workshop manual

1. University College of Engineering
Science and Technology
Workshop Manual
Department of Mechanical Engineering

2. TABLE OF CONTENTS
Sr.
No.
Date Name of Experiment Page
No.
Remarks Signature
1 Study of DifferentParts of
Lathe Machine
2 Facing, Plain Turning and
Step Turning
3 Taper Turning using
Compound Rest
4 Right Hand Metric Thread
Cutting on Lathe Machine
5 Knurling Operation on Lathe
Machine
6 Study of DifferentParts of
Shaper Machine
7 Machining a Block on
Shaper Machine

3. 8
Producing V-Shape on
Rectangular Block on
Shaper Machine
9 Study of DifferentParts of
Milling Machine
10 To perform Milling Operation
According to Drawing

4. GENERAL INSTRUCTION
1. Every student should obtain a set of instruction sheets entitled
manufacturing processes Laboratory.
2. For reasons of safety, every student must come to the laboratory in
shoes (covering the whole feet). It is unsafe for the students to come to
the laboratory wearing garments with parts that hang about loosely and
as such the lab users are requested to avoid wearing garments with
loose hanging parts. Students should preferably use half-sleeve shirts
wherever possible. The Students should also ensure that floor around
the machine is clear and dry (not oily) to avoid slipping. Please report
immediately to the lab staff on seeing any coolant / oil spillage.
3. An apron will be issued on a returnable basis (returnable after each lab
turn) to each student. Students not wearing an apron will not be
permitted to the work in the laboratory.
4. Instruments and tools will be issued from the tool room. Every student
must produce his identity card for the purpose. Tools, etc. must be
returned to the tool room on the same day after work hours.
5. The student should take the permission and guidance of the Lab Staff /
Tutors before operating any machine. Unauthorized usage of any
machine without prior guidance may lead to fatal accidents and injury.
6. The student will not lean on the machine or take any kind of support of
the machine at any point of time. If found leaning on a machine without
proper reasons serious action would be taken
7. Power to the machines will be put off 10 minutes before the end of
laboratory session to allow the students to return the tools.

5. 8. Students are required to clear off the chips from the machine and
lubricate the guides etc. at the end of each laboratory session.
9. Laboratory reports should be submitted on A4 size sheets. The students
must fill these reports and hand it over to their CR after the laboratory
session. These have associated some grades.
10. Reports will not be returned to the students. Students may see the
graded reports while in the laboratory.

6. SAFETY
PRECAUTIONS
1. Do not wear watch, ring etc in your hand while machining
2. Wear shoe and lab coat
3. Attention to be paid for clamping the job, tool, tool holders or supporting
items.
4. Care should be taken for avoiding accidental contact with revolving cutters.
5. Do not handle chips with bare hands, use brush or hand gloves.
6. Pay attention while selecting tools or blades for the proposed use to avoid
accidents.
7. Do not remove chip while machine is running.
8. Care should be taken while selecting rapid feed.
9. Follow safety precautions while approach with cutter to avoid tool damage.
10. Use coolants for heat dissipation.
11. Avoid sharp edge tools.
12. Selectproperspeed or feed or depth of cut.

7. OBJECTIVES
The student will able to
 Know basic workshop processes.
 Read and interpret job drawing.
 Identify, selectand use various marking, measuring, holding,
striking and cutting tools & equipment.
 Operate, control differentmachines and equipment.
 Inspectthe job for specified dimensions.
 Produce jobs as per specifieddimensions.
 Adoptsafety practices while working on various machines

8. PartsofLatheMachine

9. Experiment No.1
Study of Different Parts of lathe Machine
Introduction
Lathe is called the father of machine tools. The main function of lathe is to
remove metals from work piece to give a required shape and size. In the lathe
the work piece is held in a chuck. The tool is moved at an angle 90o to the
axis. Various operations such as straight turning, taper turning, and
chamfering, facing, knurling, grooving, thread cutting, taper turning are
carried out. When the operations above set are done automatically, then
the lathe is called automatic lathe.
Working principle of lathe
In a lathe, the workpiece is held in chuck and rotates about its axis by means
of power. A single point cutting tool is mounted in tool post. When the chuck
rotated the work piece also rotated. The tool moves parallel to the axis of
rotation of work piece to produce a cylindrical surface, where as the tool
moves perpendicular to the work piece to produce a flat surface. The tool
moves at an angle to the axis of work piece to produce a turn surface. The
material is removed in the form of chip from the work piece by giving proper
feed and depth of cut. So, the required size and shape of the work is
obtained.
Main parts of lathe
The lathe consists of various parts. Their parts and function are discussed
below.

