IPS Academy , Indore · IPS Academy, Institute of Engineering & Science 3rd Semester Manufacturing...

IPS Academy, Indore Institute of Engineering & Science

Mechanical Engineering Department

LAB MANUAL

Manufacturing Process

(ME-305)

Name …………………………………………….

Session …………………………Semester …..…….

Enrollment No. ……………………………………

IPS Academy, Institute of Engineering & Science

3rd

Semester Manufacturing Process (ME 305) Session 2019-20

Contents

1. Vision Mission of the Institute

2. Vision Mission of the Department

3. PEOs

4. POs

5. COs

6. Content beyond Syllabus.

7. Laboratory Regulations and Safety Rules

8. Index

9. Experiments


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Vision of the Institute

“To be the fountainhead of novel ideas & innovations in science & technology & persist to be a

foundation of pride for all Indians.”

Mission of the Institute

M1: To provide value based broad Engineering, Technology and Science where education in

students is urged to develop their professional skills.

M2: To inculcate dedication, hard work, sincerity, integrity and ethics in building up overall

professional personality of our student and faculty.

M3: To inculcate a spirit of entrepreneurship and innovation in passing out students.

M4: To instigate sponsored research and provide consultancy services in technical, educational

and industrial areas.

Vision of the Department

“To be a nationally recognized, excellent in education, training, research and innovation that

attracts, rewards, and retains outstanding faculty, students, and staff to build a Just and Peaceful

Society.”

Mission of the Department

M1: Imparting quality education to the students and maintaining vital, state-of-art research

facilities for faculty, staff and students.

M2: Create, interpret, apply and disseminate knowledge for learning to be an entrepreneur and to

compete successfully in today’s competitive market.

M3: To inculcate Ethical, Social values and Environment awareness.


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Program Education Objectives (PEOs)

PEO 1: To enrich graduates with fundamental knowledge of Physics, Chemistry and advanced

mathematics with their solid foundation in Mechanical Engineering subjects.

PEO 2: To provide graduates to design the solution of mechanical engineering problems relevant to

mechanical engineering design through the process of formulating, executing & evaluating a design

solution as per need with socioeconomic impact consideration and related constraints.

PEO 3: To provide graduates with experience in learning and applying tools to solve theoretical and

open ended mechanical engineering problems.

PEO 4: To provide a contemporary grounding in professional responsibility in mechanical

engineering including ethics, global economy, emerging technologies and job related skills such as

written and oral communication skills and to work in multidisciplinary team.

PEO 5: Prepare graduates to be interested, motivated, and capable of pursuing continued life-long

learning through beyond curriculum education, short courses and other training programme in

interdisciplinary areas.


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Program Outcomes (POs)

Engineering Graduates will be able to:

PO1: Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of Mechanical

engineering problems.

PO2: Problem analysis: Identify, formulate, and analyze mechanical engineering problems to

arrive at substantiated conclusions using the principles of mathematics, and engineering

sciences.

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

and design system components, processes to meet the specifications with consideration

for the public health and safety, and the cultural, societal, and environmental

considerations.

PO4: Conduct investigations of complex problems: An ability to design and conduct

experiments, as well as to analyze and interpret data.

PO5: Modern tool usage: Create, select, and apply appropriate techniques, resources, and

modern engineering and IT tools including prediction and modeling to mechanical

engineering problems with an understanding of the limitations.

PO6: The engineer and society: Apply critical reasoning by the contextual knowledge to assess

societal, health, safety, legal and cultural issues and the consequent responsibilities

relevant to the Mechanical engineering practice.

PO7: Environment and sustainability: Understand the impact of the Mechanical engineering

solutions in societal and environmental contexts, and demonstrate the knowledge of, and

need for sustainable development.

PO8: Ethics: An understanding of professional and ethical responsibility.

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

leader in teams, and in multidisciplinary settings.


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PO10: Communication: Ability to communicate effectively. Be able to comprehend and write

effective reports documentation.

PO11: Project management and finance: Demonstrate knowledge and understanding of

engineering and management principles and apply this to Mechanical engineering

problem.

PO12: Life-long learning: ability to engage in life-long learning in the broadest context of

technological change.

Program Specific Outcomes (PSOs)

PSO1: Engage professionally in industries or as an entrepreneur by applying manufacturing and

management practices.

PSO2: Ability to implement the learned principles of mechanical engineering to analyze,

evaluate and create advanced mechanical system or processes.

Course Outcomes (COs)

CO1 Explain types of patterns and casting process.

CO2 Explain various types of welding process and demonstrate the welding

process.

CO3 Define Concepts of forging methods.

CO4 Explain press working and rolling.

CO5 Explain and demonstrate various machines.


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Content beyond syllabus

3D Printing and its application.


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Laboratory Regulations and Safety Rules

1. Read the instructions mentioned in the manual carefully and then proceed for the experiment.

2. Mishandling of lab equipment will not be tolerated at all. If any student is found guilty; he/she

should be punished/ discarded from the lab.

3. Care must be taken while dealing with electrical connections.

4. Issued the needed/ supporting equipments by the concerned teacher/lab technician & return

the same duly before leaving the lab.

5. If any defect or discrepancy noticed in the particular instrument/equipment while the students

are using, they will be fined/ punished for the same.

6. Put your bags on the rack outside the lab before entering in lab.

7. Switch off the lights, fans and all the equipments used, before leaving lab.

8. Students will replace their chairs to its specific position before leaving the lab.


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INDEX

S. No. Experiment Date Grade Signature

1. To prepare a sand mold, using the

given single piece pattern.

