KARPAGA VINAYAGA

COLLEGE OF ENGINEERING AND TECHNOLOGY

(Approved by AICTE, affiliated to Anna University and accredited by NAAC)
GST Road, Chinnakolampakkam, Madhuranthakam Taluk, Chengalpattu District – 603 308, Tamil Nadu

DEPARTMENT OF MECHANICAL ENGINEERING

ME 8462

MANUFACTURING TECHNOLOGY LABORATORY II

MANUAL
(As per anna university syllabus)

(R-2017)

IV SEMESTER

MANUFACTURING TECHNOLOGY-II Page 1

 TABLE OF CONTENTS

S. NO. CONTE PAGE

NTS NO
1. Vision & Mission(Institute & Department) 1
Programme Education Objective (PEO’s)
2. 2

3. Program Outcomes (PO’s) & Programme Specific Outcomes (PSO’s) 3

4. Syllabus 4

5. Course Outcomes (CO’s) & Mapping of CO’s, PO’s and PSO’s 5

6. List of Experiments (Cycle 1 & Cycle 2)

7. Safety Measures

List of Experiments
Contour milling using vertical milling machine
1. 1

2. Spur gear cutting in milling machine 2

Helical Gear Cutting in milling machine
3. 3

Gear generation in hobbing machine

4. 4
Gear generation in gear shaping machine
5.

Plain Surface grinding

6.

Cylindrical grinding
7.

Tool angle grinding with tool and Cutter Grinder

8.

Measurement of cutting forces in Milling / Turning Process

9.

CNC Part Programming

10.

Contain Beyond the syllabus –Additional Experiments

1. SLOTTING – KEY WAY

2. SHAPER-V SURFACE

MANUFACTURING TECHNOLOGY-II Page 2

 MISSION OF THE INSTITUTE

M1: To impart quality technical education by providing state-of-art infrastructure with dedicated faculty.
M2: To provide contemporary technical education for facing the needs and challenges of industries and research
establishment at global level.
M3: To effect socio-economic transformation of society by inculcating human values and social responsibilities.

VISION OF THE INSTITUTE

Imparting innovative higher education with greater accentuation on high value systems shaping personnel
for nation-building.

MANUFACTURING TECHNOLOGY-II Page 3

 VISION OF THE DEPARTMENT

Producing competent mechanical engineers by imparting quality education blended with human
values to cater to the growing industrial and societal demands.

MISSION OF THE DEPARTMENT

M1: To provide quality education and learning environment to the students through the state- of- the- art
infrastructure in mechanical engineering.
M2: To develop collaborations with various Research & Development organizations and industry for
excellence in research and consultancy practices.
M3: To empower our students to gain experience in team work and leadership qualities.
M4: To inculcate entrepreneurial skills, strong ethical values and professionalism among students for
contributing towards upliftment of the society.

PROGRAMME EDUCAATIONAL OBJECTIVES (PEOs)

The Programme Educational Objectives of Mechanical Engineering Undergraduate Program are as
follows:

PEO1: Graduates will have successful careers in the Mechanical Engineering or allied industries.

PEO2: Graduates will demonstrate their skills in solving challenging problems in Mechanical Engineering
and its allied areas.

PEO3: Graduates will exhibit leadership skills to adapt for the changing global scenario.

PEO4: Graduates will have good professional traits and ethical values to lead as responsible citizens.

Program outcomes (POs)

MANUFACTURING TECHNOLOGY-II Page 4

PO1: Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.

PO2: Problem analysis: Identity, formulate, review research literature, and analyse complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.

PO3: Design/development of solutions: Design solutions for complex engineering problems

and design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.

PO4: Conduct investigations of complex problems: Use research-based knowledge and

research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.

PO5: Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools, including prediction and modelling to complex engineering
activities with an understanding of the limitations.

PO6: The engineer and society: Apply to reason informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.

PO7: Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development

PO8: Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.

PO9: Individual and teamwork: Function effectively as an individual, and as a member or

leader in diverse teams, and in multidisciplinary settings.

PO10: Communication: Communicate effectively on complex engineering activities with the

engineering community and with society at large, such as being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and receive
clear instructions.

PO11: Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s work, as a member and leader
in a team, to manage projects and in multidisciplinary environments.

MANUFACTURING TECHNOLOGY-II Page 5

 PO12: Life-long learning: Recognize the need for and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological change.

PROGRAM SPECIFIC OUTCOMES (PSOs)

PSO1: Our graduates will be able to apply knowledge of Design, Manufacturing, Thermal and Materials
engineering to solve complex problems in mechanical engineering and its allied areas.

PSO2: Our graduates will be able to analyze, design and simulate mechanical engineering problems with the help
of modern CAD/CAM/CAE tools while ensuring best engineering practices.

MANUFACTURING TECHNOLOGY-II Page 6

ME8462 MANUFACTURING TECHNOLOGY LABORATORY – II LT P C
0042
OBJECTIVE:
 To Study and acquire knowledge on various basic machining operations in special purpose
machines and its applications in real life manufacture of components in the industry.

LIST OF EXPERIMENTS:
1. Contour milling using vertical milling machine
2. Spur gear cutting in milling machine
3. Helical Gear Cutting in milling machine
4. Gear generation in hobbing machine
5. Gear generation in gear shaping machine
6. Plain Surface grinding
7. Cylindrical grinding
8. Tool angle grinding with tool and Cutter Grinder
9. Measurement of cutting forces in Milling / Turning Process
10. CNC Part Programming

OUTCOMES:
Upon the completion of this course the students will be able
to CO1 Use different machine tools to manufacturing gears
CO2 Ability to use different machine tools to manufacturing gears.
CO3 Ability to use different machine tools for finishing operations
CO4 Ability to manufacture tools using cutter grinder
CO5 Develop CNC part programming
TOTAL: 60 PERIODS

LIST OF EQUIPMENT FOR A BATCH OF 30STUDENTS

S.No. Name Of The Equipment Qty.
1 Turret and Capstan Lathes 1 No each
2 Horizontal Milling Machine 2 No
3 Vertical Milling Machine 1 No
4 Surface Grinding Machine 1 No.
5 Cylinderical Grinding Machine 1 No.
6 Radial Drilling Machine 1 No.
7 lathe Tool Dynamometer 1 No
8 Milling Tool Dynamometer 1 No
9 Gear Hobbing Machine 1 No
10 Tool Makers Microscope 1 No
11 CNC Lathe 1 No
12 CNC Milling machine 1 No
13 Gear Shaping machine 1 No
14 Centerless grinding machine 1 No
15 Tool and cutter grinder 1 No

MANUFACTURING TECHNOLOGY-II Page 7

 COURSE OUTCOMES
COURS COURS
ME 8462 MANUFACTURING TECHNOLOGY SEM 4
E E LABORATORY-II
CODE NAME
CO1
Explain the mechanism of material removal processes
CO2
Describe the constructional and operational features of centre lathe and other special purpose lathes.
CO3
Describe the constructional and operational features of shaper, milling and gear cutting machines.
CO4
Explain the types of grinding and other super finishing processes
CO5
Summarize numerical control of machine tools and write a part program

