National College Of Engineering

MARUTHAKULAM, TIRUNELVELI - 627151

ME6411 / MANUFACTURING TECHNOLGY - II

LABORATORY MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

Prepared by
Mr.P.Ganesh Kumar., M.E., Asst. Prof/Mech
Ex. Page Staff
Date Experiment Name Marks
No No. Signature

1. 1
Surface grinding on flat work piece.

2. Grinding on cylindrical work piece using 3

Cylindrical grinding machine.

3. Letter engraving using Vertical milling 7

machine.

4. External blind keyway using Vertical milling 9

machine.

5. Gear cutting using Horizontal milling 11

machine.

6. Assembly of Flange coupling. 15

7. Machining an internal keyway using slotter 17

machine.

8. Plain turning, Drilling and Boring operations 19

on Turret Lathe.

9. Measurement of Cutting forces using tool 23

dynamometer.

10. Experiment on Tool maker’s microscope. 27

11. Exercises in production lathe using Single 33

and Multi Tool.

12. Exercises in Linear, Circular Interpolation 37

and Pocketing.

13. Gear cutting using Gear hobbing machine. 41

14. Cutting a slot using Planner machine. 45
Ex. No : 1
SURFACE GRINDING ON FLAT WORKPIECE
Date :

Aim:

To make a metal as per the given dimension from the given cast iron block
in the size of 60 x 60 x 10 mm by using surface grinding machine.
Tools Required:
 Surface grinding machine.
 Micrometer.
Procedure:
1. The given work piece is checked for its initial dimensions.
2. The permanent magnet work table is cleaned thoroughly.
3. Keep the work piece over the work table and push the lever to “ON”
position to hold the work piece.
4. The required depth of cut is given by raising the work table.
5. The reciprocating and cross feed is given to grind the required length and
width of the work piece respectively.
6. Finally the finished work piece is checked for the given dimensions.

Result:
Thus the given work piece was ground to the given tolerance using surface
grinding machine.
Ex. No : 2 GRINDING ON CYLINDRICAL WORK PIECE USING
CYLINDRICAL GRINDING MACHINE
Date :

Aim:

To turn and grind the given mild steel round rod to the required dimensions
using lathe and cylindrical grinding machine.
Tools Required:
 Vernier Caliper.
 Chuck Key.
 Tool Post Key.
 Dog Carrier.
Material Required:

 Mild Steel rod of given dimensions of ø26mm and length of 105mm.

Procedure:
1. The given mild steel rod of ø26mm is hold in the lathe chuck and turned to
required diameter. After turning operation completed by using Vernier
caliper check the dimensions of work piece as per the given measurements.
The dimensions all kept slightly larger on parts where grinding finish is
required.
2. Two impression are formed, one each on the two faces of the rod to enable
the holding of the rod on the cylindrical grinding machine.
3. The work piece is surfaced to the grinding machine.
4. By the use of each plate and key the work piece is rotated and is fed against
the rotating grinding wheel and the grinding operation is done.
5. The grinding operations are caused out all required dimensions and surface
finish is obtained.
 6. The job is dismantled from the cylindrical grinding machine.

Result:
Thus the given job was machined and assembled as per the given
dimensions.
Ex. No : 3
LETTER ENGRAVING USING VERTICAL MILLING MACHINE
Date :

Aim:

To machine the given letter as per the given dimensions by using vertical
milling machine.
Tools Required:
 60mm end milling cutter.
 ½ key double end spanner.
 Steel rule.
Material Required:
 50 x 50 mm Cast Iron Block.
Procedure:
1. Select the end milling cutter for the vertical milling machine.
2. Mark the letter on the surface of Cast Iron block.
3. Then clamp the Cast Iron block in the machine vice.
4. By adjusting the table, the required depth of cut is given.
5. Finally the engraving is done by moving the cutter along the side of marked
surface.

