Department of Industrial and Manufacturing

Engineering

LABORATORY MANUAL

Manufacturing Processes-II
Course Code: (IME-222L)
Instructor Name: Dr. Sana Ehsan

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 List of Experiments (Manufacturing Processes-II)
List of Experiments have been adopted by consulting
the lab manuals of MTM LAB, Non-conventional
Machining Lab, Rapid Prototyping Lab and Precision
Machining Lab)

1 Introduction to machine tools and machining lab

2 To perform turning, taper turning, drilling, boring, threading, knurling and
parting operation on lathe machine.
3 To perform slot milling and form milling operation on horizontal milling
machine.
4 To generate a part on vertical milling machine using end milling cutter.
5 To reduce the thickness of workpiece on shaper machine.
6 To perform surface grinding operation.
8 Introduction to non-conventional machining lab.
9 To perform EDM Die sinking process using different electrode materials.
10 To study the working of Wire EDM machine..
11 To generate a part using FDM technique.
12 To generate a part using 3D printer.
13 Introduction to CNC machining center and manual part programming
14 To generate Manual part program using G and M codes.
15 To generate Manual part program using G and M codes.

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 (Manufacturing Processes-II)
Experiment # 1
Introduction to machine tools and machining lab
Objective
1. To get acquaint with types and arrangement of machines in Machine Tool Lab.

2. To build basis for experimental / analysis work in the upcoming lab. sessions

Machine Tools Lab. Layout

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Experiment # 2
To perform turning, taper turning, drilling, boring, threading, knurling and parting operation on lathe
machine.
Objective
1. To understand various operations and their methodologies

2. To learn settings / adjustments necessary for these operations

3. To build realization for safe working on lath

Apparatus
Lathe machine, Mild steel bar, Cutting tools etc.
Theory
Lathe Machine
The lathe is a machine tool used in metal cutting operations called "turning." The work piece
is rotated as tooling is applied to it to remove material. Lathes can be manually operated or operated
by computer numerical control (CNC).
The Bed
The lathe bed is a mounting and aligning surface for the other machine components. Viewed
from the operating position in front of the machine, the headstock is mounted on the left end of the
bed and the tailstock on the right. The bed must be bolted to a base to provide a rigid and stable
platform.
Headstock
The headstock holds the spindle and drive mechanism for turning the work piece. The spindle
is a precision shaft and bearing arrangement rotated directly by a motor or through a motor-driven
belt. Gears or sliding pulleys mounted at the rear of the headstock allow spindle speed adjustment.
Tailstock
The tailstock supports long work that would otherwise sag or flex too much to allow for
accurate machining. Without a tailstock, long pieces cannot be turned straight and will invariably
have a taper. Some tailstocks can be intentionally misaligned to accurately cut a taper if needed. The
tailstock has a centering device pressed into a shallow, specially drilled hole in the end of the work
piece. The center can be either "live" or "dead.
Carriage
The carriage provides mounting and motion control components for tooling. The carriage
moves left and right, either through manual operation of a hand wheel, or it can be driven by a lead
screw. At the base of a carriage is a saddle that mates and aligns with the bed ways.
Cross Slide

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 The cross-slide is mounted to the top of the carriage to provide movement perpendicular to
the length of the bed for facing cuts. An additional motion assembly, the compound rest, with an
adjustable angle, is often added to the top of the cross slide for angular cuts.
Lead Screw
The lead screw provides automatic feed and makes thread cutting possible. It is a precision-
threaded shaft, driven by gears as the headstock turns. It passes through the front of the carriage
apron and is supported at the tailstock end by a bearing bracket.
Guide ways
Guideways are linear bearings for translator movement between two members of a machine
tool such as carriage and bed in a lathe. The requirements of guideways are high accuracy, high
surface finish, low value of frictional force and low wear rate.
Facing
Facing is the process of removing metal from the end of a workpiece to produce a flat
surface. Most often, the workpiece is cylindrical, but by using 4- jaw chuck we can face rectangular
or odd-shaped work to form cubes and other non-cylindrical shapes.
When a lathe cutting tool removes metal it applies considerable tangential (i.e. lateral or
sideways) force to the workpiece. To safely perform a facing operation the end of the workpiece
must be positioned close to the jaws of the chuck. The workpiece should not extend more than 2-3
times its diameter from the chuck jaws unless a steady rest is used to support the free end.
Straight turning
In this operation the work is held in the spindle and is rotated whole the tool is fed past the
work piece in a direction parallel to the axis of rotation. The surface generated is a cylindrical
surface.