10. Bed
Bed is the base of the lathe. The headstockis mounted on the left end; the
carriage is in the middle and the tailstock at the right end of bed. The bed is
made up of cast iron, alloyed with nickel, chromium. The bed is made up of
cast iron to observe shockand vibration created during machining. The guide
ways of the bed may be flatter inverted ‘V’ shape.
Headstock
It is mounted on the left end of the bed.It carries a hollow spindle.The live
center can be attached in the spindle. The spindle nose is threaded. In chuck
faceplates can be attached to the spindle. The headstock may be back
threaded type. The headstock has two types of driving mechanism
• Back geared mechanism
• Belt driven mechanism
Tailstock
It is located on the bed at the right end. It is used for supports right end of work
and also for holding drills, reamer tools for drilling, reaming and such other
operations. The tailstock can be moved along the bed and clamped at any
position, to supportthe differentlength work.
Carriage
Carriage is used for giving various feed to the tool by hand or by power. The
carriage is attached with the saddle.

11. Saddle
It is a H shaped casting fitted on the bed and moves along the guide ways. It
carries the cross slide, compound rest and a tool post.
Cross slide
It is attached to the upper side of saddle and carries compound slide and tool
post. The cross slide can be moved cross wise by hand or power. The
micrometerdial is mounted on the cross slide hand wheel, with an accuracy of
0.05mm.
Compound Rest
It is attached over the cross slide.It is used during the taper turning opening
operations to set the tool for angular cuts. Here the micrometerdial is
mounted to show the depthof cut.
Toolpost
The tool is clamped over the tool post. It is fixed over the compound rest.
There are four types of tool post
a. Single screw tool post
b. Open side tool post
c. Four bolt tool post
d. Four way tool post

12. Apron
Apron is attached to the saddle and hangs in front of the bed. It has gears,
levers, clutches for moving the carriage automatically. A split nut is attached
for engaging and disengaging the carriage from the lead screw. It is used in
thread cutting work.
Lead Screw
It is a longer screw with standard ACME square threads and used for
transmitting power for automatic feed forthread cutting operation.
Feed rod
The feed rod is the long shaft used for the movementof carriage along the
axis of bed. It is used for operations like facing, turning and boring.

13. Experiment No.2
Performing Facing, Plain Turning and Step Turning
Drawing of Stock
Drawing of Finished Job

14. Materialused
Mild steel rod.
Tools required
• Lathe
• Three-jaw chuck
• Chuck key
• Vernier caliper
• Single-point cutting tool
Procedure
1. First loosen the jaw in the chuck key to positionthe work piece,and then
tighten the jaws.
2. Fix the cutting tool in the toolpost.
3. Switch on the lathe and move the carriage near to the workpiece. Give it a
small cross feed,and then move carriage longitudinally to the required length
slowly.
4. Bring the carriage to the original position, give a small cross feed and
move carriage longitudinally. Repeatthis step until required diameter is
obtained.
5. To get smooth surface give a very small feed when the diameter is
nearing the required value.
6. To face the end surface of the workpiece, move the carriage to make
the tool touch the end surface of the work piece.

15. 7. Give a small feed in longitudinal direction, and then move the tool towards
the axis of the workpiece using the cross slide to complete the workpiece.
8. The turning operation is done with cutting tool to reduce the
diameter upto the required dimension for the two steps of various
diameters.
9. The workpiece is removed from the chuck and the dimensions of
workpiece are checked for the requirement

16. Experiment No.3
Performing Taper Turning using Compound Rest
Drawing of Stock
Drawing of Finished Job

17. Materialused
Mild steel rod.
Tools required
• Single point cutting tool
• Lathe
• Vernier caliper
• Try square
• Chuck key
Procedure
1. First loosen the jaw in the chuck key to position the work piece, and then
tighten the jaws.
2. Fix the cutting tool in the toolpost.
3. Switch on the lathe and move the carriage near to the workpiece. Give it a
small cross feed, and then move carriage longitudinally to the required length
slowly.
4. Bring the carriage to the original position, give a small cross feed and
move carriage longitudinally. Repeat this step until required diameter is
obtained.
5. To get smooth surface give a very small feed when the diameter is
nearing the required value.
6. To face the end surface of the workpiece, move the carriage to make the
tool touch the end surface of the work piece.
7. Then the taper turning operation is done on the workpiece according to
the taper angle calculated. The compound rest base is swirled and set a
calculated taper angle, for this the tool is moved by 45o to the lathe axis.