CO’S –PO’S / PSO’S MAPPING

CO
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
/
PO
CO 1
1 1 1 - - - - - - - - - 3 -
CO 1
2 1 1 - - - - - - - - - 3 -
CO 1
3 2 1 - - - - - - - - - 3 -
CO 1
4 1 1 - - - - - - - - - 3 -
CO 1
5 2 1 - - - - - - - - - 3 -

LIST OF EXPERIMENTS:
MANUFACTURING TECHNOLOGY-II Page 8
 Ex.No Name of the Experiment Hour Relevance to PAGE
s CO’s NO
Contour milling using vertical milling 4 CO1 8
1
machine
4 CO1 10
2 Spur gear cutting in milling machine
Helical Gear Cutting in milling machine 4 CO2 12
3

Gear generation in hobbing machine 4 CO2 14

4
Gear generation in gear shaping machine 4 CO3 16
5

6 Plain Surface grinding 4 CO3 20

7 Cylindrical grinding 4 CO4 24

Tool angle grinding with tool and Cutter 4 CO4 29

8
Grinder

Measurement of cutting forces in Milling / 4 CO5 31

9
Turning Process

10 CNC Part Programming 4 CO5 33

CONTENT BEYOND SYLLABUS

2 SLOTTING – KEY WAY 4 CO2 52

3 SHAPER-V SURFACE 4 CO2 54

Viva 56 To 59
Questions

MANUFACTURING TECHNOLOGY-II Page 9

 GENERAL SAFETY PRACTICES
Clothing
1. Loose clothing, jewellery, and gloves are not to be worn while you are working
with powertools.
2. Sharp, pointed tools or materials are not to be carried in clothing, Hold sharp
points and sharp edgesdown.
3. Keep hair away from equipment in operation. Long hair must be tied up andback.
Safety Glasses
4. Safety glasses must always be worn while working or watching others work in
the shop.
5. Eye glasses must not be used in place of goggles or face shields, unless they
have temperedlenses.
6. Face Shields must be used when using abrasivemachines.
7. When compressed air is used for cleaning. Wear eye protection. Take care to
direct chips, shavings, and dust away from otherstudents
Safety Zones
8. Observe safety zones. Only the operator and teacher are permitted within the
working area around a machine.
9. Don't lean on the machine. Standclear
10. Disturbing another student while he is working is a dangerous practice. Unsafe
Shop Conditions
11. If equipment is not working properly, shut it off and tell the teacher atonce.
12. Report to the teacher all breakage or damage to tools, machinery, orequipment.
13. Guards and other safety devices are for the protection of the operator and must
always be inplace.
14. Keep floors, aisles, and passageways clear of stock, tools, andmaterials.
15. Wipe up immediately any liquids spilled on thefloor.
16. Keep tools and materials from projecting over the edge of benches wheneverpossible.
17. A student who sees a dangerous situation must report it at once to theteacher.
18. The motion involved in striking or cutting must be done in a direction away from
you and otherstudents.
19. Compressed air should not be used to clean off machines, because it may
cause damage to bearingsurfaces.
Electrical
20. The main power switches in the shop must be turned "on" or "off" ONLY by
the teacher
21. Make certain your hands are completely dry before touching electrical
switches, plugs, orreceptacles.
Fire
22. Oily or paint-filled rags must be placed in a covered metal container. Oily and greasy
shop clothing must be stored in lockers. Never roll themup,
23. Gasoline, chemicals, kerosene, paints, lacquer, thinner, and other finishes or cleaning
materials are to be used in a well-ventilated room; They are never be used near an
openflame.
24. Never use water to put out an electrical or oilfire.
25. In case of fire in theshop:
a. Sound the alarm:FIRE!!!!!
b. Turn off allelectricity:
c. Put the fire out, if possible without injuringoneself.

MANUFACTURING TECHNOLOGY-II Page

 I. STUDY OF MILLINGMACHINE
INTRODUCTION:

Milling is the name given to the machining process in which the removal of metal
takes place due to cutting action of a revolving cutter when the work is fed past it. The
revolving cutter is held on a spindle and the work, clamped on the machine table, fed past the
same. Milling is the cutting operation that removes metal by feeding the work against a
rotating, cutter having single or multiple cutting edges. Flat or curved surfaces of many
shapes can be machined by milling with good finish and accuracy. A milling machine may
also be used for drilling, slotting, making a circular profile and gear cutting by having
suitableattachments.

WORKING PRINCIPLE IN MILLING:

The working principle, employed in the metal removing operation on a milling

machine, is revolving multi teeth cutter mounted either on a spindle. The cutter revolves at a
fairly high speed and the work fed slowly past the cutter. The work can be fed in a vertical,
longitudinal or cross direction. As the work advances, the cutter-teeth remove the metal from
the work surface to produce the desired shape. The work piece is holding on the worktable of
the machine. The table movement controls the feed of work piece against the rotating cutter.
The cutter is mounted on a spindle and revolves at high speed. Except for rotation the cutter
has no other motion. As the work piece advances, the cutter teeth remove the metal from the
surface of work piece and the desired shape is produced.

MILLING MACHINE

MANUFACTURING TECHNOLOGY-II Page 11

TYPES OF MILLING MACHINES:

A large variety of different types of milling machines is available. The classification of

these type machines can be done as follows:

1. Column and knee type millingmachines

2. Fixed bed type or manufacturing type millingmachines
3. Planer type millingmachines
4. Production millingmachines
5. Special purposemachines

COLUMN AND KNEE TYPE MILLING MACHINES:

These machines are all general purpose machines and have a single spindle only. They
are further classified asfollows:

(a) Hand millingmachine

(b) Plain or horizontal millingmachine
(c) Vertical milling machineand
(d) Universal millingmachine

MANUFACTURING TECHNOLOGY-II Page 12

FIXED BED TYPE OR MANUFACTURING TYPR MILLING MACHINE:

These machines, in comparison to the column and knee type, are more sturdy and rigid,
and heavier in weight and larger in size. Their further classification is as follows:

(a) Plain type (having single horizontalspindle).

(b) Duplex head (having double horizontalspindles).
(c) Triplex head (having two horizontal and one verticalspindle).
(d) Rise and fall type (for profilemilling)

PLANER TYPE MILLING MACHINES:

They are used for heavy work. Up to a maximum of four tool heads can be mounted over
it, which can be adjusted vertically and transverse directions. It has a robust and massive
construction like a planar.

PRODUCTION MILLING MACHINES:

They are also manufacturing machines but differ from the above described machines in
that they do not have a fixed bed. They include following machines:

(a) Rotary table or continuoustype.

(b) Drum typeand
(c) Tracercontrolled

SPECIAL PURPOSE MILLING MACHINES:

These machines are designed to perform a specific type of operation only. They include
following machines:

(a) Thread millingmachine

(b) Profile millingmachine

(c) Gear milling or gear hobbingmachine

(d) Cam millingmachine

(e) Planetary type millingmachine

(f) Double end millingmachine

(g) Skin milling machineand

(h) Spar millingmachine.

