Machine Shop Lab Manual Orginal PDF

MANGALAM POLYTECHNIC
COLLEGE
MACHINE SHOP PRATICE

SEMESTER V
MACHINE SHOP PRATICE S5
MLM 2
MLM 3
SYLLABUS
COURSETITLE : MACHINE SHOPPRACTICE
COURSECODE : 5029
` COURSE CATEGORY : A
PERIODS/WEEK : 4
PERIODS/SEMESTER : 60
CREDITS : 2
TIME SCHEDULE
MODULE TOPICS PERIOD
1 Lathe work 15
2 Shaper, Planning Machine. 15
3 Milling machine. 15
4 Slotting machine 15
Total 60
Course outcomes:
STUDENT WILL BE ABLE TO:
Sl.No. Sub Students will be able to

1 Do work on lathe
2 Do work on shaping machine

1 3 Carryout work on milling machine
4 Execute work on slotting machine.
5 Perform work on planning machine.
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CONTENT DETAILS
MODULEI
Lathwork
Lathe operations such as drilling, boring, threading, knurling etc.
MODULE II
Shaping Practice
Cube - V -Blocks, Key - way cuttings.
Planning Practice
Practice on planning machine.
MODULE III
Milling Practice
Simple milling operations - plain milling – side milling – vertical milling etc.
MODULE IV
Slotting practice
Splines on slotting machine
TEXT BOOKS
1. Mechanical Workshop Practice by K. C. John (PHI Learning Private Limited)
2. Mechanical Workshop & Laboratory Manual by K. C. John
REFERENCE BOOKS
1. Workshop Technology Vol. I by S K HajraChoudhary
2. Workshop Technology Vol. II by S K HajraChoudhary
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MACHINE SHOP
SAFETY PRECAUTIONS
1) Be sure that all machines have effective and properly working guards that are
always in place where machines areoperating.
2) Do not attempt to oil, clean, adjust or repair any machine while it isrunning.
3) Do not operate any machine unlessauthorized.
4) Do not try to stop the machine with your hand or body whilerunning.
5) Always check whether the work and cutting tools properly clamped on the
machine beforestarting.
6) Keep the floor clean of metal chips or curls and wastepieces.
7) When working with another, only one should operate machine orswitches.
8) Concentrate on the work, avoid unnecessary talks while operatingmachine.
9) Get first aid immediately for anyinjury.
10) Wear clothing suited for the job, wear safety shoes with thicksoles.
11) Do not wear rings, watches, bracelets or other jewellery that could get
caught in movingmachinery.
12) Do not wear neckties or loose turn clothing of anykind.
13) Wear shirts or uppers with sleeves cut off or rolled above theelbows.
14) Always remove gloves before turning on or operating amachine.
15) Keep the floor alwaysclean.
16) Passage should be clear, at all time to avoidaccident.
17) Do not leave tools or work on the table of a machine even if the machine
in not turning. Tools or work may fall off and cause the fact ofinjury.
18) Switch off the machine immediately when supplyfails.
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MEASURING INSTRUMENTS
Measuring instruments have an important role in a mechanical workshop.
The quality of different types of measuring instruments are used in a workshop;
some of them are given below.
1. Steel rule, 2. Calipers, 3. Vernier caliper,4. Micrometer, 5. Vernierheight

gauge 6. Dial test indicator 7. Screw thread pitch gauge 8. Screw cutting
gauge etc.
Steel rule
Steel rule is a direct reading and measuring instrument to read an accuracy

(least count) of 0.5 mm. These are available in different sizes, such as in 15cm,
30cm, 60cm, 1m, 1.5m, 2m, 3m, 4m, 5m & 6m..
Vernier caliper
The Vernier caliper is a precision instrument used for measuring internal and
external distances between two points with an accuracy of 0.02mm. It can also
be used to measure depth.
Least count (LC): Least Count is the smallest value that can be read
directly in that scale. A Vernier Caliper has one main scale and a vernier scale.
The accuracy of vernier caliper is the difference of one division of main scale
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and one division of vernier scale. A vernier caliper having vernier scale length of
49 mm is divided into 50 divisions.
one main scale division = 1 mm.
one vernier scale division = 49/50 mm. = 0.98 mm.
Least count = 1- 0.98 mm = 0.02 mm.
MICROMETER (screw gauge)
It is a precision measuring instrument used to read an accuracy of 0.01m.m

Micrometers are in three types
(a) Outside micrometer (b) Inside micrometer (c) Depth micrometer
They are available in the ranges of 0-25mm, 25-50mm, 50-75mm, 75-

100mm, etc.
Outside micrometer
It is used to measure external measurements with in an accuracy of 0.01

mm. The work is placed between anvil and spindle face. The working principle
of micrometer is a nut and bolt. The spindles have a thread of 0.5 mm pitch
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which is assembled with the thimble. One revolution of thimble makes

movements of 0.5 mm of spindle. The thimble is divided into 50 equal divisions
Least count (LC) = Pitch / Number of divisions on the main scale =

