on the table make sure that
off hand grinding before finish grinding on tool and cut- all the scales are set to zero degrees. (Fig 1)
ter grinder. • Swivel the scale ‘A’ to 30 degree in anticlock wise di-
• Inspect and mount the flaring cup wheel on the ma- rection. (Fig 2)
chine spindle.
2 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.115
• Swivel the scale ‘B’ to 3 degree in anticlock wise di-
rection. (Fig 2)

• Remove the tool and refix the tool keeping top side
butting on the vice base ( up side down).
• Swivel teh scale ‘B’ to 3 degree in clock wise direction
from zero degree.
• Do not change the angle on scale ‘A’
• Rough and finish grind side ‘b’
• Check the angles with protractor.
• Remove the tool from the vice set all scales to zero
degree.
• Fix the tool in vertical position keeping the face of the
tool towards the wheel.
• Swivel the scale ‘B’ to 14 degree in clock wise direc-
tion to grind top rake. (Fig 4)

• Fix the tool on the vice such that the face of the tool is
on top side and set the stop dogs.
• Start the machine rough and finish grind the side ‘a’
(Fig 3)

Skill Sequence
Preparing tool and cutter grinder for re - sharpening of single point cutting
tool
Objectives : This shall help you to
• keep the tool and cutter grinder ready for re - sharpening work
• mount and dress the grinding wheel
• study the machine and understand the purpose and effect of every handle and hand wheel.

Study the machine and understand the purpose every Make sure that the oil in the wheel head, the
handle and hand wheel. work head and the travere gearbox is main-
Refer to the Instructional manual supplied by tained at the correct level with the oil recom-
the machine manufactures for function and mended by the machine manufacturers.
identification of each operating control. Check the lubrication of the table ways each
morning as they wear rapidly if allowed to run
Clean thoroughly the working surface of the dry.
work table and other working area with a clean
banian waste. Avoid spots of oil on the grinding wheel while
refilling.
Ascertain the position of every lubricating point
and see that all get the required quantity of Always warm up the machine before commenc-
correct grade of oil regularly. ing to grind or to dress the wheel.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.115 3

Be familiar with the following electrical controls. • Adjust the height of the wheel head and direction of
rotation of the hand wheel manually for ‘UP’ & ‘DOWN’
• Wheel spindle - ‘ON - OFF’ switch for changing the
movement and the method of locking it.
direction of rotation.
• Swivel the work table to the required angle and lock it.
• Switch for power elevating ‘UP’ and ‘DOWN’
Remove Taper dowels if provided for ‘0’ set-
• Dust extractor - ‘ON-OFF’ switch.
ting before swivelling the table.
Be familar with the following mechanical arrangements
Cross - traverse movement of the work table
• Swivel the wheel head to the required angle and lock- and remember the value of the graduations
ing it firmly. on the graduated dial.

Lock the work table in position.

Mount a grinding wheel on tool and cutter grinder

Objective: This shall help you to
• mount a grinding wheel on the tool and cutter grinder.

Select and inspect grinding wheel: Select the wheel

to be mounted and visually check for cracks.
Check the bore of wheel is the same size as the spigot
diameter of the adopter.
“ Ring test”, for the wheel by holding loosely with fingers in
the bore and tap lightly with a piece of wood and listen for
a distinct ringing sound to denote wheel is free from cracks.
(Fig 1)

If the sound is a dull, the wheel is cracked and

should not be used.

Dressing a cup grinding wheel

Switch on wheel head spindle.
Hold dressing stick firmly with both hands at one end, at a
suitable angle.
Move forward until gently touches front inside face of the
wheel (Fig 3)
Slowly move dressing stick back ward and forward until
wheel space to a thin pointed edge.
When wheel looks black and shining, it needs
dressing.
Mount grinding wheel
Clean the wheel adopter.
Clean the side of the wheel.
Ensure that paper washer is on each side of the wheel
before mounting.
Fit wheel to spigot.
Place locking washer over spigot and up to the front face
of the wheel.
Screw on lock nut by hand and tighten with wheel key.
(Fig 2)

4 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.115

Capital Goods & Manufacturing Exercise 3.1.116
Machinist - Tool and cutter grinder

Demonstrate and practice of grinding of slab milling cutter

Objectives: At the end of this exercise you shall be able to
• set the cutter and the wheel head for sharpening slab milling cutter
• sharpen the slab milling cutter.

Job Sequence
Using linear setting method - Lower the wheel head (for off-set) an amount calculated
• Mount the cutter on the mandrel and between centres. to the required clearance angle formula

• Turn the wheel head to 1º to the table and lock in - Amount of off-set
position. This prevents grinding on both sides of the
wheel when the cutter passes in front of it. (Fig 1)
- = Cutter diameter x clearance angle required x 0.0087
- Start wheel head motor, contact the first tooth with the
grinding wheel.

Traverse the work table carefully across the

wheel face using hand traverse. Maintain a
turning force on the cutter to hold the tooth
firmly against the tooth rest. (Fig 3)

• Set the table graduations at ‘O’ i.e. table set parallel

to table movement.
• Adjust the grinding wheel centre height with a height
setting gauge.
• Bolt the tooth rest holder to the wheel head and set the
tooth rest to the spiral angle of the cutter.
- Set the point of tooth rest on the acute angle side of the
cutter and at the same centre height of the table
centres with a centre setting gauge. (Fig 2)

Do not over traverse the cutter tooth being

ground past the tooth rest blade.
During traverse, the tooth face moves over the
tooth rest to present the edge of the particular
tooth continuously at the correct angle to the
wheel. Great care is necessary in setting the
tooth rest for achieving the accuracy.
- Grind the tooth opposite to the 1st tooth already ground.
- With an O.S.micrometer check for taper across each
end of the ground tooth. If necessary, correct it by
aligning the work table.
- Rotate the cutter to bring the next tooth on to the tooth
rest and continue until all teeth have been ground.
5
Using angular setting gauge method - Bolt the centre setting gauge to the wheel head, rotate
Repeat steps 1 to 5. the cutter until a point on the face of the cutter, (acute
angle side) is in contact with the tip of the gauge. This
- Set the point of tooth rest at acute angle side of the point of cutter is now on its own centre line.
cutter and at the same centre height of the wheel head
such that the outer rim of the wheel and the high point
- Clamp an angular setting gauge to the mandrel with the
of the tooth rest coinside in a point. (Fig 4) gauge set at ‘O’. Rotate the cutter to the required
clearance angle and lock in position.
- Lower the wheel until the tooth rest is on the same level
as the cutter tooth, with the cutting edge of the wheel
opposite to the acute point of cutter tooth. (Fig 4)
Unlock the setting gauge, start the wheel head motor
and commence grinding.
- Repeat steps 8,9,10 & 11, of the linear setting method
and complete the grinding.

Skill Sequence
Sharpening the cutting face of a slab milling cutter
Objective: This shall help you to
• Sharpen the cutting face of a slab milling cutter.

On repeated re-sharpening the cutting face of a helical

fluted milling cutter becomes short the chip space. To
increase the life and cutting efficiency of the cutter, it has
to be reconditioned by deepening the helical flute, at the
same time maintaining the original positive rake angle on
the cutting face.
This operation is done in two stages.
i Gashing, and
ii grinding the cutting face.
Gashing or roughing: the depth of flute is deepened by
this operation. Proceed as follows.
- Mount the dish wheel on the extension spindle and true
it.
- Mount the cutter on the mandrel and set in between
centres. Avoid heavy cut to avoid the rapid wheel wear.
- Swivel and align the wheel head with the hand of helix
Grinding the cutting face
and helix angle of the flute, so that the wheel touches
the bottom of the flute but not the cutting face of the Mount the dish wheel on the extension spindle in inverted
flute. position.
- Fix the tooth rest to the wheel head and set its blade Obtain a new helical fluted cutter from stores/tool grib equal
touching the cutting face of the flute. (Fig 1) Set table to the number of teeth, helix angle, hand of helix and
stops. diameter (approximately) of the cutter to be sharpened.
This is to be used as a masterpiece during grinding of the
- Start the wheel head motor and commence grinding by
cutting face.
traversing the table and at the same time keeping in
constant touch with the tooth rest blade by manually Mount the masterpiece and the cutter to be face-ground on
applying a turning force to the mandrel. a long mandrel (Fig 2) in perfect alignment and in between
centres.
- Lower the wheel head for successive depth of cut, until
you reach the required depth of flute. Swivel and align the wheel head with the hand of helix and
helix angle of flute, so that the tapered face of the wheel,

6 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.116

 Set table stops carefully, not allowing over-travel on the
blade of the tooth rest in order to control the helical path
of the cutter.
Start the wheel head motor and commence grinding, by
traversing the table and at the same time keeping in
constant touch with the tooth rest blade by manually
applying a turning force to the mandrel.

Lower the tip of the blade of the tooth rest by

micrometer collar adjustment, for successive
depth of cut {radial cut ( Fig 1) see the arrow
head} until the entire cutting face is ground
forming a keen cutting edge on the tooth.
Apply only light cuts. Heavy cuts may cause
wheel loading or burning of the cutting edge.
While aligning the wheel, if the cutter is of a
quick helix type, utmost care must be taken to
perfectly matches with the cutting face of the tooth of the
see that the wheel does not touch the next
cutter to be ground.
tooth.
Fix the tooth rest with a micrometer adjustment to the
wheel head, set its blade touching the cutting face of the Grind and complete the cutting face of all the teeth of the
tooth of the masterpiece cutter, as done in the gashing cutter.
operation.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.116 7

Capital Goods & Manufacturing Exercise 3.1.117
Machinist - Tool and cutter grinder

Re-sharpening side and face milling cutter

Objectives : At the end of this exercise you shall be able to
• sharpen peripheral teeth of straight fluted side and face cutter
• sharpen side teeth of side and face cutter to the given thickness.

8
Job Sequence
Grinding primary clearance angle of peripheral teeth
of a side and face milling cutter
• mount taper cup wheel and true it.
• Adjust the grinding wheel centre height with a height
setting gauge.
• Set the table graduations at 0°.
• Turn the wheel head to 1° or 2°. This prevents grinding
• Repeat and complete all the other teeth leaving uniform
on both sides of the grinding wheel.
width of land on all peripheral teeth.
• Mount the cutter on the mandrel between centres.
For grinding side teeth on a side and face milling
• Set the cutter to primary clearance angle (7°) (Fig 1), cutter (primary clearance)
by using an angular setting gauge or by any other
Primary clearance
suitable method.
• Mount the cutter on the stub arbor with sufficient
• Set the tooth rest under the first tooth to be ground and
spacers behind the cutter and fix the arbor in the cutter
unlock angular setting gauge.
head. Spacers are provided to allow the grind wheel to
Where possible, place the tooth rest under the grind the other side and avoid resetting.
side teeth, as this gives greater clearance
• Set the table graduations at ‘O’.
between the wheel and tooth rest, and offers
greater convenience for adjustment. (Fig 1) • Swivel the cutter head to 90° (Fig 3)

• Tilt the cutter head to 7° for primary clearance angle.

(Fig 4)
• Fix the tooth rest on the cutter head and adjust the
tooth rest until it positions the first tooth to be ground
parallel to the table top. This is a visual setting.

• Start the wheel head motor and commence grinding the

1st tooth.
• Sharpen the opposite tooth and check for dimension
and taper.
• Correct, if necessary.
• Complete the grinding of all the teeth.
Grinding secondary clearance
• Rotate the cutter to 25°, for secondary clearance.
• Adjust the wheel head height to cover the first tooth to
• Position the wheel such that the next teeth will not be be ground without fouling the tooth above. (Fig 1)
ground by the grinding wheel.
• Set the stop dogs.
• Start grinding the secondary clearance on the first
• Start the wheel head motor and grind the first tooth.
tooth. Check the land width. It should be 1 mm
Repeat and complete all the teeth.
approximately. (Fig 2)

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.117 9

Secondary clearance
• Tilt workhead to 15°, and adjust the height of the wheel
head, to clear the above tooth.
• Grind secondary clearance on all teeth leaving 1 mm
land.
Grinding inside edge (other side) of the cutter
(Primary clearance)
• Mount the wheel in an inverted position on the
extension spindle and true. (Fig 5)
• Tilt cutter head spindle to 7° in the opposite direction of
the previous setting.
• Fix the tooth rest holder to the table, and adjust it to
position the first tooth parallel to the top of the table.
(Visual setting) Secondary clearance
Fixing the tooth rest holder on the wheel head • Tilt the cutter head to 15° and adjust the wheel head
in this set up, may cause the wheel to foul the position and tooth rest position to grind the secondary
tooth rest. Take care of it. clearance.
• Grind secondary clearance on all the teeth leaving
• Start grinding primary clearance, on all the teeth. 1 mm land.

Skill Sequence
Sharpening the cutting face of straight flute cutter
Objective: This shall help you to
• sharpen the cutting face of a straight flute cutter.

On repeated re-sharpening the cutting face of the milling

cutter becomes short , and thus reduces the chip space.
Under such condition the flute has to be deepended by
maintaining the original positive rake angle on the cutting
face.
To grind the cutting face of straight flute, follow the
steps given below.
- Mount the dish wheel on the extension spindle and
true.
- Mount the cutter, on the stub arbor with sufficient
spacers at the back of the cutter and fix it with the cutter
head.
- set the index-drum to suit the number of teeth of the
cutter.
- Lower the wheel head, adjust the cross-feed movement, Apply only light cuts, without burning the cutting
and align the cutting face parallel and touching the edge.
rotating face of the wheel, by adjusting the index drum
adjusting screws. (Fig 1) Apply depth of cut by turning the adjusting
screw of the index-drum, not by cross-feed
- Start the wheel head motor and commence grinding. movement (see the arrow in the Fig 1) which
will increase the original positive rake angle.

10 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.117

Capital Goods & Manufacturing Exercise 3.1.118
Machinist - Tool and Cutter Grinder

Demonstrate and practice of grinding of end mill cutter

Objectives : At the end of this exercise you shall be able to
• set tool and cutter grinder for sharpening end mill cutter
• sharpen peripheral teeth of helical fluted teeth
• sharpen end teeth of end mill cutter.

11
Job Sequence
Sharpen an end mill cutter
• An end mill cutter is sharpened in two separate
operations.
– Sharpening of peripheral teeth
– Sharpening of end teeth.
Peripheral teeth (Fig 1)

• Set the first tooth on the tooth rest, parallel to the top
surface of the table.(Fig 3)

• Mount the end mill in the cutter head.

• Mount a taper cup wheel and true its cutting face.
• Align the axis of the wheel spindle and cutter head
spindle using a centre gauge.
• Set the work head at zero graduation.
• Fix tooth rest to the wheel head and set it to the desired
clearance angle (7°) and helix angle of the flute.
• Offset the wheel head axis by 1° or 2° to clear opposite
rim of grinding wheel.
• Sharpen the edge of first tooth by traversing the wheel
using the table traverse and at the same time rotate the
cutter head spindle by hand following the helical path.
• Rotate the cutter through 180° and sharpen the opposite
teeth.
Tooth rest should support the peripheral tooth
• With a micrometer, check the ground teeth for taper. edge as close as possible to the edge of the
• Adjust the cutter head if necessary to eliminate taper. end tooth.

• Sharpen all other teeth. Sharpen the first tooth, taking only light cuts.

End teeth Sharpen all the remaining teeth in turn.

• Rotate the cutter head to 90°. Secondary clearance

• Mount the tooth rest on the cutter head and set it to • Tilt the cutter head to 15° and adjust the tooth rest
level with centre gauge. suitably to grind secondary clearance.
• Tilt the cutter head to the required primary clearance • Grind secondary clearance on all the teeth, leaving
angle i.e 7°. (Fig 2) 1 mm land.

12 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.118

Skill Sequence
Preparing tool and cutter grinder for re-sharpening end mill cutters
Objectives: This shall help you to
• keep the tool and cutter grinder ready for re-sharpening work
• use particular holding arrangement according to the type of cutter.

Study your machine and understand the purpose and Mount and adjust the indexing attachment on the cutter
effect of every handle and hand wheel. head.
Refer to the Instructional manual supplied by Mount the tailstock centres on the work-table.
the machine manufacturers for function and Spring loaded tailstock should always be
identification of each operating control. mounted onthe RIGHT HAND END of the work-
Clean thoroughly the working surface of the table.
work table and other working area with a – Mount the clearance angle setting gauge on the left
clean banian cloth waste. hand tailstock.
Ascertain the position of every lubricating point – Tilt the wheel head to the required clearance angle, if
and see that all get the required quantity of the machine is of tilting wheel head type.
correct grade of oil regularly.
Mount the taper cup wheel and dress the edge to 5°.
Make sure that the oil in the wheel head, the (Fig 1)
work head, and the traverse gearbox is
maintained at the correct level with the oil
recommended by the machine manufacturers.
Check the lubrication of the table ways each
morning, as they wear rapidly if allowed to run
dry.
Avoid spots of oil on the grinding wheel while
refilling.
Always warm up the machine before
commencing to grind or to dress the wheel.
If the face of the cup or saucer wheel is dressed
Be familiar with the following electrical controls.
flat and smooth with a diamond, it will not
– Wheel spindle - ‘ON-OFF’ switch for changing the freely cut, but will create heat and cause
direction of rotation. distortion. Hence it is advised to dress the
wheel by off-hand method with a carborundum
– Switch for power elevating ‘UP’ and ‘DOWN’.
stick (25 mm, SQ-8) forming an angle of 5° on
– Dust extractor - ‘ON-OFF’ switch. the face of the wheel thus presenting a single
Be familiar with the following mechanical edge to the work.
arrangements. Select and mount the correct type of cutter
– Swivel the wheel head to the required angle and locking holding device suitable for the given cutter
it firmly. and grinding operation.

– Adjust the height of the wheel head and direction of – Cutters with bore are held on plain mandrel and the
rotation of the hand wheel manually for ‘UP’ & ‘DOWN’ mandrel, in turn, is held between centres of tailstocks.
movement and the method of locking it. e.g. slab mills, side and face cutters, form relieved gear
cutters etc.
– Swivel the work table to the required angle and lock it.
– Cutters with bore, peripheral and face teeth are held in
Remove ‘Taper dowels’ if provided for `O’ setting the stub arbor, which, in turn is fitted with a cutter head
before swivelling the table. through draw-in bolt. Eg. Shell end mill or face mill,
Cross-traverse movement of the work table and angular cutters etc.
remember the value of the graduations on the – Cutters with Morse Taper shank are held in suitable
graduated dial. M.T.sleeves in the cutter head. Eg. End mills, Tee-slot
Lock the work table in position. cutters etc.
Mount the cutter head on the work table and be familiar – Cutters with parallel shank are held in suitable collets,
with the method of swivelling it or tilting it to the required which in turn are fitted in the cutter head through draw-
angle. in bolt. Eg. End mills of small sizes, slot drills, wood-
ruff key seat cutters etc.
Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.118 13
Capital Goods & Manufacturing Exercise 3.1.119
Machinist - Tool and Cutter Grinder

Resharpening of shell end mill cutter

Objectives: At the end of this exercise you shall be able to
• mount taper cup wheel and true it
• set the cutter to primary clearance angle
• start grinding.