Result:
Thus the required letter engraving was done using the vertical milling
machine.
Ex. No : 4 EXTERNAL BLIND KEYWAY CUTTING USING VERTICAL
MILLING MACHINE
Date :

Aim:

To make a metal as per the given dimension from the given Aluminium
work piece by using a vertical milling machine.
Tools Required:
 10mm end mill cutter.
 Steel rule.
Material Required:
 Ø35 x 100mm length Aluminium rod.
Procedure:
1. Select the end milling cutter for the vertical milling machine.
2. With the help of scriber mark the keyway dimensions in the work piece.
3. Fix the work piece in the machine vice of the vertical milling machine.
4. After fixing the work piece and the end mill, allow the table to moves
horizontally.
5. Slowly increase the depth of cut and repeat the procedure to make the
required shape.
6. The work piece is checked for its dimensions as per the given diagram.

Result:
Thus the given work piece was machined as per the given dimensions using
the vertical milling machine.
GEAR CUTTING USING HORIZONTAL MILLING MACHINE
Ex. No : 5
GEAR CUTTING USING HORIZONTAL MILLING MACHINE
Date :

Aim:

To machine a spur gear to the given module and number of teeth in the given
work piece by using horizontal milling machine.
Tools Required:
 Gear tooth Vernier caliper.
 Mandrel.
 Horizontal milling machine.
Material Required:
 Ø70mm Aluminium blank.
Procedure:
1. Calculate the gear teeth proportions.
Blank diameter = (Z+2) m.
Tooth depth = 2.25m.
Tooth width = 1.5708m.
Indexing calculations = 40/Z
Where, (Z) = Number of teeth required.
(m)= Module.
2. The drilling head and tail stock are bolted on the machine table. Their axis
must be set parallel to the machine table.
3. The gear blank is held between the dividing head and tail stock using a
mandrel. The mandrel is connected with the spindle of the dividing head by
a carrier and catch plate.
4. The cutter is mounted on the mandrel parallel to the table the cutter is
centered accurately with the gear blank.
 5. Set the speed and feed for the machining.
6. For giving depth of cut, the table is raised till the periphery of the gear blank
just touches the cutter.
7. The micrometer dial of vertical feed screw is set to zero in this position.
8. Then the table is raised further to given required depth of cut.
9. The machine is started and feed is given to the table to cut the first groove of
the blank.
10. After the cut, the table is brought back to the starting position.
11. Then the gear blank is indexed for the next tooth space.
12. This is continued till all the gear teeth are cut.
Calculations:
Number of gear teeth (Z) = 32
Module (m) = 2mm
Blank diameter = (Z+2) m = (32+2) x 2 = 68mm.
Tooth depth = 2.25m = 2.25 x 2 = 4.5mm.
Index calculation = 40/Z = 40/32 = 5/4 =1¼
(Multiply both up and down by [9] for indexing disc hole number) = 19/36

Result:
Thus the required gear was machined by using the horizontal milling
machine to the required number of teeth.
Ex. No : 6
ASSEMBLY OF FLANGE COUPLING
Date :

Aim:

To machine and assemble the flange coupling as shown in the figure by

using drilling and tapping operations.
Tools Required:
 Radial drilling machine.
 Drill set.
 Bolts and Nuts.
 Vernier caliper.
Procedure:
1. The given work piece are checked for its initial dimensions.
2. The centres of the work piece are marked and the pitch circle diameter is
marked in both work pieces.
3. The first work pieces are drilled and tapped in dimensions as shown in the
figure.
4. Both the work pieces are joined by using bolts and nuts.
5. Thus the flange coupling assembly is made by using both radial drilling
machine and handmade tapping tool.