18. 8. The workpiece is removed from the chuck and the dimensions of
workpiece are checked for the requirements.
Experiment No.4
Right Hand Metric Thread Cutting on Lathe Machine

19. Drawing of Stock
Drawing of Finished Job
Materialused
Mild steel rod of 25 mm diameter.

20. Tools required
• Single point thread cutting tool
• Lathe
• Vernier caliper
• Try square
• Chuck key
Procedure
1. Arrange for as much distance from the chuck to the end of the proposed
screw thread as possible, and if possible, cut a 'run-off' into the workpiece
which is of a smaller diameter than the root diameter of the proposed screw
thread. Also, long threads may require the use of one or more 'steadies'.
2. Install the appropriate gears for the thread required, and correctly mount
the cutting tool. Set the required depth of cut, and position the tool ready to
begin cutting. Note that the depth of cut is vitally important and may be
calculated or obtained from an appropriate reference manual.
3. Take all necessary precautions previously stated, and start the machine
with the automatic feed lever in the UP or disengaged position and set the
speed of the lathe as appropriate.
4. Set the depth of cut for an initial test pass. Engage the auto-feed lever
sharply whilst your left hand is on the FORWARD/OFF/REVERSE (F/O/R)
switch. As the tool approaches the end of the desired thread, turn the switch to
'OFF'. Do not disengage the auto-feed lever. Use a thread pitch gauge to
check that the pitch is as required.
5. Retract the tool, using the cross-slide feed handle, noting the exact
position on the scale and the exact number of turns. Turn the F/O/R switch to
'REVERSE', whereupon the saddle will wind back to the beginning and turn
the switch to 'OFF'. Reset the tool by winding in the cross-slide the exact
number of turns previously wound out, plus the desired depth of cut.

21. 6. Turn the F/O/R switch to FORWARD.As the tool approaches the end of the
desired thread, turn the switch to 'OFF'.Do not disengage the auto-feed lever.
7. Repeat steps 5 & 6 until the thread is completed.
Preparation for Threading

22. Check thread pitch after initial threading pass
Completing the
threading
process
Thread
Dial Indicator
Tables

23. Experiment No.5
Knurling Operation on Lathe Machine
Introduction

24. Knurling is a process of impressing a diamond shaped or straight line pattern
into the surface of a workpiece by using specially shaped hardened metal
wheels to improve its appearance and to provide a better gripping surface.
Straight knurling is often used to increase the workpiece diameter when a
press fit is required between two parts.
Knurling Tools
The knurling tool can be designed differently, but all accomplishthe same
operation. Two commontypes of knurling tools are the knuckle joint and
revolving head type of knurling tools.The knuckle joint type is equipped with a
single pair of rollers that revolve with the work as it is being knurled. The
revolving head type of tool is fitted with three pairs of rollers so that the pitch
can be changed to a differentknurl without having to change the setup. There
are two knurl patterns, diamond and straight.
Shaper Machine and its Parts

25. Experiment No.6
Study of Different Parts of Shaper Machine
Introduction
The shaper is a machine tool used primarily for:
1. Producing a flat or plane surface which may be in a horizontal, a vertical or
an angular plane.