14
Job Sequence
Sharpen shell end mill cutter End teeth
• Shell end mill cutter is sharpened in two separate Primary clearance
operations.
• Rotate the cutter head to 90°
- Sharpening of peripheral teeth
• Mount the tooth rest on the cutter head and set it to
- Sharpening of end teeth. level with centre gauge.
Peripheral teeth • Tilt the cutter head to the required clearance angle i.e
7°
• Mount the shell end mill in the cutter head.
• Set the first tooth on the tooth rest, parallel to the top
• Mount a taper cup wheel and true its cutting face.
surface of the table.
• Align the axis of the wheel spindle and cutter head
spindle using a centre gauge. Tooth rest should support the peripheral tooth
edge as close as possible to the edge of the
• Set the work head at zero graduation.
end tooth.
• Fix tooth rest to the wheel head and set it to the
Sharpen the first tooth, taking only light cuts.
desired clearance angle (7°) and helix angle of the
flute. Sharpen all the remaining teeth in turn.
• Offset the wheel head axis by 1° or 2° to clear opposite
Secondary clearance
rim of grinding wheel.
Tilt the cutter head to 15° and adjust the tooth rest suitably
• Sharpen the edge of first tooth by traversing the wheel
to grind secondary clearance.
using the table traverse and at the same time rotate
the cutter head spindle by hand following the helical Grind secondary clearance on all the teeth, leaving 1 to
path. 3mm land.
• Rotate the cutter through 180° and sharpen the The clearance angle of the cutter will vary
opposite teeth.
according to its diameter.
• With a micrometer, check the ground teeth for taper.
• Adjust the cutter head if necessary to eliminate taper.
• Sharpen all other teeth.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.1.119 15

Capital Goods & Manufacturing Exercise 3.2.120
Machinist - Advance Milling

Practice of facing on milling machine

Objectives: At the end of this exercise you shall be able to
• setting up of job on milling machine
• setting up of side and face milling cutter
• milling by side and face milling cutter.

3.2.122

16
Job Sequence
TASK 1:
• Deburr and clean the workpiece.
• Mount the plain machine vice on the plain milling
machine such that the vice jaws are parallel to the
column.
• Select the cutter size.
• Mount the long arbor and the side and face milling
cutter on the machine.
• Ensure that the cutter is mounted at the middle of the
arbor to facilitate the free traverse of the cross slide.
• Clamp the job, between the vice-jaws firmly.
• Keep the job such that face of the job is well outside the
jaws by 10 to 15 mm (Fig 1) • Set the job perpendicular to the cutter, such that side
and face cutter is next to face of the job.
• Calculate the r.p.m. for the selected dia of the side and
face cutter • Lock the vertical and cross-slides Adjust the coolant
nozzle point on the cutter.
• Set the r.p.m. & feed.
• Start the machine and coolant pump.
• Stick tissue paper to the reference sides of the workpiece
and set datum for the cross and vertical slides. • Mill the face leaving 0.4 to 0.5 mm for final finish.

Job Sequence
TASK 2:
• Check the raw material for the correctness of the size • Hold the work piece in the vice and align the milling
(deburr if necessary) cutter for machining.
• Align the machine vice with reference to the column • Move the longitudinal slide manually towards the cutter
using a dial indication. such that the workpiece comes in contact with the
cutter gently, sudden contact may damage the workpiece
• Mount 27 stub arbor and a shell end mill cutter of size
and the cutter may break.
 63 X 40 X 27 bore on vertical milling machine.
• Machine the block to size and check.
• Set the r.p.m of the cutter near to 100.

Skill Sequence
Mount a stub arbor and shell end mill cutter on vertical milling machine
Objectives: This shall help you to
• mount a stub arbor and shell end mill cutter on a vertical milling machine.

Set the lowest available spindle speed to avoid free rotation

of the spindle nose.
Ensure that the machine is switched off to avoid any
accident while fixing the stub arbor and cutter.
Clean the taper portion of the arbor and spindle nose to
make it free from dust. Chips etc and to ensure correct
fitting and true running of the arbor. (Fig 1)
For cleaning use soft cloth free from dust, chips etc, to
avoid scratches on the surfaces.
Insert the stub arbor taper shank into the spindle nose.
Hold the stub arbor in position and screw in the draw - bar Ensure that the arbor notches fit in the keys of the spindle
from the top side of the spindle nose. nose to get the drive.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.120 17

Tighten the draw - bar and lock - nut. (Fig 2) Hold the cutter in position and tighten the locking screw
using a pin spanner. (Fig 4)

Avoid excessive tightening to prevent any damage. (Fig 5)

Remove the locking screw screw from the arbor end.
(Fig 3)

Ensure that the end face of the locking screw is

not projecting beyond the cutting edges of the
cutter to avoid fouling with the work piece. This
may happen after the cutter has been re - sharp
- ened a number of times.
Clean the arbor spigot, bore and contact faces of the cutter
Switch on the machine and check visually that the cutter
and notches.
runs true.
Slide the cutter on the spigot such that the notches fit over
the arbor keys. Get famlliar thoroughly with the machine before
attempting to operate it. When in doubt, obtain
Use a rag while handling the cutter to avoid injury to the
additional instructions/ guidance from the
hands due to the sharp edges of the cutter.
instructor.

Mill a flat surface on vertical milling machine

Objectives: This shall help you to
• mill a flat surface on a vertical milling machine.

Mount and align the machine vice on the table of the

vertical milling machine.
Hold the work piece in the machine vice.
Mount the stub arbor in the spindle (ML 0601).
Mount the face milling cutter / shell end milling cutter into
the stub arbor.
Select a H.S.S cutter with right hand helix for proper
shearing of the material due to the positive rake angle.
Select the diameter or the cutter (A) more than the width
of the job (B), so that the full surface is machined in one
pass. (Fig 1).

18 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.120

Capital Goods & Manufacturing Exercise 3.2.121
Machinist - Advance Milling

Drill on P.C.D. on milling machine with accuracy ± 0.02 mm

Objectives: At the end of this exercise you shall be able to
• set rotary table on milling machine
• clamp job on rotary table
• drill on pitch circle diameter using rotary table.

Job Sequence
• Mill the Job to the size of 80 x 80 x 20 mm. • Mount the rotary table on the vertical milling machine.

• Mark the Job as per Drawing and punching witness • Hold the Job on the rotary table using suitable work
marks. (Fig 1) holding devices. (Fig 2)

19
 • Mount the drill in the vertical milling machine spindle.
• Set the drill to the centre of the Job.
• Off set the drill to the half of the pitch circle diameter.
(Fig 3)

• Now set the number of holes to be drilled say it 6.

• Rotate the table for 60º and then drill the hole.
• Perform above move for five more times.
• So that a complete 360º and six holes are achieved.
• Six holes get drilled.
• Deburr the holes.
• Remove the attachments.

Skill Sequence
Circular table attachment
Objective: This shall help you to
• drill holes on milling by using rotary table.

This attachment is used for profile milling, surfacing

quantities of small pieces in the one set up, and for many
other circular operations in the horizontal plane such as
slotting and dove tailing.
It consists of a base, a worm gear drive mechanism and a
small circular work table. (Fig 1)
The base is bolted to the table and the drive mechanism
connected with the feed mechanism of the milling machine.
A crank for manual feed is also provided.
The work piece is secured to the circular table and the
table is rotated by the feed mechanism for circular cuts.
By combining the rotary motion with one or more of the
other feeds of the machine, profiles of almost any shape indexing device for requiring accurately spaced slots,
can be milled. The hand crank can be replaced by an holes or grooves.

20 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.121

Capital Goods & Manufacturing Exercise 3.2.122
Machinist - Advance Milling

Perform tapping and reaming operation using milling machine with an

accuracy ± 0.02 mm
Objectives: At the end of this exercise you shall be able to
• set reamer and tapping attachment with tap
• set the Job on the machine vice
• tapping and reaming using milling machine.

21
Job Sequence
Reaming of Hole Tapping of Hole

• Take a MS block of size 60 x 40 x 25 mm. • Fix the Tapping attachment to the mill machine.

• Identify the drill size for reaming operation. • Calculate the tap drill size.

• Using a 11.75 mm drill bit a hole of dia 12 mm and depth Tap drill size for M 12 x 1.75
25 mm. Minor dia (Tap drill size) = Major dia - (0.6134 x Pitch)
• Calculate drill size for 12 mm reamerd hole Deapth of thread = 0.6134 x pitch of screw
Drill size = Reamed size - (Under size + Oversize) = 0.6134 x 1.75
= 12 - (0.2 + 0.05) = 1.07
= 12 - (0.25) Minor dia = 12 - 1.07
Drill size = 11.75 mm = 10.92 mm
• Use the correct reamer for reamed size 12.00 mm. • Select M12 Machine Tap.
• Ream the hole. • Mount the tap in the Tapping attachment and Tapping
the hole.
• After performing tapping it will automatically come out
in counter clockwise direction.

22 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.122

Capital Goods & Manufacturing Exercise 3.2.123
Machinist - Advance Milling

Perform spot facing operation using milling machine with accuracy

± 0.02 mm
Objectives: At the end of this exercise you shall be able to
• set the Job for spot facing
• hold the Job in correct position and hold the spot facing tool in vertical milling machine.

Job Sequence
• Take a pre drilled or bored or reamed job and fix it on • Set the spindle speed according to the dia of tool.
the machine vice.
• Bring the bore hole nearer to the point of spot facing
• The job is to be clamped such that the bored hole is just tool.
under the spot facing tool.
• Slowly bring the tool to the bore, so that no damage to
• Fix the spot facing tool on the machine. the peripheral of bore dia and tool.

23
• Spot facing 3 to 4 mm depth, use proper coolant.
• After machining bring the machine tool to its previous
position.
• Check the spot faced surface, if proper fitting achieved
for the bolt.
• If not do the machining again.

24 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.123

Capital Goods & Manufacturing Exercise 3.2.124
Machinist - Advance Milling

Make a slot on face of the Job using milling machine with an accuracy
± 0.02 mm
Objectives: At the end of this exercise you shall be able to
• set the Job on milling machine
• hold the cutter on machine spindle
• mill the slots
• select proper speed and feed.

25
Job Sequence
• Check the job to the size of 150 x 45 x 70 mm.
• Mark the slots to size as per drawing and punch
witness marks.
• Mount and align the vice on the vertical milling machine
table.
• Mount 22 mm end mill cutter for milling in the vertical
milling machine. (Fig 1)
• Set the r.p.m. closer to 300.
• Mill the slot 33.5 x 21.18 x 150 mm long to size.
• Deburr and check the dimensions of the slot with a • Mill the slot 40 x 16 x 70 mm long to size.
depth micrometer and vernier caliper.
• Deburr and check the dimensions of the slots for their
• Reset and align the job for the next slot of the job. size.

Skill Sequence
Mill a slot by end mill cutter on vertical milling machine
Objective: This shall help you to
• mill a slot on a vertical milling machine.

Mark the job as per drawing for slot milling and punch the
witness marks on the lines.
Mount the plain machine vice on the machine such that
the vice jaws are parallel to the column.
Clamp the workpiece in the machine vice such that the
face is 5 to 6 mm above the vice jaws.
Select an end mill cutter which is smaller than the width
of the slot to be milled. This is only for the manipulation of
the cutter in the slot while milling.
Mount the end mill cutter in the collet chuck.

Ensure that the end mill cutter is gripped

without any wobbling to avoid breakage of the
cutter or vibration during the cutting operation.

Set the r.p.m., table feed and clockwise cutter rotation.

Set the nearest lower speed and feed available

if the machine does not have exact values.

Stick tissue paper to the reference sides of the workpiece

and set the datum for the cross and vertical slides.
Set the cutter at the middle of the slot to (X + W/2) mm The maximum depth of cut that can be applied is equal to
taking reference from the side datum where X is marked the diameter of the end mill.
in the drawing. W is the width of the slot. (Fig 1) If the diameter of the end mill is between 2 and 6 mm apply
Set the depth of cut taking reference from the top surface a small depth of cut (e.g. 0.4 to 0.5 mm).
of the job. (Fig 2) Keep 0.4 to 0.5 mm on both the sides and depth of the slot
for final finish.
Be sure that whenever depth of cut or setting
is carried out the cutter is away from the job. Lock the vertical and cross-slides.
Adjust the coolant nozzle point on the cutter.
Consider the following hints while setting the depth of cut.
Start the spindle and the coolant pump.

26 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.124

 Ensure that the datum is set again whenever
the cutter is changed or the cutter overhang is
adjusted or the job disturbed.

Move the cutter to the right to a distance of (X + W) -

0.5 mm and mill the right slide of the slot. (Fig 5)

Move the longitudinal slide manually towards the cutter

such that the workpiece comes into contact with the cutter
gently.

Sudden contact may damage the workpiece

and the cutter may break.

Mill the depth at the middle of the slot leaving 0.4 to 0.5 mm
for the final finish. (Fig 3)

Follow the above procedure and mill the slot to size.

(Fig 6)

Move the cutter to the left to a diameter of X + 0.5 mm and

mill the side of the slot. (Fig 4)

Deburr the job.

Check the slot for dimension.

Do not talk to anyone while operating the

machine, not allow anyone to turn on your
machine for you.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.124 27

Capital Goods & Manufacturing Exercise 3.2.125
Machinist - Advance Milling

Make Internal Grooving using Milling Machine with an accuracy ± 0.02 mm

Objectives: At the end of this exercise you shall be able to
• set the boring head on vertical milling machine
• true the Job to centre
• machine the internal groove.

Job Sequence
• Check the Raw material size. • Hold the centre drill and drill the location.
• Mill to the size of 60 x 30 x 20 mm. • Drill the pilot holes.
• Mark and punch the centre position. • Finish the drill  20 mm.
• Clamp the work piece on the vertical milling • Set the boring head with boring tool.
machine.
• Set the spindle speed.
• Align the centre of the circle with the axis of the
• Off set the boring head and machine the internal
spindle.
groove to required depth.
• Lock the longitudinal and cross feed movement.
• Deburr the groove.
• Set the collet adoptor.
• Check the groove depth with inside caliper.
• Set the spindle speed.
If boring head is not available. Use boring bar
with collet.

28
Capital Goods & Manufacturing Exercise 3.2.126
Machinist - Advance Milling

Make straight teeth rack using milling machine with an accuracy 0.05 mm
Objectives: At the end of this exercise you shall be able to
• mill the rack blank as per drawing
• calculate the rack proportions
• set the cutter in the arbor
• prepare the milling machine for linear indexing
• mill the rack using linear indexing.

29
Job Sequence
Rack cutting • Slide the job using a cross-slide to a pitch distance of
6.28 mm and reset the collar again to zero. (Fig 2)
• Calculate the required rack proportions for a 2 module
straight tooth rack.

Whole depth = 2.25 x m

= 2.25 x 2 = 4.5 mm
Linear pitch = xm
= 3.14 x 2
= 6.28 mm.
• Mill the rack blank to the given dimension as per the
drawing. • Start the machine and mill the next tooth.
• Clean the machine table and mount the machine vice • Repeat the above sequence and mill the remaining
keeping the jaws perpendicular to the machine rack teeth over the entire length of the job.
column.
Rack milling using rack milling attachment
• Align it with dial test indicator.
• Calculate the required rack proportions of a 2 module
• Clamp the job such that it projects 10 mm above the of straight tooth rack.
jaw surface.
• Mount the machine vice parallel to column face and
• Mount the 2 module rack cutter at the middle of the mount the job.
arbor.
• Mount the rack cutting attachment.
• Bring the job under the cutter such that the centre of the
• Prepare the milling machine for linear indexing with
cutter form is aligned to the edge of the job. (Fig 1)
driver 72 teeth (index head spindle), driven 24 teeth
(lead screw) and 20 hole circle plate.
• Mount the cutter number 1 on to the spindle of the rack
cutting attachment.
• Position the job under the cutter for the first tooth space
cutting. (The direction of table movement will depend
on the number of idlers for the same rotation of crank.)
• Give the depth of cut to 4.5 mm.
• Mill the first tooth space.

• Eliminate the backlash, adjust the graduated collar of • Index for the next tooth space.
the cross-slide and the elevating screw to zero. • Index the crank movement = 16 full turns and 15 hole
• Start the machine and mill the initial portion of the rack in a 20 hole circle plate.
to a depth of 4.50 mm in two steps; 3 mm for the • Cut the second tooth space.
roughing cut and 1.5 mm for the finishing cut.
• Check the thickness of the tooth 3.14 mm, using a gear
• Clear off the job from the cutter and stop the machine. tooth vernier caliper.
• Repeat the process and finish the rack.

30 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.126

Capital Goods & Manufacturing Exercise 3.2.127
Machinist - Advance Milling

Make helical teeth rack using milling machine with an accuracy 0.05 mm
Objectives: At the end of this exercise you shall be able to
• mill the rack blank as per drawing
• calculate the rack proportions
• set the cutter in the arbor
• prepare the milling machine for linear indexing
• mill the rack using linear indexing.

Job Sequence
Rack cutting Whole depth
• Calculate the required rack proportions for a 2 module = 1.93 x 2.25
helical tooth rack.
= 4.34 mm
Whole depth = nm X 2.25 (nm - normal module)
Linear pitch
nm = m x cos (module = m)
=  x nm
= 2 x cos 15°
= 3. 14 x 1.93 = 6mm
= 2 x 0.9659 = 1.93

31
• Clean the machine table and mount the swivel machine • Eliminate the backlash, adjust the graduated collar of
vice keeping the jaws perpendicular to the machine the cross-slide and the elevating screw to zero.
column.
• Start the machine and mill the initial portion of the rack
• Align it with dial test indicator. to a depth of 4.34 mm in two steps; 3 mm for the
roughing cut and 1.34 mm for the finishing cut.
• Swivel the vice 15° with respect to column.
• Clear off the job from the cutter and stop the machine.
• Clamp the job such that it projects 10 mm above the
jaw surface. • Slide the job using a cross-slide to a pitch distance of
6.00 mm and reset the collar again to zero. (Fig 2)
• Mount the 2 module rack cutter at the middle of the
arbor. • Start the machine and mill the next tooth.
• Bring the job under the cutter such that the centre of the • Repeat the above sequence and mill the remaining
cutter form is aligned to the edge of the job. (Fig 1) rack teeth over the entire length of the job.

Skill Sequence
Cutting rack teeth on universal milling machine using graduated dial
Objective : This shall help you to
• prepare machine for rack milling and cut rack teeth using graduated collar of cross-feed traverse.

If length of rack to be cut is short (ie. less than the max. Take the table far away from the column.
travel of cross feed) it can be done on normal horizontal
Mount the rack cutter (cutter No.1) in the arbor in such a
milling machine.
way that there is a 5 to 10 mm. gap between the job and
If it is more than the max. traverse of cross feed traverse the cutter.(Fig 2)
it should be done using a rack milling attachment.
Mill rack on horizontal milling machine
Clamp the vice on the table in such a way that its jaws are
parallel to the spindle axis, and align the fixed jaw with
D.T.I. (Fig 1)

Set the datum (ie ‘O’) on graduated dials of the vertical

traverse and cross traverse, when the cutter is touching
the job on the top and at the edge. (Fig 3)

32 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.127

Apply depth of cut raising the knee.
Deburr the tooth and measure the tooth thickness on the
Total depth of cut = 2.25 x m.
pitch line using a gear tooth caliper.
Cut a groove by feeding the job against the cutter
Thickness = 1.5708 x m
horizontally as per pitch and depth. (Fig 4)
Make necessary correction in the depth of cut, if necessary.
Move the cross-slide using a graduated dial by a distance,
P =  X module, towards the column and cut the next Cut the remaining teeth.
groove.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.127 33

Capital Goods & Manufacturing Exercise 3.2.128
Machinist - Advance Milling

Measurement of teeth by vernier gear tooth caliper

Objectives: At the end of this exercise you shall be able to
• clean and check the vernier gear tooth caliper
• record the each nomenclature
• measure the tooth nomenclature by vernier gear tooth caliper.

Job Sequence
• The given vernier gear tooth caliper is held over the gear Result
and the slide is moved down so that it touches the top
The addendum and tooth thickness of spur gear are
of the gear tooth.
measured using gear tooth vernier caliper.
• The jaws are made to have contact with the tooth on
either side by adjusting the knob.
• The reading on vertical scale i.e. addendum is noted
down.
• The reading on horizontal scale i.e. tooth thickness is
noted down.
• The above procedure is repeated for three times and
readings are noted.
Precautions
• Clean the measuring faces with paper or cloth.
• Check the zero reading of the instrument before
measuring.

