Record
Record
Lab Record
Register Number
Student Name
Batch 2022-2026
Regulation 2019
1. Train the students who will be able to design and manufacture Innovative,
Environment Friendly, Ergonomic and Cost-Effective Quality Products and
Services.
2. Improve the technical quality of the students to meet the challenges,
competitions and opportunities in production engineering.
3. Prepare the students who will be able to solve socially relevant engineering
problems and other complex problems by means of inculcating Managerial
Skills.
4. Enhance the department industry / research centre interaction by means of
training, internship and student projects to solve industrial problems.
MADRAS INSTITUTE OF TECHNOLOGY
ANNA UNIVERSITY
CHENNAI 600 044
CERTIFICATE
LIST OF EXPERIMENTS
Machining Exercises
1. Preparation of part drawing to machine a raw material in a lathe – (involving facing, turning, stepped
turning, knurling, taper turning, thread cutting and parting)
2. Preparation of part drawing to machine a blank material in a shaper – (involving horizontal, vertical
surface machining, V-shape, dove-tail end)
3. Preparation of part drawing to machine the given part in drilling machine – (involving single hole, multi
hole, equidistant, equi-pitch, reaming, boring, counter boring, counter sinking).
4. Preparation of part drawing to mill the groove part in a milling machine – (involving key way, slot, spur
gear, patched milling, spline, gang milling).
5. Preparation of part drawing to grind the part in a grinding machine-(involving flat surface, cylindrical
surface).
6. Preparation of part drawing to machine a part in combination of machine-( Lathe and Milling, Lathe and
Grinding, Shaper and Grinding).
Drafting Exercises
1. Any CAD software with 2D modelling to used by students for drafting exercises
2. Practice on Drafting Software using Measuring commands; Basic Draw Commands; Display Commands
GRID, SNAP, CIRCLE, LINE, ARC LIMITS, ZOOM, PAN.
3. Practice on using Editing commands; Creating layers: CHANGE, ERASE, EXTEND, TRIM, GRIPS.
Construction Commands; ARRAY, COPY, MIRROR, MOVE, OFFSET, FILLET, CHAMFER, OSNAP.
4. Placing lettering on a drawing; Crosshatching a drawing TEXT BHATCH.
5. 2D drafting of automobile components like engine crank shaft, connecting rod etc.,
6. 2D drafting of machine components.
7. 2D drafting of machine shop drawing.
8. 2D drafting of pin joints, cotter joints and bearings.
The drafting exercise include process planning sheet where student shall fill up the data for producing the
product as per drawing. As per the process planning sheet the machining operations are to be conducted.
TOTAL: 60 PERIODS
COURSE OUTCOMES:
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1 * * * * * * *
CO2 * * * * * *
CO3 * * * *
INDEX
S. Page Date Total
Particulars Signature
No. No. Start Completed Marks
Cycle – I (CAD Lab Practice)
1 Introduction to 2D Modelling Software 01
2 Basic Draw Commands 10
3 Editing Commands 23
4 Dimensioning 46
5 Isometric Modelling of Machine Components 53
6 2D Modelling of Sleeve and Cotter Joint 70
7 2d Modelling of Knuckle Joint 80
8 2d Modelling of Screw Jack 87
9 2d Modelling of Plummer Block 96
10 2d Modelling of Protected Type Flange Coupling 102
Cycle – II (CAD Lab Practice)
11 3D Basic Commands 107
12 3D Modelling of Bearing Block 128
13 3D Modelling of Bushed Bearing 133
14 3D Modelling of Screw Jack 137
15 Limits, Fits and Tolerance 144
16 Process Planning Steps, Types and Advantages 164
Cycle – III (Machine Shop Practice)
17 Step Turning and Knurling 178
18 Drilling and Tapping 182
19 Eccentric Turning 185
20 Vertical Milling 189
Verified By:
Supporting Staff: Signature with Date
Exercise No:01 INTRODUCTION TO 2D MODELLING SOFTWARE
Date: Student Name:
Semester:3rd Register No: Course: B.E. Production Engineering
AIM: To learn the basics of 2D Modelling Software Using AUTOCAD Commands and its
Coordinate Systems.
AUTOCAD COMMANDS
• As a general rule, everything you draw with AutoCAD will be drawn full size/actual
size. This often comes as quite a surprise to those who are new to CAD and have
spent a number of years working on a drawing board.
• When you start drawing with AutoCAD you do not have to decide upon a drawing
scale as you do when using a drawing board.
• When drawing on paper you must decide do draw at say, 1:20 or 1:200
depending upon the size of the object that you are drawing so that your scaled
drawing will fit on the drawing sheet, be that A3 or A1.
• In AutoCAD you do not need to decide upon a drawing scale until you come to
print the drawing and because the scaling of your drawing takes place at the
printing stage, you can create drawings at a scale of 1:1.
• This has particular advantages because you can, for example, measure lengths,
areas and volumes within an AutoCAD drawing and not need to compensate for
any scale factor.
Example:
One problem with using absolute coordinates is that all coordinate values refer back
to the origin 0, 0 fixed in the lower left corner.