2. To prepare a sand mold, using the

given split-piece pattern.

3. To make a Butt joint using the given

two M.S plate by arc welding.

4. To make a Lap joint, using the given

two mild steel plates by arc welding.

5.

To perform various lathe operations

such as facing, plain turning, step

turning and taper turning on a given bar

of mild steel.

6.

To perform Thread cutting and

Knurling operation on the given bar of

mild steel.

7.

To perform drilling, and tapping

operations on the given mild steel Flat

Plate.

8. To study of Milling machine.

9. To study of Shaper machine.

10. To create physical object by using 3D

printer.(Content Beyond Syllabus)


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Experiment No. 1

Aim: To prepare a sand mold, using the given single piece pattern.

Material Required: Moulding sand, Parting sand, facing sand, baking sand, single piece

solid pattern, bottom board, moulding box etc.

Tools Required:

1. Molding board/Platform

2. Drag and cope boxes

3. Molding sand

4. Parting sand

5. Rammer

6. Strike-off bar

7. Bellows

8. Riser and sprue pins

9. Gate cutter

10. Vent rod

11. Draw spike

12. Brush

Sequence of operations:

1. Sand preparation

2. Placing the mould flask (drag) on the moulding board/ moulding platform

3. Placing the pattern at the centre of the moulding flask

4. Ramming the drag

5. Placing runner and riser

6. Ramming the cope

7. Removal of the pattern, runner, riser

8. Gate cutting

Procedure:

1. First a bottom board is placed either on the molding platform or on the floor, making the

surface even.


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2. The drag molding flask is kept upside down on the bottom board along with the drag part

of the pattern at the centre of the flask on the board.

3. Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.

4. Freshly prepared molding sand of requisite quality is now poured into the drag and on the

pattern to a thickness of 30 to 50 mm.

5. Rest of the drag flask is completely filled with the backup sand and uniformly rammed to

compact the sand.

6. After the ramming is over, the excess sand in the flask is completely scraped using a flat

bar to the level of the flask edges.

7. Now with a vent wire which is a wire of 1 to 2 mm diameter with a pointed end, vent holes

are in the drag to the full depth of the flask as well as to the pattern to facilitate the removal

of gases during casting solidification. This completes the preparation of the drag.

8. Now finished drag flask is rolled over to the bottom board exposing the pattern.

9. Using a slick, the edges of sand around the pattern is repaired

10. The cope flask on the top of the drag is located aligning again with the help of the pins of

the drag box.

11. Sprue of the gating system for making the sprue passage is located at a small distance of

about 50 mm from the pattern. The sprue base, runners and in-gates are also located as shown

risers are also placed. Freshly prepared facing sand is poured around the pattern.

12. The moulding sand is then poured in the cope box. The sand is adequately rammed,

excess sand is scraped and vent holes are made all over in the cope as in the drag.

13. The sprue and the riser are carefully withdrawn from the flask

14. Later the pouring basin is cut near the top of the sprue.

15. The cope is separated from the drag any loose sand on the cope and drag interface is

blown off with the help of the bellows.

16. Now the cope and the drag pattern halves are withdrawn by using the draw spikes and

rapping the pattern all around to slightly enlarge the mould cavity so that the walls are not

spoiled by the withdrawing pattern.

17. The runners and gates are to be removed or to be cut in the mould carefully without

spoiling the mould.

18. Any excess or loose sand is applied in the runners and mould cavity is blown away using

the bellows.

19. Now the facing paste is applied all over the mould cavity and the runners which would

give the finished casting a good surface finish.


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20. A dry sand core is prepared using a core box. After suitable baking, it is placed in the

mould cavity.

21. The cope is placed back on the drag taking care of the alignment of the two by means of

the pins.

22. The mould is ready for pouring molten metal. The liquid metal is allowed to cool and

become solid which is the casting desired.

Result: The required mould cavity is prepared using the given Single /solid Pattern.

Questions:

1. Explain moulding sand properties in brief.

2. Justify the need of each binding material for moulding sand preparation.

3. Which pattern material you have used in this experiment? What are their advantages?


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Experiment No. 2

Aim: To prepare a sand mold, using the given Split-piece pattern.

Material Required: Moulding sand, Parting sand, facing sand, baking sand, pattern, bottom

board, moulding boxes.

Tools Required:

1. Molding board

2. Drag and cope boxes

3. Molding sand

4. Parting sand

5. Rammer

6. Strike-off bar

7. Bellows

8. Riser and sprue pins

9. Gate cutter

10. Vent rod

11. Draw spike

12. Wire Brush


1. Sand preparation

2. Placing the mould flask (drag) on the moulding board/ moulding platform

3. Placing the split pattern at the centre of the moulding flask

4. Ramming the drag

5. Placing the pattern at the centre of the moulding flask (Cope box)

6. Placing runner and riser

7. Ramming the cope

8. Removal of the pattern, runner, riser

9. Gate cutting

Procedure:

1. First a bottom board is placed either on the molding platform or on the floor, making the

surface even.


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2. The drag molding flask is kept upside down on the bottom board along with the drag part

of the pattern at the centre of the flask on the board.

3. Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer.

4. Freshly prepared molding sand of requisite quality is now poured into the drag and on the

split-pattern to a thickness of 30 to 50 mm.

5. Rest of the drag flask is completely filled with the backup sand and uniformly rammed to

compact the sand.