34
Tooth thickness is the arc distance measured along the W = AB = 2AD
pitch circle from its intercept with one flank to its intercept angle, AOD =  = 360/4T
with the other flank of the tooth.
where T = number of teeth,
Tooth thickness = m/2 where m is the module
w = 2 AD = 2 x A O sin 
m = D/N
i.e., w = 2R sin 360/4T (R = Pitch circle radius)
N= no. of teeth
Module m=P.C.D/No. of teeth
D = Pitch circle diameter of the gear.
= 2R/T
Addendum is the radial distance from the tip of a tooth to
the pitch circle. In the most of the cases, it is sufficient to Therefore, R = Tm/2
measure the chordal thickness i.e. the chord joining the and w = 2 Tm/2. sin (360/4T)
intersection of the tooth profile with the pitch circle
because it is difficult to measure length of the arc directly. i.e., w = T. m sin (90/T)

Now, from Also from (Figure 4)

d = OC - OD
But OC = OE + addendum = R + m
= Tm/2 + m
and OD = R cos 
= Tm/2 cos (90/T)
Therefore, d = Tm/2 + m - Tm/2 cos (90/T)
i.e., = Tm/2 (1 + 2/T - cos (90/T))
or = m + Tm/ 2 (1 - cos (90/T))

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.128 35

Capital Goods & Manufacturing Exercise 3.2.129
Machinist - Advance Milling

Make spur gear using simple indexing with an accuracy 0.05 mm

Objectives: At the end of this exercise you shall be able to
• mount and align the universal index head on a plain milling machine
• set the index head for simple indexing
• mount the gear blank in the mandrel between centres
• mount a module cutter on the arbor
• centralise the gear blank with the cutter
• cut spur gear on the gear blank
• check the chordal addendum with a vernier tooth caliper.

36
Job Sequence
• Check he sizes of the given blank.
• Mount the universal index head and foot stock on the
table of the plain milling machine.
• Align the index head and foot stock using a test bar
and dial test indicator.
• Set the index head for simple indexing for the number
of teeth 28 (3 full turns and 9 holes of 21 hole circle)
• Set 30 holes in between the fingers of the sector arms.
(Fig 1)

• Check the chordal thickness using a gear tooth vernier

caliper. (Fig 3)

• Mount the blank with the mandrel between the centres

of the index head using a drawing plate and drawing
dog.
• Mount a 2-module cutter number 4 on the arbor.
• Centralise the gear blank with respect to the cutter
centre. (Fig 2) using a try square and cross feed screw
as shown in the sketch (A = R - t/2).
• Give a depth of cut equal to 4.5 mm using the vertical
feed.
• Set the spindle speed to 90 r.p.m.
• Repeat the indexing and mill all the other teeth and
• Mill the first tooth space.
finish.
• Index for the next tooth space by moving the crank pin
• Repeat the indexing and anvil all the other teeth and
through 3 full turns and 9 holes of 21 hole circle.
finish eliminate backlash by moving the index crank
• Set the chordal addendum in the gear tooth vernier only in the forward direction.
caliper.
• Eliminate backlash by moving the index crank only in
the forward direction.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.129 37

Capital Goods & Manufacturing Exercise 3.2.130
Machinist - Advance Milling

Make spur gear using differential Indexing with an accuracy 0.05 mm

Objectives: At the end of this exercise you shall be able to
• calculate and set the gear train for cutting 51 teeth by differential indexing
• check gear tooth with gear tooth vernier caliper.

38
Job Sequence
• Calculate the dia of the gear blank and tooth proportions. (A - N) is Negative It Gear train is compound 80, one idle
gear is used.
• Calculation
OD = m (z + 2)
Index crank movement =
= 2 (51 + 2)
= 2 (53)
= 106 = = =
OD = 106 mm.
Indexing
=

Gear Ratio = (A - N) Index crank should be move 15 holes in 18 holes circle

plate for 51 times.
• Mount the universal index head and foot stock on the
= (48 - 51) table of the plain milling machine.
• Align the index head and foot stock using a test bar and
dial test indicator.
= -3 x
• As per calculation set up the gear train in milling
machine.
• Mount the cutter No 4 (Module 2) on the arbor.
= x
• Calculate and set the spindle speed.
• Mill the First tooth to the depth of 4.5 mm.
= x • Index and perform to cut 51 tooth in the same manner.
• Measure the tooth nomenclature by gear tooth vernier
Driver 72, 40 caliper.
Driven 24, 48

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.130 39

Capital Goods & Manufacturing Exercise 3.2.131
Machinist - Advance Milling

Perform boring operation on vertical milling machine with an accuracy

0.05 mm
Objectives: At the end of this exercise you shall be able to
• prepare vertical milling machine for boring operation
• select and mount a boring bar
• bore circular holes to an accuracy of H7 using boring bar
• check sizes using inside micrometer.

Job Sequence
• Check the raw material with steel rule.
• Mill to the size of 50 x 50 x 20mm.
• Mark and punch the centre position of 27 hole circle.
• Clamp the workpiece on the vice on vertical milling
machine.
• Align the centre of the circle with the axis of the
spindle using a centering attachment.
• Lock the longitudinal and cross slides.
.• Off set the boring bar. Such that the cutting tool just
• Set the spindle speed and power feed to suit the touches the inner surface of the bore and lower the
material. table.
• Centre drill the hole. • Give 0.8mm cut and set speed and feed.
• Drill the holes in steps. • Rough and finish bore to 27mm using boring head.
• Mount 18mm boring bar in the boring head. • Check the size using a inside micrometer.

40
Skill Sequence
Locating the job for boring on vertical milling machine
Objective: This shall help you to
• position the hole for boring within ± -0.05 mm accuracy.

Mount and align the machine vice on the table of the Set the longitudinal slide scale at zero.
vertical milling machine and clamp the workpiece.
Wind down the machine table and clear the centering
If the job is large enough, it can be clamped directly on the device.
machine table using clamps. (Fig 1)
Remove the device and the collect chuck.
Wipe the taper on the boring head and spindle. Insert the
boring head into the spindle and tighten. (Fig 4)

Note that the work-holding device may be

clamps, stops, nut, bolts, etc. depending upon
the shape and size of the workpiece to be Select the boring bar long enough to bore to full depth.
bored. Mount it in the head and tighten firmly.
Set up a centering device in the chuck in the vertical Set the workpiece so that the centre of the hole coincides
spindle, touch one edge of the workpiece with the centering with the centre of the boring head by moving longitudinal
device. (Fig 2) and cross slides to the required distance reading on the
respective graduated dials. (Fig 5)

Beware of back-lash in the slides movements.

Set the cross-slide dial at zero.

Touch the adjacent side of the workpiece with the centering
device.(Fig 3)

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.131 41

Production & Manufacturing Exercise 3.2.132
Machinist - Advance Milling

Make helical gear on milling machine with an accuracy 0.05 mm

Objectives: At the end of this exercise you shall be able to
• set the universal dividing head for helical milling using compound gear trains
• mount appropriate module cutter on arbor
• swivel table according to the hand of the helix and helix angle
• mill the helical teeth to the desired depth.

42
Job sequence
Milling helical gear
Calculation of helical gear blank Gear Ratio =
Given :
Module :2
No. of teeth : 50
Helix Angle : 20º R.H.
OD = pd + 2 nm nm = m x cosE The gears 24, 40 are the driver gears and 48,86 driven
Z X nm = 2 x 0.9396 gears.
pd = , = 1.8792
Cosθ Milling a helical gear
50 X 1.8792 • Set the universal index head for helical milling, using
pd = a compound gear train of
0.9396
= 100 mm.
(Fig 1)
∴ OD = pd + 2 nm
= 100 + (2 x 1.8792)
= 100 + 3.7584
= 103.7584 mm
Tooth depth = 2.25 x nm
= 2.25 x 1.8792
= 4.2282 mm

Selection of Cutter No 21 =

= 60.27 (or) 60
• Set the index head to index 50 divisions by simple
Cutter No. 2
indexing.

Gear Ratio =

machine lead = 40 x Pitch of the lead screw.

Assuming Pitch of the lead screw = 5mm • The index crank should be moved 16 holes in 20 holes
machine lead = 40 x 5 = 200 mm circle plate for 50 times.
• Mount the job with a mandrel in between centres and
Job lead : align it.
• Mount 2 module cutter no. 2 (55–134 teeth) on the
arbor.

Refer to related theory on selection of

cutter number for helical gear.

• Centralise the job with respect to the cutter.

• Set the depth of cut to 4.23 mm.
• Lock the vertical feed.
= 863.42 mm • Swivel the table to 20° for right hand helix.
Rounded value = 860 mm

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.132 43

 • Check form of involute curve for symmetry and thickness
Refer to Skill Sequence on helix milling for of the tooth using vernier gear tooth caliper, at a point
the correct direction of swivelling. normal to the helix angle. (Fig 2)

• Feed the blank to mill the first tooth space. • If necessary make the required adjustments.
• Repeat the same steps and mill the remaining teeth.
Ensure that the back stopper pin is disengaged
from the index plate. • Deburr the gear on the centre lathe using a second cut
file.
Stop the machine and take the table back to
starting point.

• Index the blank (16 spaces in 20 hole circle) for next

tooth space.

Eliminate backlash before indexing.

Do not move the table while indexing.

• Cut the second tooth space.

• Remove the burrs.

44 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.132

Capital Goods & Manufacturing Exercise 3.2.133
Machinist - Advance Milling

Make straight flute milling on milling machine with an accuracy 0.05 mm

Objectives: At the end of this exercise you shall be able to
• calculate, set the universal dividing head with proper index plate
• select and position the cutter in the arbor
• offset the cutter from the centre line of the job to obtain the rake angle
• mill flutes and land of the reamer.

Diameter of blank = 25.5 mm

Number of Teeth = 8

45
Job Sequence

Machining straight fluted reamer by a horizontal milling machine

• Check the size of raw material as per blank size by • Remove the single angle milling cutter from the arbor
steel rule. and then Ø4”x1/2”x1” side and face milling cutter
• Machining the blank of straight flute reamer to the mounted on the arbor.
required size on the lathe. • By left the space of land 1/8” to 1/64” touches the cutter
• A universal dividing head and tailstock bolted on the with the periphery of the blank by lifting the table.
milling machine, after setting their axis exactly
perpendicular to the machine spindle (horizontal • After that feed applied and finish the first tooth.
universal milling machine).
• The operation is repeated till all the teeth (8teeth) are
• The work (reamer blank) is mounted between the completed.
centers or supported centre of tailstock and hold it by
three jaw chuck of dividing head. • Then stop the machine.
• Ø3”x1/2”x1”x45 single angle milling cutter is mounted
o

on the middle of the arbor, and is then centered Necessary calculations

accurately with the dividing head spindle axis by Blank diameter = 25.5mm. Number of teeth = 8
adjusting the positioning of the table.
• The alignment of the cutter with the blank is checked
by raising the table when the centre of the cutter must
touch the centre point of tailstock.
• Select the proper index plate, bolt it to the dividing 25.5
= = 3.18 = 3.2 (approx)
head with set the index crank and sector arm. 8
• The table is raised till the cutter just touches the Then, Depth of cut = 3.2mm
periphery of the reamer blank. Micro dial of the vertical
feed screw is set to the zero position. 40
Indexing:
• Then the blank is set over from the radius position N
relative to the cutter centre line, by rotating the index
crank one complete turn (9 degree). The blank is again Where, N = Number of flute
centered with the cutter, by shifting the cross feed
screw. 40 40
Then, = = 5 complete turn
• The table is next raised to give the required depth of N 8
cut 3.2 mm. The machine is started and feed is applied Offset: 9 degree offset to be applied for rake angle by
to finish the first tooth space of reamer. After the end of rotating the index crank one complete turn.
cut the table is brought back to the starting position.
After that the blank is index for next tooth space by
rotating the 5 complete turn of the index plate.
The operation is repeated till all the teeth are completed.

46 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.133

Capital Goods & Manufacturing Exercise 3.2.134
Machinist - Advance Milling

Make helical flute on milling machine with an accuracy 0.02 mm

Objectives: At the end of this exercise you shall be able to
• set the cutter
• mount the indexing head (universal) and gear train
• set to the Helix angle
• cut the Helical flute.

47
Job Sequence
Mill helical flute on vertical milling machine using • Set the spindle speed to suit the 6 mm dia. end mill
end mill or slot drill for mild steel.

• Clean the working surfaces of the table, index head • Start the machine spindle. Apply depth of cut 2 mm
and foot stock. Mount the index head at the left end gradually.
of the table. • Feed the workpiece slowly by turning the index crank
• Arrange a gear train for 100 mm lead of helix and for of the index head, and mill the right hand helical flute
right hand helix. up to the finishing point. (Refer to the Job drawing.)
• Stop the machine spindle, lower the table and bring
Machine lead Driver back the position of the end mill to the starting point.
Gear ratio  
job lead Driven • Alter the gear train to mill left hand helix, by adding one
There is no need to swivel the table for the idler gear.
helix angle. (Refer to Skill Sequence 13 on • Start the spindle, raise the table and apply depth of
milling helix on universal milling machine.) cut, until the cutter face just touches the bottom of the
flute already milled.
Ensure that the gear driving mechanism • Start feeding the workpiece by rotating the index crank
operates freely and the back stopper pin is and mill the left hand helical flute up to the finishing
disengaged from the index plate. point.
• Mount a dia. 6 mm slot drill or end mill in the collet Ensure that the back stopper pin is disengaged
chuck and fix the collet chuck in the spindle of the from the index plate before starting feeding.
vertical milling machine. Take care of backlash, when you reverse the
• Mount the job between centres and fix the dog in the feed direction.
driving bracket.
• Stop the machine spindle, remove the job and deburr
• Align the end mill to the centre of the job. Adjust the helical flute using smooth flat file.
table position at the starting point. (Refer to the Job
drawing.)

Skill Sequence
Milling helix on universal milling machine
Objectives : This shall help you to
• cut helical grooves on cylindrical workpieces
• cut helical flutes on slab milling cutters, end mill cutters and hand reamers
• cut teeth on helical gear.

Helix is the form of line generated by the progressive To cut a helix on universal a milling machine, proceed as
rotation of a point around an axis of a cylinder. (Fig 1) This follows.
operation of cutting helix is often required in a machine Fix universal dividing head at the left hand end of the work
shop, when milling helical teeth on milling cutters, end table of the universal milling machine.
mills, counterbores, twist drills, reamers, helical gears
and cams. Helical milling can be done on the universal Select an index plate suitable for the number of divisions
milling machines with the help of a universal dividing head. required and fix it. Set the sector arms.
Disengage the back pin from the index plate
and insert the index plunger in the numbered
hole of the index plate.
Determine the lead of helix for the given workpiece from the
working drawing.

π  Outside dia
Rule 
Tan of helix angle

In case of helical gears instead of outside

diameter, P.D ie pitch diameter of the gear
should be taken into calculation.

48 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134

Calculate, select and fix the change gears suitable for the
lead calculated.

Lead of machine
Rule 
Lead of helix
Driving gears

Driven gears
gear on lead screw  1st gear on stud

gear on worm shaft  2nd gear on stud

Refer to Fig 2 for the correct position of gears in the gear

train for quick and correct selection of change gears.
Refer to Table I for selection of the change gears supplied
for helical milling.
Fix the work between centres, ensure that the driving dog
properly ‘fits in’ (without slack) in the dog driver.
When the job is held between the self-centering
chuck and centre, there is a chance the chuck
may be loosened particularly when cutting left
hand helix, because of the threaded end of the
spindle nose of the dividing head. This point
should be taken care of.
Swivel the table to the calculated angle of the helix.
The direction of table swivelling will be according to the
hand of the helix. (Fig 4)

Know the lead of your machine yourself . If you

are not thorough in understanding the term
“machine lead”, refer to Related Theory on
helical milling. Move the table transversely (‘cross-feed’) until there is
20 mm or so, clearance between the table and the column.
Ensure the hand of helix from the working drawing or
sample given (Fig 3) and fix accordingly one idler or two Fix the arbor (long arbor) in the machine spindle.
idlers, or no idler. (Fig 2) The diameter of the arbor should correspond to the
Check the direction of rotation of the spindle of diameter of the bore of the cutter to be selected.
the dividing head, when the work table Select a cutter suitable for the given helical operation.
advances towards the cutter. (Fig 5)
When looking from the back of the dividing
head, for R.H. helix, the spindle should rotate
in clockwise direction and for L.H. helix in
anticlockwise direction. (Fig 2)

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134 49

 Effect of Table Efects of Table
not swivelled during swivelled during
helical milling. helical milling.

Width of the groove Width of the groove

is more than the is equal to the width
cutter width. of the cutter.
Set the speed of the spindle for the machine to suit the
material of the workpiece. (Refer to Related Theory on
cutting to speed and feed of milling cutters.)
Start the machine spindle. Raise the table and get the
‘feel’ of touching the cutter on the workpiece. Set the
graduated dial of the vertical movement at ‘O’.
Apply depth of cut (full or part thereof) and feed by hand
the longitudinal movement. Ensure that the width of
Width of the groove Shape of the groove groove is exactly equal to that of the cutter.

is more than the will not be the same Direct the flow of coolant at the point of cutting and mill the
first groove.
cutter width. as the cutter.
Ensure that the cutter does not foul the dog or
the jaws of the chuck, at the end of the cut.

Stop the machine spindle. Reverse the table to the

starting position. Leave atleast 10 mm clearance between
the cutter and the edge of the workpiece.
Lock the index plate in position by inserting the ‘back pin’’
Width and shape is Width and shape is and index for the next flute/teeth.
same as the cutter. same as the cutter. Do not forget to release the back pin as soon
as indexing for the next division is over.
Only those cutters, whose side cutting edges Start the machine spindle, cut the second flute/tooth.
incline more or less towards each other, ie. a
double equal angle cutter, or double unequal Ensure that the index head spindle is not
angle cutter or convex cutter or gear tooth locked by its lock lever while the cutting
cutter may be used. operation is progressing.

Tighten the cutter on the arbor in its proper position with Stop the machine spindle and reverse the table again to
reference to the workpiece. the starting position.
Bring the table back to horizontal (zero) and set the end Check the thickness of the tooth, (in case of helical gear)
of the work under the axis of the cutter. This is in order to by the gear tooth vernier caliper at 90° to the helix angle.
have the cutter in such a position, that the full depth and In the case of grooves, check the width and depth, by
exact shape of the groove will be cut. It is easier to judge suitable measuring instruments.
the proper setting when the table is horizontal.
If necessary adjust the depth of cut to correct the width of
Adjust the position of blank to the centre of milling cutter. the groove, or the thickness of the tooth.
(Fig 6)
Repeat the above steps and complete the helical milling
Swivel the table again to the required angle and clamp operation.
tightly.

