LATHE MACHINExperiment no: 02 ro study the various operations performed on Lathe Machine and prepare 2 Job On it. Aim: APPARATUS: lathe machine, mild steel rod and tools. OBJECTIVE: To study the various operations such as turning. step turning, facing, boring, taper turning, knurling, grooving, threading of center lathe. And To make the part shown in the sketch from a mild steel rod on a Lathe careovines ~ + 2 ok. “yf | THEORY: A product is made up of many components which are manufactured by various manufacturing processes such as casting. forging. welding; machining ete depends on the application and cost of that particular component. Inthe machining prowess various operations comes like turing, step turning, facing, boring, taper turning, knurling, gro. Bs threading. All these operations can be done on center lathe hence center lathe is one Of the importance type of tnachines. In tis practical we are going to study the operations which are mentioned above. Lathe jeamachine tool which rotates the work piece on its axis to perform various operations such as uting, sanding, knurling, drilling or deformation with tools thay are applied to the work piece to freate an object which has symmetry about an axis of rotation Examples of objects that can be produced on a lathe include candlestick holders, gun barrels, sticks, table legs, bowls, baseball fats, musical instruments (especially woodwind instruments), crankshafts and camshafts, Parts of Jathe and their function: ‘Almost all lathes have a horizontal beam is ¢: ting tail stock and carriage. alled as bed. It has guide ways ‘At one end of the bed (almost always the left, as the tains drive mechanism with necessary It also has chuck whichis used to old the}A. Saddle: Its base portion, located acr : lathe bed and carries cross slide and tool post, it can moved longitudinally along the bed. B. Apron; it is attached to saddle and appears as hanging on front side, It consists of gears for motion transmission. C: Cross slide: it is mounted on top of the saddle and acts as support to compound rest D: Compound rest: It is mounted on cross slide and it consists of swivel and top slide. The tool post is mounted on top slide. E: Tool-post: it is used to hold the tool position the tool as per the requirementBea 3 Jow Chuck Headstock Feed Gear Box Cross Slide Compound Sige Saddie i Forward Reverse Fig: Schematic Illustration of center lathe Various Lathe operations Turning: Itis the process of removing the material from extended surface of rotating work piece. So it is the process by which a piece of material (wood, metal, plastic, or stone) is rotated and a cutting too! is traversed along 2 axgs of motion to produce precise diameters and depths Step Turning: It is the process of obtaining different diameters on a work piece along the length by adjusting depth of the tool.NORMAL LATHE AXIS SET OVER WORKPIECE axis * |_| os DIRECTION OF FEED, PORTION REMOVED Boring: It is the machining of internal eylindrical forms ( generating ) a) by mounting work iar uncle via a chuck or faceplate b) by. mounting work piece onto the CREE eRe placing cutting tool into the chuck. Knurling: The cutting of a serrated pattern onto the surface of a part to use as A hand grip using a special purpose knurling tool Threading: It is the process of producing the helical V grooves on the surfac with the help of lead screw. DIRECTION Of TOOL TRAVEL =pGrooving: It is the process of producing V shape cyclical groove on the surface, the tool has similar V shape as required to produce on work piece CONCLUSION: : ; f ‘We have studied various operations such as turning, step turning, facing, boring, taper turning, Jnatling, grooving. and threading which are performed on center lathe, And With the belp of Above mosedure, we have made the part of above sketch on lath from a mild steel rodthe various operations s ; uch on Milling slot shown inthe sketch on the specimert n=” And To machine the PLL DIM a work part is fed past a rotating cylindrical tool ing tool is perpendicular to the direction ed direction is one of the features that fed in a direction parallel to its axis cer and the cutting edges are called milling machine. The a machining operation in which ng edges. The axis of rotation of the cut ation between the tool axis and the fe illing, the cutting tool is led a milling cutt performs this operation is an Other work geome! can be created either to the variety of shapes possible and its high machining operations. from drilling. In dri iting tool in milling is cal tool that traditionally d by milling is a plane surface path or the cutter shape. Owing ling is one of the most versatile and