6. After the ramming is over, the excess sand in the flask is completely scraped using a flat

bar to the level of the flask edges.

7. Now with a vent wire which is a wire of 1 to 2 mm diameter with a pointed end, vent holes

are in the drag to the full depth of the flask as well as to the pattern to facilitate the removal

of gases during casting solidification. This completes the preparation of the drag.

8. Now finished drag flask is rolled over to the bottom board exposing the pattern.

9. Using a slick, the edges of sand around the pattern is repaired and cope half of the pattern

is placed over the drag pattern, aligning it with the help of dowel pins

10. The cope flask on the top of the drag is located aligning again with the help of the pins of

the drag box.

11. Dry parting sand is sprinkled all over the drag surface and on the pattern

12. Sprue of the gating system for making the sprue passage is located at a small distance of

about 50 mm from the pattern. The sprue base, runners and ingates are also located as shown

risers are also placed.

Freshly prepared facing sand is poured around the pattern.

13. The moulding sand is then poured in the cope box. The sand is adequately rammed,

excess sand is scraped and vent holes are made all over in the cope as in the drag.

14. The sprue and the riser are carefully withdrawn from the flask

15. Later the pouring basin is cut near the top of the sprue.

16. The cope is separated from the drag any loose sand on the cope and drag interface is

blown off with the help of the bellows.

17. Now the cope and the drag pattern halves are withdrawn by using the draw spikes and

rapping the pattern all around to slightly enlarge the mould cavity so that the walls are not

spoiled by the withdrawing pattern.

18. The runners and gates are to be removed or to be cut in the mould carefully without

spoiling the mould.


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19. Any excess or loose sand is applied in the runners and mould cavity is blown away using

the bellows.

20. Now the facing paste is applied all over the mould cavity and the runners which would

give the finished casting a good surface finish.

21. A dry sand core is prepared using a core box. After suitable baking, it is placed in the

mould cavity.

22. The cope is placed back on the drag taking care of the alignment of the two by means of

the pins.

23. The mould is ready for pouring molten metal. The liquid metal is allowed to cool and

become solid which is the casting desired.

Result: The required mould cavity is prepared using the given split pattern.

Questions:

1. Justify the reason of providing vent holes in the mould.

2. Explain gating ratio in mould with sketch.

3. Which pin is used to connect pattern halves?


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Experiment No. 3

Aim: To make a Butt joint using the given two mild steel plates by arc welding.

Material Required:

Mild steel plate of size 100X50X5 mm – 2 No’s

Welding Electrodes: M.S electrodes 3.1 mm X350 mm

Welding Equipment: Air cooled transformer

Voltage-80 to 600 V

3 phase supply, amps up to 350

Tools Required:

1. Rough and smooth files.

2. Protractor

3. Arc welding machine (transformer type)

4. Mild steel electrode and electrode holder

5. Ground clamp

6. Tongs

7. Face shield

8. Apron

9. Chipping hammer.


1. Marking

2. Cutting

3. Edge preparation (Removal of rust, scale etc.) by filling

4. Try square leveling


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5. Tacking

6. Welding

7. Cooling

8. Chipping

9. Cleaning

Procedure:

1. The given M.S pieces are thoroughly cleaned of rust and scale.

2. One edge of each piece is believed, to an angle of 300, leaving nearly ¼ th of the flat

thickness, at one end.

3. The two pieces are positioned on the welding table such that, they are separated slightly for

better penetration of the weld.

4. The electrode is fitted in the electrode holder and the welding current is ser to be a proper

value.

5. The ground clamp is fastened to the welding table.

6. Wearing the apron and using the face shield, the arc is struck and holding the two pieces

together; first run of the weld is done to fill the root gap.

7. Second run of the weld is done with proper weaving and with uniform movement. During

the process of welding, the electrode is kept at 150 to 250 from vertical and in the direction of

welding.

8. The scale formation on the welds is removed by using the chipping hammer.

9. Filling is done to remove any spanner around the weld.


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Drawing:

Result:

The single V-butt joint is thus made, using the tools and equipment as mentioned above.

Questions:

1. Explain the working principle of welding.

2. Draw the symbol of butt joint and lap joint.

3. Write specification of welding electrode used and selection of current and voltage.

4. Define slag and how it is removed?


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Experiment No. 4

Aim: To make a Lap joint, using the given two mild steel plates by arc welding.

Material Required:

Mild steel plate of size 100X50X5 mm – 2 No’s

Welding Electrodes: M.S electrodes 3.1 mm X350 mm

Welding Equipment: Air cooled transformer

Voltage-80 to 600 V,

3-ɸ supply, Current up to 350Amps

Tools and Accessories required:

1. Rough and smooth files.

2. Protractor

3. Arc welding machine (transformer type)

4. Mild steel electrode and electrode holder

5. Ground clamp

6. Tongs

7. Face shield

8. Apron

9. Chipping hammer.


1. Marking

2. Cutting

3. Edge preparation (Removal of rust, scale etc.) by filling

4. Try square leveling

5. Tacking

6. Welding

7. Cooling

8. Chipping

9. Cleaning

Procedure:

1. The given M.S pieces are thoroughly cleaned of rust and scale.

2. The two pieces are positioned on the welding table such that, the two pieces overlapped

one over the other as shown in drawing.

3. The electrode is fitted in the electrode holder and the welding current is ser to be a proper

value.


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4. The ground clamp is fastened to the welding table.

5. Wearing the apron and using the face shield, the arc is struck and the work pieces are tack

welded at both the ends and at the centre of the joint.