Command: LINE
Command: Specify first point: #-2,1
Specify next point or [Undo]: #3,4
Specify next point or [Undo]: #3,1
Specify next point or [Close/Undo]: #-2,1
Specify next point or [Close/Undo]: ENTER
After first points entered, your next points can be entered by specifying the next
coordinate compare/relative from the first points. The relative coordinate started with
symbol “@” tell AutoCAD it was a relative coordinate. Using relative coordinate,
points entered by typing @x, y [Enter].
Example:
Let’s make the previous example by using relative coordinates. Let’s draw the same
triangle by starting from -2,1 point, going 5 units in right direction and 3 units in upper
direction and end in same -2,1 point.
Command: LINE
Command: Specify first point: -2,1
Specify next point or [Undo]: @ 5,0
Specify next point or [Undo]: @3,0
Specify next point or [Close/Undo]: C
Entering relative coordinates is done by using @ symbol from the last point and
entering Δx, Δy values. @ represents relative coordinates.
3. Relative Polar coordinate system:
Polar coordinates used when you need to draw the next points at specify angle. Polar
coordinates system in AutoCAD specifies distance length at which angle. Using polar
coordinate, points entered by typing @distance<angle [Enter].
Example:
Command: LINE
LINE Specify first point: -2,1
Specify next point or [Undo]: @5<0
Specify next point or [Undo]: @3<90
Specify next point or [Close/Undo]: c
Example:
Coordinate Method
Point
Absolute Relative Polar
P1 #0,0 0,0 0,0
P2 #50,0 @50,0 @50<0
P3 #80,40 @30,40 @50<53
P4 #80,100 @0,60 @60<90
P5 #0,100 @-80,0 @80<180
P1 #0,0 @0,-100 @100<270
CONCLUSION: The basics of 2D Modelling Software Using AUTOCAD Commands and its
Coordinate Systems were well practiced and understood.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Exercise
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Exercise
ARRAY COMMAND
MIRRORING COMMAND
• Rectangular Array
• Circular Array
LAYERING COMMAND
• Layer 1 with Drawing
• Layer 2 with Dimension
Editing Commands in AUTOCAD were well understood and Practised using above
CONCLUSION:
exercise.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Exercise
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
PROCEDURE: Exercise 1:
Command: LIMITS
Reset Model space limits:
Specify lower left corner or [ON/OFF] <0.0000,0.0000>: 0,0
Specify upper right corner <12.0000,9.0000>: 120,90
Command: ZOOM
Specify corner of window, enter a scale factor (nX or nXP), or
[All/Center/Dynamic/Extents/Previous/Scale/Window/Object] <real time>: a
Regenerating model.
Command: LINE
Specify first point: 0,0
Specify next point or [Undo]: @40<0
Specify next point or [eXit/Undo]: @10<90
Specify next point or [Close/eXit/Undo]: @30<0
Specify next point or [Close/eXit/Undo]: @30<90
Specify next point or [Close/eXit/Undo]: @70<180
Specify next point or [Close/eXit/Undo]: c
Command: C
CIRCLE
Specify center point for circle or [3P/2P/Ttr (tan tan radius)]: 20,25
Specify radius of circle or [Diameter]: 10
Command: C
CIRCLE
Specify center point for circle or [3P/2P/Ttr (tan tan radius)]: 50,25
Specify radius of circle or [Diameter] <10.0000>: 10
Exercise 2:
Command: LIMITS
Reset Model space limits:
Specify lower left corner or [ON/OFF] <0.0000,0.0000>: 0,0
Specify upper right corner <12.0000,9.0000>: 120,90
Command: ZOOM
Specify corner of window, enter a scale factor (nX or nXP), or
[All/Center/Dynamic/Extents/Previous/Scale/Window/Object] <real time>: a
Regenerating model.
Command: LINE
Specify first point: 0,0
Specify next point or [Undo]: @50<0
Specify next point or [eXit/Undo]: X
Command: ARC
Specify start point of arc or [Center]: 50,0
Specify second point of arc or [Center/End]: C
Specify center point of arc: 50,30
Specify end point of arc (hold Ctrl to switch direction) or [Angle/chord Length]:
>>Enter new value for ORTHOMODE <0>:
Resuming ARC command.
Specify end point of arc (hold Ctrl to switch direction) or [Angle/chord Length]: 80,30
Command: LINE
Specify first point: 80,30
Specify next point or [Undo]: @5<90
Specify next point or [eXit/Undo]:
>>Enter new value for ORTHOMODE <0>:
Resuming LINE command.
Specify next point or [eXit/Undo]: @20<180
Specify next point or [Close/eXit/Undo]: @5<90
Specify next point or [Close/eXit/Undo]:
>>Enter new value for ORTHOMODE <0>:
Resuming LINE command.