MANUFACTURING TECHNOLOGY-II Page 13

PLAIN OR HORIZONTAL MILLING MACHINE

The vertical column serves as a housing for electrical, the main drive, spindle bearings,
etc. The knee acts as support for the saddle, worktable and other accessories like indexing
head, etc. Over arm provides support for the yoke which in turn, supports the free end of the
arbor. The arbor carrying the cutter rotates about a horizontal axis. The table can be given
straight motions in three directions; longitudinal, cross, vertical. For giving vertical
movement to the table the knee it, together with the whole unit above it, slides up and down
along the ways provide in front of the column. A brace is employed to provide additional
support and rigidity to the arbor when a long arbor is used. Both hand power and power feeds
can be employed for thework.

VERTICAL MILLING MACHINE:

It derives its name from the vertical position of the spindle. This is available in both
types; the fixed bed type as type as well as column and knee type. It carries a vertical column
on a heavy base. The over arm in this machine is made integral with the column and carries a
housing at its front. This housing called head can be of fixed type .In fixed type, the spindle
always remains vertical and can be adjusted up and down.

The knee carries an enclosed screw jack, by means of which it is moved up and down
along the parallel vertical guide ways provided on the front side of the column. The saddle is
mounted on the knee and can be moved, along the horizontal guide ways provided on the
knee, towards or away from the column. This enables the table to move in cross direction.
The work gets up and down movement by the knee, cross movement by saddle and
longitudinal movement by thetable.

PARTS OF MILLING MACHINE:

Main parts of the milling machines are similar; all these machine essentials consist of the
following main parts:

1. BASE:
It is a heavy casting provided at the bottom of the machine. It is accurately
machined on both the top and bottom surfaces. It actually acts as a load bearing
member for all other parts of the machine. Also it carries the screw jack which
supports and moves the knee. In addition to this it also serves as reservoir for the
coolant.
2. COLUMN:
It is a very prominent part of the milling machine and is produced with enough
care. On the front face of the column are made the vertical parallel ways in which the
knee slides up and down. It carries the enclosed motor drive. Top of the column
carries dovetail horizontal ways for the over arm.

MANUFACTURING TECHNOLOGY-II Page 14

 3. KNEE:
It is a rigid casting, which is capable of sliding up and down along the vertical
ways on the front face of the column. This enables the adjustment of the table height.
The adjustment is provided by operating the elevating jack, provided below the knee,
by means of hand wheel or application of power feed. For efficient operation of the
machine, rigidity of the knee and accuracy of its ways play an important role. On the
front face of the knee two bolts are usually provided for securing the braces to it to
ensure greater rigidity under heavy loads.

4. SADDLE:
It is the intermediate part between the knee and the table and acts as a support for
the latter. It can be adjusted crosswise, along the ways provided on the top of the
knee, to provide cross feed to the table. As its top, it carries horizontal ways, along
which moves the table during longitudinaltraverse.

5. TABLE:
It acts as a support for the work. It is made of cast iron, with its top surface
accurately machined. Its top carries longitudinal cross T-slots to accommodate the
clamping bolts for fixing the work or securing the fixtures. Also, the cutting fluid,
after it is used, drains back to the reservoir through these slots and then the pipe fitted
for this purpose. Longitudinal feed is provided to it by means of hand wheel fitted on
one side of the feed screw. Cross feed is provided by moving the saddle and vertical
feed by rising or lowering theknee.

6. OVERARM:
It is the heavy support provided on the top of both plain and universal milling
machine. It can slide horizontally, along the ways provided on the top of the column,
and adjusted to a desired position in order to provide support to the projecting arbor
by accommodating its free end in theyoke.

MANUFACTURING TECHNOLOGY-II Page 15

 1. CONTOURMILLING USING VERTICAL MILLING MACHINE

AIM:

To machine a groove in the given work piece using vertical milling machine.

TOOLS REQUIRED:

1. Millingmachine
2. Vernier caliper
3. Steelrule
4. Machinevice
5. Centrepunch

MATERIAL REQUIRED:

150 X 50 X 10 mm Cast Iron flat

PROCEDURE

1. Check whether the machine is in propercondition.

2. Check whether the work piece which gives in suitablesize.
3. The job is marked to the desired shape andpunched.
4. Hold the work piece in the vice and fix the tool in the arbor in correct position
and machine isstarted.
5. The minimum depth of cut is given and feed is given by reciprocatingtable.
6. Remove the job and check thedimensions.
7. Continue the steps to obtain requireddimensions.

DIAGRAM:

RESULT:
Thus the vertical milling operation was performed on the given work piece
using vertical millingmachine.

MANUFACTURING TECHNOLOGY-II Page 16

 2. SPUR GEAR CUTTING IN MILLING MACHINE

AIM:

To machine gear to the given module and number of teeth in the given work piece.

TOOLS AND EQUIPMENTS REQUIRED:

1. Millingmachine
2. Vernier caliper
3. Mandrel.

PROCEDURE:

1. Calculate the gear tooth

proportions. Where,
Blankdiameter = (Z + 2) m
Toothdepth = 2.25 m
Tooth width = 1.5708 m
Z = Number of teeth required
m = module

Indexing calculation

Index crank movement = 40 / Z

2. The dividing head and the tail stock are bolted on the machine table. Their axis
must be set parallel to the machinetable.
3. The gear blank is held between the dividing head and tailstock using a mandrel.
The mandrel is connected with the spindle of dividing head by a carrier and catch
plate.
4. The cutter is mounted on the arbor. The cutter is centered accurately with the
gearblank.
5. Set the speed and feed formachining.
6. For giving depth of cut, the table is raised till the periphery of the gear blank
just touches thecutter.
7. The micrometer dial of vertical feed screw is set to zero in thisposition.
8. Then the table is raised further to give the required depth ofcut.
9. The machine is started and feed is given to the table to cut the first groove of
the blank.
10. After the cut, the table is brought back to the startingposition.
11. Then the gear blank is indexed for the next toothspace.
12. This is continued till all the gear teeth arecut.

MANUFACTURING TECHNOLOGY-II Page 17

CALCULATION:

Z = No.ofteeth = 23
m = module = 2 mm
BlankDiameter = (Z + 2) *m
= (23 + 2) *2
= 50 mm

ToothDepth = 2.25m
= 2.25 *2
= 4.5 mm

Indexing Calculation
= 40 / Z
= 40 / 23
= 1.739

DIAGRAM:

RESULT:

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

MANUFACTURING TECHNOLOGY-II Page 18

 3.HELICAL GEAR CUTTING IN MILLING MACHINE

AIM:

To make a helical gear from a CI blank using milling machine

MATERIAL REQUIRED:

Cast iron blank of Ф50mm

TOOLS REQUIRED:

1. Turningtool
2. Milling cutter (2mmmodule)
3. Vernier caliper(0-150mm)
4. Drilling tool Ф 10mm,Ф20mm
5. MandrelФ20mm
6. Spanner
7. Gear toothVernier

FORMULA:

Outer diameter = (N+2)

M, Module =OD/ (N+2),
No .of teeth = (OD/M) -2
N- Numberofteeth M=module OD= outerdiameter

PROCEDURE:

1. Turn the given CI bank to required diameter in centrelathe.

2. Drill a hole in the blank of diameter equal to mandrelsize.
3. Fix the blank between two centers of the dividing head usingmandrel.
4. Set the milling cutter on the machine spindle and select the suitablespeed.
5. Raise the table (knee) vertically up until blank touches thecutter.
6. Calculate depth of cut and indexing calculation from module & number of teeth.
7. Give the depth of cut by raising the kneeup.
8. According to index calculation set the dividinghead.
9. Switch on the spindle and feed the blank against the rotating cutter by
reciprocating thetable
10. Move the index arm on the index plate according to the calculated number of
holes.
11. Feed the blank against the rotating cutter to cut the nexttooth.
12. Repeat the same for remainingteeth

MANUFACTURING TECHNOLOGY-II Page 19

DIAGRAM:

MODEL CALCULATION FOR HELICAL GEAR:

No ofteeth(z) =30
Module(m) =2mm
External dia.ofblank =(z+2)*m
= (30+2)*2=64
Depthofcut =2.25*m
=2.25*2
=4.5mm

The indexing crank rotation = one complete rotation and move arm holes in 33
concentric circle.

