School of Automotive and Mechanical Engineering

Department of Mechanical Engineering

Sustainable Design and Manufacturing – 211MEC1401

(Integrated Course Practical Component)

B. Tech First Year (All Branches)

Name of the student:

Reg. Number :

Year / Sem / Sec :

Department Name :
 School of Automotive and Mechanical Engineering

Department of Mechanical Engineering

BONAFIDE CERTIFICATE

Bonafide record of work done by of

Department _ _ _ Semester for t h e c o u r s e Sustainable
Design and Manufacturing (211MEC1401) during the academic year 2024-25.

Signature of the Course Teacher Signature of the HOD

Submitted for the Practical Examination held at Kalasalingam Academy of Research and

Education on , Krishnankoil

Internal Examiner External Examiner

 List of Experiments
S. No Name of the Experiment Mark Signature

1 Facing and plain turning operation

2 Planning

3 Tee- Halving (or) Middle Lap Joint

4 V-Fitting

Foundry
5

Rectangular tray
6

7 Drilling
LATHE
 INTRODUCTION

The lathe is used for producing cylindrical work. The work piece is rotated while the cutting tool
movement is controlled by the machine. The lathe is primarily used for cylindrical work. The
lathe may also be used for: Boring, drilling, tapping, turning, facing, threading, polishing,
grooving, knurling etc.
The purpose of a lathe is to rotate a part against a tool whose position it controls. It is useful for
fabricating parts and/or features that have a circular cross section. The spindle is the part of the
lathe that rotates. Various work holding attachments such as three jaw chucks, collets, and centers
can be held in the spindle. The spindle is driven by an electric motor through a system of belt
drives and/or gear trains. Spindle speed is controlled by varying the geometry of the drive train.

The tailstock can be used to support the end of the work piece with a center, or to hold tools for
drilling, reaming, threading, or cutting tapers. It can be adjusted in position along the ways to
accommodate different length work pieces. The ram can be fed along the axis of rotation with the
tailstock hand wheel.

The carriage controls and supports the cutting tool. It consists of: A saddle that mates with and
slides along the ways, an apron that controls the feed mechanisms, a cross slide that
controls transverse motion of the tool (toward or away from the operator), a tool compound that
adjusts to permit angular tool movement and a tool post T-slot that holds the tool post.

Feed, Speed, And Depth of Cut

Cutting speed is defined as the speed at which the work moves with respect to the tool.
Feed rate is defined as the distance the tool travels during one revolution of the part. Cutting speed
and feed determines the surface finish, power requirements, and material removal rate. The
primary factor in choosing feed and speed is the material to be cut. However, one should also
consider material of the tool, rigidity of the work piece, size and condition of the lathe, and depth
of cut. To calculate the proper spindle speed, divide the desired cutting speed by the
circumference of the work.

Parts of Lathe
1. Head Stock
The headstock houses the main spindle, speed change mechanism, and change
gears The headstock is required to be made as robust as possible due to the cutting forces
involved, which can distort a lightly built housing, and induce harmonic vibrations that will
transfer through to the work piece, reducing the quality of the finished work piece.
 2. Bed Feed and Lead Screw
The bed is a robust base that connects to the headstock and permits the carriage and
tailstock to be aligned parallel with the axis of the spindle. This is facilitated by hardened
and ground ways which restrain the carriage and tailstock in a set track. The carriage travels
by means of a rack and pinion system, leads crew of accurate pitch, or feed screw.

3. Feed and Lead Screw

The feed screw is a long driveshaft that allows a series of gears to drive the carriage
mechanisms. These gears are located in the apron of the carriage. Both the feed screw and lead
screw are driven by either the change gears or an intermediate gearbox known as a quick-
change gearbox or Norton gearbox. These intermediate gears allow the correct ratio and
direction to be set for cutting threads or worm gears. Tumbler gears are provided between the
spindle and gear train that enables the gear train of the correct ratio and direction to be
introduced. This provides a constant relationship between the number of turns the spindle
makes, to the number of turns the lead screw makes. This ratio allows screw threads to be cut
on the work piece without the aid of a die.
4. Carriage
In its simplest form the carriage holds the tool bit and moves it longitudinally (turning)
or perpendicularly (facing) under the control of the operator. The operator moves the carriage
manually via the hand wheel or automatically by engaging the feed screw with the carriage
feed mechanism, this provides some relief for the operator as the movement of the carriage
becomes power assisted. The hand wheels on the carriage and its related slides are usually
calibrated both for ease of use and to assist in making reproducible cuts.
 5. Cross-slide
The cross-slide stands atop the carriage and has a lead screw that travels perpendicular
to the main spindle axis, this permit facing operations to be performed. This lead screw can be
engaged with the feed screw (mentioned previously) to provide automated movement to the
cross-slide; only one direction can be engaged at a time as an interlock mechanism will shut out
the second gear train.