widely used rations fonst There are two basic types of milling OPSon is performed by cutti i 'Y cutting ed | milling are shown in Figure (b) Slotting Straddle of the cutter is perpendicul: ar to the surface bei mack i ing milled, a i eae on both the end and outside periphery of the cuter, a a el s of face milling exist, several of which are shown in Figur ee re sh Me Lie - ©) ry i End Profile haste ] miling ming mailing ety da table for fast as horizontal or vertical. id this design is well-suited for «d straddle milling) on work parts st provide a rotating spindle for the cuter an “the work part. Milling machines can be cl g machine has a horizontal spindle, an ing (e.g., slab milling, slotting. side this orientation is appropriate for face has a vertical spindle, and relatively flat work parts. e contouring, and die sinking 0”Milling Cutters : ‘ (A)Plain Milling Cutters 8 d : 2 i (a) (b) © @ Light duty Light duty helical Heavy duty High helix (B) Side milling cutter (a) (b) () Plain Staggered tooth Half side (©) Face and angular milling cutter Face Milling Cutters (D) High Speed Steel End Mills(a) Singio-ens hoticat teeth ang mh f ovens ani, Neca ENR en THE x (0) Forty five-decree els, angle clumnum cutting end axl {6 Stragtt-tooth fe) Rouglnng i Conventional ing and Climb milling One final consideration Concerning feed is the direction in which the work is fed into the cutter. The most commonly used method is to feed the work against the rotation direction of the cutter (Conventional or up milling) (Figure-a). However, if the machine is equipped with a backlash climinator, certain types of work can best be milled by climb milling. Climb milling, which can increase cutter life up to 50 percent, is effective for most milling applications. To know whether climb or conventional milling is being used, look at the relationship between the cutter rotation and the direction of the machine table/work feed. Climb milling is being used when the cutter and the work piece are going in the same direction (Figure-b). Conventional milling is when the cutter and the work piece are going in opposite directions Cuner rotation direction Cuma: rotation direction, v ——> Feed direction (a) Conventional miling (up milling) (8) Climb miting (down milling RESULT: We have studied various operations on milling machine. And, we have above sketch on milling machine from a mild steel rod. iDRILLING MACHINEExperiment nas a Aim: To study the various operations performed on Drilling Machine and prepare a Job 0 APPARATUS: Drilling machine, mild steel plate and tools, OBJECTIVE: To study the variow: i i i Wego ce ious operations on drilling machines such as drilling. reaming. Spot To drill ile, as shown in the sketch, ream and tap holes on the mild steel plate. THEORY: Holes in the work piece are necessary for many purposes such as fastening the object with nuts and bolts, Screws, for fixing assembly purpose so it is necessary to make holes in the work piece, So the Drilling is a process of making a hole in the blank work piece, or enlarging the existing hole. The Machine which is used for this purpose is called as drilling machine. It consist of spindle which is rotated by the motor and transmitting mechanism, The spindle in tum rotates the Gilling tool called as drill, as drill is press fitted into the spindle, Drill i fed into work by feed mechanism. The work piece is fixed on the table, as the drill fed into the work piece; the hole is ‘created by removing material in the form of chips. All the components are supported by frame. Cutting fluid is commonly used to cool the drill bit, increase tool life, inerease speeds and feeds, increase the surface finish, and aid in ejecting chips: Radial Arm Drill bea Column ‘ - fe a |. ySan sIINPLe SP cL NOSE Parts of Drilling machine and their fun Base: base is the lowest horizontal part which supports the entire structure of drilling machine, It is made up of cast iron because Nn cast iron absorbs vibrations. So the vibrations transmitted to foundation get reduced. S Work table: It is mounted on column which supports the work. Generally its has two types of motions. A. It can swing about column, B. it can move up and down, This facilitates the positioning of work piece while drilling. Spindle: It is a hollow portion which is provided with rotary motion spindle imparts this rotator motion to drill. Head; It consist of drive mechanism and feed mechanism. Operations Performed on the drilling machine Drilling: It is the process of making a hole in blank work piece with tool known as drill, ‘ze se aaBoring: It is process of enlargi ae Bing the already existing hole to meet the required Size and