Specify next point or [Close/eXit/Undo]: @20<0
Specify next point or [Close/eXit/Undo]: @25<90
Specify next point or [Close/eXit/Undo]: @80<180
Specify next point or [Close/eXit/Undo]: 0,0
Specify next point or [Close/eXit/Undo]: X
Command: CIRCLE
Specify center point for circle or [3P/2P/Ttr (tan tan radius)]: 25,45
Specify radius of circle or [Diameter]: 5
Exercise 3:
Step 1
Command: SNAP
Specify snap spacing or [ON/OFF/Aspect/Legacy/Style/Type] <5.0000>: S
Enter snap grid style [Standard/Isometric] <S>: I
Specify vertical spacing <5.0000>: 5
Step 2
Function Key F5
Command: <Isoplane Right>
Command: <Isoplane Left>
Command: <Isoplane Top>
Step 3
Change the ISOPLANE to LEFT and draw the face 1 using Line command
Command: _line
Specify first point:
Specify next point or [Undo]: 80
Specify next point or [eXit/Undo]: 45
Specify next point or [Close/eXit/Undo]: 70
Specify next point or [Close/eXit/Undo]: 15
Specify next point or [Close/eXit/Undo]: 10
Specify next point or [Close/eXit/Undo]: X
Step 4
Command: TEXT
Current text style: "Standard" Text height: 0.2000 Annotative: No Justify: Left
Specify start point of text or [Justify/Style]:
Specify height <0.2000>: 5
Specify rotation angle of text <0>:
Step 5
Function Key F5
Command: _line
Specify first point:
Specify next point or [Undo]: <Isoplane Top> 45
Specify next point or [eXit/Undo]: <Isoplane Right> 45
Specify next point or [Close/eXit/Undo]:
Specify next point or [Close/eXit/Undo]: *Cancel*
Step 6
Command: TEXT
Current text style: "Standard" Text height: 5.0000 Annotative: No Justify: Left
Specify start point of text or [Justify/Style]:
Specify height <5.0000>:
Specify rotation angle of text <0>:
Step 7
Function Key F5
Command: _line
Specify first point:
Specify next point or [Undo]: <Isoplane Left> 70
Specify next point or [eXit/Undo]: <Isoplane Top>
Specify next point or [Close/eXit/Undo]: *Cancel*
Step 8
Command: LINE
Specify first point:
Step 9
Command: _line
Specify first point:
Specify next point or [Undo]: 45
Specify next point or [eXit/Undo]:
Specify next point or [Close/eXit/Undo]: *Cancel*
Command: DIMEDIT
Enter type of dimension editing [Home/New/Rotate/Oblique] <Home>: o
Select objects: Specify opposite corner: 0 found
Select objects: 1 found (Select D3 & D4)
Select objects: 1 found, 2 total
Select objects:
Enter obliquing angle (press ENTER for none): 30
Command: DIMEDIT
Enter type of dimension editing [Home/New/Rotate/Oblique] <Home>: O
Select objects: 1 found (Select D5)
Select objects:
Enter obliquing angle (press ENTER for none): 150
CONCLUSION:
Step 1
Command: SNAP
Specify snap spacing or [ON/OFF/Legacy/Style/Type] <5.0000>: s
Enter snap grid style [Standard/Isometric] <S>: I
Specify snap spacing or [Aspect] <5.0000>:
Step 2
Command: _line
Specify first point: <Ortho on>
Specify next point or [Undo]: 35
Specify next point or [eXit/Undo]: 14
Specify next point or [Close/eXit/Undo]: 30
Specify next point or [Close/eXit/Undo]: 10
Specify next point or [Close/eXit/Undo]: 20
Step 3
Command: EL
ELLIPSE
Specify axis endpoint of ellipse or [Arc/Center/Isocircle]: i
Specify center of isocircle:
Specify radius of isocircle or [Diameter]: 15
Command: EL
ELLIPSE
Specify axis endpoint of ellipse or [Arc/Center/Isocircle]: i
Specify center of isocircle:
Specify radius of isocircle or [Diameter]: 7.5
Command: TRIM
Step 4
Command: _line
Specify first point:
Specify next point or [Undo]: 30
Specify next point or [eXit/Undo]: <Isoplane Top> 10
Specify next point or [Close/eXit/Undo]: <Isoplane Right>
Specify next point or [Close/eXit/Undo]: *Cancel*
Command: EL
ELLIPSE
Specify axis endpoint of ellipse or [Arc/Center/Isocircle]: <Isoplane Left> i
Specify center of isocircle:
Specify radius of isocircle or [Diameter]: 15
Command: EL
ELLIPSE
Specify axis endpoint of ellipse or [Arc/Center/Isocircle]: i
Specify center of isocircle:
Specify radius of isocircle or [Diameter]: 7.5
Command: _trim
Command: _copy
Select objects: 1 found
Select objects:
Current settings: Copy mode = Multiple
Specify base point or [Displacement/mOde] <Displacement>:
Specify second point or [Array] <use first point as displacement>: <Isoplane Top>
10
Specify second point or [Array/Exit/Undo] <Exit>: *Cancel*
Step 5
Command: _line
Specify first point:
Specify next point or [Undo]: <Isoplane Right> 30
Specify next point or [eXit/Undo]: <Isoplane Left> 35
Specify next point or [Close/eXit/Undo]: *Cancel*
Command: EL
ELLIPSE
Specify axis endpoint of ellipse or [Arc/Center/Isocircle]: i
Specify center of isocircle:
Specify radius of isocircle or [Diameter]:
Command: EL
ELLIPSE
Specify axis endpoint of ellipse or [Arc/Center/Isocircle]: i
Specify center of isocircle:
Specify radius of isocircle or [Diameter]: 7.5
Command: _copy
Select objects: 1 found
Select objects:
Current settings: Copy mode = Multiple
Specify base point or [Displacement/mOde] <Displacement>:
Specify second point or [Array] <use first point as displacement>: 10
Specify second point or [Array/Exit/Undo] <Exit>: *Cancel*
Exercise
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Step 1 Fix up the units of measurement and choose from the Metric or English options when you
open a new drawing file. For this example, the option will be Metric.