6. Compound rest
The compound rest is the part of the machine where the tool post is mounted. It provides a
smaller amount of movement along its axis via another lead screw. The compound rest axis can
be adjusted independently of the carriage or cross-slide.

7. Tool post
The tool bit is mounted in the tool post which may be of the American lantern style,
traditional 4-sided square styles, or in a quick-change style. The advantage of a quick-change
set-up is to allow an unlimited number of tools to be used (up to the number of holders available)
rather than being limited to 1 tool with the lantern style, or 3 to 4 tools with the 4-sided type.

8. Tail Stock
The tailstock is a tool holder directly mounted on the spindle axis, opposite the
headstock. The spindle does not rotate but does travel longitudinally under the action of a lead
screw and hand wheel. The spindle includes a taper to hold drill bits, centers and other
tooling. The tailstock can be positioned along the bed and clamped in position as required.
There is also provision to offset the tailstock from the spindle’s axis; this is useful for turning
small tapers.

Lathe Operations

Lathe machine can perform different operations like

1. Facing
2. Turning – Step Turning, Taper Turning
3. Knurling
4. Grooving, Parting off
5. Thread Cutting – Internal and External Thread Cutting
6. Drilling, Reaming, Boring
7. Slotting etc.,
Experiment No: 1
FACING AND PLAIN TURNING OPERATION
Date:

Aim
To Plan a Facing and Plain turning operation using in centre lathe.

Tools Requirement:
1. Steel rule
2. Outside caliper
3. Chuck key
4. V-tool
5. Vernier caliper

Procedure:
1. The dimensions of the given work piece are checked by steel rule or Vernier
caliper.
2. The work piece is held in the lathe chuck properly and it is tightened by the chuck.
3. The single point cutting tool is held in the tool post and it is tightened by tool post
key.
4. Facing is done with cutting tool, moving from the center of the work piece towards
outside.it is done until the required length of the job is obtained.
5. Turning is done to reduce the diameter of the job. Sufficient depth of the cut is
given and it is done until the required length of the job is obtained.
6. The workpiece from the chuck is removed and the dimensions are checked for
requirement.

Result:
Thus, the required size and shape of the workpiece is obtained by facing and plane
turning operation in center lathe.
 FACING AND PLAIN TURNING

Before Machining

After Machining
CARPENTRY
 INTRODUCTION
CARPENTRY
Carpentry may be defined as the process of making wooden articles and
components such as doors, windows, Furniture etc. Carpentry involves cutting, shaping
and fastening wood and other materials together to produce a finished product. Preparation
of joints is one of the important operations in wood work. Joinery denotes connecting the
wooden parts using different points such as lap joints, mortise and tenan joints, bridle joints,
etc.

TIMBER
Timber is the material used for carpentry. It is the name given to the wood obtained
from well grown trees called exogenous trees. Timber is made suitable for engineering
purposes by sawing into various sizes.

ADVANTAGES OF TIMBER
• It is easily available
• It is lighter and stronger to use
• It responds well for polishing and painting
• Suitable for sound proof construction
• It is easy to work with tools
• It is very economic
Classification of Timber
1. SOFT WOOD

• It is obtained from trees having long needle shaped leaves

• It is light in weight
• It is easy to work
• It is relatively less durable
• It has good tensile resistance and poor shear resistance
• It has straight fibers and fine texture
• It is widely used for construction

2. HARD WOOD
• It is obtained from trees having broad leaves.
• It is heavier in weight and dark in color.
• It is difficult to work and it is highly durable
• Its fibers are quiet close and compact. It has both tensile and shear resistance.
• It widely used for doors, windows and furniture’s.
 STUDY OF CARPENTRY TOOLS
Carpentry tools are used to produce components to an exact size. The types of
carpentry tools are as follows.