6. The alignment of the lap joint is checked and the tack-welded pieces are required.

7. The scale formation on the welds is removed by using the chipping hammer.

8. Filling is done to remove any spanner around the weld.

Drawing:

Result:

The Lap joint is thus made, using the tools and equipment as mentioned.

Questions:

1. Distinguish right handed and left handed welding.

2. Explain the role of inert gas in welding.

3. Describe the process of joining of pipe placed at 90 degree to each other.


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Experiment No. 5

Aim: To perform various lathe operations such as facing, plain turning, step turning and taper

turning on a given bar of mild steel.

Material Required:

A mild steel bar of 25 mm diameter and 100 mm length.

Tools and Equipment Required:

H.S.S. single point cutting tool,

Chuck key,

Tool post key,

Vernier caliper,

Steel rule,

Lathe Machine.


1. Facing H.S.S Single Point tool

2. Rough turning H.S.S Single Point tool

3. Finish turning H.S.S Single Point tool

4. Step turning H.S.S Single Point tool

5. Taper turning H.S.S Single Point tool

Procedure:

• The work piece is fixed in a 3 – jaw chuck with sufficient overhang.

• Adjust the machine to run the job to a required cutting speed.

• Fix the cutting tool in the tool post and centering operation is performed so that the axis of

the job coincides with the lathe axis.

• Give the feed and depth of cut to the cutting tool.


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• Facing operation is performed from the center of the job towards outwards or from the

Circumference towards the center.

• Plain turning operation is performed until the diameter of the work piece reduces to 23 mm.

• Check the dimensions by using vernier calipers.

• Perform the plain turning operation on the same work piece for the required length in order

to reduce the diameter to 18 mm so as to get the step turning.

• Using a V – cutting tool grooving operation is performed according to the given dimensions

and finishes the groove using parting tool.

• Swivel the compound slide to the required angle and perform taper turning operation by

rotating the compound slide wheel.

• The angle can be measured by using the formula

Tanα = (D – d) / 2L.

• Finally check the dimensions by using vernier calipers.

Precautions:

• The work piece should be held rigidly in the chuck before operating the machine.

• Tool should be properly ground, fixed at correct height and properly secured, and work also

be firmly secured.

• Before operating the machine see whether the job and tool is firmly secured in devices or

not.

• Optimum machining conditions should be maintained.

• Chips should not be allowed to wound around a revolving job and cleared as often as

possible.

• Apply cutting fluids to the tool and work piece properly.


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Model calculations:

The amount by which the compound rest has to be swivel is estimated using the taper angle.

Taper angle is calculated as follows.

Taper angle (α) = Tan-1

(L

dD

2

)

Where,

D = Diameter of bigger end, mm

d = Diameter of smaller end, mm

L = Length of taper, mm

DRAWING:

Result:

Accuracy: ±0.02mm


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Questions:

1. Describe facing operation and why it is perform at first.

2. Write the name of material which you have used for job and also write its properties.

3. Describe feed, speed and depth of cut and their effects on machining time and surface

finish.


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Experiment No. 6

Aim: To perform Thread cutting and Knurling operation on the given bar of mild steel.

Material Required:

Mild Steel rod of 25 mm diameter and 100 mm long

Tools Required:

Vernier calipers,

Steel rule,

Spanner,

Chuck spanner

H.S.S. single point cutting tool

Lathe machine

Procedure:

• The work piece is fixed in a 3 – jaw chuck with sufficient overhang.

• Adjust the machine to run the job to required cutting speed.

• Fix the cutting tool in the tool post and centering operation is performed so that the axis of

the job coincides with the lathe axis.

• Facing is performed by giving longitudinal depth of cut and cross feed.

• Perform plain turning operation until the diameter of the work piece reduced to 20mm.

• Using V-cutting tool and parting off tool perform grooving operation to the required

dimensions.

• Reduce speed of the spindle by engaging back gear and use Tumbler feed reversing

mechanism to transmit power through the lead screw.

• Calculate the change gears for the required pitch to be made on the work piece.

• Using half nut mechanism perform thread cutting operation(right hand threading) according

to the given dimensions and continues it until required depth of cut is obtained.

• At the same speed knurling operation is performed using knurling tool.


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• For every operation check the dimensions using vernier calipers.

Precautions:

• Before starting the spindle by power, lathe spindle should be revolved by one revolution by

hand to make it sure that no fouling is there.

• Tool should be properly ground, fixed at correct height and properly secured, and work also

be firmly secured.

• Chips should not be allowed to wind around a revolving job and cleared as often as

possible.

• Before operating threading operation, V-tool should be properly ground to the required

helix angle.

• Apply cutting fluids to the tool and work piece property.

• No attempt should be made to clean the revolving job with cotton waste.

• On hearing unusual noise, machine should be stopped.

Drawing:

Accuracy: ±0.02mm


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Result:

Questions:

1. Define the need of knurling operation.

2. List the name of cutting tools you have used in this job with material and their

specification.

3. Explain the properties of cutting fluid.


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Experiment No. 7

Aim: To perform drilling, and tapping operations on the given mild steel Flat Plate.

Apparatus Required:

1. Drilling Machine with standard accessories and tools.

2. Marking punch

Material Required:

Mild Steel flat plate mm × mm × mm

Procedure:

• The given work piece is first filed to get required length, breadth and thickness wet chalk is

applied on four sides and with the scriber lines are drawn to get center hole at required

location.