50 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134 51
 TABLE 1
CHANGE GEARS FOR SPIRAL MILLING

Lead Number of teeth Type of Dividing Head Lead Number of teeth Type of Dividing Head
in change gears in change gears
130 180 130 180

mm Za Zb Zc Zd Spiral Spiral mm Za Zb Zc Zd Spiral Spiral

R-H L-H R-H L-H R-H L-H R-H L-H

Figure Figure

24.56 100 24 86 44 B E G K 66.00 100 48 64 44 B E G K

26.06 100 28 86 40 B E G K 66.67 72 - - 24 A D F I
26.79 100 24 86 48 B E G K 68.22 86 48 72 44 B E G K
28.66 100 28 86 44 B E G K 69.77 86 48 64 40 C E H K
29.33 100 24 72 44 C E H K 70.00 100 56 64 40 B E G K
31.11 100 40 72 28 C E H K 71.11 100 64 72 40 B E G K
31.26 100 48 86 28 B E G K 72.00 100 72 64 32 B E G K
32.75 100 44 86 32 B E G K 73.14 100 64 56 32 B E G K
34.23 100 44 72 28 B E H K 73.67 100 72 86 44 B E G K
35.56 100 40 72 32 B E H K 74.42 86 - - 32 A D F I
35.72 100 48 86 32 B E G K 75.00 64 - - 24 A D F I
36.00 100 48 64 24 C E H K 75.43 100 48 56 44 B E G K
36.47 100 56 86 28 B E G K 76.44 100 32 72 86 B E G K
37.33 100 48 72 28 B E G K 77.00 100 56 64 44 B E G K
38.15 100 44 64 28 C E H K 78.55 100 24 44 72 C E H K
39.12 100 44 72 32 B E G K 79.59 86 56 72 44 B E G K
40.00 100 40 64 32 C E H K 80.00 100 - - 40 A D F I
42.00 100 48 64 28 C E H K 81.40 86 56 64 40 B E G K
42.67 100 48 72 32 B E G K 82.69 86 64 72 40 B E G K
43.41 86 56 72 24 C E G K 83.33 100 64 86 56 B E G K
44.00 100 44 64 32 C E H K 84.00 100 56 64 48 B E G K
44.65 100 48 86 40 B E G K 85.05 86 32 56 64 C E H K
46.89 100 72 86 28 B E G K 86.00 100 32 64 86 B E G K
47.63 100 64 86 32 B E G K 86.82 86 56 72 48 B E G K
48.00 100 48 64 32 B E H K 88.00 100 - - 44 A D F I
49.00 100 56 64 28 B E G K 88.90 72 - - 32 A D F I
49.65 86 48 72 32 C E H K 89.54 86 56 64 44 B E G K
49.78 100 56 72 32 B E G K 90.00 100 72 64 40 B E G K
50.65 86 56 72 28 C E H K 90.96 86 64 72 44 B E G K
52.10 100 56 86 40 B E G K 91.64 100 28 44 72 B E H K
53.34 100 48 72 40 B E G K 93.34 100 56 48 40 B E H K
54.00 100 24 64 40 B E G K 95.56 100 86 72 40 B E G K
55.00 100 44 64 72 B E G K 96.00 100 - - 48 A D F I
56.89 100 64 72 32 B E G K 97.67 86 56 64 48 B E G K
57.89 86 56 72 32 B E G K 98.29 100 32 56 86 B E G K
58.67 100 48 72 44 B E G K 99.00 100 72 64 44 B E G K
59.54 100 64 86 40 B E G K 99.56 100 64 72 56 B E G K
60.00 100 48 64 40 B E G K 100.00 64 - - 32 A D F I
61.72 100 24 56 72 B E G K 100.59 100 64 56 44 B E G K
62.22 100 56 72 40 B E G K 101.75 86 28 64 100 B E G K
62.78 86 24 64 72 B E G K 102.33 86 - - 44 A D F I
63.00 100 28 64 72 B E G K 103.20 100 24 40 86 B E G K
64.00 100 - - 32 A D F I 104.51 72 28 64 86 B E G K
64.50 100 24 64 86 B E G K 105.12 100 86 72 44 B E G K
65.12 86 56 64 32 C E H K 106.30 86 64 56 40 B E G K
52 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134
Lead Number of teeth Type of Dividing Head Lead Number of teeth Type of Dividing Head
in change gears
in change gears
130 180
130 180
mm Za Zb Zc Zd Spiral Spiral
mm Za Zb Zc Zd Spiral Spiral
R-H L-H R-H L-H
R-H L-H R-H L-H
Figure
Figure

149.34 100 64 48 56 B E G K
107.15 100 72 86 64 B E G K
150.00 64 - - 48 A D F I
108.00 100 72 64 48 B E G K
150.50 100 86 64 56 B E G K
109.10 44 - - 24 A D F I
151.52 71 24 44 100 C E H K
109.01 100 64 56 48 B E G K
152.38 72 64 56 48 C E H K
111.11 72 - - 40 A D F I
152.89 100 86 72 64 B E G K
111.63 86 - - 48 A D F I
153.49 86 44 48 72 B E G K
112.00 100 - - 56 A D F I
155.04 86 32 48 100 B E H K
113.14 100 72 56 44 B E G K
155.56 72 - - 56 A D F I
114.67 100 48 72 86 B E G K
156.36 100 40 44 86 B E G K
115.76 86 64 72 56 B E G K
157.67 100 44 48 86 B E G K
116.28 86 32 64 100 B E G K
117.34 100 64 48 44 B E G K 158.40 100 44 40 72 B E G K

118.25 100 44 64 86 B E G K 158.73 72 32 56 100 B E G K

119.07 72 24 56 100 B E G K 159.25 72 32 48 86 B E G K

120.00 100 40 48 72 B E G K 160.00 100 40 32 64 C E H K

121.53 72 28 64 100 B E G K 162.04 72 28 48 100 B E G K

122.86 100 40 56 86 B E G K 162.97 100 64 44 56 B E G K

123.43 100 72 56 48 B E G K 164.58 100 72 56 54 B E G K

124.03 86 64 48 40 B E H K 166.1 86 40 56 100 B E G K

125.00 64 - - 40 A D F I 166.67 48 - - 40 A D F I

125.58 86 72 64 48 B E G K 167.45 86 - - 72 A D F I

126.00 100 72 64 56 B E G K 168.00 100 72 48 56 B E G K

126.85 86 24 44 100 B E G K 169.30 86 32 44 100 B E G K
128.00 100 - - 64 A D F I 171.43 56 - - 48 A D F I
129.00 100 86 64 48 B E G K 172.00 100 - - 86 A D F I
130.23 86 - - 56 A D F I 172.80 100 48 40 72 B E G K
130.91 100 40 44 72 B E G K 173.64 72 40 64 100 B E G K
131.56 86 72 56 44 B E G K 174.42 86 48 64 100 B E G K
132.00 100 44 48 72 B E G K 175.00 64 - - 56 A D F I
132.89 86 32 56 100 B E G K 176.00 100 44 32 64 C E H K
133.78 100 86 72 56 B E G K 176.78 64 72 56 44 C E H K
134.38 100 56 40 43 B E H K 177.78 72 - - 64 A D F I
135.66 86 28 48 100 B E G K 178.58 64 32 56 100 B E G K
136.51 72 32 56 86 B E G K 179.17 72 48 64 86 B E G K

137.50 64 - - 44 A D F I 180.00 100 40 32 72 B E H K

138.89 72 32 64 100 B E G K 181.82 44 - - 40 A D F I

139.54 86 40 48 72 B E G K 182.28 64 28 48 100 C E H K

140.80 100 44 40 64 B E G K 182.72 86 44 56 100 B E G K

142.86 56 - - 40 A D F I 183.27 100 72 44 56 B E G K

143.34 100 40 48 86 B E G K 184.14 86 44 40 72 C E H K

144.00 100 - - 72 A D F I 185.19 72 32 48 100 B E G K

145.35 86 40 64 100 B E G K 186.05 86 32 40 100 B E G K

146.55 86 72 64 56 B E G K 187.64 100 48 44 86 B E G K

147.43 100 48 56 86 B E G K 189.20 100 44 40 86 B E G K

147.98 86 28 44 100 B E G K 190.00 72 44 64 100 B E G K

148.84 86 - - 64 A D F I 192.00 100 72 48 64 B E G K

192.86 64 72 56 48 B E H K

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134 53

Lead Number of teeth Type of Dividing Head Lead Number of teeth Type of Dividing Head
in change gears in change gears
130 180 130 180
mm Za Zb Zc Zd Spiral Spiral mm Za Zb Zc Zd Spiral Spiral
R-H L-H R-H L-H R-H L-H R-H L-H
Figure Figure

193.50 100 72 64 86 B E G K 246.86 100 48 28 72 B E G K

195.35 86 56 48 72 B E G K 250.00 32 - - 40 A D F I
196.57 100 64 56 86 B E G K 251.16 86 48 32 72 C E H K
198.00 100 44 32 72 B E G K 252.00 100 56 32 72 B E G K
252.53 72 40 44 100 B E G K
199.07 72 40 48 86 B E G K
254.63 72 44 48 100 B E G K
199.34 86 48 56 100 B E G K
255.81 86 44 40 100 B E G K
200.00 24 - - 24 A D F I 256.00 100 56 28 64 B E G K
200.67 100 56 48 86 B E G K 257.15 56 - - 72 A D F I
201.60 100 56 40 72 B E G K 258.00 100 72 48 86 B E G K
202.02 72 32 44 100 B E G K 260.61 72 48 44 86 B E G K
261.63 86 72 64 100 B E G K
203.49 86 56 64 100 B E G K
262.50 64 56 48 72 C E H K
204.76 72 48 56 86 B E G K
264.00 100 44 24 72 C E H K
206.40 100 48 40 86 B E G K
265.78 86 64 56 100 B E G K
207.41 72 56 48 64 C E H K
266.67 48 - - 64 A D F I
208.34 72 48 64 100 B E G K
267.86 64 48 56 100 B E G K
209.03 72 56 64 86 B E G K
268.75 64 - - 86 A D F I
211.17 64 44 56 86 B E G K
270.29 100 44 28 86 B E G K
213.11 86 56 44 72 B E G K
271.32 86 56 48 100 B E G K
215.00 100 40 32 86 B E G K
273.02 72 64 56 86 B E G K
216.00 100 48 32 72 B E G K
275.00 32 - - 44 A D F I
217.17 72 40 44 86 C E H K
277.78 72 - - 100 A D F I
218.18 44 - - 48 A D F I
278.71 72 56 48 86 B E G K
218.91 100 56 44 86 B E G K 279.07 86 48 40 100 B E G K
219.43 100 48 28 64 C E H K 280.00 40 - - 56 A D F I
220.00 40 - - 44 A D F I 281.45 100 86 44 72 B E G K
221.14 100 72 56 86 B E G K 284.08 64 40 44 100 B E G K

222.22 72 32 40 100 B E H K 285.72 28 - - 40 A D F I

286.46 64 44 48 100 B E G K
223.22 64 40 56 100 B E G K
288.00 100 64 32 72 B E G K
223.96 64 40 48 86 B E H K
290.68 86 40 32 100 B E G K
224.00 100 56 32 64 B E G K
293.02 86 56 32 72 B E G K
225.00 64 - - 72 A D F I
294.86 100 48 28 86 B E G K
226.28 72 56 44 64 B E H K
295.98 86 56 44 100 B E G K
227.28 64 32 44 100 C E H K
297.62 56 40 48 100 B E H K
228.58 56 - - 64 A D F I
298.67 100 56 24 64 B E H K
229.33 100 64 48 86 B E G K
299.01 86 72 56 100 B E R K
230.36 64 48 56 86 B E G K
300.00 48 - - 72 A D F I
231.49 72 40 48 100 B E G K
301.00 100 56 32 86 B E G K
232.56 86 - - 100 A D F I
303.04 72 48 44 100 B E G K
233.33 48 - - 56 A D F I
304.05 72 56 44 86 B E G K
234.40 86 56 40 72 B E G K
305.56 72 44 40 100 B E G K
236.50 100 44 32 86 B E G K
307.14 56 - - 86 A D F I
238.08 72 48 56 100 B E G K
309.60 100 72 40 86 B E G K
238.89 72 - - 86 A D F I
310.08 86 64 48 100 B E G K
240.00 40 - - 48 A D F I
312.05 64 - - 100 A D F I
240.80 100 56 40 86 B E G K
313.55 64 56 48 86 B E G K
243.06 72 56 64 100 B E G K
314.29 28 - - 44 A D F I
245.54 64 44 56 100 B E G K

54 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134

Lead Number of teeth Type of Dividing Head 342.86 56 64 48 72 C E H K
in change gears 343.75 64 44 40 100 B E G K
130 180 344.00 100 64 32 86 B E G K
mm Za Zb Zc Zd Spiral Spiral 345.54 64 72 56 86 B E G K
R-H L-H R-H L-H
347.47 72 64 44 86 B E G K
Figure 350.00 32 - - 56 A D F I
353.54 72 56 44 100 B E G K
315.34 100 44 24 86 B E G K 357.15 56 - - 100 A D F I
317.46 72 64 56 100 B E G K
358.34 72 48 32 86 C E H K
318.52 72 64 48 86 B E G K
360.00 40 - - 72 A D F I
319.77 86 44 32 100 B E G K
364.58 64 56 48 100 B E G K
320.00 40 - - 64 A D F I 365.45 86 44 28 100 B E G K
322.50 64 48 40 86 C E H K
366.67 24 - - 44 A D F I
324.08 72 56 48 100 B E G K
370.38 72 64 48 100 B E G K
325.58 86 56 40 100 B E G K
372.08 86 64 40 100 B E G K
327.38 56 44 48 100 B E G K 373.27 72 86 64 100 B E G K
329.18 100 64 28 72 B E G K
375.00 64 48 40 100 B E G K
332.23 86 40 28 100 B E G K
333.33 72 48 40 100 B E G K
334.45 72 56 40 86 B E G K
336.00 100 56 24 72 B E G K
338.27 86 64 44 100 B E G K
340.91 64 48 44 100 B E G K

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.2.134 55

Capital Goods & Manufacturing Exercise 3.3.135
Machinist - Electrical & Electronics

Measure current, voltage and resistance using simple ohms law circuits and
familiarizing multi meter
Objectives : At the end of this exercise you shall be able to
• identify available ranges in the given multimeter
• set controls, choose suitable range for measurement
• measure voltages and currents.

Requirements

Tools / Instruments Materials

• Regulated Dual DC power supply unit • AA size (R-6), Zinc-Chloride 1.5V,
0-30V, 5 Amps per batch - 1 No. primary cell - 2 Nos.
• Multimeter with probes - 1 No. • Cell holder to hold 2 Nos. of AA cells - 1 No.

PROCEDURE
TASK 1 : To measure DC Voltage

1 In the given multimeter, check the available ranges,

scales and other information and record these details in
O&T sheet.
2 Check the symbol on meter indicating its placement
position. Carryout mechanical zero setting of the
meter.
3 Connect the meter prodes ensuring proper colour of
prod at meter terminals.
4 Get your work done in Steps 1,2 and 3 checked by your 10 Set the meter range to measure the unknown
instructor. DC voltage from the regulated DC power supply unit
(RPSU) set by your instructor.
5 Record the rated output voltages of the given pentorch
(AA size) cells in O&T sheet. 11 Measure the output voltage of RPSU. Change the set
range if necessary to measure the set RPSU voltage
6 Set the meter range switch to measure cell voltages
more accurately. Record the measured voltage in O&T
and choose the scale for taking readings. Record the
sheet.
chosen range position and scale in O&T sheet.
7 Measure and record the voltage of each cell. Readings taken on meter will be more
accurate, when the range selected is such that
8 Place the two cells in the cell holder as shown in
the pointer is pointing around the middle of
Fig 1.
the scale.
In the cell holder, the cells will be in series.
12 Ask your instructor to change the set RPSU output
Therefore across the terminals of the cell holder,
voltage and repeat steps 10 and 11.
the voltage will be sum of the voltages of each
cell. 13 Get your work checked by your instructor.

9 Set the meter range suitable to measure the cell pack

voltage. Measure and record the voltage of the cell
pack.

56
TASK 2 : To measure DC current

The procedure given below should be carried out only after your instructor connects a component known
as Resistor at the one of the terminal of the RPSU.

Never connect a current meter directly across

the output terminal of RPSU. This will damage
the meter as well as the RPSU.

1 Set the multimeter to measure an unknown DC current.

2 Connect the meter terminals as shown in Fig 2.
3 Measure and record the readings shown by the meter.
Change the set range if necessary to measure the
current more accurately. See note given at Step 11 of
Task 1.
4 Ask your instructor to change the value of resistor such
that a different valve of current flows. Repeat steps 1,2
and 3.
5 Get your work checked by your instructor.

Observation and Tabulation Sheet

1. Name of the given multimeter & model number :

2. Manufacturers name :
3. Position in which the meter should be kept during measurement :
4. List the input sockets available on the meter.
i
ii
iii
5 List the available measuring ranges and scale marking on the meter:
DC voltage ranges Resistors ranges
No. of Range Suitable meter Value of No. of Range Value of
ranges setting scale marking one SSD ranges setting one SSD
Sample 1V 0-100 0.2 Volts

AC voltage ranges
DC current ranges
No. of Range Suitable meter Value of
ranges setting scale marking one SSD No. of Range Suitable meter Value of
ranges setting scale marking one SSD

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.135 57

AC current ranges 8. Give the maximum and minimum AC voltage
that can be measured using the given meter:
No. of Range Suitable meter Value of
ranges setting scale marking one SSD Max. Min.

9. Give the maximum and minimum AC current

that can be measured using the meter:
Max. Min.

10. Measured voltage of AA cells :

Cell 1 : _______ V Cell 2 : _______ V

6. Give the maximum and minimum DC voltage 11. Measured voltage of cell pack : _______ V
that can be measured using the given meter.
Max. Min. 12. Measured voltages of RPSU output:
First setting : _______ V
7. Give the maximum and minimum DC current Second setting : _______ V
that can be measured using the given meter:
Max. Min. 13. Measured currents:
First setting : _______ V
Second setting : _______ V

58 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.135

Capital Goods & Manufacturing Exercise 3.3.136
Machinist - Electrical and Electronics

Soldering Techniques, Solder copper conductor joints

Objectives : At the end of this exercise you shall be able to
• solder lug in an aluminium cable
• solder copper conductor joints using a soldering iron and resin-cored solder.

Requirements
Tools/Instruments Materials
• Combination pliers 200 mm - 1 No. • Simple twist joint as prepared in
• Electric soldering iron 60W, 250V, Exercise 506 - 1 No.
50Hz. - 1 No. • Sandpaper `00' grade - 9 sq.cm.
• File flat, bastard 150mm - 1 No. • Rosin-cored solder - 25 gms.
• Cotton cloth 30cm x 30cm - 1 piece
• Wire brush - 1 No.
• Soldering iron stand with cleaning pad - 1 No.

PROCEDURE
(A finished soldered joint will look as shown in Fig 1.) 3 If found corroded, file the tip with a flat file, so that the
surface is smooth and clean. (Fig 4)

1 Select a 60W, 230V AC 50 Hz. soldering iron (Fig 2) and

ensure that the iron has no physical damage, the body
is well insulated from the element and is of the correct
voltage and power rating.

4 Connect the soldering iron to the supply and switch it

`ON'.
5 When the bit becomes sufficiently hot, apply a small
quantity of resin-cored solder, and tin the bit. (Fig 5)

A soldering iron should show continuity

between its terminals. Insulation resistance
between the terminal and the body should not
be less than 2 mega ohms. Report to your
instructor in case the insulation resistance is
less than 2 mega ohms. Do not use the iron
unless cleared by your instructor.

2 Check the bit (Fig 3) to see whether the surface is

smooth and clean.
If the bit is not completely and evenly covered
with solder, clean and tin it again.
Never flick excess solder off the bit. The hot
solder may cause burns to someone or fall into
part of the work, and cause a short circuit.

59
6 Wipe the bit gently on the cleaning pad to remove 9 When the joint is heated, keep the rosin-cored solder
excess solder as shown in Fig 6. on the joint and allow it to melt as shown in Fig 9.

7 Clean the joint to be soldered with the help of sandpaper

10 Melt the solder with the heat of the bit and make sure
`O O', grade as shown in Fig 7, and wipe the dust with
the solder flows freely and evenly on the joint.
a wire brush.
11 Remove the soldering iron. use cotton cloth to wipe off
the excess solder from the surface of the joint when it
is still hot as shown in Fig 10.

8 Keep the soldering iron bit on the joint and heat it for
soldering as shown in Fig 8.

12 Allow the joint to cool naturally. Do not blow air for

cooling.

A shining solder surface ensures a good

soldering. Do not move the joint until the
solder solidifies.