1. Marking tools 2.Measuring tools 3. Holding tools

4. Cutting tools 5. Planning tools 6. Boring tools
7. Striking tools 8. Miscellaneous tools

MARKING TOOLS
Accurate marking is important in carpentry to produce components to exact
size.
1. Marking gauge
It consists of a square wooden stem with a sliding wooden stock on it. On the stem, a
marking pin is attached which is made up of steel. This stem is provided with a steel nail to
scratch the surface of the work.

Marking gauge

2. Mortise gauge
It consists of two pins; the distance between the pins is adjustable. It is used to draw
parallel lines on the stock.

Mortise gauge
3. Try Square
The engineer’s try-square is composed of two parts, the stock and the blade. They are
usually made from mild steel with blade being hardened and tempered to resist damage. The
try square is pushed against a straight side of the material. An engineer’s scriber is then used to
scratch a line onto the surface of the material.

4. Scriber

A Scriber is a hand tool used to mark lines on workpieces. This is used instead of pencil.
They consist simply of a rod of high carbon steel with a sharpened point.

5. Spirit level
Spirit levels are used for testing the position of large surfaces. It is used for testing
horizontal position of the workpieces. It is having a glass tube with air bubble.

Spirit level
 MEASURING TOOLS
The carpentry measuring tools are used to measure the dimensions in the wood for
exact measurement in cutting.

1. Carpenter’s steel rule

Large measurements can be made by steel rule. It is also suitable for measuring
circumference of curved surfaces.

Steel Ruler
HOLDING TOOLS
The carpentry holding tools are shown in figure

1. Carpentry vice or Bench vice

A carpentry vice is the common work holding device. It consists of one fixed jaw and
one movable jaw. It’s one jaw is fixed to the side of the table while the other is movable by
means of a screw and a handle.
2. Bench stop
It is a simple straight flat plank of wood having two projected rectangular sections of
wood screwed on opposite side of the plank. The work is placed in such a way that it is always
butting against the projected portion so as to resist the work from moving.
3. G-clamp
G-clamp is made up of malleable iron with acme threads of high-quality steel. It can be
used for clamping small work when gluing up.
CUTTING TOOLS
1. Saws
A saw is used to cut wood into pieces. There is different type of saws, designed to suit
different purpose. A saw is specified by the length of its tooled edge. The following saws are
used in the carpentry section.
Rip Saw

The blade of rip saw is either straight or skew-backed. The teeth are so set that the
cutting edge of this saw makes a steeper angle about 600
Cross Cut saw

This is similar in shape of a rip saw. It is used to cut across the grain of the stock. The
correct angle for cross cutting is 450. T h e teeth are so set that the saw kerfs are wider
than the blade thickness. This allows the blade to move freely in the cut without sticking.
Tenon or back saw
A tenon saw is used for fine and accurate work. It consists of a very fine blade, which
is reinforced with a rigid steel back. The teeth are shaped like those of cross cut saw.
2. Chisels
Chisels are used for cutting and shaping wood accurately. Wood chisels are made in
various blade widths, ranging from 3 to 50mm. Most of the wood chisels are made into tang
type, having a steel shank which fits inside the handle.

Firmer chisels

These are general purpose chisels and are used either by hand pressure or by a mallet.
The blade of a firmer chisel is flat and their sloping face is at an angle 15 degree to 52 degree.

Mortise Chisels

These are general purpose chisels and are used for cutting mortises above 9mm wide.
The blade of a firmer type is in which they have a thicker section and a stronger neck. By
means of this chisel we can apply more Leverage to remove waste wood from the mortise.

Bevel chisels or Dove tail chisel

A bevel chisel is similar in construction to the firmer chisel. Its edges are beveled to
allow access to difficult corners. It has a blade with a beveled back due to which it can enter
sharp corners for finishing in dove tail joints.

PLANNING TOOLS
In general, planes are used to produce flat surfaces on wood. The cutting blade used in
a place is very similar to a chisel. The blade of a plane is fitted in a wood or metallic block at
an angle.

1. Jack plane

Jack plane which is about 35 cm long is used for

general planning. A Jack plane that is about 20 to 25cm long
is used for smoothening the stock. It can follow even the
slight depressions in the stock better than the jack plane.
Smooth plane is used after using the jack plane.

2. Rebate plane
A rebate plane is used for making a rebate. A rebate is a recess along the edge of a piece of
wood which to generally used for positioning glass in frames and doors. A plough plane is
used to cut grooves, which are used to fix handle in a door.
BORING TOOLS
Boring tools are used to make holes in wood. Common types of boring tools are as follows.
1. Gimlet
It has cutting edges like a twist drill. It is used for boring holes with the hand pressure.