0.50mm/50= 0.01 mm
How to take measurements
Total observed reading = main scale reading + (circular scale division

coinciding the base line of main scale) x least count
True diameter = observed diameter – zero error
SCREW THREAD PITCH GAUGE
A screw thread pitch gauge is used to check or find the pitch of a thread. It
is a series of thin marked blades which have different pitched teeth
Screw cutting gauge (centre gauge)
Screw cutting gauge is an important tool used in a machine shop, made

from hardened and polished stainless steel. It is also known as Center gauge. It is
used for checking tool angles while machining threads in metal turning lathes.
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CUTTING TOOLS
Cutting tool is a device with one or more cutting edges used to create
chips and remove metal from the work piece. Generally, cutting tools are
classified as single point cutting tools and multi point cuttingtools.
Cutting tool materials and their uses
Tool material Properties
Carbon Steels Low cost. Used for low-grade drill bits, taps and dies,
hacksaw blades, reamers.
High Speed Steel Low cost. Used for drill bits, taps, lathe cutting tools.
(HSS)
HSS Cobalt Expensive. Excellent for machining abrasives, work

hardening materials such as Titanium and Stainless
steel. Used for milling cutters and drill bits.
Cemented Carbide Expensive. Used for turning tool bits although it is

very common in milling cutters and sawblades.
Tool Signature
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It specifies the active angles of the tool normal to the cutting edge. The
seven elements that comprise the signature of a single point cutting tool can be
stated in the following order:
Tool signature angles
Back rake angle (°) 10
Side rake angle (°) 20
End relief angle (°) 7
Side relief angle (°) 6
End cutting edge angle (°) 8
Side cutting edge angle (°) 15
Nose radius mm 0.8
LATHE
Introduction
The process of machining a work piece to the required shape and size by moving
the cutting tool either parallel or perpendicular to the axis of rotation of the work
piece is known as turning. In this process, excess unwanted metal is removed.
Principal parts of an engine lathe
Bed: The bed is the foundation of the lathe. It is made of cast iron.
Head Stock: Headstock is mounted permanently at the left hand side of the bed.
The headstock houses a hollow spindle and the mechanism for driving the
spindle at multiple speeds. It contains cone pulleys, v pulleys, or gears to
provide the necessary range of spindlespeeds.
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Tail Stock: The tailstock supports the ‘free’ end of the work. The
tailstock is also used in the drilling and reaming of work held in chuck or on
faceplate
Carriage or Saddle: Carriage forms the base of the unit, which supports
the cutting tool. Carriage can be traversed along the whole length of the bed by
hand control or by power feed
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Cross Slide: The cross slide is mounted on the top of saddle, and it
provides a mounted or automatic cross movement for the cutting tool.
Apron: Apron houses the control for hand or power feeding
Lead Screw: Lead screw transmits feed motion for screw cutting
Feed Shaft: Feed shaft is employed in operating the carriage or the cross
slide in automatic turning.
Work holding and supporting devices
Chucks: for holding work pieces, they are
1.3 jaw -Self centering chuck: The three-jaw chuck is a self-centering

chuck. Self-centering means that all three jaws move in or out depending on the
direction of rotation of the key. Three-jaw chuck will not directly hold square
material. The 3-jaw self-centering chuck will automatically centre rounds or
hexagons.
2. 4-jaw-independentchuck: Itisusedforholdingworkofirregular
shape.
 It can also be used for holding squares or rounds. All jaws are
controlled independently of each other. The jaws are reversible.
This allows the holding of largerwork.
FacePlate:Faceplateisusedformountingworkofawkwardshapes,
which cannot be chucked
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Steadies
Steadies are used for supporting long work against the pressure of the
tool.
a. Fixedsteady
b. Travellingsteady
The fixed steady is secured to the lathe bed. The travelling steady is
mounted on the carriage. This steady move along the work behind the tool, as
each cut is taken.
Mandrels
Mandrels are slightly tapered spindle. Previously bored components or

part machined work can be mounted for further turning operations. Commonly
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used mandrels are: Plain mandrel, Step mandrel, Gang mandrel, Screwed
mandrel, Collar mandrel, Cone mandrel, Expansion mandrel
Tool Post: Tool posts are classified as follows
(1) Pillar Type Tool Post:

(2) 4-Way ToolPost
(3) Quick – Release Type ToolPost:
Lathe specifications
1. Length ofbed
2. Length betweencentres
3. Centreheight
4. Swing diameter overbed
5. Swing diameter overcarriage
6. Bore diameter of thespindle
7. Spindle nosediameter
Lathe operations
The most common operations performed on a lathe are turning, facing,

parting, grooving, knurling, drilling, boring, taper turning and threading.
Facing: It is to produce a flat surface normal to the rotational axis of the spindle.
Plain Turning: It is to remove excess material from the work-piece and to

produce a cylindrical surface.
Parting: Parting or cutting–off is the operation of separating a piece of initial

work from the bar-stock.
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Drilling: It is an operation of producing cylindrical hole by means of a cutting

tool i.e., drill.
Grooving or necking: Grooving is the operation of reducing the diameter of

work-piece to a narrow surface.
Boring: It is operation of enlarging a hole previously made by a drilling
Taper: A taper may be defined as a uniform increase or decrease in diameter of

a piece of work measured along itslength.
Taper turning methods
1. Form tool method 2. Compound rest method
3. Tailstock setovermethod 3. Taper turning attachmentmethod
Reaming: It is the process of finishing a drilled or bored hole with great

degree of accuracy. The drilled or bored hole not always is straight oraccurate.
Knurling: It is the process of making easy-to-grip geometric pattern on a

finished outer surface of work pieces like handles, knobs, rollers, etc. to hold
them firmly.
Knurling Tool
Forming: Forming is a process of produces a convex, concave or any irregular

profile on the work piece by using a form tool.
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Chamfering: Chamfering is a process of beveling the extreme end of a work

piece. This is done to remove the burrs and sharp edges from the extreme end of
the work piece.
Thread cutting
The process of thread cutting is to produce a helical groove on a

cylindrical surface by feeding the tool longitudinally. The job is revolved
between centers or by a chuck. The longitudinal feed should be equal to the pitch
of the thread to be cut per revolution of the work piece.
THREAD PARTS
In thread cutting operation the first step is to remove the excess

material from the work piece to make its diameter equal to the major diameter of
the thread to be cut. The shape or form of the thread depends on the shape of the
cutting tool to be used. The tool point must be ground so that it has the same
angle as the thread to be cut. In a metric thread the included angle of the cutting
edge should be ground exactly 60°. Typical angles are 60° for ‘V’ threads, and
29° for ACME threads. The top of the nose of the tool should be set at the same
height as the centre of the work piece.
The correct gear ratio is required between the machine spindle and the
lead screw. This can be determined in the following manner:
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Thread cutting calculations:
To calculate the gears required for cutting a thread of certain pitch can
calculated from the following formula:
�� ℎ �� ℎ ��ℎ ��

��ℎ =
�� =
�� ℎ ��ℎ � ��
�ℎ �ℎ ��
The gear of the spindle shaft is the driver and the gear on the lead screw is the
driven gear.
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SHAPING MACHINE(SHAPER)
Shaping is a process of machining a flat surface which may be
horizontal, vertical, inclined, concave or convex using a reciprocating single
point tool. A shaping machine is a reciprocating type of machinetool.
Common types of shaper
Shapers are classified in many ways, i.e. According to the length of the
stroke, type of driving mechanism, direction of travel of the ram, the type of
work etc. The different types of shapers are,
1. Crank shaper
2. Universal shaper
3. Horizontal shaper
4. Vertical shaper
Principal parts of a shaper
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Base: The base is hollow and is made of cast iron. It provides the necessary
Column: It is a box like casting mounted vertically on top of the base. It is

mounted on the front vertical guide ways of the column. The table may be raised
or lowered by adjusting the cross rail vertically.
Table :It is an important part useful in holding the work firmly on it. It is
mounted on the saddle which is located above the cross rail. Work pieces are
held on the table with the help of shaper vise, clamps and straps.
Ram :Ram supports the tool head on its front. It reciprocates on the accurately
machined guide ways on the top of the column
Toolhead: Thetoolheadisfittedonthefaceoftheramandholdsthetool rigidly.

Itprovidesverticalandangularfeedmovementofthetool.
Shaper operations
A shaper is a machine tool primarily designed to generate a flat surface by

a single point cutting tool. Besides this, it may also be used to perform many
other operations. They are
1. Machining horizontal surface 2. Machining vertical surface
3. Machining inclined surface 4. Slot cutting 5. Key ways cutting
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Shaper specifications
The size of a shaper is determined by the maximum length of cut or stroke it can
make.
1. Length ofstroke
2. Maximum horizontal travel oftable
3. Maximum vertical travel oftable
4. Maximum distance from table toram
5. Maximum vertical travel of toolslide
6. Length and width of tabletop
Work holding devices
1. Shaper vise 2. Clamps and stop pins 3. T- bolts & step bolts
4.Angleplate 5. Blocks
Tools used in a shaping machine
The materials of the cutting tool used in a shaping machine are as follows:
1. High Carbon Steel
2. High Speed Steel
3. Carbide tipped tool
4. Stellitetool
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Quick return mechanisms
The ram moves at a comparatively slower speed during the forward cutting stroke.
During the return stroke, the mechanism is so designed to make the tool move at a faster
rate to reduce the idle return time. This mechanism is known as quick return
mechanism.
Stroke length calculation and adjustment
The length of the stroke is calculated to be nearly 30mm longer than the work. The
position of stroke is so adjusted that the tool starts to move from a distance of 25mm
before the beginning of the cut and continues to move 5mm after the end of the cut.
Stroke length calculation and adjustment
The length of the stroke is calculated to be nearly 30mm longer than the work. The
position of stroke is so adjusted that the tool starts to move from a distance of 25mm
before the beginning of the cut and continues to move 5mm after the end of the cut.
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MILLING MACHINE
Introduction
A milling machine is a machine tool that removes metal as the work is

fed against a rotating multipoint cutter. The milling cutter rotates at high speed
and it removes metal at a very fast rate with the help of multiple cutting edges.
One or more number of cutters can be mounted simultaneously on the arbor of
milling machine. Milling machine is used for machining flat surfaces, contoured
surfaces, surfaces of revolution, external and internal threads, and helical
surfaces of various cross-sections.
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Common types of milling machines
1. Column and knee type millingmachines
a) Horizontal millingmachine
b) Universal millingmachine
c) Vertical millingmachine
2. Planer milling machine
3. Machining centermachines
4. Special types of millingmachines
(a) Rotary tablemillingmachine. (b) Duplicatingmachine.
Principles of milling
In milling machine, the metal is cut by means of a rotating cutter having

multiple cutting edges. For cutting operation, the work piece is fed against the
rotary cutter. As the work piece moves against the cutting edges of milling
cutter, metal is removed in the form of chips.
Parts of milling machine
Base
It is a foundation member and it carries the column at its one end. In some
machines, the base is hollow and serves as a reservoir for cutting fluid.
Column
The column is the main supporting member mounted vertically on the base. It is
box shaped, heavily ribbed inside and houses all the driving mechanism for the
spindle and table feed.
Knee
The knee is a rigid grey iron casting which slides up and down on the vertical
ways of the column face. An elevating screw mounted on the base is used to adjust
the height of the knee and it is also supports the knee.
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Saddle
The saddle is placed on the top of the knee and it slides on guide ways set exactly
at 90° to the column face. The top of the saddle provides guide-ways for thetable.
Table
The table rests on ways on the saddle and travels longitudinally. A lead screw
under the table engages a nut on the saddle to move the table horizontally by hand
or power. In universal machines, the table may also be swiveled horizontally. For
this purpose the table is mounted on a circular base.
Overhanging arm
It is mounted on the top of the column, which extends beyond the column face
and serves as a bearing support for the other end of the arbor.
Frontbrace
It is an extra support, which is fitted between the knee and the over-arm to ensure
further rigidity to the arbor and theknee.
Spindle
It is situated in the upper part of the column and receives power from the motor
through belts, gears and clutches and transmit it to the arbor.
Arbor
It is like an extension of the machine spindle on which milling cutters are
securely mounted and rotated. The arbors are made with taper shanks for proper
alignment with the machine spindles having taper holes at their nose.
Milling methods
There are two distinct methods of milling classified as follows:
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1. Up-milling or conventionalmilling
2. Down milling or climbmilling.
Up-milling or conventional milling
In the up-milling or conventional milling, the metal is removed in form of