60 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.136

Capital Goods & Manufacturing Exercise 3.3.137
Machinist - Electrical & Electronics

Step up and step down transformers

Objectives: At the end of this exercise you shall be able to
• identify the terminals of HT and LT winding
• connect step up transformer in single phase supply and measure the voltage
• connect step down transformer in single phase supply and measure the voltage.

61
 Requirements
Tools / Instruments
Materials
• Voltmeter M.I. 0 - 250/300V - 2 Nos
• Connecting cables - as reqd.
• Ohmmeter (0 - 500 ohms) - 1 No.
Equipment / Machines
• Single phase transformer
415/230 volts, 1 KVA - 1 No.

PROCEDURE
1 Find out the corresponding terminals of two windings. Table - 1
(HT & LT) with ohm meter as shown in Fig 1. Step up Transformer
2 Determine HT and LT winding be measuring resistance
wih the ohm meter.
LT HT
LT windings will have low resistance mark
accordingly.
230V
3 Connect LT winding to the AC single phase 230 V and
measure voltage on the HT winding and record the same
in the Table - 1.
Step down Transformer
4 Switch the supply and disconnect the meters.
5 Then connect AC 3 phase 415V to the HT winding and HT LT
measure voltage on the LT winding and record the same
in Table - 2.
415V
6 Disconnect the supply and keep all the meters and
Transformer in the original plate.

62 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.137

Capital Goods & Manufacturing Exercise 3.3.138
Machinist - Electrical - Electronics

Working with solenoids and relays

Objectives: At the end of this exercise you shall be able to
• check the continuity of solenoid winding
• test the solenoid
• identify the parts of relay
• ascertain the operation of the magnetic and thermal relays .

Requirements
Tools / Instruments
Equipments / Machines
• Packer metalic - 1 No.
• DC magnetic relay 6 V or 12 V - 1 No.
• DC ammeter 0 - 1A - 1 & 2A - 1 No.
• Variable DC power supply 0-30 V-2A - 1 No.
• DC voltmeter 0 - 30 VOC - 2A - 1 No.
• Solenoid pulling power test Jig - 1 No. Materials
• Multimeter or ohm meter - 1 No. • PVC flexible cable 14/0.2 mm -5m
• Milliammeter 100 mA DC - 1 No. • Resistor 470 ohms, 5w - 1 No.
• PVC insulated copper cable 45 & mm - 1 No.
250 V graze

PROCEDURE
TASK 1: Test solenoid
1 Solder 0.5 meters wires at terminals A and B of the
solenoid.
2 Place the solenoid on a wooden board and clamp the
solenoid as shown in Fig 2.
3 Set current limit of PSU to 1A. Set output voltage to
Zero. Switch OFF PSU. Make circuit connections as
shown in Fig 1.

4 Place a soft iron rod slightly inside (10 to 15mm) the

hole of the solenoid as shown in Fig 2a.
In case a 6mm soft iron rod is not available, If the soft iron is not attracted even when the
use a thick & lengthy iron nail. circuit current is more than 250 mA, switch
OFF PSU and consult your instructor.
5 Switch ON PSU. Increase the output voltage of the
PSU gradually from 0 volts till the soft iron rod gets 6 Pull-out the iron rod slightly from the solenoid and
attracted by the solenoid as shown in Fig 2b. Record release it. Check if the rod is pulled back inside the
the circuit voltage and current in O & T sheet. hole.
7 Repeat steps 5 and 6 a few more times till you are
Observe that the pulled iron rod rests at the
satisfied about the working of the solenoid. Get it
center along the length of the solenoid (refer
checked by your instructor.
lesson).
8 Switch OFF PSU. Remove circuit connections. Take
out the solenoid by removing the clamp.

63
 Observation & Tabulation Sheet
TASK 1
1 Total number of turns of coil :
2 Gauge of wire used :
3
Sl. No. Applied Current Initial reading of Final reading of Pulling power of
DC voltage consumed by the the spring balance the spring balance the solenoid
to solenoid solenoid (W1) (W2) (W2 - W1)
1 12V
2 15V
4 Complete the sentences given below :
a With 12V DC applied, the mmf developed is _________ A.t.
b With 15V DC applied, the mmf developed is _________ A.t.
c The pulling power of the solenoid _________ as the mmf developed is increased.
d The pulling power of the solenoid can be increased by increasing the _________ and/or _________.

TASK 2: Identify a relay

1 Collect the relays along with the instruction booklet.
TABLE - 1
Data of the relay
Type of relay _________________
Coil Voltage _________________
Relay range _________________
Back up fuse rating _________________

2 Determine by INspection the terminal connection of 4 Record the relay and contact terminal number in
the coil and the number contacts. Table 2.
3 Also identify the normally open and closed contacts 5 Draw the connection diagram of the relay in your record.
by using ohmmeter or multimeter.
6 Measure the coil resistance and record in Table 2.

TASK 3: Connect a relay in a circuit & test for its working

1 Connect the relay as per diagram shown in Fig 1. 6 Slowly reduce the voltage of the power supply till the
ohmmeter/multimeter connected across the normally
2 Adjust the power supply voltage to minimum.
open contact shows infinity deflection.
3 Switch on the switch ‘S’.
7 Observe the minimum current (reset current) required
4 Slowly increase the DC voltage till the ohmmeter/ to reactivate the relay and enter the value in Table 2.
multimeter connected across the normally open
8 Repeat steps 2 and 7 and verify the previous pick up
contact shows deflection.
and reset reading.
5 Observe the minimum current (pick up current) required
9 Repeat your working steps if necessary until your
to activate the relay and enter the value in Table 2.
readings are constant.

TABLE - 2
Relay characteristics
Function Terminal connection Relay characteristics
Relay coil Coil resistance _________ ohm
Normally open contacts Pickup current _________ mA
Normally closed contacts Reset current _________ MA

64 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.138

Capital Goods & Manufacturing Exercise 3.3.139
Machinist - Electrical and Electronics

Working of motor & generators

Objectives: At the end of this exercise you shall be able to
• connect 3-phase motor with the starter
• connect a DC shunt generator, field regulator, ammeter and voltmeter
• start the 3-phase AC motor
• adjust the field regulator and build up DC voltage
• determine combined efficiency of the M.G set.

Requirements
Tools / Instruments
- DC shunt generator - 5 KW
• Electrician Tool kit - 1 set 220V with field regulator
• Voltmeter MI 0-500V - 1 No. • Lamp bank of 5 KW - 240 V - 1 No.
• Ammeter MI 0-15A - 1 No.
Materials
• Ammeter MC 0 to 2.5A - 1 No.
• Ammeter MC 0 to 15A - 1 No. • ICDT switch 16A 415V - 1 No.
• Voltmeter MC 0 to 250 volt - 1 No. • ICTP switch 16A 415V - 1 No.
• Power factor meter 500V • Lamp holder pendent - 2 Nos.
15A 0.5 lag to 0.5 lead - 1 No. • Lamp 240V, 60 or 100 watts bulb - 2 Nos.
• Tachometer multi-range • Stranded PVC insulated wire
0-300/1000/3000 rpm - 1 No. 7/1.5 aluminium cable -4m
• D.P.S.T. Switch 16A, 240V - 1 No.
Equipment / Machines
• PVC insulated connecting cable - as reqd.
• 3-phase squirrel cage induction • ICDP switch 16A 240V - 1 No.
motor 5 HP, 415V, 50 Hz - 1 No. • ICTP switch 16A 415V - 1 No.
- with star-delta starter 415V, 16A • Graph sheet - as reqd.

PROCEDURE
TASK 1: Start, run and load a M.G. set
1 Couple the 3-phase induction motor with the DC shunt 5 Observe the voltmeter reading.
generator and check for proper alignment.
Take care not to exceed the excitation current
2 Connect the AC motor and generator as shown in Fig 1. beyond its rated value.
Keep the field regulator at ‘Zero/Minimum’
position. Keep the load switch ‘S2’ open. 6 Read and record the excitation current and the induced
voltage.
3 Start the motor by operating star/delta starter (Y/ - Excitation current : ____________________A
starter) and note down the reading of V2. Voltage : ____________________Volt

4 Slowly decrease the DC generator field resistance and 7 Read the input current and AC supply voltage on no-
increase the exciting current until the generated voltage load operation of M.G set.
builds up to its rated value.
65
 Input current _________________________ A (AC) 11 Compare the no-load input to M.G set with that of no-
Ac supply voltage V between lines ________ load input of motor only in the earlier experiments on the
AC machines. Why is there a difference?
8 Calculate no-load input to M.G set.
9 Gradually reduce the excitation current to zero ampere.
10 Switch ‘off’ the motor, operating the stop switch of the
starter and the supply switch (S1).

TASK 2: Determine the combined efficiency of the M.G. set

1 Connect the AC motor and generator as shown in 10 Calculate the output power.
Fig 1.
Keep the field regulator at a position to include
zero resistance in the circuit. Keep switch S1
and S2 in ‘off’ position.
2 Start the AC motor. Measure the speed using a
tachometer.
3 Build up the DC generator terminal voltage to its rated
value and observe the voltmeter (V2) reading. 11 Calculate the total loss and the efficiency at full load.
4 Switch ‘ON’ the load switch S2.
5 Gradually increase the load by switching ‘on’ the lamps
in steps up to the rated capacity of MG set.
6 Measure the speed of the generator for each load
condition and record in Table 1.
7 Record input current, voltage and power factor in Table
1. Read and record the load current and terminal voltage 12 Stop the prime mover of the M.G set and isolate supply.
of generator in Table 1.
CONCLUSION
8 Switch ‘OFF’ the load in steps and open the load switch
Observe from the readings in Table 1 that the terminal
S2.
voltage drops with increase in load. State your reasons.
9 Calculate the input power.

TABLE 1
OUTPUT INPUT
Load Terminal Speed Line Line Power
current (I) voltage (V) in r.p.m (N) current (IL) voltage (VL) factor

66 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.139

Capital Goods & Manufacturing Exercise 3.3.140
Machinist - Electrical - Electronics

Behaviour of proximity sensors

Objectives : At the end of this exercise you shall be able to
• construct capacitive proximity sensor circuit and test it
• construct inductive proximity sensor circuit and test it
• construct photo electric proximity sensor circuit and test it
• defect different objects using proximity sensors.

Requirements
Tools / Instruments • Resistor CR 25-2k2, 3k9, 4k7 - 1 No.each
• Resistor 150 Ohm/ W/CR25 - 2 Nos.
• Trainees tool kit - 1 Set
• PC 817 Optocoupler - 1 No.
• Soldering iron 25 watts/240 V - 1 No.
• Bread board - 1 No.
• Regulated power supply
• Proximity sensor PNP type - 1 No.
0-30V/2A - 1 No.
• Photo electric sensor - 1 No.
• DMM with probes - 1 No.
• Microswitch - 2 Nos.
Materials • LM 7805 - 1 No.
• PSA - 6B inductive sensor - 1 No.
• IC CD 4026 - 2 Nos.
• Hook up wire - 2m
• 7 Segment display common cathode - 2 Nos.
• Resin cored solder - as reqd.

PROCEDURE
TASK 1: Construction and testing the inductive type proximity sensors

The instructor has to guide the trainees to fix 6 Repeat the object number of times and observe the
the proximity sensor (inductive/photo electric display shows incremental numbers confirming the
sensors) and adjust the distance detection detection of the object.
sensitivity to detect the objects. 7 Record the number observed in Table - 1
1 Collect all the components, plan the layout of the Table - 1
display device, counter IC and all other components on
the bread board / PCB S. No. No. of Number Remarks
2 Check all the components and assemble the counter attempts displayed
circuit as per the schematic diagram shown in Fig 1
except the proximity sensor 1 First

3 Switch on the 12V DC power supply, press the reset 2 Second

switch1 and observe the seven segment display shows 3 Third
zero
.......
4 Pick and identify the terminals of the inductive proximity
sensor, connect it on the circuit as input. .......

5 Bring a piece of iron object and move it in front of the 8 Get the work checked by the Instructor and switch off
sensor such that it detect the object and the display the circuit
changed to show the number ‘1’.

67
TASK 2: Construction and testing of photo electric type of proximity sensor

1 Use the asembled counter circuit as per the step 1 to Table - 2

3 of Task -1
2 Pick the photoelectric proximity sensor, identify the S. No. No. of Number Remarks
terminals and connect it to the counter circuit input. attempts displayed

3 Switch ON the 12 V DC power supply and observe the 1 First

display.
2 Second
4 Pick any item/object, bring it closer to the proximity
sensor and observe for any changes in the display 3 Third

5 Repeat the above step with any ferrous or non-ferrous .......

objects and observe the change in display to confirm .......
the detection of the object.
6 Record the number observed in Table - 2
7 Get the work checked by the instructor and switch OFF
the circuit

68 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.140

TASK 3: Construction and testing of capacitive proximity sensor

1 Use the counter circuit assembled as per the step 1 to Table - 3

3 of Task - 1
S. No. No. of Number Remarks
2 Pick the three wire capacitive proximity sensor and
attempts displayed
identify the terminals, connect it to the input of counter
circuit
1 First
3 Switch ON the 12V DC power supply and observe the
2 Second
display
3 Third
4 Pick any object and bring it very closer to the proximity
sensor input and observe the display for any change .......
5 Repeat the above step number of times and observe the .......
increment of number in the display to confirm the
detection of the object The circuit will display upto the number 99.
6 Record the number observed in Table - 3 Exceeding this limit another set of IC CD 4026
and seven segment display may be added.
7 Get the work checked by the instructor and switch off
the circuit.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.140 69

Capital Goods & Manufacturing Exercise: 3.3.141
Machinist - Electrical - Electronics

Behaviour of ultrasonic sensors

Objectives : At the end of this exercise you shall be able to
• identify and test the components for the circuit
• assemble the Ultrasonic transmitter and receiver circuit
• operate and test the behavior of ultrasonic sensors.

Requirements
Tools / Instruments • Ultrasonic transmitter and receiver
40kHz, - 1 No each
• Trainees tool kit - 1 Set • Resistors CR25 - 100,1K, 2.2K,10K
• DMM with probes - 1 No. (Ohms) - 1 No each
• Regulated power supply • Potentiometer 10Lin - 2 Nos
0-15V/1A - 1 No. • Capacitor (25VDC working)10 uF - 4 Nos
• Semiconductor data manuals - as reqd • Capacitor (25VDC working)3.3nF - 1 No.
Materials • Transistor 2N2222 or equivalent - 1 No.
• Bread board / general purpose PCB - 2 Nos
• IC 555 timer - 1 No.
• Hook up wire jumpers/ flexible wires - as reqd.
• IC KA2284, - 1 No.
• Rosin cored Solder wire - as reqd.
• LED 5mm Red - 5 Nos
• Piezo buzzer, - 1 No.

Safety precaution
1 Plan the layout of components on the
breadboard before assembling the circuit.
2 Handle the ICs carefully when inserting the
pins into the breadboard slots.

70
PROCEDURE
1 Collect all the components required and check them. Table 1
2 Refer to the data manual, identify the pin connections/ Sl Distance LED Status Remarks
terminals and arrange them.. No. Trasducer (Dim / Bright)
and object
3 Assemble the circuits as per the circuit diagrams
Fig-1 (a), Fig-1(b) on separate bread boards and verify 1
their connections. 2
4 Switch ON the 5 VDC power supply and position the 3
transmitter and receiver circuit boards side by side.
4
5 Keep an object in front of the transducer on the
ultrasonic transmitter circuit board and observe the
LEDs on the receiver board. 7 Change the distance between the object and transducer
on the transmitter board, observe the LEDs and record
Adjust the position of object for maximum your observation in Table-1.
brightness of LEDs on the receiver board. 8 Change the position of the transmitter/ receiver board
and repeat steps 5 to 7.
6 Measure the distance between the transducer and the
object; record your observation in Table-1. 9 Get the work checked by the Instructor.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.141 71

Capital Goods & Manufacturing Exercise: 3.3.142
Machinist - Electrical & Electronics

Logical Operation of Sensors

Objectives : At the end of this exercise you shall be able to
• identify and test the components for the circuit
• assemble the circuit and test the and logical operation
• assemble the circuit and test the or logical operation
• assemble the circuit and test the or logical operation.

Requirements
Tools / Instruments • Transistor BC 548 or equivalent - 1 No.
• Trainees tool kit - 1 No. • LED 5mm Red - 1 No.
• DMM with probes - 1 No. • Relay 5V/2 c/o contact - 1 No.
• Regulated Power Supply 0 -15v /1 A - 1 No. • Resistors CR25 - 1Kilo Ohms - 1 No.
Materials • Bread board / general purpose PCB - 1 No.
• Hook up wire jumpers - as reqd.
• Opto-coupler MCT2E or equivalent - 1 No.
• Micro limit switch - 2 Nos

Safety precautions
1 Plan the layout of components on the bread
board before assembling the circuit.
2 Handle the ICs carefully when inserting the
pins into the breadboard slots.

PROCEDURE
TASK 1: And logical operation of sensor
1 Collect all the components, identify their terminals and 3 Switch ON the 5 VDC supply, observe the status of the
test their working condition. LED and relay.
2 Assemble the circuit as per the circuit shown in Fig 1 4 Press limit switch-LS1 only, observe status of the LED,
and verify their connections. relay and record the observations in Table 1.

Table 1 - AND logic gate truth table

Sl. Input Input Output
No A B Y
1 0 0 0
2 0 1 0
3 1 0 0
4 1 1 1

5 Press limit switch-LS2 only, repeat step 3 and record 7 Confirm the sensor activated as per the AND logic gate
the observations. truth table.
6 Press both the LS1 & LS2 simultaneously and observe 8 Get the work checked by the Instructor.
the LED, relay and record the observations.

72
TASK 2: OR logical operation of sensor
1. Re-arrange the limit switch connections as per the 2 Repeat steps 3 to 6 of Task 1 and record the
circuit shown in Fig 2. observations in table 2.

Table 2 - OR logic gate truth table

Sl. Input Input Output
No A B Y
1 0 0 0
2 0 1 1
3 1 0 1
4 1 1 1

3 Confirm the sensor activated as per the OR logic gate 4 Get the work checked by the instructor.
truth table.

TASK 3: NOT logical operation of sensor

1 Re-arrange the limit switch connections as per the 2 Repeat steps 3, 4 and 7 of Task 1.
check diagram (Fig 3)

Table 3 - NOT logic gate truth table

Sl. Input Output
No A B
1 0 1

2 1 0

3 Confirm the sensor activated as per the NOT logic gate 4 Get the work checked by the Instructor.
truth table.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.3.142 73

Capital Goods & Manufacturing Exercise: 3.3.143
Machinist - Electrical & Electronics

Limit & Level control using sensors

Objectives : At the end of this exercise you shall be able to
• construct and test the water level
• control using controllers.

Requirements
Tools / Instruments
• Trainees tool kit - 1 No. • Resistors
• DC power supply 12 volt/1A - 1 No. 1 M 1/4 W - 2 Nos
• Digital multimeter with probes - 1 No. 10 k 1/4 W - 3 Nos
100 k1/4 W - 1 No.
Materials •
1
Capacitor 0.01 F/25 VDC
4 - 1 No.
• General purpose PCB for IC circuit - 1 No. • Diode 1N 4007 - 1 No.
• IC 555 with IC base - 1 No. • Connecting wires - as reqd.
• Transistors BC 547 (NPN) - 1 No. • Solder, flux - as reqd.
• Relay 12 V/2CO contracts/10A - 1 No. • Buzzer (5V to 25 VDC) - 1 No.

PROCEDURE
1 Refer the circuit diagram. List the component and 5 Connect the power supply and observe the working of
quantity required. the circuit.
2 Check and confirm good condition of given components. 6 When water level reaches low level (in diagram below
L) relay gets ON and connects power to motor to run.
3 Assemble the circuit as shown in the figure. 1 on the
general purpose PCB. 7 When water level reaches high level (in diagram it is
indicated as H) circuit buzzer indicator ON.
4 Get the assembled circuit checked by your instructor.
8 Get the working of the circuit checked by your instructor.