• The centers are punched with a Punch and hammer.

• The work piece is fixed firmly in the vice of the Drilling Machine

• Drill bit is fixed firmly in the chuck and drilling is performed giving uniform depths.

• The drill bit is removed from the drill chuck and is replaced by a reamer.

• The reaming operation is performed on the hole which has been previously drilled.

• The work is removed from the vice for performing tapping operation.

• The job is fixed firmly in a bench vice.

• Tap is fixed in the tap handle and pressure applied on the taps to obtain internal thread.

Precautions:

• Reaper should be free from moisture

• Marking is done without parallax error

• Care should be taken while cutting and drilling.


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• While performing drilling and tapping operations lubricant should be used to minimize the

friction.

Drawing:

Result:

Questions:

1. Describe the construction of drill bit and its specification with sketch.

2. Explain the need of reaming operation.


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Experiment No. 8

Aim: To study of Milling machine.

Apparatus Required: Milling Machine and related tools.

Theory:

Milling is the machine operation in which the removal of metal from the work piece takes

place due to a rotating cutting tool (cutter) when the work is fed past it. The cutter has

multiple cutting edges and rotates at a very fast rate. The rotating cutting tool known as the

“Milling Cutter” is a multiple point tool having the shape of a solid revolution with cutting

teeth arranged either on the periphery or on end or on both. The revolving cutter is held on a

spindle or arbor and the work piece is clamped or bolted on the machine table or may be in a

vise or a three jaw chuck or an index head held or a rotary table etc. The milling process is

employed for producing flat contoured or helical surfaces, for making helical grooves, to cut

teeth and toothed gears.

Working principle of milling:

Below figure illustrates the working principle employed in metal removing operation on a

milling machine. The job or work piece is rigidly clamped on the table of the machine or in a

chuck or an index head and revolving multiteeth cutter is mounted either on a spindle or an

arbor. The job is fed slowly past the cutter. The work can be fed in a vertical, longitudinal or

cross direction. With the movement of the work piece, the cutter teeth remove metal from the

job in the form of chips to produce the desired shape.

Fig.: Working Principle of Milling Machine


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Milling methods:

There are two distinct methods of milling classified as follows:

1. Up-milling or conventional milling- In the up-milling or conventional milling, the metal

is removed in form of small chips by a cutter rotating against the direction of travel of the

work piece.

2. Down milling or climb milling- Down milling is also known as climb milling. In this

method, the metal is removed by a cutter rotating in the same direction of feed of the work

piece.


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Types of milling machines:

The milling machines are available in different shapes and sizes. These machines may be

classified as follows:

(1) Column and knee type milling machines:

These general purpose machines have two main structural elements a vertical column, and a

knee like casting. The knee which is attached to a vertical column can slide in a vertical

direction on the column so that the various heights of work pieces can be accommodated in

the work table. The traversal movement of the work table is provided by mounting the table

on the saddle which in turn is mounted on the knee. The table which is mounted on the saddle

moves at right angles to the saddle. The work piece is positioned and clamped on the table.

The horizontal, vertical column and knee type milling machines are illustrated below:

(a) Horizontal milling machines:

These machines can be further classified as plain or universal milling machines. In a plain

milling machine, the table cannot be swiveled in a horizontal plane. The table may be fed in a

longitudinal, cross or vertical directions on a plain milling, machine. In case of universal

milling machine, the table can be swiveled up to 45° in a horizontal plane to the right or left.

This arrangement makes the angular and helical milling operations by using the universal

milling machine. In addition to the three principal movements as incorporated in a plain

milling machine, the table can be fed at an angle to the milling cutter.


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Fig.: Horizontal Spindle Column and Knee Type

(b) Vertical milling machines:

In vertical knee type milling machines, the position of the cutter spindle is vertical. Though it

has the same table movements as in plain milling cutter, the spindle head swivel or it may be

a combination of the sliding and swivel head type. These machines are suitable for end

milling and face milling operations.


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Fig.: Vertical Spindle Column and Knee Type

(c) Ram type milling machines:

In the ram type milling machines, the milling head is mounted at the front end of the ram

through a single or double swivel joint which in turn is mounted on the top of the column.

The ram can move forward and backward in a direction parallel to the saddle movement.

These additional features enable the spindle axis to move in a horizontal, vertical and an

angular direction. These ram type milling machines can be further classified as,

(i) Turret ram type milling machine

(ii) (ii) Ram head milling machine.

(2) Bed type milling machines:

Bed type milling machines are comparatively heavier and rigid than column and knee type

milling machines. In these machines, the table is mounted over a fixed bed in the place of a

knee. The spindle head imparts the cross or vertical motion instead of a table. Depending on

the number of spindle heads provided in these machines, they can be ‘named as simplex,


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duplex and triplex milling machines. Their types may be classified as horizontal or vertical,

based on the orientation of the spindle axis.

(a) Manufacturing or fixed bed type milling machine:

In addition to the manual adjustment of all slides in these machines, the automatic cycle of

operation for feeding the table feature is incorporated to give an advantage in repetitive type

of work. This automatic feeding cycle of the table includes the start, rapid approach, cutting

feed, rapid traverse to the next job, quick return and stop. These machines are particularly

suitable for large production work.

(b) Horizontal bed type milling machines:

These machines are usually provided with the above said features. As the name implies, the

spindle is mounted horizontally and it can be adjusted up or down a column fitted to the side

of the bed. The available types of horizontal bed type milling machines are the simplex and

duplex milling machine.