26. 2. Making slots, grooves and keyways
3. Producing contour of concave/convexor a combination of these
Working Principle
The job is rigidly fixed on the machine table. The single point cutting tool held
properly in the tool post is mounted on a reciprocating ram. The reciprocating
motion of the ram is obtained by a quick return motion mechanism. As the ram
reciprocates, the tool cuts the material during its forward stroke. During return,
there is no cutting action and this stroke is called the idle stroke. The forward
and return strokes constitute one operating cycle of the shaper.
Base
The base is a heavy and robust in construction which is made of cast iron by
casting process. It is the only part to support all other parts because all parts
are mounted on the top of this base. So, it should be made to absorb
vibrations due to load and cutting forces while machining.
Column
The column has a box type structure which is made of cast iron. The inside
surface is made as hollow to reduce the total weight of the shaper. It is
mounted on the base. The ram driving (Quick return) mechanism is housed.
The two guide ways are supplied on the top. The ram reciprocates on the
supplied guide ways. Similarly, there are two guide ways at the front vertical
face of the column to move the cross rail along these guide ways.
Table

27. It is also a box type rectangular hollow cast iron block. This table slides along
the horizontal guide ways of the cross rail. The work is held in the table. The
table has machined surfaces on the top and sides of T-slots for clamping
work. It can be moved vertically by the elevating screw. An adjustable table
supports the front face of the table.
Ram
Ram of cast iron has cross ribs for rigidity. Generally, it is a reciprocating type
which slides over the guide ways on the top of the column. It is linked to
driving mechanism of any one and also it carries the tool head at the front end.
Tool Head
It holds the tool rigidly having swivel base with degree graduation. So, the tool
head can be swiveled to any angle as required. The tool head has a vertical
slide and apron to provide vertical and angular feed to the tool. A feed screw
with graduated dial moves the vertical slide vertically to set the accurate
movement.
Apron is clamped upon the vertical slide which can be titled to right or left and
also clamped at a correct position. The clapper box hinges a tool block
previously fixed with apron. The tool block holds a tool post to hold the tool.
The tool block fits inside the clapper box rigidly. In the return stroke, the tool
block lifts out of clapper box to minimizing rubbing of the tool on the job.
Cross rail
It is also a heavy cast iron construction. It glides on the front vertical ways of
the column with two mechanisms. One is aimed at elevating the table and the
other one is for cross travel of the table. A saddle slides over two guide ways
already provided in the front face of the cross slide. The crosswise movement

28. of the table is obtained by cross feed screw and the vertical movement of the
cross rail is obtained by an elevating screw.
Vise
A vise, fastened to the shaper table, is used to hold most of the work in place
for machining on the shaper. It has a movable jaw, a fixed jaw, and a base
that is graduated in degrees. The vise can be rotated on its base to any
desired angle. A workpiece in the vise is held either parallel to or at right
angles to the ram.
Saddle
Saddle is gibbed to the cross rail and supports the table. If the table is
removed, the work can be bolted or clamped to the T-slots in front of the
saddle. Crosswise movement of the saddle causes the work table to move
sideways.
Calculate shaper speeds
Shaper cutting speedsand feeds are dependentupon a number of factors,
including:
 the type of cutting tool
 the type of material to be machined
 the depth of cut required
 the amount of feed
Following Table presents standard shaper cutting speeds and feeds when
using HSS and carbide cutting tools to cut machine steel, tool steel, cast iron
and brass.

29. Shaper Cutting Speeds and Feeds
x 0.06N =
With the information in Table 1 and two standard formulas (one for imperial
measurements and one for metric measurements)you can calculate the
number of strokes per minute that the shaper ram should deliver (i.e., shaper
speed).
To Find Strokes/minute
If you are using a HSS cutting tool to cut a piece of brass 300 mm long, to
determine how many strokes per minute the ram should deliver, you can use
the metric speed calculation formula:
C S
T
Where N = number of strokes per minute
CS = standard cutting speed in metres per minute of a
particular kind of cutting tool for a particular material
(see Table above)

30. x 0.06 = 88 stroke/minuteN =
L = length of work in metres,plus 25 mm to provide too
clearance
48
0.375
To cut a 300 mm piece of brass with a HSS cutting tool requires the ram
to deliver 88 strokes/minute:
Setting Shaper Stroke Length and Position
1. Correctly mount the workpiece in the vise.
2. Measure the length of the workpiece and add 25 mm (or 1") to determine
the length of stroke.
3. Use the start-stop button or the stroke regulator shaft crank and move the
ram to the back end of its stroke.
4. Loosenthe stroke regulator locknut.
5. Turn the stroke regulator shaft until the stroke indicator shows the
desired stroke length.
6. Tighten the stroke regulator locknut.
7. With the ram still at the back end of its stroke, loosenthe ram positioning
lock.
So