small chips by a cutter rotating against the direction of travel of the work piece.
In this type of milling, the chip thickness is minimum at the start of the cut and
maximum at the end of cut.
Down-milling or climb milling :In this method, the metal is removed by a

cutter rotating in the same direction of feed of the work piece. Chip thickness is
maximum at the start of the cut and minimum in the end. In this method, there is
less friction involved and consequently less heat is generated on the contact
surface of the cutter and work piece.
Various milling machine operations
Following different operations can be performed on a milling machine:
1. Plain millingoperation
2. Face millingoperation
3. Side millingoperation
4. Angular millingoperation
5. End millingoperation
6. Gear cuttingoperation
7. Thread millingoperation
Types of milling cutters
Milling cutters are made in various forms to perform certain classes of work, and
they may be classified as:
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1. Plain millingcutter
2. Side millingcutter
3. Face millingcutter
4. End millingcutter
Depending upon the shape of their shank, these are,
1. Taper Shank Mill :Taper shank mill have taperedshank.
2. Straight Shank Mill :Straight shank mill having straightshank.
3. Shell End Mills :These are normally used for face millingoperation.
4. Formedcutters
1. Convex MillingCutters
These cutters have profile outwards at their circumference and used
to generate concave semicircular surface on the work piece.
2. Concave Milling Cutters
These milling cutters have teeth profile curve in words on their

circumference. These are used to generate convex semicircular
surfaces.
Specification of a milling machine
1. Size of the worktable and itsmovement
2. Table movements: (Longitudinal travel x Cross x Vertical)
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3. Number of feeds available (specify theirvalues).
4. Number of spindle speeds (specify theirvalues).
5. Total poweravailable.
6. Spindle nosetaper.
TOOL HOLDING DEVICES
Milling machine spindle provides the driving force for milling cutter. Several
different devices are used to hold and drive cutters on milling machine. The most
common devices are;
ARBOR
An arbor is considered as an extension of the machine spindle on which milling

cutters are mounted. One end of the arbor is tapered and fits in to socket in the spindle
nose where it is secured by means of drow bolt. Cutter with a bored centre can be
mounted on an arbor, positioned by spacing collars and keyed to provide a positive
drive. Arbor is supported at the other end by a yoke (arbor steady). Two lugs of the
spindle front end fit in the two slots of the arbor and thus rotates the later with the
spindle.
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COLLET
It is a taper sleeve fitted into the nose of the spindle. It is used to secure an arbor
or taper shank cutter with smaller shank than the spindle taper.
ADAPER
Adapter is attached to spindle by a draw bolt or directly bolted to it. It is used to

mount cutters having shank that cannot be mounted on arbor.
SPRING COLLET
Spring collet is a special type of adapter used to secure straight shank cutters. It
has a threaded end, a spring collet body, a nut and an adapter. The tool shank is
introduced in to the cylindrical hole of adapter.
MILLING CUTTERS-MATERIAL
The common materials used for the manufacture of milling cutters are;
1) Carbon steel2) High speed st3) Sintered carbide4) Ceramic
5) Diamonds
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SLOTTING MACHINE
INTRODUCTION
The slotting machine is a reciprocating machine tool in which, the ram holding
the tool reciprocates in a vertical axis and the cutting action of the tool is only during
the downward stroke. It operates almost on the principle as that of shaper; the only
difference is that in slotter the ram reciprocates in a vertical axis.The slotting machine is
used for cutting grooves, keys and slots of various shapes making regular and irregular
surfaces both internal and external cutting internal and external gears and profiles. The
slotter machine can be used on any type of work where vertical tool movement is
considered essential and advantageous.
Common types of slotting machine
1. Punch slotter: a heavy duty rigid machine designed for removing large amount of
metal from large forgings or castings
2. Tool room slotter: a heavy machine which is designed to operate at high speeds.
This machine takes light cuts and gives accurate finishing.
3. Production slotter: a heavy duty slotter consisting of heavy cast base and heavy
frame, and is generally made in two parts.
Parts of a slotting machine
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1. BASE
The base of the slotting machine is a massive casting rigidly built to take up all the
cutting forces and entire load of the machine. The top of the bed has guideways to carry
the saddle.
2.COLUMN
It is the vertical member which is cast integral with the base and it houses the driving
and feeding mechanisms, also it carries the ram perpendicular to the bed.
3. SADDLE
It mounted on the guide ways of the bed. The longitudinal feed can be given to the work
by moving the saddle. It is fitted with a cross-slide on its top.
4. CROSS-SLIDE
It is mounted upon the guideways of the saddle and may moved perpendicular to the
direction of movement of the saddle.
5.ROTARY TABLE
It is a circular table mounted on the top of the cross-slide The table may be rotated by
rotating a worm which meshes with a worm gear connecting to the underside of the
table by means of a circular feed handle.
6.RAM AND TOOL HEAD
The ram carries the tool head at its bottom and reciprocates vertically on the front of the
column. The position of the ram stroke can be adjusted. The weight of the ram is
balanced by a counter weight which is connected to the oscillating slotted link.
RAM DRIVE MECHANISM
In slotting machine, the material removal takes places only in the downward cutting
stroke. The upward stroke is just a return idle stroke, to reduce the idle time a is
commonly employed as shown in below figure. The bull gear (A) takes its drive from
the gear and carries the sliding die block (B). This sliding block is connected to another
block (C) which slides in the ways cut on the face of the large oscillating slotted link
(D), hinged at (E), This slotted link is connected to the ram (F) of the machine by a
connecting link (G). One side of the
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Slotted link is big and heavy to balance the weight of the ram. Thus the circular motion
of the bull gear is converted into reciprocating motion of the ram with the help of the
slotted link, sliding block and connecting rod.
In the above figure the sliding block is at position ‘A’ the ram will be with the lowest
position ‘B’ the ram will be at the highest position of the stoke. For the cutting stroke,
the block will cover an arc ACB, and for the return stroke, it will cover an arc of BDA.
ie the cutting stroke is more than the return stroke. Thus, the quick return motion is
obtained.
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WORK HOLDING DEVICES