(c) Vertical bed type milling machine:

The spindle is mounted vertically in these machines. All the other features in horizontal bed

type milling machines are incorporated in this machine. The transverse movement can be

obtained by mounting the head unit over a cross-arm.

(3) Planer type milling machines:

As the name implies, the machines structure resembles a planer. The table which carries the

work piece moves longitudinally and it is fed against a revolving cutter. This machine is

distinguished from a planer machine by the variable table feeding movement and the rotating

cutter features. These machines are used for heavy stock removal in large work pieces and for

duplication of profiles and contours.

(4) Special purpose milling machines:

Special purpose milling machines have been developed to suit for specific kinds of work

more easier than the conventional machines. Some of the common features incorporated from

conventional machines are the provision for moving the work piece or tool in different

directions and the spindle for rotating the cutter.


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(a) Rotating table milling machine:

These high-production machines have a circular table which rotates about a vertical axis.

Their construction is a modification to a vertical milling machine. The rotary table milling

machines are adapted for machining fiat surfaces by using face milling cutters. The cutters

are mounted on two vertical spindles, one for roughing and the other for finishing the work.

These machines can vertical ways of the column and while the milling is in progress the

operator can continuously load or unload the work pieces in the machine.

(b) Drum type milling machine:

The drum milling machines are adopted for the machining of two end faces of a work piece

simultaneously in a continuous machining cycle. The drum which rotates in a horizontal axis

is used for clamping the work pieces. The face milling cutters are mounted on a number of

horizontal spindles and removes metal from the two end faces of the work piece. The parts

are finished in one complete turn of the central drum have two or more cutter spindles.

(c) Tracer controlled milling machine:

It reproduces the complex shapes like mold cavities and core, cams, dies, etc., by tracing the

shape of the master model or template. The shapes are reproduced in the work pieces by

synchronized movements of the cutter and tracing element. This provides an automatic

control to the feeding motion of the machine. The stylus traces the master or template to

produce the coordinates of the cutter path which is used to produce the work piece shapes.

(d) Thread milling machines:

This machine is used for cutting threads and worms. Threads produced by this thread milling

operation give better finish and greater accuracy than the conventional thread cutting

methods. The milling tools having single row of teeth or a number of such rows used for

these thread milling operations.

(e) key-way milling machine:

The key-way milling machines are used for parts requiring the key-ways in a high degree of

accuracy. These machines are used in large batch production. It uses an automatic cycle to

machine the key-way which includes the horizontal movement of the work table, to feed of

cutter, transverse movement of cutter, etc.


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(f) Skin and spar milling machines:

The structure of both these machines resembles a planer machine in appearance. In ‘spar

milling machine’, the work remains stationary and the rotating cutters are moved to and fro to

perform the operations. In addition to the above said principle, the skin milling machine’ uses

another design for the machining purposes in which the work piece is mounted on a table

which is moved past the revolving milling cutters. The machines may have horizontal or

vertical spindle axis. These machines are mostly used in aircraft industries.

(g) Planetary milling machine:

These machines are so called because of their planetary (circular) path of the cutters during

the operation. The work is held stationary while all the movements which are essential for the

cutting are made by the revolving cutters and are the principal features that distinguish this

machine from the normal method. The spindle types of both horizontal and vertical designs

are available. The planetary milling machines are used for milling both internal and external

threads and surfaces.

Indexing:

Indexing is the operation of dividing the periphery of a piece of work into any number of

equal parts. In cutting spur gear equal spacing of teeth on the gear blank is performed by

indexing. Indexing is accomplished by using a special attachment known as dividing head or

index head as shown in Figure below-

Milling machine operations:

The operations that can be performed on a milling machine are broadly classified as follows:


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(1) Plain Milling (2) Face Milling (3) Angular Milling (4) Staggered Milling (5) Form

Milling (6) End Milling

Plain milling:

It is also known by slab milling. A plain milling cutter is used to produce a plain, flat,

horizontal surface parallel to the axis of rotation. The work is mounted on a table and the tool

is secured properly on the spindle. The speed and feed of the machine is set up before starting

the operation and the depth of cut is adjusted by rotating the vertical feed screw of’ the table.

Face milling:

The face milling operation is used for machining flat surfaces by a face milling cutter which

is rotating in an axis perpendicular to the work surface. The depth of cut is adjusted by

rotating the tables cross feed screw.

Angular milling:

The angular milling is the operation used for machining flat surfaces at an angle. Depending

upon whether the machining has to be carried out in a single or two mutually inclined

surfaces, a single or double angle cutter may be used. The V-blocks of any size can be

machined by this operation.

Staggered milling:

These types of cutters are narrow and cylindrical having staggered teeth and with alternate

teeth having opposite helix angles. These cutters are used for milling deep slots.

Form milling:

These types of milling cutters are used to cut some profile or contour on the work piece.

These can be used to cut convex, concave, corner rounding and gear tooth in the work piece.

End milling:

These types of cutters have teeth on the circumferential surface at one end. They are used for

facing, profiling and end milling operations.

All the operations of Milling Machine are shown in the following figures:


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Questions:

1. Differentiate up milling and down milling.

2. List the operation which can be performed on milling machine.


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Experiment No. 9

Aim: To study of shaper machine.

Apparatus Required: Shaper Machine and related tools.