Neresieon Spot facing: It is the process of machining a flat circular surface around a hole to provide a seat for a bolt head nut or washer.ous Operations such as drilling, n Drilling machine. And With th mild-steel plate Teaming, spot facing, counter boring which ¢ help of above Procedure, we have made theAim: To study the various operation: performed on Shaper Machine and prepare a J APPARATUS: haper machine and mild steel rod, OBJECTIVE: To study the various operations such on shaper machine, And To machine a V-block as shown in the sketch out of the work piece provided on a Shaper Machine. ~ THEORY: The shaper is a reciprocating type of machine tool intended primarily to produce flat surfaces. These surfaces may be horizontal, vertical or inclined. In general, the shaper can produce + any surface composed of straight line elements. Modern shaper can generate contoured surface = RAM: The ram is the reciprocating member of the shaper. This is semi-cylindrical in form and heavily ribbed inside to make it more rigid. It slides on the accurately machined dovetail guide-ways on the top of the column, It houses a screwed shaft for altering the position of the tam with respect to the work and holds the tool head at the extreme forward end TOOL HEAD: The tool head of a shaper holds the tool rigidly, provides vertical and angular feed movement of the tool and allows the tool to have an automatic relief during its retum= : SHAPER MECHANISM: In a shaper. rotator movement of the drive is converte movement by the mechanism contained within the column of the machine. The ram holdi gets the reciprocating movement, In a standard shaper, metal is removed in the forws stroke, while the return stroke goes idle and no metal is removed during this period. To ae total machining tim necessary to reduce the time taken by the return stroke. Thus the shaper mechanism should be so designed that it can allow the ram holding the tool to move at_ comparatively slower speed during the forward cutting stroke, the cutting speed depending upon the type of material and machining condition, whereas during the return stroke it can allow the ram to move at a faster rate to reduce the idle return time. This mechanism is known as quick return mechanism. Cutting Too! Too! ~ Return Stroke (Gavan tone! 4 “Liss get e material required for the job. -2.Now, with the | lp of -sure ma ran engthand > mm eaKLU— CARPENTRY Introduction: F Carpentry may be defined as the process of making wooden components. It deals with the building work, furniture, cabinet making etc. Jointly, i.e., Preparation of joints is one of the important operations in all wood works, It deals with making joints for a variety of applications viz, door frames, window frames, wardrobes, cupboards, stairs etc. In this chapter tools and works associated with joinery are presented. ‘ial — Timber: Timber is the basic material used for any class of carpentry work. The term timber is applied to the wood obtained from; well-grown trees. The trees are cut, sawn into various sizes to suit the required purpose. Common Varieties of Indian Timber: Indian timbers most commonly used for various carpentry words are as follows: Babul, Deodar, Mahogany, Mango, Sal, Sissy and teak. arpentry Tools: In carpentry large numbers of hand tools are used for processing the wood. Here, the details of tools that are being used in our workshop only are presented Marking and Measuring Tools: Steel Rule: It is strip of steel with graduations on its edges and is used for measuring and setting out dimensions Try Square: Try squares are used for marking and testing of right angles and for testing flatness of surface. Marking Gauge: It is a tool which has one projected marking pin and is used to mark accurate lines parallel to the true edge of a wooden piece. Holding Tools: Carpenter’s Vice: It is used for holding the work for planning, sawing and chiseling. The whole vice is made of iron and steel. It has two jaws one of which is fixed to the side of the table while the other is movable. €-Clamp; It is used for holding the work projecting above the top surface of the Bench. This is used to prevent the wood from moving forward when being planned. Bench Stop: Itis simply a block of wood projecting above the top surface of the bench, This 'SUsed to prevent the wood from moving forward when being planed. aKLU a Firmer Mortise Chisel Chisel Wood rasprfile i | Pincer Claw Hemmer SS | Morse ang tenon Lap Wood JointsWooden Jack Plane: It consists of wooden body in which blade is set at an angle of 45 degrees to the body or sole. The cutting blade used is made of high carbon steel and is very similar to a chisel. Jack