The work is held on a slotter table by a vise, T-bolts and clamps or by special
fixtures. T-bolts and clamps are used for holding most of the work on the table. Fixtures
are used for holding repetitive work.
Uses of slotting machine
1. It is used for machining vertical surfaces
2. It is used angular or inclined surfaces
3. It is used to cut slots, splines, keyways for both internal and external jobs
such as machining internal and external gears
4. It is used for works as machining concave, circular, semi-circular and convex

surfaces
5. It is used for works as machining concave, circular, semi-circular and convex

surfaces
Slotting machine operations
Operations which can be performed on the slotting machine are, cutting of:
1. Internal grooves or keyways
2. Internal gears
3. Recesses
4. Concave, circular and convex surfaces etc
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PLANER MACHINE
Introduction
The planer is a machine tool designed to produce plane and flat surface on a
work piece which is too large or too heavy. The work piece is securely fixed on
a table called platen, and it reciprocates horizontally against a single edged
cutting tool. The surface machined may be horizontal, vertical or at anangle.
Construction:
The main parts of the double Housing Planer machine is Bed and table,
Housings, Cross rail,, Tool heads, Driving and feed mechanism.
Bed and table:
The bed is a long heavy base and table made of cast iron. Its top surface is flat
and machined accurately. The flat top surface has slots in which the workpiece
can be securely clamped.
Housings:
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The housings are the rigid and upright column like castings.
These are located near the centre on each side of the base.
Cross rail:
The cross rail is a horizontal member supported on the machined ways of the
upright columns. Guide ways are provided on vertical face
of each column and that enables up and vertical movement of the cross rail. The
vertical movement of the cross rail allows to accommodate workpiece of
different heights. Since the cross rail is supported at both the ends, this type of
planer machine is rigid in construction.
Tool heads:
Generally, two tool heads are mounted in the horizontal cross rail and one on
each of the vertical housing. Tool heads may be swiveled so that angular cuts
can be made.
Driving and feed mechanism:
The tool heads may be fed either by hand or by power in crosswise or vertical
direction. The motor drive is usually at one side of the planer near the centre and
drive mechanism is located under the table.
The size of the planer is specified by the maximum length of the stroke, and also
by the size of the largest rectangular solid that can be machined on it.
Operations of planer machine: The planer is used for:
1. Planing flat horizontal, vertical and curvedsurfaces.
2. Planing at an angle and machiningdovetails.
3. Planing slots andgrooves.
The planer are available in different types for doing different types and
sizes of job; the most common being the standard and double housing planer.
Size and Specification of Planer Machine:

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Planers are prepared different sizes and they are specific are given below:
1. Table surfacespeed
(a) Return stroke 14 metres perminute
(b) Forward stroke 9.5 metres per minute
2.Maindrive
(a) Cross rail elevating motor = 0.7kW
(b) Main drive motor(kW) = 22kW
3. Height under cross rail (vertical traverse) = 914mm
4. Table size (working surface)= 1830 x686mm
5. Length of bed = 2910mm
6. Width of bed = 550mm
Planer Machine Tool.Planing Machine Cutting Tools uses on planer are