Theory:

The shaper (also called shaping machine) is a reciprocating type of machine tool used for

producing small flat surfaces with the help of a single point tool reciprocating over the

stationary work piece. The flat surface may be horizontal, inclined or vertical. The

reciprocating motion of the tool is obtained either by the crank and slotted lever quick return

motion mechanism or Whitworth quick return motion mechanism.


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Principal parts of a shaper:

The principal parts of a shaper, as shown in the previous Figures are as follows:

1. Base:

It is a heavy structure of cast iron which supports other parts of a shaper.

2. Column:

It is a box-like structure made up of cast iron and mounted upon the base. It contains the

driving mechanism and is provided with two machined guide ways on the top of it on which

the ram reciprocates.

3. Ram:

It is a reciprocating member which reciprocates on the guide ways provided above the

column. It carries a tool-slide on its head and a mechanism for adjusting the stroke length.

4. Tool head:

It is attached to the front portion of the ram with the help of a nut and a bolt. It is used to hold

the tool rigidly; it also provides the vertical and angular movements to the tool for cutting.

5. Cross-rail:

It is attached to the front vertical portion of the column. It is used for the following two

purposes:

(a) It helps in elevating the table over the column in the upward direction, and

(b) The table can be moved in a direction perpendicular to the axis of the ram over this cross

rail.


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6. Table:

It is used for holding the work piece. It can be adjusted horizontally and vertically with the

help of spindles.

Working principle and operation of a shaper:

We have already discussed that in a shaper, a single point cutting tool reciprocates over the

stationary work piece. The tool is held in the tool post of the reciprocating ram and performs

the cutting operation during its forward stroke. It may be noted that during the backward

stroke of the ram, the tool does not remove material from the work piece. Both these strokes

(i.e., forward and backward strokes) form one working cycle of the shaper. For shaping in

horizontal direction, as shown in Fig. (a). the clamped work piece is fed against the

reciprocating tool after every cutting cycle. The depth of cut is adjusted by moving the tool

downward towards the work piece. For shaping in vertical direction, as shown in Fig. (b). the

tool is fed vertically towards the work piece after every cutting cycle. The depth of cut is

adjusted by moving the work piece sideways.

(a) Shaping in Horizontal Direction (b) Shaping in Vertical Direction

Shaper mechanism:

In a shaper, rotary motion of the drive is converted into reciprocating motion of the ram by

the mechanism housed within the column or the machine. In a standard shaper metal is

removed in the forward cutting stroke, while the return stroke goes idle and no metal is

removed during this period. The shaper mechanism is so designed that it moves the ram

holding the tool at a comparatively slower speed during forward cutting stroke, whereas

during the return stroke it allow the ram to move at a faster speed to reduce the idle return

time. This mechanism is known as quick return mechanism.


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Classifications of shapers:

The shapers are classified as follows:

1. According to the ram driving mechanism:

According to the ram driving mechanism, the shapers are classified as follows:

(a) Crank shaper:

In a crank shaper, a crank and a slotted lever quick return motion mechanism is used to give

reciprocating motion to the ram. The crank arm is adjustable and is arranged inside the body

of a bull gear (also called crank gear).

(b) Geared shaper:

In a geared shaper, the ram carries a rack below it, which is driven by a spur gear. This type

of shaper is not widely used.

(c) Hydraulic shaper:

In a hydraulic shaper, a hydraulic system is used to drive the ram. This type of shaper is more

efficient than the crank and geared shaper.

2. According to position and travel of ram:

According to the position and travel of ram, the shapers are classified as follows:


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(a) Horizontal shaper:

In a horizontal shaper, the ram moves or reciprocates in a horizontal direction. This type of

shaper is mainly used for producing flat surfaces.

(b) Vertical shaper:

In a vertical shaper, the ram reciprocates vertically in the downward as well as in upward

direction. This type of shaper is very convenient for machining internal surfaces, keyways,

slots or grooves.

3. According to the direction of cutting stroke:

According to the direction of cutting stroke, the shapers are classified as follows:

(a) Push-cut shaper:

In a push-cut shaper, the ram pushes the tool across the work during cutting operation. In

other words, forward stroke is the cutting stroke and the backward stroke is an idle stroke.

This is the most general type of shaper used in common practice.

(b) Draw-cut shaper:

In a draw-cut shaper, the ram draws or pulls the tool across the work during cutting operation.

In other words, the backward stroke is the cutting stroke and forward stroke is an idle stroke.

4. According to the design of the table:

According to the design of the table, the shapers are classified as:

(a) Standard or plain shaper:

In a standard or plain shaper, the table has only two movements i.e., horizontal and vertical,

to give the feed. It cannot be swiveled or tilted.

(b) Universal shaper:

In a universal shaper, in addition to the above two movements, the table can be swiveled

about a horizontal axis parallel to the ram and the upper portion of the table can be tilted

about the other horizontal axis perpendicular to the first axis. This type of shaper is mostly

used in tool room work.


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Specifications of a shaper:

The shaper is specified as follows:

1. Maximum length of stroke in millimeters,

2. Size of the table, i.e., length, width and depth of the table,

3. Maximum vertical and horizontal travel of the table,

4. Maximum number of strokes per minute,

5. Power of the drive motor,

6. Type of quick return mechanism,

7. Floor space required,

8. Weight.

Questions:

1. Explain the quick return mechanism of shaper and why it is selected?

2. Which type of shaper will be used for making slots in gear or pulley?


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Experiment No. 10

Aim: To create physical object by using 3D printer.

Material Required: PLA or ABS material.

Apparatus and Tools Required:

3D printer

CAD software like Solidworks etc.