2. Hand drill
A straight shank drill is used with this tool. It is small, light in weight and may be conveniently
used. The drill bit is clamped in the end.

3. Ratchet brace
It consists of crank made of steel, wooden handle in the middle, head at the top and chuck at
the bottom. The bit rotates when the crank is rotated by hand.

STRIKING TOOLS
1. Hammers
The cross peen hammer is mostly used for positioning small nails. The head is tightly
held in the handle with the help of iron wedges. The claw hammer is effective in removing
very large nails and also for driving the nails using the other end of the hammer.

2. Mallet
A mallet is used to drive the chisel, when considerable force is to be applied, which may
be the case in making deep rough cuts. A steel hammer should not be used for this purpose, as it
may damage the chisel.
MISCELLANEOUS TOOLS

1. Pincers
They are made up of steel with a hinged joint and are used for pulling out small nails
from wood.

2. Screwdrivers
Screwdriver is used for driving wood screws into wood or unscrewing them. The
screwdriver used in carpentry is different from the other common types.

3. Rasp file
A rasp file is a file used for finishing the surface of wood. The rasp has sharp cutting
teeth on its surface for this purpose. The file is used for removing rasp marks end finally the
scratches left by the fix are removed with the scraper and glass paper.

4. Oil stone
This is an essential flat used for providing sharp edges on cutting tools. The oil stones
may be artificial or natural stones. The carborundum is the best artificial stones where as the
Arkansas are the natural stones.
 CARPENTRY PROCESSES
In a carpentry shop, a number of operations are performed to get the finished
workpiece. The different types of process performed in a carpentry shop can be classified as
follows.

1. Marking and Measuring

It is the process of setting of dimensions on wooden pieces to obtain the required shape.
This is the first step for further carpentry operations. The marking operation is done with use
of marking tools. Before marking, one end is planned for reference.
2. Sawing

Sawing is the process of cutting wood to the required shape and size such as straight,
inclined or curved. Sawing can be done along the grains or across the grains. In sawing, wooden
work is fixed in a vice and wood is moved up to prevent vibrations during sawing.

3. Planning

Planning is an operation of obtaining, smooth, dimensionally true surface of wood by

using a planer. It is done along the grains. So, smooth surface is achieved. This process can be
also called facing or edging.

4. Chiseling
It is the process of cutting a small stock of wood to produce required shapes.

5. Mortising and Tenoning

Mortising is the process of producing a mortise, i.e. a rectangular or square holes and
recesses in wooden pieces. A tenon is a projected piece of wood that fits into the
corresponding mortise. This process is done by using mortise chisels and a mallet.

6. Boring

Boring is the process of producing through holes or blind holes in wooden piece. This
process can be done straight or inclined according to the type of work. The small holes are
produced by using bradawl and gimlet, whereas large holes are produced by using braces,
drills.

7. Grooving

Grooving is the process of making grooves tonguing is the process of producing

corresponding projections of wood for fitting into grooves. Grooving and tonguing operation
can be seen in drawing boards, floor boards and partitions. Grooving is done with a plough
plane tool, and tonguing is done with a molding plane tool.
Experiment No: 2
PLANNING
Date:

Aim
To plane the given workpiece for the required shape.
Material Required
Soft wood of size 300 x 50 x 30 mm

Tools Required
1. Jackplane
2. Bench vice
3. Try square
4. Marking gauge
5. Steel rule
6. Tenon saw
7. Rip saw
8. Firmer chisel
9. Mallet

Procedure
1. The given workpiece is firmly clamped in the bench vice and any two adjacent
surfaces are planed to get right angles using the jack plane.
2. Using the try square, the right angles of planed faces are checked.
3. Now the other two surfaces are planed to get smooth surface.
4. Based on the planed surfaces, the markings are made on the two sides by using
marking gauge.
5. After marking, the workpiece is planed such that it should have required
dimensions.
6. Finally, the finished job is checked for required size using the steel rule and try
square.