like to those used for shaper or lathe. Cutting ends of cutting tools are shaped for
different cutting position. A small tool bits fixed in holders are moreover use for
planing mechanism. Tool bits are choose as they are economical than a set of
hard tool.
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Ex.No.1
All dimensions are in mm
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Ex. No 1
Date:
PLAIN TURNING
AIM:
Plain turning and chamfering operations of Mild Steel round rod .
MATERIAL REQUIRED:
MS round rodofØ mmx length mm.
TOOLS REQUIRED :
H.S.S. Single point cutting tool, chuck key, tool post key,
verniercaliper,steel rule, jenny caliper,
OPERATIONS REQUIRED
Work setting, Facing, Centering, Plain turning, Chamfering,
PROCEDURE
 The work piece is fixed in a 3-jaw chuck with sufficientoverhang.
 Adjust the machine to run the job to a required cuttingspeed.
 Fix the cutting tool in the toolpost
 Facing operation is performed from the center of the job towards to
outwards or from the circumference towards thecenter.
 Centering operation is performed so that the axis of the job coincideswith
the latheaxis.
 Refix the work with tail stocksupport.
 Give the feed and depth of cut to the cuttingtool
 Plain turning operation is performed until the diameter of the workpiece
reduces to mmandlength mm.
 Finish the job as per correctdimensions
 Finally check the dimensions by using vernier calipers and submitfor
inspection
RESULT: Plain turning as perdimensions
MLM 38
Ex. No. 2
MLM 39
Ex No:2
Date:
COLLAR TURNING
AIM:
To practice collar turning
MATERIAL REQUIRED:
MS round rodof Ø mmx length mm.
TOOLS REQUIRED :
H.S.S. Single point cutting tool, parting tool, chuck key, tool post key,
vernier caliper, steel rule, jenny caliper,
OPERATIONS REQUIRED
Work setting, Facing, Centering, Plain turning, step turning , grooving ,
champhering, knurling
PROCEDURE
 The work piece is fixed in a 3-jaw chuck with sufficientoverhang.
 Adjust the machine to run the job to a required cuttingspeed.
 Fix the cutting tool in the toolpost.
 After facing and centering operation is performed, refix the work withtail
stock support.
 Give the feed and depth of cut to the cuttingtool
 Plain turning operation is performed until the diameter of the workpiece
reduces to mmandlength mm.
 Again step turning and collar turning as per dimensions of givendrawing.
 Using parting tool, grooving operation is performed according tothe
given dimensions and finish thegrooves
 Finish the job and check all dimensions by using verniercaliper.
RESULT :
Complete the job as per drawing.
MLM 40
EX NO:3
COLLAR AND KNURLING
MLM 41
Ex No:3
Date: KNURLING
AIM:
knurling practice
MATERIAL REQUIRED:
TOOLS REQUIRED :
H.S.S. Single point cutting tool, parting tool, chuck key, tool post key,
verniercaliper,steel rule, jenny caliper, knurling cutter.
OPERATIONS REQUIRED
Work setting, Facing, Centering, Plain turning, step turning , grooving
champhering, knurling.
PROCEDURE
 Fix the cutting tool in the toolpost.
 After facing and centering operation is performed, refix the workwith
tail stocksupport.
 Plain turning operation is performed until the diameter of thework
piecereducesto__mmand length mm.
 Again, step turning and collar turning as per dimensions of
given drawing.
 Using parting tool, grooving operation is performed according to the
 Fix knurling tool on lathe centre and perform knurlingoperation.
 Finish the job and check all dimensions by using verniercaliper.
RESULT: Complete the job as per drawing.
MLM 42
EX NO:4
FORM TURNING, TAPER AND THREAD CUTTING
MLM 43
Ex No:4
Date:
BALL, TAPER AND THREAD CUTTING
AIM:
Practice form turning taper and thread cutting
MATERIAL REQUIRED:
TOOLS REQUIRED :
H.S.S. Single point cutting tool, parting tool, threading tool, chuck key,
tool post key, vernier caliper, steel rule, jenny caliper,
OPERATIONS REQUIRED
Work setting, Facing, Centering, Plain turning, step turning , grooving ,
taper turning, champhering, threading ,form turning.
PROCEDURE
 Fix the cutting tool in the toolpost.
 After facing and centering operation is performed, refix the workwith
tail stocksupport.
 Plain turning operation is performed until the diameter of thework
piecereducesto mmand length mm.
 Again step turning and collar turning as per dimensions of given
drawing.
 Using parting tool, grooving operation is performed according tothe
MLM 44
 Swivel the compound slide to the required angle and taper turning
operation by rotating the compound slide wheel. The angle can be
calculated by using theformula
 Fix the V tool or forming tool on tool post and forming ball by the
movement of carriage and crossslide.
 Reduce speed of the spindle by engaging back gear and useTumbler
feed reversing mechanism to transmit power through the leadscrew.
 And calculate the change gears for the required pitch to be made onthe
workpiece.
 Using half nut mechanism perform thread cutting operation (right hand
threading) according to the given dimensions and continues it until
required depth of cut is obtained.
 Check the depth of thread using thread pitchgauge
 Finish the work and check alldimensions
RESULT
To complete the job as per dimensions.
EXP NO;5
MLM 45
DATE
KEY WAY / SLOT CUTTING ON SLOTTING MACHINE
Aim: To make a slot on a given cast iron blank
Material required: Cast iron block of 48 x 48 x 48mm
Operations to be carried out: marking, punching, job setting,