31. 8. Pull the toolhead and the ram (or turn the ram adjusting screw) until the
toolbit is within 12 mm (1/2") of the workpiece.
9. Tighten the ram positioning lock.
10. With the cutting tool clear of the workpiece,start the machine and check
that the toolbit clears each end of the workpiece by 12 mm (1/2"); if so, the
shaper stroke length and positionare now correctly set.
Experiment No.7
Machining a Block on Shaper Machine
Drawing of
Block

32. Materialused
Mild steel block having sides greater than 75 mm each side.
Tools required
• Single point thread cutting tool
• Shaper Machine
• Vernier caliper
• Try square
• Vise
Procedure
1. The job was checked to the given dimensions.
2. The square 75 mm sides was marked one side of block and Punching was
done.
3. The job was attached in the vise of a shaper

33. 4. Strokes / mm was calculated for Mild Steel and Shaper was set
accordingly.
5. Stroke Length was adjusted according to length of workpiece.
6. Single point cutting tool was fixed in the tool holder.
7. After finishing one side,the job surface is inverted and again fixed in the
vise.
8. The job was checked for perpendicularparallelism.
9. The job was checked for dimensions.
8. Then the square of 75 mm from stock was obtained in the shaper
9. The work piece was removed and burns are removed with accuracy was
checked.
Experiment No.8
Producing V-Shape on Rectangular Block on Shaper Machine

34. Drawing of V-Groove on Job
Length of Block = 75 mm
Material
used
Mild steel block having sides 75x30x75 mm sides.
Tools required
• Single point thread cutting tool
• Shaper Machine
• Vernier caliper
• Try square
• Vise
Procedure
1. Work piece of required dimensionto be cut on power hack saw.
2. The job is fixed in vice of shaper machine.
3. Top surface is machined first.

35. 4. The Job surface is inverted and clamped tightly in the vice.
5. All the remaining surfaces are machined in sequence.
6. Then marking is done as per the drawing for making groove.
7. The groove is machined using round nose cutting tool.
8. For making the groove feed to the table and tool is given simultaneously.
9. The groove is shaped in differentcuts to achieve the desired depth.

36. PARTS OF MILLING MACHINE

37. HORIZONTALMILLING MACHINE
INTRODUCTION:
Milling is the cutting operation that removes metal by feeding the work
against a rotating, cutter having single or multiple cutting edges. Flat or
curved surfaces of many shapes can be machined by milling with good
finish and accuracy. A milling machine may also be used for drilling,
slotting, making a circular profile and gear cutting by having suitable
attachments.
WORKING PRINCIPLE: The workpiece is holding on the worktable of
the machine. The table movement controls the feed of workpiece
against the rotating cutter. The cutter is mounted on a spindle or arbor
and revolves at high speed. Except for rotation the cutter has no other
motion. As the workpiece advances, the cutter teeth remove the metal
from the surface of workpiece and the desired shape is produced.

38. HORIZONTAL MILLING MACHINE CONSTRUCTION:
The main part of machine is base, Column, Knee, Saddle, Table, Overarm,
Arbor Support and Elevating Screw.
Base:
It gives support and rigidity to the machine and also acts as a reservoir for the
cutting fluids.
Column:
The column is the main supporting frame mounted vertically on the base. The
column is box shaped, heavily ribbed inside and houses all the driving
mechanisms for the spindle and table feed.
Knee:
The knee is a rigid casting mounted on the front face of the column. The knee
moves vertically along the guide ways and this movement enables to adjust
the distance between the cutter and the job mounted on the table. The
adjustment is obtained manually or automatically by operating the elevating
screw provided below the knee.
Saddle:
The saddle rests on the knee and constitutes the intermediate part between
the knee and the table. The saddle moves transversely, i.e., crosswise (in or
out) on guide ways provided on the knee.
Table:
The table rests on guide ways in the saddle and provides support to the work.
The table is made of cast iron, its top surface is accurately machined and
carriers T- slots which accommodate the clamping bolt for fixing the work. The
worktable and hence the job fitted on it is given motions in three directions:
a). Vertical (up and down) movement provided by raising or lowering the knee.