Result:
Thus the given work piece was machined and assembled as per the given
dimensions by using both drilling and tapping operation.
Ex. No : 7 MACHINING AN INTERNAL KEYWAY USING SLOTTER
MACHINE
Date :

Aim:

To machine an internal keyway in the given work piece to the given

dimensions as shown in figure by using slotter machine.
Tools Required:
 Slotter machine.
 Scriber.
 Divider.
Material Required:
 Ø60mm Aluminium blank.
Procedure:
1. The given work piece is measured for its initial dimension.
2. With the help of scriber mark the keyway dimension in work piece.
3. Fix the work piece in machine vice of the slotter machine.
4. After fixing the work piece and slotting tool allow the ram to vertical
reciprocation.
5. Start the slotting process by giving the required depth by horizontally
moving machine vice.
6. Slowly increase the procedure to make the required shape.
7. The work piece is now checked for final dimensions as per the given
diagram.

Result:
The internal keyway was machined on the given work piece regarding given
dimensions as shown in the figure using slotter machine.
Ex. No : 8 PLAIN TURNING, DRILLING AND BORING OPERATIONS ON
TURRET LATHE
Date :

Aim:

To perform the Facing, Plain turning, Drilling and Boring operations on the
given work piece by using turret lathe.
Tools Required:
 Turret Lathe.
 Steel rule.
 Drill bit.
Material Required:
 Mild steal rod [ø20mm x 30mm length].
Procedure:
1. The given work piece is held firmly in a lathe chuck.
2. The cutting tool is set in a turret index such that the point of cutting tool
coincides with the lathe axis.
3. The machine is switched on to the rotation of work piece at the selected
speed.
4. By giving cross feed and longitudinal feed to the cutting tool the facing and
turning operations are done respectively.
5. The speed of the work piece is machined and drilling operations performed
by adjusting the turret index.
6. Then the boring operation is done by using boring tool for the given
dimension by changing the tool through moving turret index again.
7. The work piece is removed from the chuck and all the dimensions are
measured and checked.
Result:
Thus the given work piece is subjected to Facing, Plain turning; Drilling and
Boring operation was performed by using turret lathe.
MEASUREMENT OF CUTTING FORCES USING TOOL
DYNAMOMETER
Ex. No : 9
MEASUREMENT OF CUTTING FORCES USING TOOL
Date : DYNAMOMETER

Aim:

To study the effect of cutting parameters such as speed, feed and depth of
cut on cutting forces in a lathe.

Tools Required:

 Lathe tool dynamometer.

 Indicator box.
Construction of Dynamometer:

 Electric resistance strain gauges are generally used as measuring device in

dynamometers.
 The strain gauge consists of a grid of fine (0.001in) wire bonded between
two thin insulating strips of paper.
 Each end of the grid is wired into a Wheatstone bridge circuit.
 The strain gauge assembly is then permanently cemented to either the
cutting tool or a component of the dynamometer that will be strained
(deflected) by the forces involved in cutting operation.
 Upon being strained, the wire cross section of the strain gauge is changed.
Its resistance to change is indirect proportion to the strain or force being
measured.
 With proper calibration, the cutting forces in Kg can be read directly.
Procedure:
1. First set the job in the chuck.
2. Fix the single point cutting tool in the lathe tool dynamometer holder.
 3. Fix the dynamometer in a lathe tool holder.
4. Make proper connections between the dynamometer and output
measuring device.
5. Start the machine and give minimum depth of cut by keeping speed and
feed constant. Note the values of three components of forces tangential
force, radial force and longitudinal force from the measuring device.
6. Similarly vary the depth of cut and note down the values of forces. (Take
minimum four readings).
7. Next keep the depth of cut and feed constant and vary the feed note the
various forces.
8. Next keep the depth of cut and feed constant and vary the speed note the
various forces.
9. Draw the graph between force and measured parameters.

Graph:
 Plot a graph between cutting parameters and cutting force and write the
inferences.