Design Considerations for Turning Operations

• Parts should be designed so that can be fixtured and clamped in the work holding devices.
• Dimensional accuracy and surface finish specified should be as wide as possible.
• Avoid sharp corners, tapers, and major dimensional variations in the part.

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• Use near-net-shape forming.
• Cutting tools should be able to travel across workpiece without obstruction.
• Standard cutting tools, inserts, and toolholders should be used.
• Materials should be selected for their machinability.
Taper Turning
A taper may be defined as a uniform increase or decrease in diameter of a work piece
measured along its length. In a Lathe taper turning is an operation to produce a conical surface by
gradual reduction in diameter from a cylindrical job.
Contour turning
Instead of feeding the tool along a straight line parallel to the axis of rotatation as in turning,
the tool follows a contour that is other than straight, thus creating a tapered cylinder or conical shape.
Form turning
In this operation, sometimes called forming, the tool has a shape that is imparted to the work
by plunging the tool radially into the work.
Chamfering
The cutting edge of the tool is used to cut an angle on the corner of the cylinder, forming
what is called a "chamfer."
Cutoff
The tool is fed radially into the rotating work at some location along its length to cut off the
end of the part. This operation is sometimes referred to as parting.
Threading
A pointed tool is fed linearly across the outside surface of the rotating workpart in a direction
parallel to the axis of rotation at a large effective feed rate, thus creating threads in the cylinder.
Boring
A single-point tool is fed linearly, parallel to the axis of rotation, on the inside diameter of an
existing hole in the part.
Drilling
Drilling can be performed on a lathe by feeding the drill into the rotating work along its axis.
Reaming can be performed in a similar way.
Knurling
This is not a machining operation because it does not involve cutting of material. Instead, it is
a metal forming operation used to produce a regular cross hatched pattern in the work surface.

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Machining operations other than turning that are performed on a lathe: (a) facing, (b) taper
turning, (c) contour turning, (d) form turning, (e) chamfering, (f) cutoff, (g) threading, (h)
boring, (i) drilling and (j) knurling

Questions
 What type of guide ways are present in Lathe Machine.

 Differentiate the following processes as generationg or forming.

 Turning
 Chamfering
 Boring

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 What is the level of labour skill in different operation on Lathe.
 Form turning
 Contour turning
 Taper turnin

Machining operations other than turning that are performed on a lathe: (a) facing, (b) taper
turning, (c) contour turning, (d) form turning, (e) chamfering, (f) cutoff, (g) threading, (h)
boring, (i) drilling and (j) knurling

Questions
 What are the steps generally required for performing boring operation on Lathe Machine?

 Differentiate the following processes as generating or forming.

 Drilling
 Knurling
 Boring

 How many different patterns of knurling operation on Lathe are seen by you?

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Experiment # 3
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To perform slot milling and form milling operation on horizontal milling machine.
Objective
1. To develop an understanding of milling machines and their classifications

2. To learn functions of its various parts

3. To observe basic operations performed by milling

Apparatus
Horizontal Mill, Job clamping devices etc.
Theory
Milling Machine
Milling is the process of machining flat, curved, or vertical or irregular surfaces by feeding the
workpiece against a rotating horizontal cutter containing a number of cutting edges.
Machine consists basically of a motor driven spindle, which mounts and revolves the milling cutter,
a reciprocating adjustable worktable, which mounts and feeds the workpiece.
Classification
Milling machines are basically classified as horizontal or vertical types to indicate the axis of the
milling machine spindle.. These machines are also classified as knee-type, ram-type, manufacturing
or bed type, and planer-type.