Step 2 Next set the Limits of your drawing area. This will depend upon the basic dimensions of the
object and the number of projection views to be represented. You may have to set aside some space
for a clear margin all around the drawing and also space for the title block, parts list and so on.
Based on the dimensions of different components of the joint mentioned in Figure 1, the two comer
points are chosen such that the entire drawing can be accommodated in full scale (1:1). For the
present case, the following limits are provided.
Limits: Lower left comer > 0, 0
Upper right comer > 450, 300
Step 3 You should create suitable layers so that the outline of the object, center lines, hidden lines,
dimensions, text objects, borders, and so on can be drawn on separate layers. Each layer should
have different line types with specified thicknesses (and colors, if applicable). For beginners, it may
be advisable to create one layer for construction lines (Geometry) which may be turned off in the final
drawing. Using the layer command, create the layers shown in Table 1.
Table 1 Different Layers Created for the Example
Step 4 First of all, it is recommended to draw a rectangle (in construction layer) with lower left and
upper right corners as 0, 0 and 450, 300 respectively, indicating the limits of the drawing area. Then
draw the border (in Border layer) taking offset distances as per the margins to be left. Next, decide on
the allocation of space for the drawing area and title block. In Figure 2 a rectangular border (ABCD) is
drawn in the construction layer where different views are to be drawn. Standard title box space (185
mm x 65 mm) is also located at the bottom right comer. The layout of the drawing is thus complete.
CONCLUSION: 2D Modelling of Sleeve and Cotter joint is performed using AUTOCAD software.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
3D Basic Commands in AUTOCAD were well understood and Practised using above
CONCLUSION:
commands.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
AIM: The aim of this experiment is to study the various terminology in limits, fits, and
tolerances to develop a common and precise language for specifying and
understanding the dimensional and geometric requirements of mechanical parts and
assemblies.
TOLERANCE
Due to the inevitable accuracy of manufacturing methods, it is not possible to make a
part precisely to a given dimension. Therefore, in practice, the variations which can be
permitted in the size of a part are given. The amount of variation permitted in the size of a part
is called tolerance and lies between two limits, upper and lower.
Thus, the difference between the upper and lower limit on a dimension of a part is called the
tolerance.
50.02
If the diameter of a shaft is written in mm as 50 ±.02 or , the tolerance is 0.04 mm 49.98
49.98
on 50 mm diameter (see Fig. 2.1). The following examples will make tolerance more clear
ALLOWANCE
The difference between the dimension of two mating parts is called the allowance or It is
difference between the smallest hole and largest shaft as shown in Fig. 2.2.
Allowance = Smallest hole - largest shaft
= 50.00-49.96
= 0.04
If the tolerance zone is a circular or cylinderical, its width is in the direction of the arrow
terminating the line joining the symbols frame to the feature which is toleranced. If the
tolerance zone is circular or cylinderical, the sign is placed after the tolerance value in the
symbol frame as shown in Fig. 2.3.
The symbols for tolerance of form and position are shown in Fig. 2-4. These symbols
represent the types of characteristics to be controlled by the tolerance. Tolerance of form and
position should be specified in addition to the dimensional tolerances only on functional
ground.
The necessary indications are written in a rectangular frame which is divided into two
components or some times into three components. These sections are filled in from left to right
in the following order
(a) Tolerance symbol,
(b) Tolerance value in the unit used for length dimensioning.
Unilateral Tolerance: A unilateral tolarance is one in which the variation is permitted in one
direction i.e, either plus or minus, from the design size (see Fig. 2.6).
For example 50 +−0.000
0.035
In this, the tolerance .053 is all in one direction towards smaller size.
If the tolerance .070 specifies equal variations in both directions, then the bilateral
tolerance is written as ± .035.
GRADE OF TOLERANCE
In a standardized system of limits and fits, grade of tolerance considered is corresponding to
the same level of accuracy for all the basic sizes.
SIZE OF TOLERANCE
1. Size: A number expressing the numerical value of a length in a particular unit, is called
size.
2. Actual size: The size of a part as may be found by measurement is called actual size.
3. Limit of size: The two extreme permissible possible sizes between which the actual
size contained is called limit of size (see Fig. 2.1).