slotting
Tools required: surface plate, spanner, single point cutting tool,

Square nose tool, Vernier height gauge, ballpeen hammer, dot punch etc.
Procedure:
 Set the single point HSS tool on toolholder
 Adjust the length of stroke ofram
 Square blank is prepared to the required dimension on
slottingmachine.
 Marking is carried out on the work piece forslotting.
 Set the square nose tool for slottingoperation.
 Slotting machine is operated to perform the necessary cutting action
and complete the model as per the requireddimension.
Result: The model is prepared as per the sketch
MLM 46
Ex.No.5. Key way / Slot cutting
MLM 47
EXP NO:6
DRILLING & BORING ON LATHE
AIM:
To perform the drilling and boring operations as per the given dimensions
MATERIALS REQUIRED:
MS Rod of 52x42 mm dia
OPERATION TO BE CARRIED OUT:
Job setting, facing, counter sinking, plane turning, drilling, boring etc.
TOOLS REQUIRED:
Chuck key, surface gauge, Drill chuck, Centre drill, Double end spanner, HSS tool,
vernier caliper, steel rule, boring tool etc.
PROCEDURE: -
Hold the job in the four-jaw chuck and set the job with help of surface gauge, Centre
drill the end portion and fix the turning tool in the tool post and Centre it.Start the
machine, the speed is controlled by the nature of the job. Turn the job to 32 mm dia to a
length of 50 mm and check the dia with a vernier caliper. Drill pilot holes at the end of
the job starting from 6mm dia up to at a distance of 50mm, finally drill 18mm hole to
the same distance. Then replace the turning tool and mount the boring tool on the tool
post of the compound rest. The boring tool level & parallel to the Centre line of the
lathe. Set the lathe on proper spindle speed for boring. Bore the hole to the dia of 20
mm to a distance of 50mm with boring tool. Measure the bore size using inside
micrometer and finish the job as per the given dimensions and clean the machine well .
MLM 48
EXP NO :7
CUBE MAKING ON SHAPER
AIM:
To make a cube on a given Cast Iron block in the required dimensions
Materials required:
Cast Iron block of 52x52x52 mm
Marking, Punching, Job setting, shaping etc
TOOLS REQUIRED:
Surface plate, Double end spanner, Single point cutting tool, vernier height
gauge, vernier caliper, Ball peen hammer, Dot punch steel rule etc.
PROCEDURE
Measure the given casting and check; it is suitable for the required job as per the
drawing. Keep one of the better surfaces on the parallel block and clamp the job
in the machine vice. Then adjust the stroke length 30mm more than the length of
the job. Fix the tool in the tool post and the shaper for machining. After shaping
one face, that face is close to the fixed jaw and shape the adjacent face with both
are exact perpendicular with the help of try square. The work piece is placed on
surface plate, mark and punches the job as per the given dimension. After the
punching, the work piece is mounted on the machine vice and shapes the surface
maintaining the side of width 48 mm. Check the flatness and squareness with a
try square. Finally check all sides and clean the machine well.
MLM 49
EXP NO:8
PLANING PRACTICE ON PLANNER
AIM: -
To machine a Flat surface on a given Cast Iron block in the required dimensions
Materials required: -
Marking, Punching, Job setting, planning etc
TOOLS REQUIRED:
PROCEDURE
Measure the given casting and check, it is suitable for the required job as per the
in the machine vice which is aligned to the machine table. Clamp a left-hand
planning tool in the tool head and adjust the stroke length & position according to
the job. Bring the tool just to touch the top surface of the job & note the reading
of the graduated collar. Take the tool away from the job, apply 2mm depth and
start the table movement. Apply cross feed by hand approximately 0.5mm stroke,
rough-cut and complete the flat surfaces. Mark and punches the job as per the
given dimension. After the punching, the work piece is mounted on the machine
vice and planning the surface. Debur the job & check the flatness and squareness
with a try square. Finally check all sides and clean the machine well.
All dimensions are in MM
MLM 50
EXP NO:9
DATE:
PLAN MILLING PRACTICE
AIM:
To perform plane milling operation on the given specimen (mild steel) & get to
its correct dimensions.
Materials required:
OPERATION TO BE CARRIED OUT
Marking, Punching, Job setting, milling etc.
TOOLS REQUIRED:
Surface plate, Double end spanner, Milling cutters, vernier height gauge, vernier
caliper, Ball peen hammer, Dot punch steel rule etc.
PROCEDURE:
in the machine vice. A face milling cutter is mounted on the horizontal milling
machine spindle and one end of the rod is face milled, by raising the table so that
the end of the rod faces the cutter. The rod is removed from the vice and fitted in
the reverse position. The other end of rod is face milled such that, the length of
the job is exactly 100 mm. The table is lowered and the rod is removed from the
vice and refitted in it such that, the top face of the rod is projected from the vice
jaws. The face milling cutter is removed from the spindle and the Arbor is
mounted in the spindle; followed by fixing the plain milling cutter. The top
surface of the job is slab milled; first giving rough cuts followed by a finish cut.
The job is removed from the vice and refitted in it such that, the face opposite to
the above, comes to the top and projects above the vice jaws. The top surface of
the job is milled in stages; giving finish cuts towards the end such that, the height
of the job is exactly 40 mm. The burrs if any along the edges, are removed with
the help of the flat file.
MLM 51
RESULT:
The rectangular block of 50 x 40 x 100 mm, is thus obtained, by
following the stages described above.
MLM 52
EXP NO;10
DATE
KEY WAY / SLOT CUTTING ON SHAPER
Aim: To make a slot on a given cast iron blank
Material required: Cast iron block of 48 x 48 x 48mm
Operations to be carried out: marking, punching, job setting,