RESULT:

Thus the spur gear has made by using milling machine to the required size.

MANUFACTURING TECHNOLOGY-II Page 20

 II. STUDY OF GEAR HOBBINGMACHINE

INTRODUCTION:
Gear Hobbing is a continuous generative process in which the tooth flanks of the
constantly moving work piece are formed by equally spaced cutting edges of the hob. The
profile produced on the gear is a curve comprising of a number of flats, varying with the
number of flutes in the hob which pass a given tooth during the generative movement. Every
hob tooth which contacts the gear along line of action produces one enveloping cut. Like the
straight flank of the hob tooth, the individual cut is straight and in tangent plane to the
involutes of the tooth flanking.

WORKING PRINCIPLE OF OPERATION:

The generative process requires an accurate relationship between various elements of the
machine in order to achieve the desired results. The work table rotates in a definite
relationship with the rotation of the hob. This relation is timed by index change gears. For
hobbing helical gears, the rotation of the work table is slightly advanced or retarded in
relation to the rotation of the axial feed screw by means of another set of change gears called
different change gears. The direction of feed of the hob relative to the work piece can be
achieved in any of the three ways, but these basic feeds can be combined to form other
permutations.

HOB Nomenclature

MANUFACTURING TECHNOLOGY-II Page 21

TYPES OF HOBBING:
The hobbing process is classified in to different types according to the directions of
feeding the hob for gear cutting.

1. HOBBING WITH AXIALFEED.

This type of feeding method is mainly used for cutting spur and helical gears, as
explained in the previous article. It involves moving the hob towards the gear blank or the
blank towards the hob to bring the two in such a relative position that the required tooth depth
is blank towards obtained .this is followed by feeding the rotating positions that the required
tooth depth is obtained. This is followed by feeding the rotating hob along the face of the
blank parallel to the axis of the latter. This feeding can be from below the blank upwards or
from above the blankupwards.

2. HOBBING WITH RADIALFEED.

This method of hob in-feed is mainly used for cutting worm wheels. In this method the
hob and gear blank are set with their axes normal tom each other. The gear blank continues to
rotate at a set speed about its vertical axis and the rotating hob is given in-feed in a radial,
direction towards the centre of blank rotation.
An important point to be noted here is that while the use of radial in feed results in higher
rate of production the accuracy of the tooth profile produced is of low order.

3. HOBBING WITH TANGENTIALFEED:

It is yet another common method used for cutting teeth on worm wheels. In this method,
the worm wheel blank is rotated in a vertical plane about horizontal axis. The hob is held with
its axis horizontal but at right angles to the axis of the blank. The hob in feed is tangential to
the blank face and hence, the name ‘tangentialfeeding’

ADVANTAGES:
1. It is a faster and continues process. Hence, quite economical as compared to
other generativeprocesses
2. It enables a high rate of production.
3. The gear teeth generated through this process are veryaccurate.
4. The process can be adopted with equal advantage for both medium and large
batch productions.
5. Hobbing machines, their setting and operation aresimpler.

MANUFACTURING TECHNOLOGY-II Page 22

 4. GEAR GENERATION IN HOBBING MACHINE

AIM:

To generate a spur gear using Gear Hobbing machine to the given dimensions.

TOOLS REQUIRED:

1. Vernier caliper
2. Mandrel
3. Drill bitø25mm

PROCEDURE:

1. The given job is turned to required outerdiameter

2. The given job is held firmly in the mandrel against the gearHobber
3. The position of work table is adjusted, so that the job and cutter are on
the same line
4. The machine is switched ON and the table is fed parallel to thecutter.
5. The feed is given longitudinally again and again, this procedure is repeated
for completion of 16teeth.

DIAGRAM:

RESULT:

Thus the spur gear is generated using Gear Hobbing machine

MANUFACTURING TECHNOLOGY-II Page 23

 III. STUDY OF GEARSHAPING MACHINE

AIM:
To study the working of gear shaping machine

INTRODUCTION
A gear shaper is a machine tool for cutting the teeth of internal or external gears. The
name shaper relates to the fact that the cutter engages the part on the forward stroke and pulls
away from the part on the return stroke, just like the clapper box on a planer shaper.

The cutting tool is also gear shaped having the same pitch as the gear to be cut.
However number of cutting teeth must be less than that of the gear to be cut for internal
gears. For external gears the number of teeth on the cutter is limited only by the size of the
shaping machine. For larger gears the blank is sometimes gashed to the rough shape to make
shapingeasier.

The principal motions involved in rotary gear shaper cutting are of the following

1. Cutting Motion: The downward linear motion of the cutter spindle together with the
cutter.
2. Return Stroke: The upward linear travel of the spindle and cutter to withdraw the
latter to its startingposition.
3. Indexing Motion: Slow speed continuous rotation of the cutter spindle and work
spindle to provide circular feed, the two speeds being regulated through the change
gears such that against each rotation of the cutter the gear blank revolves through n/N
revolution, where "n" is the number of teeth of the cutter, and "N" is the number of
teeth to be cut on theblank.
4. Completion of Cutting Operation: The indexing and reciprocating motions continue
until the required number of teeth to the required depth are cut all along the periphery
of the gearblank
WORKING PRINCIPLE OF OPERATION
Gear shaping is similar to the rack type cutting process, excepting that, the linear type
rack cutter is replaced by a circular cutter as indicated in figure, where both the cutter and the
blank rotate as a pair of spur gears in addition to the reciprocation of the cutter Generation
method is characterized by automatic indexing and ability of a single cutter to cover the
entire range of number of teeth for a given combination of module and pressure angle and
hence provides high productivity andeconomy.

The gear type cutter is made of HSS and possesses proper rake and clearanceangles. The
additional advantages of gear shaping over rack type cutting are:

• Separate indexing is not required atall

• Straight or helical teeth of both external and internal spur gears can
be produced with high accuracy andfinish
• Productivity is alsohigher

Result:
Thus the working of gear shaping machine has been studied

MANUFACTURING TECHNOLOGY-II Page 24

 5. GEAR GENERATION IN GEAR SHAPING MACHINE

AIM:

To make a Spur Gear form a CI blank using Gear Shaping machine.