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Classification of Horizontal Milling Machines
 Floor-mounted Plain Horizontal Milling Machine
 Bench-type Plain Horizontal Milling Machine
 Floor-mounted Universal Horizontal Milling Machine.
Major Components.
The machinist must know the name and purpose of each of the main parts of a milling machine to
understand the operations
Column. The column, including the base, is the main casting which supports all other parts of the
machine. An oil reservoir and a pump in the column keeps the spindle lubricated. The column rests
on a base that contains a coolant reservoir and a pump that can be used when performing any
machining operation that requires a coolant.
Knee. The knee is the casting that supports the table and the saddle. The feed change gearing is
enclosed within the knee. It is supported and can be adjusted by the elevating screw. The knee is
fastened to the column by dovetail ways. The lever can be raised or lowered either by hand or power
feed. The hand feed is usually used to take the depth of cut or to position the work, and the power
feed to move the work during the machining operation.
Saddle and Swivel Table. The saddle slides on a horizontal dovetail, parallel to the axis of the
spindle, on the knee. The swivel table (on universal machines only) is attached to the saddle and can
be swiveled approximately 45° in either direction.
Power Feed Mechanism. The power feed mechanism is contained in the knee and controls the
longitudinal, transverse (in and out) and vertical feeds. The desired rate of feed can be obtained on
the machine by positioning the feed selection levers as indicated on the feed selection plates. On
some universal knee and column milling machines the feed is obtained by turning the speed selection
handle until the desired rate of feed is indicated on the feed dial. Most milling machines have a rapid
traverse lever that can be engaged when a temporary increase in speed of the longitudinal, transverse,
or vertical feeds is required. For example, this lever would be engaged when positioning or aligning
the work.
METHODS OF MILLING
Up Milling
Up milling is also referred to as conventional milling. The direction of the cutter rotation opposes the
feed motion. For example, if the cutter rotates clockwise, the workpiece is fed to the right in up
milling.
Down Milling
Down milling is also referred to as climb milling. The direction of cutter rotation is
same as the feed motion. For example, if the cutter rotates counter clockwise, the work
piece is fed to the right in down milling.

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Questions
 What is the purpose of chip rake?

 Why splash guard is used?

 What is the basic difference between a universal horizontal milling machine and a plain
horizontal milling machine?

 List down few precautions for safe working on milling machine.

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Cutter Diameter _________________
Length of Workpiece _________________
Width of Workpiece _________________
Depth of cut _________________
Spindle speed _________________

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Feed per tooth _________________
Number of teeth _________________

Selecting a milling cutter

Selecting a milling cutter is not a simple task. There are many variables & opinions to consider, but
essentially the machinist is trying to choose a tool which will cut the material to the required
specification for the least cost. The cost of the job is a combination of the price of the tool, the time
taken by the milling machine, and the time taken by the machinist.
Often, for jobs of a large number of parts, and days of machining time, the cost of the tool is lowest
of the three costs.
Material: High speed steel (HSS) cutters are the least-expensive and shortest-lived cutters. Cobalt
steel is an improvement on HSS and generally can be run 10 faster. Carbide tools are more expensive
than steel, but last longer, and can be run much faster, so prove more economical in the long run.
HSS tools are perfectly adequate for many applications. The progression from HSS to cobalt steel to
carbide could be viewed as very good, even better, and the best.
Diameter: Larger tools can remove material faster than small ones, therefore the largest possible
cutter that will fit in the job is usually chosen.
Coating: Coatings, such as Titanium nitride, also increase initial cost but reduce wear and increase
tool life.
Helix angle: High helix angles are typically best for soft metals, and low helix angles for hard or
tough metals.
Swarf Removal
Another important quality of the milling cutter to consider is its ability to deal with the swarf
generated by the cutting process. If the swarf is not removed as fast as it is produced, the flutes will
clog and prevent the tool cutting efficiently, causing vibration, tool wear and overheating. Several
factors affect swarf removal, including the depth and angle of the flutes, the size and shape of the
chips, the flow of coolant, and the surrounding material. It may be difficult to predict, but a good
machinist will watch out for swarf build up, and adjust the milling conditions if it is observed.

Types of Milling Cutters:

Plain Milling Cutters
These are used for peripheral or slab milling. They are cylinder shaped with several rows of teeth on
periphery. These are generally used for flat surfaces. The cutting edges are usually oriented at a helix
angle to reduce impact on entry into the work and these cutters are called helical milling cutters.

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 Tool Geometry

FIGURE: Tool geometry element of an 18-tooth plain milling cutter

Face Milling Cutters

These are designed with teeth that cut on both sides as well as the periphery of the cutter. Face
milling cutters can be made of HSS or cemented carbide inserts,

Face Milling Cutters

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Questions
 List down main parts of horizontal milling macines.

 Differentiate the following processes.

 Straddle
 Form Milling
 Slicing

 What is the level of labour skill in different operation on Lathe.