Printing software like voxelizer etc.

Tool kit of printer.

Theory: 3D printing allows for rapid prototyping and onsite manufacturing of products layer

by layer. It is initially done with plastic, 3D printing now uses new techniques with new

materials, such as aluminum, bronze, and glass. Biomaterials are also being incorporated,

such as 3D printing ear cartilage and liver tissue. As the 3D printing industry grows, 3D

printing will become a big part of many engineering fields.

Flow layout of Pre 3D Printing:

Components of 3D Printer: -

1. Axes

Fixed Rods The three axes that the 3D printer utilizes are on the Cartesian coordinate system.

The linear fixed rods are maintained at right angles to each other and each represents a

coordinate axis. The timing belts and pulleys allow the movement of the hot end (or the print

bed, depending on the type of 3D printer) along each axes according to the g-code (generated

by slicing software). The stepper motors power this movement.


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2. Extruder

Extrusion is the feeding of filament into the hot end of the 3D printer. This movement is also

powered by a stepper motor. Retraction this mechanism is the pulling of the melted filament

from the hot end. This movement is primarily programmed through the g-code to prevent the

formation of unwanted filament creating a bridge between two areas. The bridging of

unwanted filament is referred to as stringing or the formation of cobwebs.

Dual Extrusion some models of 3D printers are equipped with dual extrusion capabilities.

This allows for mixed material objects to be printed. Dual extrusion can be used to print out

complex objects with a different colour material as the support, making it easy to differentiate

between the object and the support.

3. Hot End

The hot end is heated to temperatures ranging from 160 C to 250 C, depending on the type of

filament to be used. The hot end melts the filament and pushes the melted filament through

the nozzle. The hot end needs to be thermally insulated from the other components of the 3D

printer to prevent any damage.

4. Print Bed

Heated Print beds that are heated improve print quality of 3D printed objects. The heated bed

is heated to the glass transition temperature of the filament being used. This allows the model

layers to slightly melt and stick to the heated bed. Non-Heated Print beds that are not heated

require adhesion in the form of glue, tape, hairspray, etc. In the innovation lab, painters tape

is frequently used for adhesion.

5. Filament

Filament is a consumable used by the 3D printer to print layers. Filament comes in a variety

of materials and colors. Filament can be composed of metal, wood, clay, biomaterials, carbon

fiber, etc.

i). ABS: - ABS is a thermoplastic that needs to be heated to temperatures from 210C to 250C.

ABS can only be printed on a 3D printer with a heated bed, which prevents the cracking of

the object. When ABS is heated, it emits a strong unpleasant odor. ABS requires a complete

enclosure while printing.

ii). PLA: - PLA is a thermoplastic that needs to be heated to temperatures from 160C to

220C. PLA is also biodegradable and emits slight odors. PLA is most frequently used in the

Innovation Lab on all 3D printers. PVA is a water soluble plastic that is frequently used for

support in dual extrusion 3D printers. The printed object is left in water where the PVA

support is dissolved and the finished object printed in the other filament remains.


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Preparing 3D Model in CAD Software: -

CAD software is used to create 3D models and designs. This software is available on our

computers and the level of difficulty varies. With the exception of Sketch up Pro and the

industry standard software mentioned, all of these programs are available on the innovation

lab computers. Solid works main idea is user to create drawing directly in 3D or solid form.

From this solid user can assemble it directly on their workstation checking clashes and

functionality of it. Creating drawing is pretty easy just drag and drop the solid to drawing

block.

Step1 Prepare the design Model using designing Software (Solids Work, AutoCAD etc.)

a. Click New, Option.

b. Click Part and OK.

c. Click on Top Plane and click Sketch.

d. Click Rectangle sketch a rectangle start from origin.

e. Click Smart Dimension , click side edge and click top edge to dimension it

as 1.0in x 1.0in.


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f. Click Features>Extruded Boss/Base.

Set D1 as 1.0in and click on green right tick mark symbol.


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g. It’s done.

Step:-2 Convert the designed Model file in Stl ,obj format.

Step:-3 Prepare the design model for printing Using Software like voxelizer, Idea Maker and

Ultimaker. Then Check options related to printing in this software like layer height, bed

temperature, infill ratio, nozzle temp., build table temp. , support and also repair your design

using software options. Then after generate the file in gcode format.

Step:-4 On the 3D Printer and load the filament in nozzle and give the command print by

using software.

Application of 3D Printer: -

• Automotive

• Marine

• Aerospace

• Medical

• Engineering

• Architecture

Advantages: -

• Complex shapes

• Freedom for design

• Customize parts

• Less waste


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• Fewer unsold products

• Less transport

Limitations: -

• Time

• Cost

• Skill

• Materials

Precaution of 3D Printer machine: -

These are some following precaution when you print the design in 3D Printer

1. Mechanical: Do not place limbs inside the build area while the nozzle is in motion. The

printer nozzle moves in order to create the object.

2. High Temperature: Do not touch the printer nozzle – it is heated to a high temperature in

order to melt the build material.

3. Always buy replacement parts from the manufacturer for safety related equipment.

4. Choose an area that has adequate ventilation and exhaust capability.

Questions:

1. Explain the properties of PLA and ABS material in tabular form.

2. Write the application of 3D printer.

IPS Academy , Indore · IPS Academy, Institute of Engineering & Science 3rd Semester Manufacturing...

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Transcript of IPS Academy , Indore · IPS Academy, Institute of Engineering & Science 3rd Semester Manufacturing...