Result
Thus the required Dimension is obtained by planning.
 Experiment No: 3
TEE HALVING (OR) MIDDLE LAP JOINT
Date:

Aim:
To make a tee halving (or) middle lap joint from the give wooden piece for the give
dimensions.
Material Supplied:
A wooden piece of size 300 x 50 x 30 mm
Tools required:
1. Jackplane
2. Bench vice
3. Try square
4. Marking gauge
5. Steel rule
6. Tenon saw
7. Rip saw
8. Firmer chisel
9. Mallet
Sequence of operations:
1. Rough planning, 2. Marking, 3. Cutting (or) Sawing, 4. Finish Planning. 5. Chiseling

Working steps:
1. Ensure the workpiece is given as per the dimension.
2. The workpiece is clamped in the carpentry vice and any two surfaces are planned by
Jackplane to get right angle.
3. The workpiece is checked to set the right angle using try square.
4. Now all the four sides of the wooden pieces are plane to get the smoother and finished
surface
5. Now the workpiece is cut into two halves using Rip saw.
6. Then proper marking is done for middle lap joint on the two pieces using steel rule and
marking gauge.
7. Half of the workpiece is taken and to clamp in the vice to remove the unwanted portions
are removed as per the drawing using Tenon Saw and Firmer Chisel.
8. The above procedure is repeated for the other half of the workpiece.
9. Jack plane is used to plane the other two faces up to the marked portion.
10. Now the two pieces are assembled to check proper fitting.
11. The finished job is again checked for it accurate shape and size using try square and steel
rule.
Skills Developed:
To plane, saw and inspect a completed job for dimensional accuracy.
Result:
Thus, the desired Tee halving or Middle lap joint is obtained
‘T’ Halving or Middle Lap Joint
FITTING
 INTRODUCTION TO FITTING
In engineering, particularly in heavy and medium engineering, even today with the use of
automatic machines, bench work and fitting have important roles to play to complete and finish
a job to desired accuracy.

“Bench work” generally denotes the production of an article by hand on the bench.

“Fitting” is the assembling together of parts and removing metals to secure the necessary fit,
and may or may not be carried out at the bench. There is no clear meaning between these two
terms hence it is used rather loosely. Both these two types of work require the use of large number
of tools and equipment’s and involve number of operations to finish the work piece to desired
dimensions, shape.

The operations that are carried out are:

1. Marking out
2. Sawing
3. Chipping
4. Filing
5. Scraping
6. Grinding
7. Drilling
8. Reaming
9. Tapping etc.,
Marking out:
Marking out consists of marking out on the job a series of definite lines or positions. All
marking should be done with reference to true edge or surfaces, preferably low at right angles
or with reference to certain datum lines. These edges or positions of datum line can be
determined from the drawing which is necessary for each job. The surfaces of work to be marked
out are usually treated with chalk, or with copper sulphate solution, which leaves a thin film
of copper on iron or steel.
After the solution is dried then it is ready for marking out. It is either placed in 'V' block if it is
round, or laid on a surface plate if it is flat job or work piece. Horizontal or vertical lines are
scribed by Try-Square, provided a true surface on the edge of the job to be marked is available.
The required dimensions of the job based on design is marked using a steel rule or spring calipers,
hermaphrodite calipers, divider etc. Boundary marks, which later are to be cut away, are made
permanent by light dot punching along the part out wards to which the part has to be removed.
Leading to the scribed line as a reference of comparison after the job is finished.
Measuring Instruments:
There are difference types of measuring instruments but for workshop purpose these
different types of tools are used.

Steel rule:
It is one of the most useful tools in the workshop for taking linear measurements of
blanks and articles to an accuracy of from 1.0 to 0.5 mm.

Calipers:
Calipers are used to transfer and compare a dimension from one object to another
or from a part to a scale or micrometer, where the measurement cannot be made directly.
Types of calipers

• Outside spring calipers

• Inside spring caliper

• Vernier caliper

• Micro meter

• Divider
 Marking tools:
Marking tools are used for lay outing the work or marking for further
processing or the job. Some of the marking tools are:
1. Surface plate 4. ‘V’ block
2. Scriber 5. Angle plate
3. Punch 6. Try – Square
1. Surface plate:
It is square or rectangular in shape, made of grey cast iron of solid design. It is used for
testing the flatness of work or for measuring or layout the work. The surface is ground and
scraped to very high accuracy.

Surface gauge

It has ground flat base carrying scriber arm, which is fitted

with an adjustable scribble point, so that lines can be inscribed on the
work at a predetermined distance from the surface plate.

Scriber:
It is used for drawing lines in the metal parts to layout the job. It is made of hardened
steel.

Punch:

It is used for making punch marks on the layout of parts for further processing. It is
made of hardened steel rod.
Twist Drill:

Twist drills are used for making holes. These are made of High speed steel. Both straight and
taper shank twist drills are used. The parallel shank twist drill can be held in an ordinary self –
centering drill check. The tapper shank twist drill fits into a corresponding tapered bore provided
in the drilling machine spindle.