slotting
Tools required: surface plate, spanner, single point cutting tool,

Square nose tool, Vernier height gauge, ballpeen hammer, dot punch etc.
Procedure:
 Set the single point HSS tool on toolholder
 Adjust the length of stroke ofram
 Square blank is prepared to the required dimension on Shaping
machine.
 Marking is carried out on the work piece forslotting.
 Set the v tool for slottingoperation.
 Shaping machine is operated to perform the necessary cutting action
and complete the model as per the requireddimension.
Result: The model is prepared as per the sketch
MLM 53
Ex.No.5. Key way / Slot cutting on shaper
MLM 54
EXP NO :11
V-BLOCK ON SHAPER
AIM:
To make a V-BLOCK on a given Cast Iron block in the required dimensions
Materials required:
Marking, Punching, Job setting, shaping etc
TOOLS REQUIRED:
PROCEDURE
Measure the given casting and check; it is suitable for the required job as per the
drawing. Shape the cast iron block of 52x52x52mm, the job is placed on surface
plate, mark the angular shape and slot of 20mm width and depth of 5mm on
either sides of the block, punch the job as per the given dimensions. After the
punching the work piece is mounted on the shaping machine. Set the stroke
length and position. Fix the tool in the tool post of the machine. Slotting
operation is performed on either side of the work piece to the required
dimensions, shape the angular surfaces by swiveling the tool post at 45degree
without disturbing the job setting. The shape the slot maintaining the dimensions
as 5x4mm.at last remove and deburr the work piece. Finally check the job and
clean the machine.
RESULT
As per the given dimensions the work piece is completed
MLM 55
EXP NO:11
V-BLOCK ON SHAPER
ALL DIMENSIONS ARE IN MM
MLM 56
EXP NO:12
DATE:
VERTICAL MILLING PRACTICE
AIM:
To perform vertical milling operation on the given specimen (mild steel) & get
to its correct dimensions.
Materials required:
TOOLS REQUIRED:
Surface plate, Double end spanner, Milling cutters (side milling cutter), vernier
height gauge, vernier caliper, Ball peen hammer, Dot punch steel rule etc.
PROCEDURE:
drawing. Align the machine vice with reference to the column using a dial
indicator. Mount and align the machine vice on the table of the vertical milling
machine. Mark the slot of 20mm width and depth of 5mm on either side of the
case and punch the job as per the given dimensions. After the punching, the work
piece is mounted on the machine vice. Fix the collet and the endmill cutter of
10mm diameter on the machine. Vertical milling operations is performed on one
side of the work piece on the required dimensions, and brings the tool to its initial
positions and continue the machining process for cutting the second slot. Remove
and deburr the work piece. Finally check the slot and clean the machine.
RESULT
As per the given dimensions the work is completed
MLM 57
EXP NO:12
VERTICAL MILLING PRATICE
MLM 58
EXP NO:12
DATE:
SIDE MILLING PRACTICE
AIM:
To perform side milling operation on the given specimen (mild steel) & get to its
correct dimensions.
Materials required:
TOOLS REQUIRED:
Surface plate, Double end spanner, Milling cutters (side milling cutter), vernier
height gauge, vernier caliper, Ball peen hammer, Dot punch steel rule etc.
PROCEDURE:
drawing. Align the machine vice with reference to the column using a dial
indicator. Mount and align the machine vice on the table of the vertical milling
machine. Mark the slot of 20mm width and depth of 5mm on either side of the
case and punch the job as per the given dimensions. After the punching, the work
piece is mounted on the machine vice. Fix the collet and the side mill cutter of
10mm on the machine. Side operations is performed on one side of the work
piece on the required dimensions, and brings the tool to its initial positions and
continue the machining process for cutting. Remove and deburr the work piece.
Finally check the slot and clean the machine.
RESULT
As per the given dimensions the work is completed
MLM 59
EXP NO:12
SIDE MILLING PRATICE
MLM 60
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MANGALAM POLYTECHNIC

MACHINE SHOP PRATICE

STUDENT WILL BE ABLE TO:

Sl.No. Sub Students will be able to

2 Do work on shaping machine

4 Execute work on slotting machine.

5 Perform work on planning machine.

1. Steel rule, 2. Calipers, 3. Vernier caliper,4. Micrometer, 5. Vernierheight

Steel rule is a direct reading and measuring instrument to read an accuracy

one main scale division = 1 mm.

one vernier scale division = 49/50 mm. = 0.98 mm.

Least count = 1- 0.98 mm = 0.02 mm.

MICROMETER (screw gauge)

It is a precision measuring instrument used to read an accuracy of 0.01m.m

(a) Outside micrometer (b) Inside micrometer (c) Depth micrometer

They are available in the ranges of 0-25mm, 25-50mm, 50-75mm, 75-

It is used to measure external measurements with in an accuracy of 0.01

which is assembled with the thimble. One revolution of thimble makes

Least count (LC) = Pitch / Number of divisions on the main scale =

How to take measurements

Total observed reading = main scale reading + (circular scale division

True diameter = observed diameter – zero error

SCREW THREAD PITCH GAUGE

Screw cutting gauge (centre gauge)

Screw cutting gauge is an important tool used in a machine shop, made

Cutting tool materials and their uses

Tool material Properties

HSS Cobalt Expensive. Excellent for machining abrasives, work

Cemented Carbide Expensive. Used for turning tool bits although it is

Tool signature angles

Back rake angle (°) 10

Side rake angle (°) 20

End relief angle (°) 7

Side relief angle (°) 6

End cutting edge angle (°) 8

Side cutting edge angle (°) 15

Nose radius mm 0.8

Principal parts of an engine lathe

Apron: Apron houses the control for hand or power feeding

Work holding and supporting devices

Chucks: for holding work pieces, they are

1.3 jaw -Self centering chuck: The three-jaw chuck is a self-centering

Mandrels are slightly tapered spindle. Previously bored components or

Tool Post: Tool posts are classified as follows

(1) Pillar Type Tool Post:

4. Swing diameter overbed

5. Swing diameter overcarriage

6. Bore diameter of thespindle

The most common operations performed on a lathe are turning, facing,

Plain Turning: It is to remove excess material from the work-piece and to

Parting: Parting or cutting–off is the operation of separating a piece of initial

Drilling: It is an operation of producing cylindrical hole by means of a cutting

Grooving or necking: Grooving is the operation of reducing the diameter of

Boring: It is operation of enlarging a hole previously made by a drilling

Taper: A taper may be defined as a uniform increase or decrease in diameter of

Taper turning methods

1. Form tool method 2. Compound rest method

3. Tailstock setovermethod 3. Taper turning attachmentmethod

Reaming: It is the process of finishing a drilled or bored hole with great

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