 Form turning
 Contour turning
 Taper turning

Comments
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Experiment # 4
To generate a part on vertical milling machine using end milling cutter.
Objective
1. To develop an understanding of vertical milling machines

2. To learn functions of its various parts

3. To observe basic operations performed on it

Apparatus:
Vertical milling machine, Mild steel plate, Milling cutters etc.
Theory

Milling Machine

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 A milling machine is a machine tool used for the shaping of metal and other solid material.
Unlike a drill press, in which the workpiece is held stationary and the drill is moved vertically to
penetrate the material, milling also involves movement of the workpiece against the rotating cutter,
the latter which is able to cut on its flanks as well as its tip. Milling machines may be manually
operated, mechanically automated, or digitally automated via computer numerical control (CNC).
Types of Milling Machines
1. Horizontal 2. Vertical
Horizontal milling machine:
Horizontal mill has the same sort of x–y table, but the cutters are mounted on a horizontal
arbor across the table. While end mills and the other types of tools available to a vertical mill may be
used in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side and face
mills, which have a cross section rather like a circular saw, but are generally wider and smaller in
diameter. Because the cutters have good support from the arbor, quite heavy cuts can be taken,
enabling rapid material removal rates.
Uses:
These are used to mill grooves and slots. Plain mills are used to shape flat surfaces. Several
cutters may be ganged together on the arbor to mill a complex shape of slots and planes. Special
cutters can also cut grooves, bevels, radii, or indeed any section desired. These specialty cutters tend
to be expensive. Simplex mills have one spindle, and duplex mills have two. It is also easier to cut
gears on a horizontal mill.
Vertical milling machine:
Vertical milling machine is so named because spindle is at right angle to the surface of the table.
Parts of Vertical Milling Machine
The vertical knee mill is the most common milling machine found in machine shops today.
Therefore it will be used as an example to describe the general parts of all mills.

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 Fig. 10.1 The complete description of parts as shown in diagram
Head
The head (drive) is that part of the drive system that transforms electrical power from a
motor to mechanical power in the spindle. The drive system also allows the machinist to change the
speed of the spindle (RPM) and therefore the cutting tool. The quill moves vertically in the head and
contains the spindle in which cutting tools are installed.
Column
The column is the most important part which is mounted on the base and acts as a support
and holding device for all the other parts of a milling machine. It acts as a support for table and all
feed mechanisms. The column should be rigid enough to sustain all the forces produced due to the
drilling action of the tool. The head and worktable are mounted with column.
Work table
It gives the motion in X-direction.
Saddle
It gives the motion in Y-direction.

Knee
It gives the motion in Z-direction.

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The saddle sits on the knee and allows translation of the worktable. Sitting on the base is the column
whose main function is to hold the turret. The turret allows the milling head to be rotated around the
column's center. The over arm (ram) slides on the turret and allows the milling head to be
repositioned over the table.
Base
The whole machine is mounted on this part. The base is that part of a machine on which the
column is mounted. In the belt driven milling machines both the fast and loose pulley and cone
pulley are also mounted on the base. In general the base is of a circular cross section when viewed
from top. The base also has T-slots on it facilitating holding of large pieces for machining.

Questions
 Differentiate between up milling and down milling.

 Down milling provides more surface finish than up milling. How?

 Write down some methods to increase the production rate in case of machining
thousand of parts on a milling machine.

End Milling Applications

There are many different operations that come under the term 'end milling'. For each different
operation there is a different MRR (Material Removal Rate) that increases with the
engagement section of the cutter on the workpiece.

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 MRR - or 'Q' - can be calculated as the volume of material removed divided by the time taken
to cut. The volume removed is the initial volume of the workpiece minus the final volume.
The cutting time is the time needed for the tool to move through the length of the workpiece.
This parameter strongly influences the finishing grade of the workpiece.
Material Removal Rate;
M.R.R = w×d
Specimen calculation
Width of cut = w =
Depth of cut =d=
Length=
Time= t =
Feed rate = Length/machining time
=L/t=
M.R.R=
Questions
 List down various operations that can be performed by vertical milling.

 What is the impact of tool flutes on tool rigidity?

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Experiment # 5
To reduce the thickness of workpiece on shaper machine.
Objective
1. To develop an understanding of shaper machines

2. To learn functions of its various parts

3. To observe basic operations performed on it

Apparatus:

Shaper machine, shaping tools, fixing clamps etc.

Theory

A shaping machine is used to machine surfaces. It can cut curves, angles and many other
shapes. It is a popular machine in a workshop because its movement is very simple
although it can produce a variety of work.
Shaping machines come in a range of sizes but the most common size is seen below with
main parts labelled:

The tool feed handle can be turned to slowly feed the cutting tool into the material as the 'ram' moves
forwards and backwards. The strong machine vice holds the material securely. A small vice would
not be suitable as the work could quite easily be pulled out of position and be damaged. The vice
rests on a steel table which can be adjusted so that it can be moved up and down and then locked in
position. Pulling back on the clutch handle starts the 'ram' moving forwards and backwards.