Taps and Tap wrenches

A tap is a hardened and steel tool, used for cutting internal thread in a drill hole. Hand Taps
are usually supplied in sets of three in each diameter and thread size. Each set consists of a
tapper tap, intermediate tap and plug or bottoming tap. Taps are made of high carbon steel or
high-speed steel.
V block:
V blocks are made of mild steel with v shaped grooves. When circular bar
needs lay outing or for drilling, V-block can be used. V‐block is a rectangular or square
block with a V‐groove on one or both sides opposite to each other. The angle of the ‘V’
is usually 900. V‐block with a clamp is used to hold cylindrical work securely, during layout
of measurement, for measuring operations or for drilling for this the bar is faced
longitudinally in the V‐Groove and the screw of V‐clamp is tightened. This grip the rod is
firm with its axis parallel to the axis of the v‐groove. It consists of beam to which blade is
fixed. It is used to check the flatness and trueness of the surface.

Try square:
It is a woodworking or a metal working tool used for marking and measuring a piece of wood
The square refers to the tool's primary use of measuring the accuracy of a right angle (90
degrees); to try a surface is to check its straightness or correspondence to an adjoining surface.
A piece of wood that is rectangular flat, and has all edges (faces, sides, and ends) 90 degrees is
called four square. A traditional try square has a broad blade made of steel that is riveted to a
wooden handle or 'stock'. The inside of the wooden stock usually has a brass strip fixed to reduce
wear. Some blades also have graduations for measurement. Modern try squares may be all-metal,
with stocks that are either die-cast or extruded.
Angle plate:
It is made of grey cast iron. It has two planed and ground surface at right angles to each
other. It is used along with surface plate to hold the vertically for marking.

CUTTING / SAWING TOOLS

1. Hacksaw Frame
2. Hacksaw Blade

Chipping: Chipping is the process of removing

thick layers of metal by means of cold chisels. In
chipping job is held firmly in vice and the metal is
removed by striking the chisel on the work piece
by a hammer.

Chipping tools
1. Hammer
2. Chisel
 Files:
Filing is an important operation. It serves to remove the burr from the cut and clean the
face of the cuts, and to finish the final shape of the workpiece.

Flat file: It is used commonly for general work; it is double cut on face and single cut on
sides.

Hand File: It is used for finishing flat surfaces.

Square file: It is used for filling square corners, square and rectangular openings splines
and keyways.

Triangular file: It is triangular in cross section, double cut and tapers towards the point, used
for filing corners, which have less than 90°

Half round file: It is less than half round used in filing curved surfaces. It is tapered and
double cut.
 Experiment No: 4
V-FITTING
Date:

Aim:
To make a V-Fitting from the given workpiece.
Material Supplied:
70x50x3 mm Mild Steel Flat
Tools required:
1) Steel rule 6", 2) Scriber 6".
3) Try square 6", 4) Dot punch 4".
5) Ball peen hammer 1/2 Ib”, 6) Flat file (B) 12",
7) Flat file (S) 6". 8) Hacksaw frame 12",
9) Triangular file (B) 6"x1/2"
Sequence of operations:
1. Checking
2. Marking
3. Punching
4. Sawing
5. Filing
6. Finishing,
Working steps:
1. The given workpiece is checked as per the given dimension using Steel rule.
2. Workpiece is fixed on a vice and two adjacent sides are filed by using Flat file and to
set the right angles in the workpiece.
3. Chalk is applied uniformly on the surface of the workpiece.
4. The workpiece is placed on the surface plate and to mark the given dimensions by
using the Caliper and Steel rule.
5. Now using dot punch dots are punched over the marked line.
6. Then the unwanted portions are removed by using the Hacksaw.
7. Cutting edges are filed by using the round half and Triangular files.
8. Check the required dimensions using Try Square for squareness and flatness of the
surfaces in the workpiece.
9. Assembly is checked for the required fit.
Skills Developed:
To mark, punch, file and inspect a completed job for dimensional accuracy.
Result:
Thus, the required V-fitting is obtained from the given workpiece.
V - FITTING
 Experiment No: 5 FOUNDRY
Date:

Aim:
To prepare a mould cavity by using a solid / single piece pattern.