4. Maximum limit of size : The greater of the two limits of size is called maximum limit
of size.
5. Minimum limit of size : The smaller of the two limits of size is called minimum limit
of size.
6. Nominal size : The size refered to as a matter of a convenience is called nominal
size. In Fig. 2.1 the norminal size of shaft is 50 mm.
7. Basic size : The basic size is the size with reference to which the limit of size is fixed (see
Fig. 2.8). In other words, we can say that the basic size of a dimension or part is the size
in relation to which all limits of variations are determined. The basic size is same for both
members of a fit. The basic size is expressed in decimal equivalent of the nominal size. If
the nominal size of a shaft is 501/2 mm, the basic should be written as 50.5 mm.
8. Deviation : As we know, a basic size is fixed to the part and each of the two limits
is defined by its deviation from the size. The magnitude and sign of the deviation is obtained
by subtracting the basic size from the limit problem.
Thus, the algebraic difference between a size (actual, maximum, minimum, etc) and the
corresponding basic size is called deviation.
Fig. 2.9
Fig. 2.8 illustrating the basic size; deviation and tolerances. The axis of the part is to be
maintained below the diagram. Fig. 2.9 shows the simplified diagram conventionally used.
9. Actual deviation : The algebraic difference between the actual size and the
corresponding basic size is called actual deviation
10. Upper deviation : The algebric difference between the maximum limit of size and
the corresponding basic size is called upper deviation (see Fig. 2.9).
11. Lower deviation : The algebraic difference between the minimum limit of size and
the corresponding basic size is called lower deviation (see Fig. 2.11).
12. Zero line : In a graphical representation of limitis, a straight line to which the deviations
are referred is called zero line. The zero line is the line of zero deviation and represents
the basic size (see Fig. 2.12). By convention, when the zero line is drawn horizontally,
positive deviations are shown above and the negative deviations below it.
13. Basic shaft : A shaft whose upper deviation is zero (see Fig. 2.13)
14. Basic hole : A hole whose lower deviation is zero (see Fig. 2.14)
15. Design size: In unilateral tolerance the design sizes are the maximum metal limits
and those for a pair of mating parts differ by the amount of allowance.
TOLERANCE OF ANGLES
CLEARANCE
In a fit a positive difference between the size of the hole and the shaft (the hole being greater
than the shaft) allowing relative movement between them is called a clearance (see Fig. 2.17).
Maximum clearance: The positive difference between the maximum size of a hole and the
minimum size of a shaft is known as maximum clearance (see Fig. 2.18).
Minimum clearance: The positive difference between the minimum size of hole and the
maximum size of shaft is known as minimum clearance (see Fig. 2.19). The arithmetical mean
of the maximum and minimum clearance is known as mean
clearance (see Fig. 2.19).
INTERFERENCES
In a fit, a negative difference between the sizes of the hole and the shaft (the shaft being
greater than the hole) is called an interference (see Fig. 2.20).
Maximum interference: The negative difference between the maximum size of the hole and
the shaft and the minimum size of the hole is known as maximum interference (Fig. 2.21).
Minimum interference: The negative difference between the minimum size of the shaft and
the maximum size of the hole is known as minimum interference (see Fig. 2.22).
TYPES OF FITS
Depending upon the actual limits of the hole or shaft, the fit may be divided into three
main classes as follows:
(i) Clearance fits
(ii) Interference fits
(iii) Transition fits
CLEARANCE FITS: In a clearance fit there is always a positive allowance between the largest
possible shaft and the smallest possible hole. In this the shaft is smaller than hole. Such type
of fits give loose joint i.e. there must be some degree of freedom between shaft and a hole
(see Fig. 2.23). Clearance fits may be (1) slide fit (2) easy slide fit, (3) running fit (4) slab
running fit, (5) loose running fit.
INTERFERENCE FITS: In a interference fit there is always a negative allowance between the
largest hole and the smallest shaft (see Fig. 2.23).In this, the shaft is larger than hole.
Interferences fits may be (1) shrink fit (2) heavy drive fit and (3) light drive fit.
TRANSITION FITS: In a transition fit, the fit might be either clearance fit or interference fit. In
this, any pair of parts mating with transition may fit with interference, while another pair with
the same fit may be a clearance fit (see Fig. 2.23 and 2.24).
Transition fit may be (i) force fit (ii) tight fit (iii) driving fit and (iv) push fit.
In ordinary machine construction the following classes of fits are commonly used:-
(1) Running fit (2) Push fit (3) Driving fit (4) Forced fit or shrink fit.
1. RUNNING FIT: In a running fit, one part can be assembled into the other so as to rotate or
slide freely e.g., shaft freely rotating in a bearing.
2. PUSH FIT: In push fit, one part can be assembled into other with light hand pressure and
there being no sufficient clearance to allow shaft to rotate, as in locating plugs, dowels etc.
3. DRIVING FIT : In a driving fit, one part can be assembled into the other with a hand
hammer or by medium pressure e.g., a pulley fitted on a shaft with a key.