74
Capital Goods & Manufacturing Exercise 3.3.144
Machinist - Electrical & Electronics

Interfacing of sensors with electrical actuators

Objectives : At the end of this exercise you shall be able to
• connect the sensor with electrical actuator circuit
• operate the circuit and verify the principle of operation.

Requirements
Tools / Instruments 47  - 1 No.
• Trainees tool kit - 1 No. 1K - 1 No.
• Ammeter 25mA, Dc, MC type - 1 No. 2.7K - 1 No.
• Regulated power supply 0-15 volts/1A - 1 No. 10K - 1 No.
• Variac 0-24V AC/1A - 1 No. • Pre - set 2.2K vertical mounting - 1 No.
type 1/2 W, disc type
Materials • IN 4001 - 1 No.
• General purpose CB - 1 No. • Transistor BC307 - 1 No.
• IC 741 with base - 1 No. • Photo transistor BP X 81 with base - 1 No.
• Resistors (1/4 W), carbon film • 12 V Dc linear actuator motor - 1 No.

PROCEDURE
1 Check the circuit components to confirm their good 6 Vary the ouput of the variac and check variation in the
working condition. brightness of emitted light from the incandescent lamp.
2 Refer circuit at Fig 1 and wire the circuiton a GP -PCB 7 Power - on d.c supply to the circuit and check if any of
following the hints given below. the circuit component is getting unduly heated - up
rectify the defect found if any.
8 Block the 10mm hole on the card board such that light
does not fall on the phototransistor. Measure and
record the voltage at the output of the IC.
9 Set the output of variac to 160 volts such that the light
intensity is dim. Remove the blocked hole and allow the
light to fall on the phototransistor.
10 Record the output voltage of the IC. If the voltage is not
high, adjust the value of R 1 such that the output voltage
becomes high.

Although the light is falling on the

phototransistor, since the intensity of light is
adjusted to be low, it is required to see that the
• Use base for mounting the IC 741 and phototransistor output is held high as in the case when no light
BP X81. is falling on the phototransistor.
• Mount the transistor at one end of the board
horizontally such the light can be made to fall on the 11 Increase the output of the variac such that the lamp
phototransistor without ay obstruction. glows bright and the intensity of light falling on the
• Mount the 2.2k preset in a convenient position such phototransistor is high enough.
that it is easy to adjust the value as and when 12 Measure and record the output of IC. If the output of IC
required. is not zero, adjust R1 such that the output goes to zero.
• Fix a thin card board sheet of 10 x10 cm2 with a 10
mm dia hole at a distance of around 3 to 5 Cms 13 Repeat steps 7,9 to 11 and fine tune R1 for required
facing the phototransistor. performance.
3 The wired circuit checked by your instructor. 14 Multi meter collection and ground voltage.
4 Connect variac to AC supply and adjust the output to 15 Set supply voltage as DC 12 V in between collector and
240 VAC ground terminals for as an input supply of linear actuation
5 Connect a table lamp to a 240 Volts a.c variac and motor to create the same.
position the lamp directly facing the photo transistor
through the 10mm hole made on the card board and 16 Get the record recording and warning of the circuit
placed in front of the phototransistor. checked by your instructor
75
Capital Goods & Manufacturing Exercise 3.4.145
Machinist - CNC Turning

Personal and CNC machine safety, safe handling of tools safety switches &
material handling
Objectives : At the end of this exercise you shall be able to
• follow personal safety in CNC workshop
• maintain safety of CNC machine .

Do’s
• A well trained operator should operate the CNC Machine. • Learn the basic maintenance schedule for your
machine as per Autonomous maintenance.
• Only one operator should operate the machine at a
time. • Ensure that the stabilizer is ON before starting.
• Check the lubrication oil and Hydraulic oil level before Don’ts
starting the machine.
• Do not operate machine without the working knowledge
• Ensure doors are closed before switching ON the of the machine.
Machine.
• Do not operate the machine when covers are removed.
• Keep less speed while operating in JOG mode, especially
• Do not insert any bar or tool holder in the spindle while
when the tool is near the chuck/Job.
rotation.
• Operator should ensure the machine zero point while
• Do not open the control panel, without switching OFF
starting the machine.
power.
• Operator should check the work offset for every required
• Do not operate the machine without trying in simulation.
set tool and the same to be entered in the program.
• Do not attend electrical fault, without removing the main
• Special care should be taken while changing the tool.
fuse carriers.
• Check the part program for correction before operating.
CNC machine safety system
• Learn all G codes, and M codes, of the control installed
The built-in safety system on a CNC machine includes
in your machine .
guards and protective devices which should be securely
• Learn all offset, Referrence points pertaining to your fitted and always kept in position while the machine is
machine. being used. It may include.

76
Emergency Stop Button Do:
Used to shut down the machine immediately. It is located • Always check that the machine is not operating
on the control panel and at other points on the machine, for when loading a tool magazine.
example the hand held unit.
• Always check that tools are in good condition, for
Soundproof Casing example, sharp and free of cracks.
Reduces noise emission generated by the operating section • Always check that tools are set correctly.
and protects the operator from the risk of flying objects or
• Always check that the correct tool data is entered
tool fragments.
into the CNC program.
Curtain Guards
• Always test tools before use.
Made of PVC and designed to protect the operator from the
• Always check that the seating surfaces are clean
risk of airborne chips or tool fragments.
before installing tools.
Guard Fence
• Always check that spindle direction is correct for
The fence marks the working area in which the machine right-hand or left-hand operation.
moves. It protects the operator from the risk of interference
• Only use tools within the limits specified by the
with moving parts. The guard may be of an open type or
manufacturer.
made of mesh.
• Only tighten tools to recommended torque values.
Contact Mats
Material handling
When the operator stands on the mat, the machine stops
immediately, protecting the operator from moving parts of Material handling now features technology that matches
the machine. the sophistication of the machines that prepare the pieces.
Swing arm panel feeders ensure continuous operation;
Below are some general personal safety rules that you can
panel stackers provide many options for storage and
use as a guide only. You might like to add any other rules
retrieval; robotics transfer pieces from machine to machine;
that apply to you.
conveyors and lift systems speed the transfer of materials
Tool Safety with a minimum of human involvement; fully automated
stacking/destacking machines easily handle input from
Below are some general tooling safety rules that you can
multiple conveyors and trolleys.
use as a starting guide. You might like to add any other
rules that apply to you.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.145 77

Capital Goods & Manufacturing Exercise 3.4.146
Machinist - CNC Turning

Demonstration of CNC lathe machine its parts and function

Objectives : At the end of this exercise you shall be able to
• identify the parts of CNC lathe machine
• list out the functions of each part of the CNC lathe machine.

Job Sequence
• Identify the parts of CNC lathe machine. • Instructor will demonstrate the parts.
• List out the name of the parts shown in figure, in the
Instructor to guide to identy CNC machine parts
given table 1
and axis control.
• List out the function of each part in the given table 2.

78
 TABLE 1 TABLE 2
Part No. Name of the parts Part No. Name of the parts Function of the part

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

9 9

10 10

11 11

12 12

13 13

Get it checked by the instructor

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.146 79

Capital Goods & Manufacturing Exercise 3.4.147
Machinist - CNC Turning

Working of CNC machine parts by using multimedia based simulator

Objectives: At the end of this exercise you shall be able to
• operate the multimedia based simulator
• identify the CNC machine simulator parts.

• Instructor will show the C.N.C Machine

parts by using multimedia basd simulator
Trainees should identify parts and write
in the parts given below table - 1
• Instructor to refer the previous exercise.

Table - 1

Sl No. CNC parts Identified by trainee

1
2
3
4
5
6
7
8
9
10
11

80
Capital Goods & Manufacturing Exercise 3.4.148
Machinist - CNC Turning

Identify machine over travel limits and emergency stop on the machine
Objectives: At the end of this exercise you shall be able to
• identify limit switches
• identify emergency stop and release emergency stop.

• Instructor to demo the function of the switches

Job sequence
• List the name and purpose of the switches in table 1. TABLE - 1
Sl. No Name of the switch Purpose of the switch

81
Production & Manufacturing Exercise 3.4.149
Machinist - CNC Turning

Tool path for turning, facing, grooving, threading and drilling

Objectives: At the end of this exercise you shall be able to
• various CNC turning operations - tool path.

Positioning to required depth of cut

and take facing operation
G01 X55 Z0.0 F0.1;
G01 X0.0 F0. 1
G00 X55 Z50.0;

Positioning for required depth

of cut and take the turning
operation
G01 X 36.0 Z 5.0 F0.1;
G01 Z-55.0 F0.1;
G01 X 50.0 F0.1;
G00 X 50.0 Z50.0;

82
 Positioning for required depth of
cut, length and take grooving
operation
G00 X37.0 Z-33.0;
G01 X35.5 F0.1;
G00 X37.0;
G01 X32.0 F0.1;

Positioning for required safe X, Z

Positioning for required safe X, Z
position and take Drilling
position and take threading
operation
operation
G00 X0.0 Z5.0;
G00 X25.0 Z2.0;
G01 Z-10.0 F0.08;
G92 X23.8 Z-27.0 F1.5;
G00 Z2.0;
X25.0;
G01 Z-20.0 F0.08;
X2.0;
G00 Z2.0
X23.6;
(or)
G76 P030060 Q150 R20;
G76 X22.065 Z-27.0 P9675
Q200 F1.5;

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.149 83

Capital Goods & Manufacturing Exercise 3.4.150
Machinist - CNC Turning

Identification of safety switches and interlocking of DIH modes

Objectives: At the end of this exercise you shall be able to
• identify safety switches in CNC lathe
• identify inter locks used in CNC lathe.

Job sequence
1 Trainer shall demonstate the safety
switches are provided in CNC lathe.
2 Identify and demonstrate the various
interlocking system provided in CNC
lathe.
3 Ask the trainees to identify, observe and
record in the table 1.

Table 1

Sl Condition Operation Observation

No

1 Edit key is OFF position Enter the part program ......

2 Keep door in open position Press cycle start

3 Chuck, open position Start spindle rotation in ......

MDI mode

4 Emergency stop switch in Homing the axis ......

pressed condition

5 Close the feed rate over ride Move the axes ......
switch to ‘Zero’ position

6 “ Machine lock” switch in Start the auto cycle to ......

‘ON’ position machine the job

7 Optional stop switch in ‘OFF’ Start the Auto cycle to

position machine job with various
operation ......

8 Block skip switch in OFF Start the auto cycle to

position (part program with/ machine job .....
blocks)

Get it verify with trainer

84
Capital Goods & Manufacturing Exercise 3.4.151
Machinist - CNC Turning

Identify common tool holder and insert shapes by ISO nomenclature

Objectives: At the end of this exercise you shall be able to
• identification of common tool holder
• inserts shapes as per ISO nomenclature.

External turning tool Holder PCLNL 2525 M12

Detail Example Alphabetical and numerical codes

Type of P
insert
clamping

Shape of C Alphabetical code designating shape of insert e.g.

insert C rhomboidal 80° S Square R round
D rhomboidal 55° T Triangular.
Style of L
holder

Clearance N Alphabetical code designating the clearance angle of insert.

angle of
insert C7°, NO°, P11°

Hand of L R right hand cutting N right and left hand cutting.

cutting L left hand cutting

Shank 25 Numerical code representing shank height h in mm.

height

Shank 25 Tool holders: Numerical code represents shank width in mm.

width Cartridges : Shank width is not specified and instead alphabets ‘CA’ inserted.

Tool M A B C D E F G H I J K L M N P
length mm 32 40 50 60 70 80 90 100 110 125 125 140 150 160 170

Q R S T U V W X Y
mm 180 200 250 300 350 400 450 SPL 500 STD LENGTH

Insert size 12 Numerical code representing size of insert ,cutting edge lenght in mm. Neglect
ing decimal value. For single digit figure ‘0’ is prefixed. For round inserts:
diameter in mm.

85
Tool holders for lathe Style of the tool holder body (L) -5° side cutting
edge angle, 5° end
There is an ISO designation system for tool holders also,
cutting edge angle
to suit various types of inserts. The first five characters
and offset shank
describe insert clamping method, compatible insert shape,
insert holding style of the tool holder (side cutting edge Clearance angle (C) 7°
angle/end cutting edge angle and straight shank/offset
Cutting direction (R) Right-hand
shank), clearance angle and cutting direction, respectively.
Next four digits specify shank height and shank width in Boring bars for lathe (Figs 3 & 4)
mm (two digits for each). Tool length is specified next, by
There is a similar ISO designation system for the internal
a character code. The next and the last two digits specify
tool hodlders also (which are called boring bars). See Fig.8
cutting edge length in mm. Manufacturers, specific codes
and Fig.9 for details. Refer to Table 1 also for shapes not
may be appended in the end. (Figs 1 & 2)
shown in these figures. In fact, tool length, clamping
method, compatible insert shape, body style, clearance
angle and cutting edge length have the same
representation for tool holders as well as boring bars.
For a boring bar, the cutting. If cutting is possible with
clockwise rotation (MO3) of the spindle. The example,
considered in the figure is S32u SSKCR12 type boring
bar. Manufacturer-specific information may be appended
in the end, after a gap. Separating dash (1) is also used in
place of gaps. Referring to Table 1 and Figs 3&4, the
description of S32U SKCR12 is as follows:

Shank type (S) Steel shank

Shank diameter (32) 32 mm
Tool length (U) 350 mm
Insert clamping method Retained via central screw
Compatible insert shape (S) Square
Style of the boring bar -15o end cutting edge
body (R) angle. offset shank.
Clearance angle (C) 7o
Insert clamping method (S) Retained via central
screw Cutting direction (R) Right-rotated (CW spindle)
Compatible insert shape (C) 80° diamond Cutting edge length (12) 12 mm
Manufacturer-specific
86 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.151
information None Inserts are produced in various sizes and thicknesses.
Shank height (25) 25 mm Smallest possible size is chosen to produce the desired
depth of cut. Thickness of an insert affects its strength.
Shank width (25) 25 mm
Hence, for a large depth of cut and feed, a thicker insert is
Tool length (M) 150 mm chosen.
Cutting edge length (12) 12 mm
ISO standard is commonly followed for specifying inserts.
Manufacture specific information None An example is CNMG120408. The first letter, C in this
case, indicates the shape of the insert. The common types
are:
Symbol Shape
S Square
T triangular
H hexagonal
O octagonal
P pentagonal
L rectangular
R round
A, B, K parallelogram (nose angles
85°, 82° and 55° respectively)
C, D, E, F, M, V Diamond shaped or rhombic
(nose angles 80°, 55°, 75°, 50°,
86°, 35 ° respectively)
Tool inserts W Trigon (nose angle 80°)
Carbides and other harder tool materials are very costly. The second letter specifies the relief angles (Fig 6)
Moreover, they cannot be machined. So, only tool tips are
Symbol Relief Angle
made for such materials using powder metallurgy
technique. In this method, the tool material is taken in a N 0°
powder form. It is mixed with a suitable binder (in powder A 3°
form) and compressed in the shape of an insert.
B 5°
Inserts are available in various shapes such as triangle,
square, rectangle, pentagon, hexagon, octagon, diamond C 7°
shaped and circle. They cannot be resharpened, but they P 11°
have a number of cutting edges. (Fig 5)
D 15°
E 20°
F 25°
G 30°
The third letter specifies tolerances on various dimensions
(e.g., thickness) of the insert. The different tolerance
classes are A, F, C, H, E, G (absolute values) and J, K, L,
M, N, U (tolerance values depend on the diameter of the
inscribed circle of the insert).
Significance of the fourth letter
The fourth letter describes the overall geometrical features
of the insert (refer table). For example, an insert may or
may not have a hole at the centre. The hole may be
cylindrical or cylindrical with single or double countersink.
The insert may or may not have a chip-breaker. The chip -
breaker may be single-sided or double-sided.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.151 87

 Table 1

Symbol Hole Shape of Hole Chip-Breaker

N without

R without no hole single-sided

F double -sided
A cylindrical without
M single-sided
G double -sided

W cylindrical without
with 40o-60o
T countersiink single sided
Q with cylindrical without
with 40°-60°
 Cutting edge condition
double double-sided
F for sharp, countersink
T for chamfered,
E for honed and B cylindrical without
S for chamfered and honed. with 70°-90°
This information , however, is non-obligatory. H countersink single-sided

 Cutting direction (Fig 7) C cylindrical without

L for machining with left - rotated (CCW) spindle (M04), J with 70°-90° double-sided
R for machining with right - rotated (CW) spindle (M03) double
and N for both left-and right - rotated. countersink
The appropriate character designations are appended
X special shape
to the right, after the radius specification.

88 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.151

Capital Goods & Manufacturing Exercise 3.4.152
Machinist - CNC Turning

Select cutting tool holder and insert for each operation

Objectives: At the end of this exercise you shall be able to
• identify the ISO tool holders
• factors involved in selecting cutting tool & Inserts.

Selection of cutting tool holders

Fig 1 shows various CNC operations and their tool
holders used

Factors for selection of insert Use small nose radius for : small depth of cut, slender
parts when you want to reduce vibrations Use large nose
Nose radius radius for: High feed rates, large depth of cut, sturdy parts.
Selection of the nose radius depends on the depth of cut Chip breaker
and the feed rate that you propose to use.
Decide based on the workpiece material and application
The nose radius decides : (roughing / medium machining / finishing).
1 The surface finish Insert shape
2 Insert strength Decided when you selected the holder.
3 Chip breaking. Clearance angle
Axial cutting forces are preferable to radial, because radial Decided when you selected the holder.
forces cause part bending, vibrations and poor surface
finish. Cutting edge length

Chip breaking depends on the nose radius and feed rate. Decided when you selected the holder.
At the same feed rate, a smaller nose radius gives better Thickness
chip breaking. Ensure that is general the depth of cut is
more than 2/3 of the nose radius. Decided when you selected the holder, by the tool
manufacturer’s design.

89
Capital Goods & Manufacturing Exercise 3.4.153
Machinist - CNC Turning

Fix inserts on the tool holder

Objectives: At the end of this exercise you shall be able to
• remove the insert from the tool holder
• fix the insert on the tool holder.

Job Sequence
• Clean the tool holder.
• Select the proper size allen key.
• Remove blunt insert.
• Select and fix new insert in the tool holder.

• Clamp the insert.

90
Capital Goods & Manufacturing Exercise 3.4.154
Machinist - CNC Turning

Cutting tool material for various applications

Objective: At the end of this exercise you shall be able to
• decide cutting tool material for various applications.

Job Sequence
Write the suitable tool material for the job material
mentioned in the table 1
Table 1

Sl No. Job material Tool material

1 Low carbon steel

2 High carbon steel
3 Stainless steel
4 Grey cast iron
5 Brass & Bronze
6 Aluminium
7 Aluminium casting

91
Capital Goods & Manufacturing Exercise 3.4.155
Machinist - CNC Turning

Cutting parameters from tool manufacturer’s catalogue, cutting speed and

feed
Objectives: At the end of this exercise you shall be able to
• select the recommended cutting parameters by using catalogue.

Job Sequence
Trainer shall collect catalogue from tool
manufacturer and ask the trainees to fill the
dates in table 1 according job material.

Table
Speed / feed /depth of cut for general turning
Sl. Part Material Cutting speed Feedrate /mm/rev Depth of cut mm
No Vc m/min Rough Finish Rough Finish
0.4 R 0.8R

92
Capital Goods & Manufacturing Exercise 3.4.156
Machinist - CNC Turning

Linear interpolation and circular interpolation assignments and simulation

on software
Objectives: At the end of this exercise you shall be able to
• prepare the various programme in linear, circular interpolation
• check the simulation on software in multimedia system.