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The tool post and the tool slide can be angled as seen below. This allows the shaper to be used for
different types of work
1. DIA A: The tool post has been turned at an angle so that side of the material can be
machined.
2. DIA B: The tool post is not angled so that the tool can be used to level a surface.
3. DIA C: The top slide is slowly feed into the material so that a ‘rack’ can be machined for a
rack and pinion gear system

Questions
 List down various operations that can be performed by shaper.

 Draw a diagram to represent a shaping machine and label the important parts.

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Experiment # 6
To perform surface grinding operation.
Objective
1. To develop an understanding of surface grinding

2. To learn functions of its various parts

3. To observe basic operations performed on it

Apparatus
Universal grinding machine, Mild steel plate, coolant etc..
Theory
Grinding:
Grinding is a process carried out with a grinding wheel made up of abrasive grains for removing very
fine quantities of material from the work piece surface. The required size of abrasive grains are
thoroughly mixed with the bonding material and then pressed into a disc shaped of given diameter
and thickness. Grinding process is used for two reasons
(i) Higher value of surface finish and accuracy that cannot be provided with the machining
process.

(ii) Hard and brittle materials that cannot be machined or it is uneconomical to use machining

Grinding wheel
A grinding wheel is made of abrasive grains held together by a bond. These grains cut like teeth
when the wheel is revolved at high speed and is brought to bear against a work piece. The properties
of a wheel that determine how it acts are the ginding parameters including the kind and size of an
abrasive matereial, how closely the grains are packed together and the type and amount of the
bonding material.

Grinding Parameters
(i) Abrasive materials

Different abrassive materials are appropriate for grinding different work material. Abrasives are hard
substances used in various forms as tools for grinding and other surface finishing operations. They
are also able to cut materials which are too hard for other tools and give better finishes and hold
closer tolerances.Commonly used abrasive materials are Al2O3, SiC etc
(ii) Grain size

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It is an important parameter in determining surface finish and material removal rate. Small grit sizes
produce better finishes, larger grit sizes permit larger material removal rates. Also, harder materials
need smaller grain sizes to cut effectively, while softer materials require larger grit size. Larger
grains produce less surface finish and smaller grains produce poor finish.
(iii) Bonding material

A strong bond is required for the good performance of a grinding wheel. Different bonding materials
serve the purpose.
(iv) Wheel Structure and Wheel Grade

A grinding wheel contains the proportion of the bonding materials, pores and abrasive material.
Wheel structure represents the relative amount b/w the abrasive material and pores. While wheel
grade represents the strength of the bonding materials. Amount of the bonding material represents
the wheel grade.

Types of Grinding Machines

Grinding machine is employed to obtain high accuracy along with very high class of surface finish
on the work piece. However, advent of new generation of grinding wheels and grinding machines,
characterized by their rigidity, power and speed enables one to go for high efficiency deep grinding
(often called as abrasive milling) of not only hardened material but also ductile materials. General
types of grinding machines are:
(i) Surface Grinding
(ii) Cylindrical Grinding
(iii) Center less Grinding
(iv) Creep feed Grinding

Surface Grinding
This machine may be similar to a milling machine used mainly to grind flat surface. However, some
types of surface grinders are also capable of producing contour surface with formed grinding wheel.
Basically there are four different types of surface grinding machines characterized by the movement
of their tables and the orientation of grinding wheel spindles as follows:
I. Horizontal spindle and reciprocating table
II. Vertical spindle and reciprocating table
III. Horizontal spindle and rotary table
IV. Vertical spindle and rotary table

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 Various form of surface grinding
Grinding Parameters
A: rotation of grinding wheel
B: reciprocation of worktable
C: transverse feed
D: down feed

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 Horizontal spindle reciprocating table surface grinder

Cylindrical Grinding
Cylindrical grinding is used for the rotational parts. A rotating cylindrical work piece is ground by a
rotating grinding wheel. Two types of cylindrical grinding are;
(i) Internal cylindrical grinding (grinding of internal holes)
(ii) External cylindrical grinding (grinding of external cylindrical parts)
Universal Grinding Machine
This machine is closely related with cylindrical grinding machine but differs in its configuration. It
has a swivel table and a headstock. It has a wheel head that can be rotated on its base is called a
universal grinding machine. Cylindrical grinding machine has not these swiveling features. Due to
these features, cylindrical parts can be ground at an angle.

Questions
 What is the difference between a cylindrical grinder and a universal grinder?

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  What type of grinding parameters will be used to grind hard material with high surface
finish?

Comments
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