4. FORCED FIT OR SHRINK FIT: In force fit or shrink fit, one part (say shaft) is assembled
into the other (hole) either with great pressure or the hole is expanded by heating, so as to
shrink on the shaft. It is specially used when two parts are to be fixed together e.g., cart
wheels, railway and tram car wheels are fitted.
Fundamental deviations for shafts j and k and for holes j to ZC slightly vary or different
grades or sets of grades for the same diameter step and letter symbol. Therefore, Grade 7 for
shafts j, k and holes J,K and grade above 7 for holes M to SC have been represented in those
cases to avoid confusion in the example.
The tolerance, the number which is a function of the basic size, is designated by a
number symbol, called the grade.
The position of the tolerance zone with respect to the zero line, which is a function of the
basic size is indicated by a letter symbol (in some cases, two letters) a capital letter for
holes and a small letter for shaft as shown in Fig. 2.25.
STANDARD TOLERANCES
The B.I.S. has provided, 18 grades of standard tolerances with designations ITO1, ITO and
IT1 to IT 16. The numerical values of these standard tolerances have been determined in
terms of the standard tolerance unit i.
i.e. i=0.45 3 D +0.001D
where
i = standard tolerance unit in microns
D = Diameter in mm
The above formula has been empirically calculated on the basis of former national
standards of other countries and taking account of the fact that in most usually the
tolerance varies more or less parabolically in terms of diameter for the same
manufacturing conditions. The relative magnitude to each grade is given as under for the
grade 5 to 6 in terms of standard tolerance unit 'I’.
For grade IT7, the value is 16i and above it the tolerance magnitude is multiplied by 10 to
each fifth step.
The value of standard tolerances corresponding to grade ITOI, ITO, ITI are:
The values of IT2 to IT4 are scaled approximately geometrically between the values of ITI
and 1+5.
The most commonly used shafts and holes in the industries are given in Table 2.1.
HOLE BASIS SYSTEM: In the hole basis system the hole is the constant member and
different fits are obtained by varying the size of the shaft (see Fig. 2.28 (i)). Here the high
and low limits of the hole are constant (or fixed) for all fits of the same accuracy grade and
for the same basis size.
SHAFT BASIS SYSTEM: In the shaft basis system the shaft is constant member
and different fits are obtained by varying the size of the shaft (see Fig.2.28 (ii)). Here, the
high and low limits of the shaft are constant for all fits of the same accuracy grade and for
the same basis size.
Surface roughness
Standard symbol for surface roughness
The basic symbol used for indication of surface roughness consists of two legs of unequal
length inclined at 60°to the line representing the surface under consideration (see Fig. 2.32).
It may only be used alone when its meaning is expressed by a note.
a. Thus when the surface is produced by any method , it is indicated as by the shown in Fig.
2.33 (a).
b. When the removal of material by machining is required, a bar is added to the basic
symbol [see Fig. 2.33 (b)]
c. Wherever the romoval of material is not permitted, a circle is added to the basic
symbol [see Fig. 2.33(c)]
d. When some special surface characteristics are to be indicated (say a milled surface) a
line is added to the longer leg of the basic symbol [see Fig. 2.33 (d)]
Exercise
1. Find the values of allowance, hole tolerance and shaft tolerance for the following
dimensions of mated parts according to basic hole system.
Hole : 37.50 mm Shaft : 37.47 mm
37.52 mm 37.45 m
Solution.
(i) Hole tolerance = High limit – Low limit
= 37.52 – 37.50 mm
= 0.02 mm
(ii) Shaft tolerance = High limit – Low limit
= 37.47 – 37.45
= 0.02 mm
(iii) Allowance = Maximum metal condition of Hole
– Maximum metal condition of shaft
= Low limit of hole – High limit of shaft
= 37.50 – 37.47
= 0.03 mm
2. A 75 mm shaft rotates in a bearing. The tolerance for both shaft and bearing
is 0.075 mm and the required allowance is 0.10 mm. Determine the dimensions of the
shaft, and the bearing bore with the basic hole standard.
3. A medium force fit on a 75 mm shaft requires a hole tolerance and shaft tolerance each
equal to 0.225 mm and an average interference of 0.0375 mm. Determine the proper
hole and shaft dimensions with the basic hole standard.
4. Calculate the fundamental deviation and tolerances and hence the limits of size for the
shaft and hole for the following fit: 60 mm H8–f7. The diameter steps are 50 mm and 80
mm.
i = 0.45 X 3
D + 0.001D
D= 50 X 80 = 63.25 mm
i = 0.45 X 3 63.25 + 0.001 X 63.25 = 1.856 microns
i = 0.001856 mm
Hole H 8, the tolerance = 25i = 0.046 mm
Shaft f 7, the tolerance = 16i = 0.030 mm
(b) We know that for hole ‘H’, fundamental deviation is zero. The fundamental deviation for
shaft ‘f’ (Table) is,
i = − 5.5 D 0.41
i = − 5.5 D 0.41 = − 0.030 mm
5. In a limit system, the following limits are specified to give a clearance fit
between a shaft and a hole:
shaft 30 −−0.005
0.018 mm
hole 30 −−0.020
0.000 mm
Determine: (a) Basic size (b) shaft and hole tolerances (c) the shaft and hole limits (d) the
maximum and minimum clearance.