MATERIAL REQUIRED:

Cast iron blank of Ф50mm

TOOLS REQUIRED:

1. Vernier caliper
2. Mandrel
3. Drill bitø25mm

PROCEDURE:

1. The given job is turned to required outerdiameter

2. The given job is held firmly in the mandrel against the Gear Shapingmachine.
3. The position of work table is adjusted, so that the job and cutter are on
the same line
4. The machine is switched ON and the table is fed parallel to thecutter.
5. The feed is given longitudinally again and again, this procedure is repeated
for completion of 16teeth.

DIAGRAM:

RESULT:

Thus the Spur Gear is Generated using Gear Shaping machine

MANUFACTURING TECHNOLOGY-II Page 25

 IV. STUDY OF GRINDINGMACHINE
INTRODUCTION:
Grinding is metal cutting operation performed by means of a rotating abrasive wheel
that acts as a tool. This is used to finish work pieces which must show a high surface quality,
accuracy of shape and dimension. The art of grinding goes back many centuries. Columns
and statues were shaped and finished with a globular stone which abraded thesurface.

Mostly grinding is a finishing operation because it removes comparatively littlemetal

0.25 to 0.50 mm in most operations and the accuracy is in the order of 0.000025 mm. many
different types of grinding machines have now been developed for handling various kinds of
work to which the grinding process is applicable. A grinding machine is a machine tool used
for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each
grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear
deformation.

The grinding machine consists of a power driven grinding wheel spinning at the
required speed and a bed with a fixture to guide and hold the work-piece. The grinding head
can be controlled to travel across a fixed work piece or the work piece can be moved whilst
the grind head stays in a fixed position. Very fine control of the grinding head or table
position is possible using a Vernier calibrated hand wheel, or using the features of numerical
controls. Grinding machines remove material from the work piece by abrasion, which can
generate substantial amounts of heat; they therefore incorporate a coolant to cool the work
piece so that it does not overheat and go outside its tolerance. The coolant also benefits the
machinist as the heat generated may cause burns in some cases.

MANUFACTURING TECHNOLOGY-II Page 26

KINDS OF GRINDING:
1. Rough or non-precisiongrinding
2. Precisiongrinding

ROUGH OR NON PRECISION GRINDING

The common forms of rough grinding are snagging and offhand grinding, where the
work is held in the operator’s hand. The work is pressed hard against the wheel, or vice versa.
The accuracy and surface finish obtained of secondary importance.

PRECISION GRINDING
This is concerned with producing good surface finish and high degree of accuracy.
Yarn wheel or work both are guided in precise paths.

CENTRELESS GRINDERS
Centre less grinding is a method of grinding exterior cylindrical tapered and formed
surfaces on work pieces that are not held and rotated on centres. The principle elements of an
external centre less grinder are the grinding wheel, regulating or back up wheel and the work
rest. Both wheels are rotated in the same direction. The work rest is located between the
wheels. The work is placed upon the work rest and the latter together with the regulating
wheel, is fed forward forcing the work against the grinding wheel. Centre less grinding may
be done in one of the three ways
a) Throughfeed
b) Infeed
c) Endfeed

SURFACE GRINDERS:
Surface grinding machines are employed to finish planes on flat surfaces. They are
also capable of grinding irregular, curved, convex and concave surfaces. Conventional
surface grinders may be divided into two classes: one class has reciprocating tables for work
ground along straight lines, while the other covers the machines with rotating work tables
continuous rapid grinding. Surface grinders may also are classified according to whether they
have horizontal or vertical grinding wheelspindles.

Horizontal Spindle Reciprocating Table Surface Grinder:

 Base: The base has a column at the back for supporting the wheel head. The base also
contains the drivemechanism.
 Table: The table is fitted to the saddle on carefully machined ways. It reciprocates along
ways to provide the longitudinal feed. If slots are provided in the table surfaces for
clamping work pieces directly on the table or for clamping grinding fixtures or a magnetic
chuck;
 Wheel Head: The wheel heads are mounted on the column secured on the base. It has
ways for the vertical slide which can be raised or lowered with the grinding wheel only
manually by rotating a hand wheel to accommodate work pieces of different heights and to
set the wheel for depth ofcut.
 Operation: The work piece reciprocates under the wheel, and the wheel on the table beds
axially between passes to produce a fine flat surface. Wheel down feed determines depth
of cut and final height of the piece from the table to the wheel. The amount of feed must
only be equal to a few hundredths of milling meters. For example steel is rough ground
withadepthofcutbetween0.02and0.05mmandfinishgroundwithadepthofcutof
0.005 to 0.01mm.

MANUFACTURING TECHNOLOGY-II Page 27

 6. PLAIN SURFACE GRINDING

AIM:
To finish the surface of the given specimen using surface grinding machine

TOOLS REQUIRED:
1. Magnetic power machinetable
2. Vernier caliper(0-150mm)
3. Micrometer(0-25mm)
4. Aluminum oxide grindingwheel.

MATERIAL REQUIRED:

100mmΧ50mmΧ6mm M.S. flat

PROCEDURE
1. Check the dimensions of the givenflat.
2. Mark the dimensions as per the given drawing using steel rule andscriber.
3. Clamp the work piece by means of a magneticchuck.
4. Then start the machine with slowspeed
5. The table is started toReciprocate.
6. Then feed is given with minimum depth of cut.
7. Remove the job and check thedimensions.
8. Continue the steps to achieve the requireddimensions.

DIAGRAM:

RESULT:
Thus the surface grinding operation is performed on the work piece.

MANUFACTURING TECHNOLOGY-II Page 28

www.vidyarthiplus.com www.veltechengg.com

7. CYLINDRICAL GRINDING
AIM:
To grind a given cylindrical work piece by using cylindrical grinding machine as per
dimensions in the drawing

TOOLS REQUIRED:
1. Dogcarrier
2. Vernier caliper
3. Vernier heightgauge
4. Chuck key
5. Double endedspanner
6. V-block
7. Punch andHammer

MATERIAL SUPPLIED:

1. Φ25mmХ100mm cylindrical workpiece

2. Material mildsteel

PROCEDURE:
1. Check the dimensions of the given workpiece.
2. Mark the dimensions as per the given drawing using steel rule andscriber.
3. Make drilling on both side of the markedcenter.
4. Hold the job in dog carrier and between the centers to remove the excess material
from the workpiece.
5. Grind the work piece of givendimension.
6. Check the dimension of thejob.

DIAGRAM:

RESULT:
Thus the cylindrical grinding is operation performed on the work piece.

MANUFACTURING TECHNOLOGY-II Page 29

www.vidyarthiplus.com www.veltechengg.com

8. TOOL ANGLE GRINDING WITH TOOL AND

CUTTERGRINDER AIM:

To perform the angle grinding with tool and cutter grinder on the given work
piece for the given dimensions.

REQUIREMENTS:
1. Tool GrindingMachine
2. Work Piece
3. GrindingWheel

PROCEDURE:

1. At first work piece is placed in the magnetic chuck.

2. The work piece should be light weight so that it cannot be removed
from the magnetic chuck easily.
3. Various arrangements regarding the positions of work piece is done.
4. Grinding wheel and grinding spindle are kept in position with the workpiece.
5. Before switching on the motor, necessary steps should taken. For proper
grinding process wheel speed, work speed, transverse speed of the
wheel in feed, area of contact is to benoted.
6. While running the area of contact is adjusted accordingly to the spindle
in order to remove thesurface.
7. It is done slowly to remove the materials on all surface of the work piece

RESULT:

To Study about the angle grinding with tool and cutter grinder on the
given work piece for the given dimensions.