Tools required:
1. Moulding Flasks,

2. Solid / Single piece pattern,

3. Sand Rammers,

4. Trowel,

5. Leveller,

6. Vent Road,

7. Moulding Sand Mixture.

Working steps:
1. Prepare the moulding sand mixture by adding adequate amounts of clay and water to it.

2. Keep the drag on the bottom board in the inverted position.

3. Locate the centre of the drag half by drawing two diagonals.

4. Place the pattern in the center.

5. Fill the drag half of the mould flask by green sand prepared as in step 1.

6. Ram the sand by using a sand rammer to form a hard mass.

7. Strike off the excess sand a level with a leveler (Strike off bar).

8. Sprinkle parting sand on the top surface of the drag half of the mould.

9. Place the cope on the drag half of the mould.

10. Place the riser pin on the pattern centre and place the sprue pin on the drag at a convenient
distance from the pattern.
11. Now by holding the sprue and the sprue and the riser pins fill the cope with the moulding
sand and ram it properly.
 12. By using a vent rod pierce the holes on the top surface of the cope half.
13. Loosen the sprue pins and remove them from the rammed portion carefully.
14. Remove the cope and place it inverted.
15. By using sand lifters remove the drag and cut in – gates and sprue base.
16. Shake the pattern by using a mallet without disturbing the mould cavity.
17. Remove the pattern carefully.
18. Clean the pattern carefully.
19. Place the cope on the drag and close the mould cavity.

Skills Developed:
Mold cavity creation

Result:
The mold cavity similar to the drawing specifications shown is obtained.
 Experiment No: 6 RECTANGULAR TRAY
Date:

Aim:
To make a rectangular Tray and cylinder as per required dimensions.

Tools required:
1. Steel rule
2. Flat file
3. Scriber
4. Try square
5. Snips
6. Dot punch
7. Stakes
8. Mallet
Sequence of operations:
1. Planning
2. Marking
3. Cutting
4. Bending
5. Seaming
6. Soldering

Working steps:
1The size of the given sheet is checked with steel rule.
2. Mark the measurement and make the development surface sketch diagram.
3. The layout of the tray is marked on given sheet.
4. The layout of the tray is cut by using the straight snips.
5. The sheet is bent to the required shape using stakes and mallet.
6. Now the bent edges are made to overlap each other and stuck with a mallet to get the required joint.
7. The joint is soldered.

Skills Developed:
Planning, marking, cutting and bending of sheet metal

Result:
The rectangular tray is done success fully made
 STUDY OF DRILLING MACHINE

Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter
called Drill. The machine used for drilling is called drilling machine.

➢ The drilling operation can also be accomplished in lathe, in which the drill is held in tailstock and the
work is held by the chuck.
➢ It is the simplest and accurate machine used in production shop.
➢ The work piece is held stationary ie. Clamped in position and the drill rotates to make a hole.

TYPES OF DRILLING MACHINE

1) Based on construction:
1. Portable,
2. Sensitive,
3. Radial,
4. up-right,
5. Gang,
6. Multi-spindle
2) Based on Feed:
Hand driven
Power driven

COMPONENTS OF DRILLING MACHINE SPINDLE

The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve.

SLEEVE

The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel to
its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool is fed into the
work: and when it’s moved upward, the cutting tool is withdrawn from the work. Feed pressure applied
to the sleeve by hand or power causes the revolving drill to cut its way into the work a fraction of an mm
per revolution.

COLUMN

The column is cylindrical in shape and built rugged and solid. The column supports the head and
the sleeve or quill assembly.

HEAD

The head of the drilling machine is composed of the sleeve, a spindle, an electric motor and feed
mechanism. The head is bolted to the column.
WORKTABLE
The worktable is supported on an arm mounted to the column. The worktable can be adjusted
vertically to accommodate different heights of work or it can be swung completely out of the way. It may
be tilted up to 90 degrees in either direction, to allow long pieces to be end or angle drilled.

BASE

The base of the drilling machine supports the entire machine and when bolted to the floor,
provides for vibration-free operation and best machining accuracy. The top of the base is similar to the
worktable and may be equipped with t- slot for mounting work too larger for the table.

HAND FEED

The hand- feed drilling machines are the simplest and most common type of drilling machines in
use today. These are light duty machine that are operated by the operator, using a feed handled, so that
the operator is able to “feel” the action of the cutting tool as it cuts through the work piece. These drilling
machines can be bench or floor mounted.