Plane is a general purpose plane and is used to produce flat and smooth surfaces on wood. Hand or Cross-cut Saw: It is used to cut across the grains of the stock or thick wood. The teeth are set alternately to the right and left of the blade, and its purpose is to make the cut wider than the thickness of the blade. This allows the blade to move freely in the cut, without sticking. Her teeth are set at 2.5 mm apart. Tenon Saw or Back Saw : This saw is mostly used for cross cutting when a finer and more acourate finish is required. The teeth are shaped in the form of an equilateral triangle and generally have 13 teeth for 25 mm length. - Firmer Chisel or Straight Edge Chisel : It is a general-purpose chisel and is used for cutting and shaping wood accurately. The width of the blade varies from 1.5 to 50 mm. Adze: Adze is a side axe used to chop extra wood quickly by carpenters. Adze with very long handle is used to plane long palm tree barks in standing position and also used as a hammer. Miscellaneous Tools: Pincer: Itis made of steel with a hinged joint and is used for pulling out small nails from wood Claw Hammer : Itis a dual-purpose hammer. It has a hammer face, which is used to drive in nails and claw at the other end for pulling out mails from the wood. Wood Rasp File: It is a finishing tool used to make the wood surface smooth, remove the sharp edges and other interior, surfaces. Sharp cutting teeth are provided on its surface. This file is exclusively used in woodwork. 7 lere are many kinds of joints used tc connect wood stock. Each joint has a definite use and ired marking, cutting and joining together. The strength of the joint depénds on the amount tact area. Ifa particular joint does not have much contact area, then it must be rei , screws or dowels. inforced int: Also called halving joint. The aim of this joint is to secure the corners and of the framing and at the same time in the same plane. They may be usefully many types of framing where strength and appearance are of secondaryKL U— All dimensions are in mm.qi — 7 LU Mortis 8 ily of j @ and Tenon Joint: This family of joints is a large one and does probably the wood worker u: i ise the commonest. It consists of a rectangular peg (tenon) fitting into a rectangular hole (mortise). Briddle Joint: These are the reverse of mortise and tenon joints in form arid are often called the open mortise tenon. These joints are used where the members are of ‘square or near- Sqliare or near-square section and thus unsuitable for making a mortise and tenon joint of good proportions. Instructions A, When you are using your thumb as a guide for cross cutting and ripping, raise it sufficiently high. 2. Planing should be done along grains only. Push the chisel away from you while chiseling. Always use marking gauge (or) a mortise gauge for drawing lines. Check the squareness of planned surfaces with try square. ‘Use wooden mallets for driving chisel not test sharpness of the edge of the cutting tools on your hand. t keep your hands In front of the sharp edged tools while they are in use. ‘unwanted material should be removed.4, MORTISE & TENON JOINTKL U— Safety Precautions : General : Make sure that your hands are not in front of sharp edged tools while you are using them. Saws : Be careful when you are using your thumb as a guide in cross cutting Chisels : 1. Never chisel towards any part of the body. 2. Test the sharpness of the Cutting edge on wood or paper, not on your hand. Exercise: 1. Lap Tee Joint 2. Cross Lap Joint or Lap ‘+’ Joint 3. Dovetail Lap Joint 4. Mortise & Tenon JointKLU— 1, Lap Tee Joint All di ions are ilht LAP TEE JOIN Date: pare a Lap Tee Joint as per dimensions given in sketch quired: Teak wood 300mm X 45mm X 35mm Steelrule 300mm 2. Handsaw~ 300mm 3. Wooden jack plane 450mm 4. Try square 200mm 5. Marking gauge 200mm. 6. C-Clamp 200mm 7. Firmer chisel 150mm 8. Adze 150mm ice of Operations: Marking 2. Planning 3.Cutting 4. Setting re: _ 1. Select a teak wood materia! and mark the size as per drawing with the help of marking tools like steel rule, marking gauge, try square. Planning of sides with the help of wooden jackplane to maintain the required dimensions. Fix the work piece in carpentry vice and cut into two equat pieces of size 150mm 10mm with the help of handsaw. the two work pieces for male cutting and groove cutting as per dimensions. work pieces one by one on the bench with the help of ‘C’ Clamp and a is made as shown in drawing with the help of chisels and adze. york pieces are fitted to make Lap Tee Joint as per drawing. areful while marking and planning uired while cutting the groove with firmer chisel so that the ded.