39. b). Cross (in or out) or transverse motion provided by moving the saddle in
relation to knee.
c). Longitudinal (back and forth) motion provided by hand wheel fitted on the
side of feed screw.
In addition to the above motions, the table of a universal milling machine
can be swiveled 45° to either side of the centre line and thus fed at an angle
to the spindle.

40. Overarm: The Overarm is mounted at the top of the column and is guided in
perfect alignment by the machined surfaces. The Overarm is the support for
the arbor.
Arbor support:
The arbor support is fitted to the Overarm and can be clamped at any
location on the Overarm. Its function is to align and support various arbors.
The arbor is a machined shaft that holds and drives the cutters.
Elevating screw:
The upward and downward movement to the knee and the table is given by
the elevating screw that is operated by hand or an automatic feed.
MILLING OPERATIONS
1. Plain or slab milling
2. Face Milling
3. Angular Milling
4. Straddle Milling
5. Form Milling
6. Gang Milling

41. Plain or slab milling:
Machining of a flat surface which is parallel to the axis of the rotating cutter.
Face milling:
Machining of a flat surface which is at right angles to the axis of the
rotating cutter.
Angular milling:
Machining of a flat surface at an angle, other than a right angle, to the
axis of revolving cutter.

42. Straddle milling:
Simultaneous machining of two parallel vertical faces of the work-pieces by
a pair of side milling cutters.
Form milling:
Machining of surfaces which are of irregular shape. The teeth of the form
milling cutter have a shape which corresponds to the profile of the surface
To be produced
.
Gang milling:
Simultaneous machining of a number of flat horizontal and vertical surfaces of
a workpiece by using a combination of more than two cutters mounted on a
common arbor.

43. 8. STRADDLE MILLING OPERATION
1. AIM:To perform straddle milling operation on the given specimen(mild
steel) & get to its correct dimensions.
2. MATERIALS REQUIRED: mild steel specimen.
3. MACHINE REQUIRED: horizontal milling machine
4. MEASURING INSTRUMENTS:Vernier calipers
5. CUTTING TOOLS:side and milling cutter
6. MARKING TOOLS:steel rule, scriber
7. Work holding fixtures:workpiece supporting fixtures
8. Miscellaneous tools: Hammer, brush, Allen keys
Straddle Milling
When two or more parallel vertical surfaces are machined at a single cut, the
operation is called straddle milling. Straddle milling is accomplished by mounting
two side milling cutters on the same arbor, set apart at an exact spacing. Two
sides of the workpiece are machined simultaneously and final width dimensions
are exactly controlled.

44. PROCEDURE FOR SETTING UP STRADDLE
MILLING
1. Select and mount a work-holding device that will hold the workpiece
with the faces to be milled exposed.
2. Securely mo unt the workpiece in the work-holding device, use
solid fixed abutments where possible.
3. Select a matched pair of side and face milling cutters and a range of
spacing collars.
4. Mount both side and face milling cutters on the machine’s arbor,
separated by collars.
5. The width of the collars should be equal to the required distance
between the component’s faces.
6. Carefully measure the distance between the milling cutter’s cutting
edges. The distance can be adjusted by changing collars for once with
different widths or adding shims. Adjustable milling collars may also be
used if available.
7. Set the machine spindle speed and feed rate.
8. Position the machine’s table so that the cutters cut the workpiece as
required.
9. Take a cut across part of workpiece.

45. 10. Stop the machine and measure the workpiece accurately, and if
necessary adjust the collar distance between the cutters on the arbor by
either inserting, changing or removing milling collar shims.
11. Re-cut the workpiece if necessary.
PRECAUTIONS
1. The milling machine must be stopped before setting up or removing a
work piece, cutter or other accessory.
2. Never stop the feeding of job when the cutting operation is going on,
otherwise the tool will cut deeper at the point where feed is stopped.
3. All the chips should be removed from the cutter. A wiping cloth
should be placed on the cutter to protect the hands. The cutter should
be rotated in the clockwise direction only for right handed tools.
4. The work piece and cutter should be kept as cool as possible (i.e.
coolant should be used where necessary to minimize heat absorption).
5. The table surface should be protected with a wiping cloth.
RESULT
The workpiece has been produced as per drawing