The concept of Limits, Fits and Tolerance is been well understood and implemented
CONCLUSION:
in the above exercise.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
AIM: To learn about what is process planning? what are the requirements for this process?
what are the process planning steps, types, advantages, disadvantages and the
sequence of activities included.
The purpose of process planning is to determine and describe the best process
needed to produce a part. In order to accomplish these objectives, the following
Process Planning Steps may be followed:
➢ Both product cost and product quality are closely related to operation
sequence. A different sequence of operations performed will result in different
operational times, different transportation time to the work center, different
tooling in view of different locating and clamping surfaces.
➢ If a new plant is set up for a product, the process planner has much more
freedom in determining the sequence of operation that may be best suited for
the purpose.
➢ In the case of an existing plant the operation sequence for a new product is
to be determined on the basis of available equipment and loading condition of
the equipment.
➢ In the latter case the process planner must be provided with the following
information:
1. List of available machines.
2. List of available general-purpose tooling.
3. Capability of equipment.
4. Machine load charts.
5. Standard data.
➢ However, in any case, there are certain fundamental principles which must be
followed in planning the optimum operation sequence. These are:
1. First the datum surfaces should be selected with due attention. The selection
of datum influences all subsequent machining operations and inspections. A
surface which is to remain unmachined should be selected as the first setting-
up datum surface only in the case of first machining operation. In the
subsequent operations only machined surfaces may serve as setting-up
datum.
2. Surfaces, whose machining will not reduce the rigidity of the work to any
appreciable extent, should be machined earlier in the sequence.
3. Internal operations are performed in advance of external operations. This is
not a rule that need always to be observed. The
principal reason for performing internal operations early is that internal
surfaces are less likely to be damaged in material handling and subsequent
processes so their surfaces frequently provide a better means of holding the
work and thus help ensure concentricity between inside and outside
diameters.
4. The operation in the sequence should begin with removing the largest layer
of metal. Removing thick layers by heavy cuts will reveal internal defects in
the raw materials (usually castings or forgings) much more readily than light
cuts. The workpiece is also relieved of internal stresses which eliminate the
danger of warping in subsequent – operations.
5. The large cutting and clamping forces that may be associated with heavy cut
affect the accuracy of finished surfaces of another part of the same workpiece
and call for those machines which are intended for roughing operations.
Furthermore, heavy cuts involving coarse or rough finishes are usually faster
with less expensive workmen than fine finishes.
➢ The description of the operations and their elements indicated in the process
sheet should give extremely concise but comprehensive information on what
is to be done and why.
➢ The data should clearly indicate how and with what the job is to be done and,
if possible, the time expenditure it will require.
➢ The form of such sheets may vary for different production conditions.
➢ The character of a process sheet will depend mainly on the scale of production
and the degree of importance of the product being manufactured.
➢ Furthermore, different types of sheets are used in manufacturing concepts
which are already in operation and in organizations designing new plants.
➢ In the majority of cases, however, the following information are listed in
process sheets:
1. Information concerning the workpiece which includes name, drawing, and
service function, if possible.
2. Information concerning the blank which includes material, size of stock
when used as a blank, character etc.
3. Descriptions and numbers of operations and those of their elements.
4. Information concerning the manufacturing equipment such as machine
accessories, tools, auxiliary equipment etc.
5. Data on jigs, fixtures and tools such as description, sizes or code numbers.
6. Elements of standard time such as setting time, handling time and
machining time, etc.
7. Job rating of the worker for each operation.
XYZ PRODUCT
ROUTING SHEET PAGE NO.
COMPANY NO.
PART NO.
PART NAME
NUMBER OF
MATERIAL BLANK PARTS PER LOT SIZE
UNIT
OPERATION NUMBER OF JIG OR STANDARD
EQUIPMENT TOOL GAUGE REMARKS
NO. OPERATION FIXTURE HOUR
PLANNER APPROVAL
DATE DATE
➢ Computer Aided Process Planning (CAPP) has become the most critical
link to integrated CAD/CAM systems.
➢ CAPP is the application of computers to assist the human process planner to
execute the process planning function.
➢ CAPP not also reduces the time and effort required to prepare consistent
process plans, but only creates an automated interface between Computer
Aided Design (CAD) and Computer Aided Manufacturing (CAM) to
achieve complete integration within the manufacturing system.
➢ The input of this process is a CAD-model of the workpiece to be created and
the result of this process is a detailed process plan from which the workpiece
can be created/manufactured.
➢ A complete CAPP system would include:
1. Design input.
2. Material selection.
3. Process selection and sequencing.
4. Machine and tool selection.
5. Intermediate surface determination.
6. Fixture selection,
7. Machining parameter selection.
8. Cost/time estimation.
9. Plan preparation.
10. NC tape image generation.
CONCLUSION: Thus, process planning steps, definition, types, sequences of activities, advantages
and disadvantages of different types of process planning are studied.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
AIM: To perform the Step Turning and Knurling in a centre lathe on the given cylindrical
work piecefor the given dimensions.