MANUFACTURING TECHNOLOGY-II Page 30

www.vidyarthiplus.com www.veltechengg.com

9. MEASUREMENT OF CUTTING FORCES IN MILLING/ TURNING PROCESS

AIM:
To measure the cutting forces for the given cutting conditions

TOOLS AND EQUIPMENTS REQUIRED:

1. Lathe
2. Lathe ToolDynamometer

PROCEDURE:

1. The Lathe Tool Dynamometer is initially set to zeroreading.

2. The known depth of cut is given and take the readings of Px and Pz force
components from the Lathe ToolDynamometer.
3. Calculate the resultant cutting
force P= √𝑃𝑥2 + 𝑃𝑧2
4. Repeat the same procedure to get few more readings and calculate the mean cutting
force.
5. Repeat the same procedure for different depth ofcuts

DIAGRAM:

NOTE:

1. Pz – the main or tangential component, determines the torque on main drive mechanism,
the deflection of the tool and the required power. This component acts in the direction of the
cuttingspeed.
2. Px – the axial component, acts in the direction of the tool traverse and it is at right angles
to Pz. It contributes very little to the power consumption.
3. Py – the radial component, acts along the tool shank and perpendicular to the other two
components. It has no share in the powerconsumption

MANUFACTURING TECHNOLOGY-II Page 31

www.vidyarthiplus.com www.veltechengg.com

TABULATION :

VERTICAL RESULTANT AVERAGE

DEPTH HORIZONTAL
COMPONENT (Kg)
S.NO OF CUT- COMPONENT
PZ(Kg) P= √𝑷𝒙𝟐 + 𝑷𝒛𝟐
(mm) PX(Kg) (Kg)
1. 0.25
2. 0.50

3. 0.75

RESULT:

Thus the cutting forces are measured for different depth of cuts

MANUFACTURING TECHNOLOGY-II Page 32

www.vidyarthiplus.com www.veltechengg.com

V. CNC PARTPROGRAMMING

INTRODUCTION

The part program is a sequence of instructions, which describe the work, which has to
be done on a part, in the form required by a computer under the control of a numerical control
computer program. It is the task of preparing a program sheet from a drawing sheet. All data
is fed into the numerical control system using a standardized format. Programming is where
all the machining data are compiled and where the data are translated into a language which
can be understood by the control system of the machinetool.
The machining data is as follows
(a) Machining sequence classification of process, tool start up point, cutting depth, toolpath,
(b) Cutting conditions, spindle speed, feed rate, coolant,etc.
(c) Selection of cuttingtools.

While preparing a part program, need to perform the following steps

(a) Determine the startup procedure, which includes the extraction of dimensional data
from part drawings and data regarding surface quality requirements on the
machinedcomponent.
(b) Select the tool and determine the tooloffset.
(c) Set up the zero position for the workpiece.
(d) Select the speed and rotation of thespindle.
(e) Set up the tool motions according to the profilerequired.
(f) Return the cutting tool to the reference point after completion ofwork.
(g) End the program by stopping the spindle andcoolant.

The part programming contains the list of coordinate values along the X, Y and Z directions of
the entire tool path to finish the component. The program should also contain information,
such as feed and speed. Each of the necessary instructions for a particular operation given in
the part program is known as an NC word. A group of such NC words constitutes a complete
NC instruction, known as block. The commonly used words are N, G, F, S, T, and M. The
same is explained later on through examples.
Hence the methods of part programming can be of two types depending upon the
two techniques as below

(a) Manual part programming,and

(b) Computer aided part programming.

MANUFACTURING TECHNOLOGY-II Page 33

www.vidyarthiplus.com www.veltechengg.com

Manual Part Programming

The programmer first prepares the program manuscript in a standard format.
Manuscripts are typed with a device known as flexo writer, which is also used to type the
program instructions. After the program is typed, the punched tape is prepared on the flexo
writer. Complex shaped components require tedious calculations. This type of programming
is carried out for simple machining parts produced on point-to-point machinetool.To be able
to create a part program manually, need the following information

(a) Knowledge about various manufacturing processes andmachines.

(b) Sequence of operations to be performed for a givencomponent.
(c) Knowledge of the selection of cuttingparameters.
(d) Editing the part program according to the designchanges.
(e) Knowledge about the codes and functions used in partprograms.

Computer Aided Part Programming

If the complex-shaped component requires calculations to produce the component are

done by the programming software contained in the computer. The programmer
communicates with this system through the system language, which is based on words. There
are various programming languages developed in the recent past, such as APT
(Automatically Programmed Tools), ADAPT, AUTOSPOT, COMPAT-II, 2CL, ROMANCE,
SPLIT is used for writing a computer programme, which has English like statements. A
translator known as compiler program is used to translate it in a form acceptable toMCU.The
programmer has to do only following things

(a) Define the work partgeometry.

(b) Defining the repetitionwork.
(c) Specifying the operationsequence.

Over the past years, lot of effort is devoted to automate the part programme
generation. With the development of the CAD (Computer Aided Design)/CAM (Computer
Aided Manufacturing) system, interactive graphic system is integrated with the NC part
programming. Graphic based software using menu driven technique improves the user
friendliness. The part programmer can create the geometrical model in the CAM package or
directly extract the geometrical model from the CAD/CAM database. Built in tool motion
commands can assist the part programmer to calculate the tool paths automatically. The
programmer can verify the tool paths through the graphic display using the animation
function of the CAM system. It greatly enhances the speed and accuracy in tool path
generation.

MANUFACTURING TECHNOLOGY-II Page 34

www.vidyarthiplus.com www.veltechengg.com

STANDARD G AND M CODES

The most common codes used when programming NC machines tools are G-codes
(preparatory functions), and M codes (miscellaneous functions). Other codes such as F, S, D,
and T are used for machine functions such as feed, speed, cutter diameter offset, tool number,
etc. G-codes are sometimes called cycle codes because they refer to some action occurring on
the X, Y, and/or Z-axis of a machine tool. The G-codes are grouped into categories such as
Group 01, containing codes G00, G01, G02, G03, which cause some movement of the
machine table or head. Group 03 includes either absolute or incremental programming. A
G00 code rapidly positions the cutting tool while it is above the work piece from one point to
another point on a job. During the rapid traverse movement, either the X or Y-axis can be
moved individually or both axes can be moved at the same time. The rate of rapid travel
varies from machine to machine. The total numbers of these codes are 100, out of which
some of important codes are given as under with their functions :

MANUFACTURING TECHNOLOGY-II Page 35

www.vidyarthiplus.com www.veltechengg.com

G-Codes (Preparatory Functions)