Basic movement blocks

TASK 1
Rapid positioning G00 X...Z

TASK 2
Linear Interpolation G0 1 X... Z.. F

TASK 3
Circular Interpolation (CW) G02 G90 X.. Z.. R

TASK 4
Circular Interpolation (CCW) G03 G90 X..Z.. R

93
Rapid positioning Circular interpolation (CW)

Write and simulate the program Write and simulate the program

TASK 1 TASK 3

Linear interpolation Circular interpolation (CCW)

Write and simulate the program Write and simulate the program

TASK 2 TASK 4

94 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.156

Capital Goods & Manufacturing Exercise 3.4.157
Machinist - CNC Turning

Write simulate CNC part programming using simulator with canned cycles
Objectives : At the end of this exercise you shall be able to
• switch on the CNC machine simulator
• write part program in fanuc control
• input the program & simulate
• set the tools
• take work offset
• take geometrical offset
• execute the program.

Job Sequence
• Write the part program in fanuc system. • Input the part program in the simulator.
• Check up with the instructor. • Run and check the correctness of the program using
the simulator.

95
Control system T0404 ;
Fanuc - series oimate TD G00 X0.0 Z5.0 M08 ;
Part program G74 R2.0 ;
O0009; G74 Z-20.0 Q10000 F0.06 ;
N1 ; (Turning) G00 Z5.0 M09 ;
G28 U0 W0; G28 U0 W0 ;
G92 S2000 T0101 ; M05 ;
G96 S200 M03 ; M01 ;
G00 X30.0 Z5.0 M08 ;
N4 ; (OD Grooving 3 mm width)
Z0.0 ; G28 U0 W0 ;
G01 X-1.0 F0.1 ; G97 S600 M03 ;
G00 X28.0 Z2.0; T0303 ;
G71 U1.0 R1.0 ; ;
G00 X22.0 Z5.0 M08 ;
G71 P10 Q20 U0.0 W0.0 F0.1 ;
G01 Z-23.0 F0.1 ;
N10 G01 Z0.0 F0.1 ;
G75 R2.0 ;
X16.0 ;
G75 X16.0 Z-25.0 P500 Q2000 F0.06 ;
X20.0 Z-2.0 ;
G00 X25.0 ;
Z-25.0 ; Z5.0 M09 ;
X24.0 Z-40.0; G28 U0 W0 ;
N20 G01 Z-50.0 F0.1 ; M05 ;
G00 X30.0 Z5.0 M09 ; M01 ;
G28 U0 W0 ;
N5 ; (Threading)
M05 ; G28 U0 W0 ;
M01 : G97 S600 M04 ;

N2 ; (Centre drill) T0505 ;

G28 U0 W0 ; G00 X22.0 Z5.0 M08 ;

G97 S800 M04 ; G01 Z3.0 F0.1 ;

T0202 ; G76 P030060 Q150 R20 ;

G00 X0.0 Z5.0 M08 ; G76 X16.755 Z-22.0 P1622 Q300 F2.5 ;

G01 Z-6.0 F0.08 ; G00 X25.0 Z5.0 M09 ;

G00 Z5.0 M09 ; G28 U0 W0 ;

G28 U0 W0 ; M05 ;
M01 ;
M05 ;
M30 ;
M01 ;
%
N3 ; (6 Drill)
G28 U0 W0 ;
G97 S1000 M04 ;

96 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.157

Capital Goods & Manufacturing Exercise 3.4.158
Machinist - CNC Turning

Avoiding collisions caused by program errors, by making deliberate

program errors and verification/simulation software
Objectives: At the end of this exercise you shall be able to
• various causes for collisions
• effects of collisions and rectification.

Job sequence
• Plain turning and Facing operation program is written. • Identify the errors if any.
• Verify the program on simulation software. • Rectify the errors.

97
 Wrong program Correct program
O5555 O5555;
N1; N1;
G28 U0 W0; G28 U0 W0;
G97 S1000 M03; G97 S1000 M03;
T0101; T0101;
G00 X60.0 Z0.0 M08; G00 X60.0 Z0.0 M08;
G00 X0.0 F0.1; G01 X0.0 F0.1;
G00 X48.0 Z2.0; G00 X48.0 Z2.0;
G00 Z-50.0 F0.1; G01 Z-50.0 F0.1;
G00 X60.0 Z0.0 M09; G00 X60.0 Z0.0 M09;
G28 U0 W0; G28 U0 W0;
M05; M05;
M30; M30;

Collisions and rectifications

Sl No Identification of errors Effects Rectification of errors

1 G00 X0.0 F0.1; Will damage turret & Tool holder, G01 X0.0 F0.1;
Machine Alignment, and affect
Accuracy

2 G00 Z-50.0 F0.1; - do - G01 Z-50.0 F0.1;

3 Operator alter the programme - do - Check the programme

in wrong format. and correct it.

4 Improper holding the job and tool. - do - Check the reason for
inproper holding and
correct it.

5 Wrong selection and mismatch the - do - Select proper tool for the
tool for operation particular operation.

6 Wrong offset for Job and Tool - do - Check offset for Job and
Tool.

98 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.158

Capital Goods & Manufacturing Exercise 3.4.159
Machinist - CNC Turning

Conduct a preliminary check of readiness of the CNC turning centre

Objectives: At the end of this exercise you shall be able to
• check cleanliness of the machine
• check oil levels
• check correct working of lubrication system
• send the turret to machine reference point.

Job sequence
• Ensure the cleanliness of machine. • Send the turret to machine Reference point.
• Use banian waste to clean. • Check the lubrication oil level and ensure it is within
the acceptable level.
• Ensure there is no oil spill around the machine.
• Check hydraulic oil level.
• Switch ‘ON’ the Machine.
• Check coolant oil level.
• Move the tool in JOG mode to a safe place.
• Check correct working of lubrication system by
manual operation.

99
Capital Goods & Manufacturing Exercise 3.4.160
Machinist - CNC Turning

Starting the machine, do homing on CNC simulator

Objectives: At the end of this exercise you shall be able to
• switch ON CNC virtual simulator lathe.
• start the machine, and operate in JOG mode
• start the machine and operate in incremental JOG mode.

100
 “ Machine ON” Procedure & Homing

Job sequence
Switch ON (System)

Select the simulator software for turning

Select the fanuc oit CNC system

Release emergency button

Unlock the edit key using cursor

Press ‘X’ button to move x axis to the origin

Press ‘Y’ button to move ‘Y’ axis to the origin


CNC machine simulator ‘Zero Ref’ homing reached

Give little movement by pressing x + Z +, x - y -

101
Capital Goods & Manufacturing Exercise 3.4.161
Machinist - CNC Turning

Facing and turning program

Objective : At the end of this exercise you shall be able to
• prepare the CNC part program with G00 and G01.

Job Sequence
• Hold the job in required length outside from chuck.
• Set the work offset.
• Select the tool for facing & turning
• Clamp the tool in turret
• Set tool offset
• Enter the programme.
• Select auto mode and run single block, complete the
machining.
• Remove the job from chuck.
• Check the dimensions.

Part program
O0005  Program Number G00 X55.0 Z0.0 M08 ;  Positioning and
coolant on
N1;  Sequence Number
G01 X-1.0 F0.1 ;  Facing
G28 U0 W0  Return to home position.
G00 X49.0 Z1.0 ;  Positioning
G92 S1500 T01 01
G01 Z-50.0 F0.1 ;  Turning
Offset Number
G00 X55.0 Z10.0 M09 ;  Releasing and
Tool Number - 01 coolant off
Spindle r.p.m.
G28 U0 W0 ;  Return to home
position
Maximum Spindle speed

G96 S150 M03

M05; Spindle Stop

Spindle CW direction M30 ;  Programme end

and Rewind
Cutting speed

Constant surface speed control

102
Capital Goods & Manufacturing Exercise 3.4.162
Machinist - CNC Turning

Mounting Jaws to suit the part holding area on CNC machine

Objectives : At the end of this exercise you shall be able to
• remove the jaw and reload it
• check the concentricity with dial test indicator.

Job Sequence
• Loosen allen screws of all the three jaws

• Count the number of serration radially outwards

• Leave equal number of serration (rack) outwards
and hold jaws firmly
• Ensure the space slightly higher than the diameter of
job
• Tighten the allen screw using suitable allen key.
• Check the clamping of job.

103
Capital Goods & Manufacturing Exercise 3.4.163
Machinist - CNC Turning

Mounting tools on the turret according to part & process required

Objectives : At the end of this exercise you shall be able to
• CNC Lathe tool turret rotates programe commands
• CNC Lathe tool holder.

Job Sequence
• Fasten the Tool Holders in turret head.
• Fix the selected tool according to the operation.
• Sequence tools as per operation to be carried out.
• Index and Check the turret head in MDI mode.
• Execute the operation.

Skill Sequence
CNC tool turret rotation
Objectives : This shall help you to
• understand the CNC lathe turret tool capacity
• practice on tool holder.
CNC Lathe Tool Turret Rotation. Fig 22
Fig
CNC lathe tool turret rotates with the CNC program
commands.
Normally a letter “T” is used to call a tool in the working
position.
The tool rotation is dependent on CNC lathe machine.
Some CNC lathe tool turret rotate in one direction (CW or
CCW)
Some CNC lathe tool turret rotates both directions, such
tool turret direction is optimized for the nearest tool station.
Some CNC lathe give full control over tool call up, you can
call by optimized direction or you can call tool by rotating
such as 50 mm diameter. For the small tool turret this
tool turret by CW direction or CCW.
might be 40 mm diameter or less. Tool hoders come in
CNC Lathe Tool Turret Tool Capacity variety of shapes to suit the tool to hold.
Tool Capacity for CNC lathe machines varies machine to CNC lathe machine tool turret is part of the CNC machine
machine. Small CNC lathe machines normally comes with where all tooling is mounted. CNC lathe tool turret has an
a tool turret capacity of 4 or 8 tools stations. Bigger and Integral Disk like part (Tool turret disk) on which all the
heavy CNC lathe machines tool turrets are big and heavy tools are mounted. CNC lathe tool turret is mounted on
and accordingly will hold more tools such as 12 or more. the x-axis carriage.
Tool Holder On some CNC lathe machines x-axis carriage with the
tool turret is located behind the spindle (such CNC lathe
Tool holder is the actual part which fastens the tool to the
machines are called slant bed CNC lathe machines) and
CNC lathe tool turret Disk. Tool holder size also depends
on other CNC lathe it is located at the front (as normal
upon the CNC lathe tool turret sie, heavy CNC lathe
lathe machines) such CNC lathe machines are called flat
machine tool turret comes with big bore for tool holders
bed CNC lathe machine.
104
Capital Goods & Manufacturing Exercise 3.4.164
Machinist - CNC Turning

Perform work and tool setting

Objectives : At the end of this exercise you shall be able to
• set the job in CNC machine chuck
• set the tool in the respective slot of the turret
• setting job zero/with coordinate system.

PROCEDURE
• Ensure the work secured firmly in chuck. • Do not distrub X-axis.
• Now bring the tool in JOG mode near the face of • Take tool away in Z- direction only.
job.
• Stop the spindle.
• Switch ‘ON’ spindle.
• Measure the outer diameter of the job using
• Carry out light facing of the job. micrometer.
• After the finish cut,move the tool back in X-direction • Go to OFFSET softkey .
only.
• Press GEOM softkey .
• Now switch off spindle.
• Position the cursor to the required tool offset
• Go to Tool off set mode. number and enter the measured value. [eg : X32.62]
• Press GEOM soft key and position the cursor using • Press measure softkey.
cursor movement button and select the offset
• Repeat the procedure for all the tools.
number.
• After taking offset select MDI .
• Enter the Z-axis value Z0.0.
• Ensure the work zero.
• Press measure softkey.
• Now rotate the spindle in appropriate direction
and machine the outside diameter (‘OD’)

3.4.164

105
Capital Goods & Manufacturing Exercise 3.4.165
Machinist - CNC Turning

CNC turning centre operation in various modes (JOG, MDI, MPG & AUTO Mode)
Objectives : At the end of this exercise you shall be able to
• utilise effectively the edit mode function
• utilise effecively the MDI Auto mode functions.

106
Job Sequence Example
% 0001;
JOG Mode
N1 G01 X50 Z5 F0.1 ;
• Set in Jog mode, use mode selector switch
N2 S1200 M03 ;
• Press X- (or) X+axis button
N4 M08 ;
• To move in X - (or) X + as per required direction
N5 G01 X48 F0.1 ;
• In the same manner we can move in Z direction also.
N6 G01 Z-25 F0.1 ;
• Keep pressing the direction switch till the tool reaches
the desired position. N7 G00 X60 Z10 ;

Edit Mode N8 M09 ;

• Set edit mode using mode selector switch N9 M05 ;

• Enter the New programme in block by block N10 M30 ;

• To use input /alter/delete/ EOB keys. Auto Mode

• To alter the program, if any correction of the program • To select the programme number before selecting the
is needed, go to edit mode. Auto mode.

MDI mode • To set Auto mode using mode selector switch.

Manual data input key and functions. • Press the cycle start button.

• When the machine is not running a part program the • With this mode, program will be executed continously
operator may use this mode. in block- by - block.

• Only one block is executed at a time. • While machine is running in this mode do not change to
any other mode or function.
• Once it is executed, it is gone from the computer in
memory. Before machine running continously in Auto
• An operator can use MDI mode to change cutting tool, mode, first job will be executed in single
spindle ON /OFF, Coolant ON/OFF, etc., block.

Single block mode

The instructor will demo the various modes.
Single block mode allows an operator to check the
program by executing only one program block at a time.

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.165 107
Capital Goods & Manufacturing Exercise 3.4.166
Machinist - CNC Turning

Entering the tool offset, tool nose radius and orientation for TNRC in offset
page on CNC simulator
Objectives : At the end of this exercise you shall be able to
• measure the tool offset in x direction and enter in the tool offset page
• measure the tool offset in z direction and enter in the tool offset page
• set the tool nose radius compensation
• set the tool imaginary nose position to ‘T’ in tool geometry offset.

Job Sequence
• To study the drawing • Identify the tool type.
• To select the suitable tool for the operation

Skill Sequence
Tool offset method
Objectives : This shall help you to
• Practice on tool offset method
• Practice on X axis tool offset method

Reference tool is T01 and offset is zero in X • Select MDI mode. Press in MDI prog-screen.
and Z axis. • Enter tool number : T0202(Turning tool).

• Clamping job in chuck. Insert button ® Press ® Cycle start button ® Press

108
• Tool cutting edge position with spindle ON CW or CCW Ex: x28.62 ® Measure button ® Press in soft key
in MDI mode. • Now tool cutting edge in job centre is OK.
Enter MO3 SI500 ® Reset button press ® • Tool offset in X axis is saved
Cycle start button.
Z axis offset method
• To select jog mode or MPG mode to move x and z
axis. • Spindle ON rotate the job.
• Touch the job in x axis just clean OD turning to ensure • Select jog mode or MPG mode to move axis. Manually
no disturbance in x axis. (Fig 1) turning job facing position no disturbance Z axis.
(Fig 2)

• Then stop spindle button.

• To measure job OD diameter, use vernier (or) • Select offset button press in geomentry mode.
micrometer for sample Example X 28.62 mm. • To use cursor select tool no 1 and z axis.
• Select Offset button ® Press ® displayed in geometry • Enter Z0.
mode.
• Enter Z0 ® Measure ® Press in soft key
• Using cursor in geomentry screen select Tool no : 1 x
axis select. • Now z axis tool offset OK.

• Enter job diameter • Tool offset is Z axis is saved

Tool nose radius compensation

Objectives : This shall help you to
• Practice on tool nose radius compensation to obtain profile.

The following data’s must be specified to carryout • To study the tool nose radius
automatic tool nose radius compensation to obtain
• To input the value of tool nose radius in G41 & G42 in
required profile exactly.
the program.
• For internal turning like boring and to move left with • Input the radius of tool to R in geometry offset.
respect to the job the tool program as G41 (Tool left)
and to move the tool right with respect to job program • Input the imaginary nose position in ‘T’ in geometry
as G42 (Tool right) offset.

• For internal turning like boring and to move left with

respect to the job the tool program as G41 (Tool left)

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.166 109
Capital Goods & Manufacturing Exercise 3.4.167
Machinist - CNC Turning

Program checking in dry run single block mode

Objectives : At the end of this exercise you shall be able to
• check the program in Dry run
• check the program in single block mode.

Job sequence
Program check in dry run, single block mode The instructor demo the ‘Dry Run’ to the
Dry run is to be carried out to check : students
• To perform trial option of the part programming
• The path or profile of the job
Press Simulation
• The error in the programme
• To avoid any Accidental incident
• The effectiveness of the program.
Reset
• The program for correctness.

Note : After entry of the program it should be

checked through simulation

• Single block mode is used to allow the operator, to START

execute the part program at a time on the single block.
• It is also used to execute the first job.

110
Capital Goods & Manufacturing Exercise 3.4.168
Machinist - CNC Turning

Absolute & incremental programming assignments by simulation

Objective: At the end of this exercise you shall be able to
• learn absolute and incremental programming of job.

Method of Programming Absolute program in table 1.

There are two methods of dimensioning . TABLE 1
1 Absolute system of programming (or) fixed Absolute
2 Incremental system of Programming (or) floating zero Position X Z
system of dimensioning. (or) previous point zero system
of dimensioning. 1 0. 0 0. 0
Absolute Programming 2 50.0 0. 0
In absolute dimensions programming all the point of the 3 50.0 -70.0
tools is coming from the datum point (or) zero point.
4 70.0 -70.0
Incremental Programming
5 70.0 -100.0
In this system, tool move form the previous point.
Incremental program in table 2.
TABLE 2

Incremental

Position U W
1 0.0 0.0
2 50.0 0.0
3 0.00 - 70.0
4 20.0 0.0
5 0.0 - 30.0
Exercise for Absolute & Incremental Methods
Write the points for the following figures in absolute &
Example 1 : The points 1 to 5 in the drawing indicates
incremental programming.
the absolute in Table 1 and Incremental in Table 2

TASK 2 : (Fig 2)
Absolute

Position X Z

1
2
3
4
5
6
7

111
 Incremental

Position U W

TASK 3 : (Fig 3)
Trainees to indicate the co-ordinate values in the given Absolute
tables.
Position X Z

Incremental

Position U W
1
2
3
4
5
6

112 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.168
Capital Goods & Manufacturing Exercise 3.4.169
Machinist - CNC Turning

Checking finish size by over sizing through tool offset on CNC simulator
Objective: At the end of this exercise you shall be able to
• do the correction of size in tool offset.

PROCEDURE
• Switch ON machine as per procedure Note
• Enter the program as per drawing • Required size of the is job X 20 ± 0.00
Z 45 ± 0.00
• Run the simulation on dry run with machine
• Go to wear offset page and input the X,Z difference
• If there is no error run the machine in SBL or Auto
value
mode
Tool Number X axis Value Z axis Value
• Check the finished dimensions
1 - 0 .02 - 0.05
• If there is any error compared to the required dimension
calculate the difference 2
• Add the difference in value to the respective axis in the 3
tool offset 4
• Run and produce a sample to the correct measurement.
• Add the Tool wear offset difference value on the table
After complete the operation enter actual value of
column
job
• To avoid the rejection of job the first piece is made,
slightly increased in size in offset.
Tool Numbers X axis Value Z axis Value
• After completion of the first piece,check all the
1 20.02 45.05 dimension without removing the chuck.
2 • Observe the difference value of drawing size and Acutal
size, and this difference, if any, should be ‘input’ in
3
the wear off set.
4

113
Capital Goods & Manufacturing Exercise 3.4.170
Machinist - CNC Turning

Part programming for combined facing, turning and chamfering (sinumeric)

Objectives : At the end of this exercise you shall be able to
• write the part program for the given job in sinumeric control
• input the part program into the machine and simulate the programme
• set the machine with necessary tools
• run the machine to produce the job.