POWER FEED

The power feed drilling machine are usually larger and heavier than the hand feed ones they are
equipped with the ability to feed the cutting tool in to the work automatically, at preset depth of cut per
revolution of the spindle these machines are used in maintenance for medium duty work or the work that
uses large drills that require power feed larger work pieces are usually clamped directly to the table or
base using t –bolts and clamps by a small work place are held in a vise. A depth –stop mechanism is
located on the head, near the spindle, to aid in drilling to a precise depth.

SENSITIVE OR BENCH DRILLING MACHINE

• This type of drill machine is used for very light works.

• The vertical column carries a swiveling table the height of which can be adjusted according to the
work piece height.
• The table can also be swung to any desired position.
• At the top of the column there are two pulleys connected by a belt, one pulley is mounted on the
motor shaft and other on the machine spindle.
• Vertical movement to the spindle is given by the feed handle by the operator.
• Operator senses the cutting action so sensitive drilling machine.
• Drill holes from 1.5 to 15mm
UP-RIGHT DRILLING MACHINE

• These are medium heavy-duty machines.

• It specifically differs from sensitive drill in its weight, rigidity, application of power feed and
wider range of spindle speed. Fig shows the line sketch of up-right drilling machine.
• This machine usually has a gear driven mechanism for different spindle speed and an
automatic or power feed device.
• Table can move vertically and radially.
• Drill holes up to 50mm

Up-Right Drilling Machine

RADIAL DRILLING MACHINE

• It the largest and most versatile used for drilling medium to large and heavy work pieces.
• Radial drilling machine belong to power feed type.
• The column and radial drilling machine support the radial arm, drill head and motor. Fig shows
the line sketch of radial drilling machine.
 Radial Drilling Machine

• The radial arm slides up and down on the column with the help of elevating screw provided on
the side of the column, which is driven by a motor.
• The drill head is mounted on the radial arm and moves on the guide ways provided the radial arm
can also be swiveled around the column.
• The drill head is equipped with a separate motor to drive the spindle, which carries the drill bit. A
drill head may be moved on the arm manually or by power.
• Feed can be either manual or automatic with reversal mechanism.
 Nomenclature of twist drill

TOOL HOLDING DEVICES

Fig shows the different work holding. The different methods used for holding drill in a drill spindle are

• By directly fitting in the spindle hole.

• By using drill sleeve
• By using drill socket
• By using drill chuck

Tool Holding Devices

DRILLING OPERATIONS

Operations that can be performed in a drilling machine are

➢ Drilling
➢ Reaming
➢ Boring
➢ Counter boring
➢ Countersinking
➢ Tapping
Drilling:
It is an operation by which holes are produced in solid metal by means of revolving tool called ‘Drill’.
Fig. shows the various operations on drilling machine.
Reaming:
Reaming is accurate way of sizing and finishing the pre-existing hole. Multi tooth cutting tool. Accuracy
of 0.005mm can be achieved

Boring:
Boring is a process of enlarging an existing hole by a single point cutting tool. Boring operation is often
preferred because we can correct hole size, or alignment and can produce smooth finish. Boring tool is
held in the boring bar which has the shank. Accuracy of 0.005mm can be achieved.

.
Various operations on drilling machine

Counter Bore:

This operation uses a pilot to guide the cutting action to accommodate the heads of bolts. Fig.
illustrates the counter boring, countersunk and spot facing processes.

Countersink:

Special angled cone shaped enlargement at the end of the hole to accommodate the screws. Cone
angles of 60°, 82°, 90°, 100°, 110°, 120°.
 Counter boring, countersunk and spot facing

Tapping:

Tapping is the process by which internal threads are formed. It is performed either by hand or by
machine. Minor diameter of the thread is drilled and then tapping is done. Fig. shows the tapping
processes.

Hand taps and tapping process using tap wrench

 Experiment No: 7 DRILLING
Date:

Aim:
To perform the drilling, in a drilling Machine on the given work piece for the given
dimensions.
Materials Required:
Mild steel Plate of Length 50x50 mm
Tools required:
1. Steel rule,
2. Flat file (rough and smooth),
3. Drill bit (8 mm, 10 mm, 10.5 mm),

4. Reaming tool,
5. Try square
Working steps:
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. The work piece was removed from the radial drilling machine.

Skills Developed:
Marking, Punching

Result:
Thus, the work piece for the required dimensions is obtained by performing drilling in a
drilling Machine.
BEFORE MACHINING

AFTER MACHINING

All dimensions are in mm