G00 Rapid positioning
G01 Linear interpolation
G02 Circular interpolation clockwise (CW)
G03 Circular interpolation counterclockwise
(CCW) G20 Inch input (in.)
G21 Metric input (mm)
G24 Radius
programming
G28 Return to reference point
G29 Return from reference
point G32 Thread cutting
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation positive (+) direction
G44 Tool length compensation minus (-) direction
G49 Tool length compensation cancels
G 53 Zero offset or M/c
reference G54 Settable zero
offset
G84 canned turn cycle
G90 Absolute programming
G91 Incremental programming
M-Codes (Miscellaneous Functions)
M or miscellaneous codes are used to either turn ON or OFF different functions,
which control certain machine tool operations. M-codes are not grouped into categories,
although several codes may control the same type of operations such as M03, M04, and M05,
which control the machine tool spindle. Some of important codes are given as under with
theirfunctions
M00 Program stop
M02 End of program
M03 Spindle start (forward CW)
M04 Spindle start (reverse
CCW) M05 Spindle stop
M06 Tool
change M08
Coolant on M09
Coolant off
M10 Chuck - clamping
M11 Chuck - unclamping
M12 Tailstock spindle out
M13 Tailstock spindle in
M17 Tool post rotation normal
M18 Tool post rotations
reverse
M30 End of tape and rewind or main program
MANUFACTURING TECHNOLOGY-II Page 36
www.vidyarthiplus.com www.veltechengg.com
end M98 Transfer to subprogram
M99 End of subprogram

MANUFACTURING TECHNOLOGY-II Page 37

www.vidyarthiplus.com www.veltechengg.com

10. FACING ANDTURNING

AIM:
To machine a given work piece for given dimension using turning and facing
operations.

PROGRAM:
[BILLET X32 Z70
G21 G98
G28 U0 W0
M06 T3
M03 S1500
G00 X28 Z1
G94 X0 Z-0.5
F80 Z-1
Z-2
G00 X32 Z1
G90 X28 Z-50 F100
X27.5
X27
X26.5
X2
X25
G28 U0
W0 M05
M30
DIAGRAM

All dimensions are in

mm Material -
Aluminum
RESULT:

Thus the given work piece was machined for the required dimensions.

All dimensions are in

mm Material -

Aluminum

MANUFACTURING TECHNOLOGY-II Page 38

www.vidyarthiplus.com www.veltechengg.com

11. STEPTURNING

AIM:
To machine a given work piece for given dimension using step turning operations.

PROGRAM:
[BILLET X28
Z75 N10 G21
G98 N20 G28 U0
W0 N30 M06 T1
N40 M03 S1500
N50 G00 Z2
N60 G00 X28
N70 G94 X-1Z-.5F1.2 FACING
Z-1
Z-1.5
Z-2
N80 G71U0.5R1 CANNED CYCLE
N90 G71 P100 Q140 U0.1 W0.1F100
N100 G01X20 Z0 CYCLE
START N110 G01 X20 Z-25
N120 G01 X25 Z-
25 N130 G01
X25Z-50
N140 G01X28 Z-50 CYCLE END
N150 G28 U0 W0
N160 M05
N170 M30

DIAGRAM

All dimensions are in

mm Material -
RESULT: Aluminum

The work piece is machined as per the dimensions.

MANUFACTURING TECHNOLOGY-II Page 39

www.vidyarthiplus.com www.veltechengg.com

12. TAPERTURNING

AIM:
To machine a given work piece for given dimension using taper turning operations.

PROGRAM:

[BILLET X28
Z75 N10 G21
G98 N20 G28 U0
W0 N30 M06 T1
N40 M03 S1500
N50 G00 Z2
N60 G00 X28
N70 G94 X-1Z-.5F100 FACING
Z-1
Z-1.5
Z-2
N80 G71U0.5R1 CANNED CYCLE
N90 G71 P100 Q120 U0.1 W0.1F100
N100 G01 X20 Z0
N110 G01 X20 Z-25
N120 G01 X28 Z-50
N130 G28 U0 W0
N140 M05
N150 M30
DIAGRAM:

All dimensions are in

mm Material -
Aluminum

All dimensions are in

mm Material - Aluminum

RESULT:

The work piece is machined as per the dimensions.

MANUFACTURING TECHNOLOGY-II Page 40

www.vidyarthiplus.com www.veltechengg.com

13. CONTOURMILLING

AIM:
To machine a given work piece for the given dimension using contour milling

PROGRAM:

Example:1 Example :2
[BILLET X100 Y100 Z10 G17 G71 G90 G94 G54; (Parameters
[EDGE MOVE X-50 Y-50 Setting)
[TOOL DEF T1 D6 T2 L90; (Home position)
G21 G94 G00 D2 Z50 M3 S700 X10 Y-25;
G91 G28 Z0 (Position of tool)
G28 X0 Y0 G01 Z-1.5; (Position of cut)
M06 T01 G01 X4 F100 M8;
M03 S1500 (Cuttingslat)
G90 G00 X-25 Y-25 Z5 G00 Z100 M9; (Final position of tool)
G01 Z-1 F30 M30; (Main programme end)
G01 X25 Y-25
G01 X25 Y15
G03 X15 Y25
R10 G01 X-
15Y25
G02 X-25 Y15 R10
G01 X-25 Y-25
G00 Z5
G91 G28
Z0 G28 X0
Y0 M05
M30

DIAGRAMS

RESULT:

T
h
u
MANUFACTURING TECHNOLOGY-II Page 41
www.vidyarthiplus.com www.veltechengg.com
All

The work
piece is
machined
as per the
dimension
s

MANUFACTURING TECHNOLOGY-II Page 42

 VIVA QUESTIONS

I. DRILLING & BORING

1. Classify drilling machines.

Portable drilling machine, Sensitive drilling machine, upright drilling machine, radial
drilling machine, Multi spindle drilling machine, Automatic drilling machine and Deep hole
drilling machine.

2. What are the various types of drilling machines

Plain type, Semi-universal type, Universal type.

3. What is gang drilling machine?

When a number of single spindle with essential speed and feed are mounted side by
side on one base and have common worktable, is known as gang drilling machine.

4. Specify a drilling machine.

Maximum size of the drill in mm that the machine can operate. Table size of
maximum, dimensions of a job can mount on a table in square meter. Maximum spindle
travel in mm. Number of spindle speed and range of spindle speeds in r.p.m.

5. List any four machining operations performed on a drilling machine Drilling,

countersinking, Tapping, Trepanning.

6. What is meant by Reaming?

Reaming is sizing and finishing the already drilled hole. The tool used for reaming is
known as reamer.

7. What is the use of a tapping tool?

A tap is a tool which is used for making internal threads in a machine component.

8. What are the types of boring machines?

Horizontal, Vertical, Precision, Jig boring machine.

9. What are the types of horizontal boring machine?

Table type , floor type, planer type, multi-spindle type.

10. What are the three types of vertical boring machine?.

Vertical boring mill, Vertical turret lathe boring machine, Vertical precision boring
machine.

11. Name the various operations performed on a horizontal boring

Machine Boring, facing, drilling and reaming.

12. List out the possible operations on a vertical boring machine.

Cylindrical, taper turning, boring, turning plane surface and forming.
www.vidyarthiplus.com www.veltechengg.com

13. Specify the importance of jig boring machine.

A jig boring machine is a precision boring machine used for boring accurate holes at
proper center to center distances.