MATERIALS Mild steel rod of diameter 25 mm and length 105 mm
REQUIRED
TOOLS Single point cutting tool, Knurling tool, Vernier caliper, and chuck key & tool post key
REQUIRED
PROCEDURE: 1. The dimensions of the given cylindrical work piece are checked
2. The work piece is held in the chuck properly and tightened by chuck key
3. The single point cutting tool is held on tool post and tightened by tool post key
4. The facing operation is done on both side of the work piece to get the required
length
5. The plain turning operation is done on work piece to get the initial dimension
6. Then the plain turning operation is further continued to specific dimension to form
steps
7. Thus, the step turning operation is done on the given work piece
8. After that one side of the work piece is knurled by using knurling tool
9. Finally, the dimensions are checked using Vernier caliper before work piece is
removed from thechuck.
Before
Machining
Steps in Stage I
Machining
Stage II
Stage III
Stage IV
Stage V
RESULT Thus, the work piece for the required dimensions is obtained by performing Step
Turning and Knurling operations in lathe.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 >0& ≤ 0.5 >0.5& ≤ 1 1
AIM: To perform the drilling, Boring and Tapping in a drilling Machine on the given work
piece forthe given dimensions.
MATERIALS Mild steel Plate of Length 50x50 mm
REQUIRED
TOOLS Steel rule, Flat file (rough and smooth), Drill bit (8 mm, 10 mm, 10.5 mm), Reaming
REQUIRED tool, Trysquare
PROCEDURE: 1. The work piece was fitted in the vice and filed to the required dimensions.
2. The squareness of the work piece was checked.
3. Drawing punches were made for various drills.
4. The job was fitted on the radial drilling machine.
5. The 10 mm & 8 mm drill bit were used for drilling in the required place and drilling
operation was made on the work piece.
6. Boring was done on the 10mm hole using the boring tool.
7. Reaming was done on the 8 mm hole using the Reaming tool size of 8 mm
diameter.
8. Tapping was done on the 8mm and 10mm hole diameters.
9. The work piece was removed from the radial drilling machine.
Before
Machining
50.0 50.0
55.0 55.0
Steps in Stage I
Machining
45.0 45.0
50.0 50.0
Stage II
45.0 45.0
50.0 50.0
15.0 15.0
15.0 15.0
Stage III
45.0 45.0
Ø10.0
Ø8.5
50.0 50.0
15.0 15.0
15.0 15.0
RESULT Thus, the work piece for the required dimensions is obtained by performing drilling,
Boring, Reaming and Tapping in a drilling Machine.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 >0& ≤ 0.5 >0.5& ≤ 1 1
AIM: To perform the Eccentric turning in a centre lathe on the given cylindrical work
piece for the given dimensions.
MATERIALS Mild steel rod of diameter 25 mm and length 105 mm
REQUIRED
TOOLS Single point cutting tool, Vernier calliper, chuck key & tool post key
REQUIRED
PROCEDUR 1. The dimensions of the given cylindrical work piece are checked
E: 2. The work piece is held in the chuck properly and tightened by chuck key
3. The single point cutting tool is held on tool post and tightened by tool post
key
4. The facing operation is done on both side of the work piece to get the
required length
5. The plain turning operation is done on work piece to get the initial dimension
6. Then the Eccentric turning operation is further continued to specific
dimension to form steps
7. Finally, the dimensions are checked using Vernier calliper before work piece
is removed from the chuck.
Before
Machining
RAW MATERIAL
Ø25
105
Steps in Stage I
Machining
Ø25
50±0.5
Stage II
50±0.5
Stage III
Ø14±0.2
e=4
35±0.25 15±0.25
RESULT Thus, the work piece for the required dimensions is obtained by performing
facing & plain turning operations in lathe.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 > 0 & ≤ 0.5 > 0.5 & ≤ 1 1
AIM: To perform the milling operation in a milling Machine on the given work piece for the
given dimensions.
MATERIALS Mild steel Plate of Length 110x60 mm
REQUIRED
TOOLS Steel rule, vernier calliper.
REQUIRED
PROCEDURE: 1. The work piece was fitted in the vice.
2. The squareness of the work piece was checked.
3. Drawing punches were made for pocket milling.
4. The job was fitted on the milling machine.
5. The required milling tool were used for milling in the required place and milling
operation was made on the work piece.
6. Pocket was taken for 3 mm depth in the work piece.
7. The milling operation was done on the workpiece to the required dimension.
8. The work piece was removed from the milling machine.
Before
Machining
60
110
Raw material
Steps in Stage I
Machining
3
60
110
Surface milling
Stage II
40
60
80
110
Pocket milling
RESULT Thus, the work piece for the required dimensions is obtained by performing by face
milling and pocket milling operation.
Max marks
RUBRICS Low Medium High
Actual obtained
Aim ≤0 >0& ≤ 0.5 >0.5& ≤ 1 1