Job sequence
• Check the work offset and tool offset.
• Study the part drawing and list the tools required.
• Prepare the CNC program using simulator. If there is any mistake, correct the programme
ask your instructor for guidance.
• Simulate and verify the program in simulator software.
• Run the programme in single block by setting the
• Get it checked by the instructor.
offset away from the work zero.
• Check the raw material size and confirm with the part
drawing. Observe the spindle direction speed tool
position carefully.
• Hold the job on chuck by projecting 55 mm length in
turning. • Run the programme in auto mode in original tool and
work set.
• Enter the part program in CNC machine (or) transfer
the programme by simulator to CNC machine. • Check the dimensions. If any corrections change the
wear offset and run the programme.
• Set the tool to required turret station.
• Check the dimension and surface finish.
• Measure work offset in X and Z direction and enter
the work offset page say G54 / G55. • Remove the job from the machine, check all the
dimension once again.
• Measure the tool offset all tools in X and Z direction
and enter the tool geometry offset page. • Switch off the machine.
• Enter the tool type and tool nose radius.

114
Part Programme:- 2nd Operation:-
1 Operation:-
st
%2
%1
N1 G0 G90 G53 X180 Z04LF
N1 G0 G90 G53 X180 Z04LF
N2 S1200 M03LF
N2 S1200 M03LF
N3 T1 D1 M06LF
N3 T1 D1 M06LF
N4 G0 X50 Z5 M08LF
N4 G0 X50 Z5 M08LF
N5 G0 Z1LF -1
N5 G0 Z3LF -1
N6 G01 X0 F100LF
N6 G01 X0 F100LF
N7 G0 X50 Z2LF
N7 G0 X50 Z5LF
N8 G0 Z2LF -2
N8 G0 Z2LF -2
N9 G01 X0 F100LF
N9 G01 X0 F100LF
N10 G0 X43 Z2LF -1
N10 G0 X50 Z5LF
N11 G01 Z-35 F100LF
N11 G0 Z1LF -3
N12 G0 X45 Z2LF
N12 G01 X0.0 F100LF
N13 G0 X42LF -2
N13 G0 X50 Z5LF
N14 G01 Z-35 F100LF
N14 G0 Z0LF -4
N15 G0 X45 Z2LF
N15 G01 X0.0 F100LF
N16 G0 X38LF
N16 G0 X43 Z2LF -1
N17 G01 Z0 F100LF
N17 G01 Z-50 F100LF
N18 G01 X40 Z-1 F100LF - 3
N18 G0 X45 Z2LF
N19 G01 Z-35 F100LF
N19 G0 X41LF -2
N20 G0 X50 Z10 M09LF
N20 G01 Z-50 F100LF
N21 G0 G90 G53 X180 Z0LF
N21 G0 X45 Z2LF
N22 D0LF
N22 G0 X38LF
N23 M30LF
N23 G01 Z0 F100LF - 3

N24 G01 X40 Z-1 F100LF

N25 G01 Z-50 F100LF

N26 G0 X50 Z10 M09LF

N27 G0 G90 G53 X180 Z0LF

N28 D0LF

N29 M30LF

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.170 115
Capital Goods & Manufacturing Exercise 3.4.171
Machinist - CNC Turning

Recovering from axes over travel, on CNC simulator

Objective: At the end of this exercise you shall be able to
• axes over travel to be released.

Job Sequence
• Observe on CNC simulator monitor screen the axes • Accordingly select the axis
over travel in 'x' or 'z' axes • Move the axis in opposite direction to re cover the
• Press reset button to clear over travel alarm over travel limit
• Select MPG mode. • Continue the further operation (AUTO, MDI)

116
Capital Goods & Manufacturing Exercise 3.4.172
Machinist - CNC Turning

Part program preparation, for turning with chamfering & radius turning with
TNRC
Objectives: At the end of this exercise you shall be able to
• write the part program for given job in SINUMERIC / FANUC
• input the program into the computer / CNC machine
• operate the simultor
• transfer to machine and execute simulated programe.

Job Sequence
• Switch ON the CPU and Monitor. • Run the Simulation in AUTO mode .

• Select the software. • Transfer the programe to the machine.

• Enter the program in edit mode. • Take the offset.

• Select required tool and clamping device. • Execute the job.

• Select the path. • Check the dimension and remove the job.
• Switch off the machine.

117
 PART PROGRAM (IN SINUMERIC)
% 225
N5 G71 G90 G95;
N10 G00 G53 X180 Z0;
N15 D5 T5
N20 M03 S900 F0.1;
N25 G00 X65 Z2;
N30 R20 =185 R21=65 R22=0 R23=0.3 R24=0.3
R26 =1 R27=42 R29=41 L95 P1; (stock
Removal cycle)
N35 D0 M05;
N40 G00 G90 G53 X180 Z0;
N45 M30;
L185 (SUB PROGRAM)
N5 G01 X0 F0.1; N35 Z-35;
N10 G01 Z0 F0.1; N40 G90 G02 X50 Z-40 B5;
N15 G01 G42 X22 F0.1; N45 G01 Z-55;
N20 G90 G03 X30 Z-4 B4 F0.1; N50 X56 Z-58;
N25 G01 Z-15 F01.; N55 G01 G40 Z-70;
N30 X40; N60 X65;
N65 M17;
R - PARAMETER FOR STOCK REMOVAL CYCLE(L95)
R 20 = Sub Program Number or Sub routine No. R26 = Roughing cuts
R 21 = Starting position of X axis (Absolute) R27 = Tool Nose Radius compensation
R22 = Starting position of in Z axis (Absolute) R29 = Type of turning (Roughing , Finishing)
R23 = Finishing allowance of X (Incremental) L95 = Stock removal cycle
R24 = Finishing allowance of Z (Incremental) P1 = No.of Tool passes
PART PROGRAM [ FANUC]
O0002 G03 X30.0 Z- 4.0 R4 F0.1;
N1; G01 Z-15.0 F0.1;
G28 U0 W0 X40.0;
G97 S1500 M03; Z-35.0;
T0101; G02 X50.0 Z - 40 R5 F0.1;
G00 X65.0 Z5.0 M08; G01 Z-55.0 F0.1;
G01 Z2.0 F.01; X56.0 Z-58.0 ;
G71 U1.0 R1.0; N20 G01 G40 Z-70.0 F0.1;
G71 P10 Q20 U0.0 W0.0 F0.1; G00 X65.0 Z5.0 M09;
N10 G01 X0.0 F0.1; G28 U0 W0;
G01 Z0.0 F0.1; M05;
G01 G42 x 22.0 F0.1; M30;
G71 - Turning Cycle

G71 U --- R --- ; Q : Ending block number

G71 P --- Q --- U --- W --- F --- ; U : Finishing Allowance in ‘X’ axis
U : Depth cut per pas in ‘X’ axis (Radial Value) W : Finishing Allownace in ‘Z’ axis
R : Relief Amount F : Feed
P : Starting block number

118 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.172
Capital Goods & Manufacturing Exercise 3.4.173
Machinist - CNC Turning

Part program writing and execute

Objectives: At the end of this exercise you shall be able to
• write the part program
• check the setup
• execution of turning operation in automatic mode with TNRC
• grooving and threading.

119
O1111 G97 S600 M03;
N1; [Turning Tool] T0303;
G28 U0 W0; G00 X41.0 Z5.0 M08;
G97 S1200 M03; G01 Z-23.0 F0.1;
T0101; G75 R2.0;
G00 X45.0 Z5.0 M08; G75 X20.0 Z-25.0 P500 Q2000 F0.08;
G01 X45.0 Z2.0 F0.1; G00 X45.0 M09;
G01 Z0.0 G28 U0 W0;
G71 U1.0 R1.0; M05;
G71 P10 Q20 U0.0 W0.0 F0.1; M01;
N10 G01 Z0.0 F0.1; N3; [Threading]
X24.0, G28 U0 W0;
X28.0 Z-2.0; G97 S800 M04;
Z-25.0; T0505;
X-32.0; G00 X41.0 Z5.0 M08;
X40.0 Z-55.0; G01 Z3.0 F0.1;
N20 G01 Z-85.0 F0.1; G76 P030060 Q150 R20
G00 X45.0 Z5.0 M09; G76 X26.065 Z-22.0 P9675 Q300 F1.5;
G28 U0 W0; G00 X45.0 Z5.0 M09;
M05; G28 U0 W0;
M01; M05;
N2; [3mm Grooving Tool] M01;
G28 U0 W0; M30;

120 Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.173
Capital Goods & Manufacturing Exercise 3.4.174
Machinist - CNC Turning

Checking finish size by over sizing through tool offset on the machine
Objective: At the end of this exercise you shall be able to
• do the correction of size in tool offset.

PROCEDURE
• Switch ON machine as per procedure Note
• Enter the program as per drawing • Required size of the is job X 20 ± 0.00
Z 45 ± 0.00
• Run the simulation on dry run with machine
• Go to wear offset page and input the X,Z difference
• If there is no error run the machine in SBL or Auto mode value
• Check the finished dimensions Tool Number X axis Value Z axis Value
• If there is any error compared to the required dimension 1 - 0 .02 0.05
calculate the difference
2
• Add the difference in value to the respective axis in the
tool offset 3

• Run and produce a sample to the correct measurement. 4

After complete the operation enter actual value of • Add the Tool wear offset difference value on the table
job column
• To avoid the rejection of job the first piece is made,
Tool Numbers X axis Value Z axis Value slightly increased in size in offset.
1 20.02 45.05 • After completion of the first piece,check all the
2 dimension without removing the chuck.

3 • Observe the difference value of drawing size and Acutal

size, and this difference, if any, should be ‘input’ in the
4 wear off set.

121
Capital Goods & Manufacturing Exercise 3.4.175
Machinist - CNC Turning

Machining parts on CNC lathe with parallel, taper, step, radius turning,
grooving and threading
Objectives : At the end of this exercise you shall be able to
• input the program into machine
• set the machine with necessary tools
• take the tool offset
• run the machine to produce the job.

122
Job Sequence
• Study the part drawing and list the tools required Z0.0;
• Prepare the CNC programme X12.0;

• Get it checked by the instructor. X16.0 Z-2.0;

Z-30.0;
• Check the raw material size and confirm with the part
drawing, for its correctness X20.0;
• Hold the job on chuck by projecting 55mm length in X30.0 Z-45.0;
turning X38.0;
• Enter the above part programme in your CNC machine G03 X44.0 Z-48.0 R3 F0.1;

• Set the tool to the required turret station . N20 G01 Z-80.0 F0.1;
G00 X60.0 Z10.0 M09;
• Measure the work offset in X and Z direction and enter
in the relevant work offset page G54/G5. G28 U0 W0;

• Measureall the tool offset in X ‘and Z and enter the N05;

geometry offset page. M01;
• Enter the tool type and tool nose radius N2; [3MM Grooving]
G28 U0 W0;
• Check the work offset and tool offset
G97 S800 M03;
If there is any mistake, correct the programme T0303;
and ask your instructor for guidance.
G00 X17.0 Z5.0 M08;
• Run the programme in single block by shifting the G01 Z-29.0 F0.1;
offset away from the work area.
G75 R1.0;
Observe the spindle direction, speed, tool G75 X13.5 Z-30.0 P500 Q1000 F0.08;
position carefully.
G00 X25.0;
• Run the programme in auto mode in original work Z10.0 M09;
offset. G28 U0 W0;
• Check the dimensions. If there is variation in the M05;
programme correct the tool wear offset and run the M01;
programme, once again
N3; [Threading ]
• Check the dimension and surface finish.
G28 U0 W0;
• Remove the job from the machine. G97 S600 M04;
• Switch off the machine. T0505;
O5122 G00 X16.5 Z5.0 M08;
N1; G01 Z3.0 F0.1;
G28 U0 W0; G76 P030060 Q150 R20;
G97 S1200 M03; G76 X14.053 Z-27.0 P9735 Q300 F1.5;
T0101; G00 X60.0 Z10.0 M09;

G00 X52.0 Z5.0 M08; G28 U0 W0;

G71 U1.0 R1.0; M05;

G71 P10 Q20 U0.0 W0.0 F0.1; M01;

N10 G01 X0.0 F0.1; M30;

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.175 123
Capital Goods & Manufacturing Exercise 3.4.176
Machinist - CNC Turning

Machining long part on CNC lathe held in chuck and tail stock - between
center
Objectives : At the end of this exercise you shall be able to
• steady rest prevent long part from deflecting
• steady rest can be open and close through prop. and control
• the follows rest keep the job from the stress of the cutting operation.

Job Sequence
• Hold the long part between centre of the machine. G00 X30.0 Z5.0 M08;
• Select the supporting accessories steady rest/follower G71 U0.5 R1.0;
rest accounding the dia & length of the Job.
G71 P10 Q20 U0.0 W0.0 F0.1;
• Fix the follower rest on the carriage.
N10 G01 Z0.0 F0.1;
• Enter the program. X23.0;
• Select the auto mode and run single block complete X25.0 Z-1.0;
the operation.
N20 G01 Z-250 F0.1;
O9461;
G00 X30.0 Z5.0 M09;
N1;
G28 U0 W0;
G28 U0 W0;
M05;
G97 S1200 M03;
M01;
T0101;
M30;

124
Capital Goods & Manufacturing Exercise 3.4.177
Machinist - CNC Turning

Starting from interruption due to power shut down

Objectives : At the end of this exercise you shall be able to
• Precaution for restart the machine after power failure
• Restart the machine after power failure.

Job Sequence
1 Considering there is a power failure and CNC Turning 7 Reset your Z to the proper position .
is stopped. 8 The program is ready to go.
2 Restart the machine.
In modern machine if at all power failure the
3 REF all HOME operation is continue no interruption will
4 Zero X, Z on the screen with the buttons, This sets happend
the Job zero at the machine home zero
Tool breakage
5 Go to the MDI mode.
• Due to power shut down the tool being used for
6 The machine will then slow feed to the X, Z coordinate.
operation may break.

125
Production & Manufacturing Exercise 3.4.178
Machinist - CNC Turning

Changing wear offset to take into account tool wear

Objectives : At the end of this exercise you shall be able to
• types of offset used in CNC machine
• input tool wear in wear offset page.

Job Sequence
• Clamp the Job in the chuck of the machine.

• Set the tool in required order in the machine turret.

• Check with a piece of paper whether the contact of
tool with the Job is proper.
• Command the program.
• Now check the diameter.

• Long running the tool tip may wear out and the
dimension of Job may over size.
• Program the reduced due to tool wear.
• Rectify the defect wear off set is used.
• Rectify by tool offset number of the worn out tool.

Skill Sequence

Wear offset rectification

Objectives : This shall help you to
• Practice on wear offset rectification.

Wear offset
Because of long running the tool tip may wear out and To rectify this take the tool offset number of the worn out
the dimension of the job may increase or decrease from tool.
the original programmed dimension.
In that tools wear offset number enter the value U0.04.
To rectify this defect wear offset is used.
In the inner diameter defects instead of positive value put
Procedure for entering wear offset U-0.04 in the wear offset number.
If the programmed size is X40.49 and the machined size Tool offset number and wear offset number are same.
is 40.44 in this 0.04 mm is reduced due to tool wear.

126
Capital Goods & Manufacturing Exercise 3.4.179
Machinist - CNC Turning

Part program preparation simulation & automatic mode execution of CNC

machine for the exercise on blue print programming contours with TNRC
Objectives : At the end of this exercise you shall be able to
• write the part program for the given Job in fanuc control and simulate the programme
• input the program to the CNC machine
• execute the program in AUTO mode.

Job Sequence N1;

• Write the part program in fanuc control system G28 U0 W0
G97 S1200 M03;
• Check with the instructor.
T0101;
• Input the part program in the simulator G00 X55.0 Z5.0 M08;
• Run and check the correctness of the program using G01 Z2.0 F0.1;
the simulator. G71 U1.0 R1.0;
• Input the program to the CNC machine/input the G71 P10 Q20 U0.0 W0.0 F0.1;
program using interface cable PC to PC M/C. N10 G01 Z0.0 F0.1;
X0.0;
• Clamp the job in the machine.
G01 G42 X20.0 F0.1;
• Select the tools required for the given job. X24.0 Z-2.0;
• Set the tools in the turret. Z-20.0;
• Take work offset G02 X32.0 Z-24 R4 F0.1;
• Take geometrical offset G01 Z-40.0 F0.1;
G03 X44.0 Z-46.0 R6 F0.1;
• Dry run with the input program. N20 G01 Z-58.0 F0.1;
• Check the correctness of the program with instruc- G00 X60.0 Z5.0 M09;
tor. G40;
• Execute the program. G28 U0 W0;
M05;
O0003;
M30;

127
Capital Goods & Manufacturing Exercise 3.4.180
Machinist - CNC Turning

Carryout drilling / boring cycles in CNC turning

Objectives : At the end of this exercise you shall be able to
• write the part program for given job in fanuc control and simulate the programme
• input the program into the machine
• set the machine with necessary tools
• run the machine to produce the job.

TASK : 1 Simulate the Program.

• Switch ON the CPU and Monitor • Select the path
• Select the software • Run the simulation in Auto mode
• Enter the program in edit mode • Produce the Components
• Select required tool and clamping device

Job Sequence
• Check the raw material size and confirm with the • Enter the tool type and tool nose radius.
part drawing • Check the work offset and tool offset.
• Hold the job on chuck by projecting 40mm length in
turning. If there is any mistake, correct the programme
ask your Instructor for guidance.
• Enter the part programme in CNC machine (or)
transfer the programme by simulator to CNC machine • Run the programme in single block by setting the
• Set the tool to required turret station. offset away form the work zero.
• Measure work offset in X and Z direction and enter Observe the spindle direction speed tool
the work offset page say G54 / G55. position carefully.
• Measure the tool offset all tools in X and Z direction • Run the program in auto mode in original work offset.
and enter the tool geometry offset page.

128
• Check the dimensions. If there is any correction, G28 U0 W0;
change the wear offset and run the program. M05;
• Check the dimension and surface finish. M01;
• Remove the job from the machine, check all the N3 [ Φ 14mm Drill ]
dimension once again.
G28 U0 W0;
• Switch OFF the machine.
O 9461; G97 S1800 M04;
T0404;
N1;
G28 U0 W0; G00 X0.0 Z5.0 M08;
G74 R2;
G97 S1500 M03;
T0101; G74 Z-73.0 Q 10000 F0.1;
G00 Z10.0 M09;
G00 x 52.0 Z5.0 M08;
G01 Z4.0 F0.1; G28 U0 W0;

G71 U1.0 R1.0; M05;

G71 P10 Q20 U0.0 W0.0 F0.1; M01;

N10 G01 Z0.0 F0.1; N4; [ Boring Tool ]

G28 U0 W0;
X0.0;
Z1.0; G97 S1200 M04;
T0606;
X36.0;
Z0.0; G00 X12.0 Z5.0 M08;
G01 Z3.0 F0.1;
X40.0 Z - 2.0;
Z - 30.0; G71 U0.5 R1.0;
G71 P30 Q40 U0.0 W0.0 F0.1;
X 48.0;
N20 G01 Z - 70.0 F0.1; N30 G01 Z-70.0 F0.1;
X16.0;
G00 X60.0 Z5.0 M09;
G28 U0 W0; Z-47.0;

M05; X20.0 Z-45;

M01; Z-25.0;

N2; [ Centre Drill ] G03 X28.0 Z-21.0 R4 F0.1;

G01 Z-2.0 F0.1;
G28 U0 W0;
G97 S1800 M04; N40 X32.0 Z0.0 F0.1;
G00 X10.0 Z5.0 M09;
T0202;
G00 X 0.0 Z5.0 M08; G28 U0 W0;
M05;
G01 Z-7.0 F0.08;
G00 Z10.0 M09; M01;
M30;

Instructor for guidance of the IInd operation to

trainees

Capital Goods & Manufacturing : Machinist (NSQF Level - 5) - Exercise 3.4.180 129