14. What is super finishing?

The process of obtaining a surface of the highest class of finish is known as super
finishing.

15. What is meant by honing?.

An abrading process of finishing previously machined surfaces.

II. MILLING

1. What are the specifications of milling machine?.

The table length and width, Maximum longitudinal cross and vertical travel of the
table, number of spindle speeds and feeds, Power of driving motor, Floor space and net
weight.

2. Classify milling machine.

1. Column and knees type – a. plain milling machine, b.Vertical milling machine, c.
Universal milling machine, d. Ram- type milling machine, e. Omniversal milling
machine.
2. Bed-Type milling machine – a. simplex milling machine b. duplex milling machine
c. Triplex milling machine.
3. Plano-type milling machine.
4. Special purpose milling machine – a. Rotary table milling machine b. Drum
milling machine c. Profile milling machine.

3. List the principle parts of horizontal or plain milling machine.

Base, column, knee, saddle, table, overarm and arbor.

4. How omniversal milling machine differs from universal milling machine?.

This is a modified form of a plain milling machine. It is provided with two spindles,
one of which is in the horizontal plane while the other is carried by a universal swiveling
head.

5. Classify bed type milling machine.

Simplex, duplex and triplexmachine.

6. What are the various types of special purpose milling machines?.

Rotary table or continuous milling machine, Drum type milling machine Profile or
contour milling machine.
www.vidyarthiplus.com www.veltechengg.com
7. List the various types of milling attachments.
Vertical milling attachment, universal milling attachment, High speed milling
attachment, Rotary attachment, slotting attachment, Rack milling attachment, Universal
spiral milling machine.

8. What are the advantages of up milling process?

It does not require a backlash eliminator. Safer operation due to separating forces
between cutter and work.

9. Write any ten nomenclature of plain milling processes.

Body of cutter, cutting edge, face fillet, Gash, Lead, Land, Outside diameter, Root
diameter, Cutter Angles.

10. Classify peripheral milling processes.

Up milling or conventional milling, Down milling or climb milling.

11. What are the advantages of down milling process?

Cutter with higher rake angles can be used. This reduces power requirements.
Cutter wear is less because chip thickness is maximum at the start of the cut.

12. Define “face milling”.

Face milling is the operation performed by a milling cutter to produce flat machined
surfaces perpendicular to the axis of rotation.

13. What is meant by plain or slab milling.

Plain or slab milling is the operation of producing flat horizontal surface parallel to
the axis of the cutter using a plain or slab milling cutter.

14. List out various milling operations.

Plain milling, Face milling, Angular milling, Straddle milling, Gang milling, Form
milling, End milling, T-slot milling, Gear cutting.

15. Define Straddle and Gang milling.

Straddle milling operation is the production of two vertical flat surfaces on the both
sides of the job by using two side milling cutters which are separated by collars. Gang
milling is the production of many surfaces of a job simultaneously by feeding the table
against a number of required cutters.

16. What is meant by term indexing?

Indexing is the process of dividing the periphery of a job in to equal number of
divisions.

17. What are the three types of dividing heads?.

Plain or simple dividing head, Universal dividing head, Optical dividing head.

18. What is cam milling?.

www.vidyarthiplus.com www.veltechengg.com
Cam milling is the operation of producing cams in a milling machine by the use of a
universal dividing head and a vertical milling attachment.

19. What are the specifications of milling machine?.

The table length and width, Maximum longitudinal cross and vertical travel of the
table, number of spindle speeds and feeds, Power of driving motor, Floor space and net
weight.

III. GRINDING

1. What is the process of self –sharpening of the grinding wheel?.

During machining, the blunt abrasive grains will be released from the wheel
surface. In their place, new abrasive grains project from the surface of the wheel.
This process is called self-sharpening of the grinding wheel.

2. State the purpose of grinding.

To remove small amount of metal from work pieces and finish then to close
tolerances. To obtain a better surface finish.

3. Classify grinding machine.

Precision grinders, Rough grinders, Cylindrical grinders, Internal grinders, surface
grinders, tool grinders, Special purpose grinding machines.

4. What is meant by centerless grinding?

Centerless grinding is performed on work pieces which do not have centers, such as
pistons, valves, rings, tubes, balls, wrist pins, drills, bushings, shafts etc. Centerless grinding
can be done on both external and internal cylindrical surfaces.

5. What are the various methods of centerless grinding?

Through feed, In feed, End feed.

6. What are the different methods used in gear grinding process?

Forming process, Generating process.

7. What are the purposes of gear grinding process?

To improve the surface finish of teeth.
To increase the accuracy of teeth.
To remove the distortion due to heat treatment process.

8. List the various gear finishing process.

Gear shaving, Gear Burnishing, Gear grinding. Gear lapping.
www.vidyarthiplus.com www.veltechengg.com

IV. GEAR GENERATING

1. What do you understand by gear generating?

Gear generating process is based on the fact that any two motives gear of the some module
will mesh exactly. In this process one of the gears act as cutter. Due to relative rolling motion of the
cutter and blank, gear teeth are generated.

2. Distinguish between the forming and generating methods?

Single point Tool (Forming): Here the tool is a single point tool. The job should be indexed
for every tooth; The tool is fixed.

Pinion type cutter (Generating): Here the tool is also a gear made of hard steels, (Used as
cutter). The job is not indexed for every tooth. The cutter as well as the blank rotates simultaneously
meshing with each other.

3. Factors affecting geometrical accuracy of the circular component .in shape?Geometrical

accuracy of the circular component depends upon: a) The trueness of the work piece rotation, b)
Parallelism of the tool movement with the work spindle axis, c) The effect of the tool wear.

4. Write the advantages of gear shaping (Generating)?

The advantages of Gear shaping are: a) with a particular module of DP cutter, gears having
the same module of DP but different number of teeth can be cut accurately, b) Quicker and
economical, c) Only one cutter is used for cutting all spur gears of same pitch, d) Both internal and
external gears can be cut.

5. What is the main disadvantage of gear shaping?

The main disadvantage of gear shaping is that Worm and worm wheels cannot be generated
on a gear shaper.

6. When do you prefer shaping process for generating a gear?

Gear shaping is preferred for operations like cutting gear segments, cutting, spur gear,
herring-bone gears, splines and sprockets etc., of gear shaping over other diameter.

7. What are the advantages of gear shaping over the other methods?
The advantages are:

a) The finished gear has a generated profile

b) It is suitable for cutting internal gears
c) Only one cutter is used for cutting all spur gears of the same pitch.

8. Specific types of gears that could be formed specifically by gear shaping process?
Shaping process can operate on classes of gearing outside the capacity of other methods.
Example is: a) Internal gears with or without back shroud, b) Cluster gears.
www.vidyarthiplus.com www.veltechengg.com

9. Distinguish between gear shaping and gear planning?

a) The job is indexed and tool reciprocates

b) Gear can be generated by using form tool as well as pinion cutter.

a) Job is indexed and reciprocated but the tool is fixed.

b) Gear can be produced by means of form tool and Rack cutters.

10. What is the basic condition to use 'Bobbing' in gears?

Hobbing can be done only if the gear blank to be generated is of the same modules