Result:

 The cutting forces are found to increase with increase of cutting

parameters.
 The tangential cutting force is higher compared to other cutting forces.
Tabulation:
TABLE: 1 (STUDY)
Depth of cut: ________________ Feed: _______________

S.No Speed Tangential force Longitudinal Radial force (FR)

(FT) force (FL)

TABLE: 2
Speed: ________________ Feed: _______________

S.No Depth of Tangential force Longitudinal Radial force (FR)

cut (FT) force (FL)

TABLE: 3 (STUDY)
Depth of cut: ________________ Speed: _______________

S.No Feed Tangential force Longitudinal Radial force (FR)

(FT) force (FL)
Ex. No : 10
EXPERIMENT ON TOOL MAKER’S MICROSCOPE
Date :

Aim:

To perform an experiment for measuring the tooth angle and pitch length of
a sawing tool by using the tool maker’s microscope.
Tools Required:
 Tool maker’s microscope.
 Sawing blade.
Theory:
Introduction:
 The tool maker’s microscope is a versatile instrument that measure by
optical means with no pressure being involved thus very useful for
measurement on small and dedicate parts.
 It is designed for:
 Measurements on parts of complex from example, profile of external
thread, Tool templates etc..,
 Measuring center to centre distance of holes in any plane.
 A variety if linear measurements.
 Accurate angular measurements.
 Tool maker’s microscope is shown in figure. The optical head can be moved
up (or) down the vertical column and can be clamped of at any height by
means of clamping screw. The table which is mounted on the mutually
perpendicular horizontal direction (Longitudinal and Lateral) by means of
accurate micrometer screw having thimble scale and venires.
Principle of measurement:
 A ray of light from a light source is reflected by a mirror through 900. Then
passes through a transparent glass plate. A shadow of the outline (or) counter
of the work faces passes through the objective of the optical head and is
projected by a system of three prisms to a ground glass screen; observations
are made through on eyepiece. Measurements are made by means of cross
lines engraved on the ground glass screen. The screen can be rotated through
3600. The angle of rotation is read through an auxiliary eye piece.
Procedure:
Pitch measurement:
1. Take the hacksaw blade is mound on the moving blade of tool maker’s
microscope in horizontal position.
2. Focus the microscope on the blade.
3. Make the cross line in the microscope coincided with one of the edge of the
blade.
4. Take the reading on ground glass screen, this is the initial reading.
5. The table is again moved until the next edge of the blade coincides with the
cross line on the screen and the final reading takes.
6. The difference between initial and final reading gives pitch of the blade.
Teeth Angle:
1. Place the blade on the table is same position.
2. Rotate the screen until a live on the angle of screen rotation is noted.
3. Take the angular reading, the initial one.
4. Again rotate the screen until the same line coincides with the other flank of
the teeth.
5. Take the final angular reading.
6. The teeth angle of blade in the difference between the two angular readings.
Result:
 Pitch of blade = _________________.
 Teeth Angle = __________________.
Observation Table:

For
S.No Initial reading Final reading Difference Mean
Measurements

Pitch of Blade 2

Teeth Angle 2

3
Ex. No : 11 EXERCISE IN PRODUCTION LATHE USING MULTI TOOL AND
SINGLE TOOL
Date :

Aim:

To study and evaluate a part programming which consists of linear

interpolation and angular interpolation operation and validate by using NC-Lathe
machine.

Tools Required:

 Chuck Key.
 Steel rule.
Materials Used:
 Mild steel rod [25mm diameter and 100mm length]
Procedure:
1. Given dimension of job was analyzed.
2. Operation sequence for programming the given job in NC-Lathe machine
was framed.
3. By using G-Codes and M-Codes was framed the CNC-Program as given.
4. Work piece was damped in chuck as same as the clamping done in
conventional lathe.
5. The program was given as input to the machine by the way of computer
system.
6. Check the predefining manufacture modal layout.
7. After verification machine was start operation weather there is no need
for any damage in modal layout.
8. After finished the operation, work piece removed from the chuck and
verify the dimensions.
Program:

G21 G98

G28 U0 W0

M03 S1000

M06 T0101

G00 X0 Z1

G71 U1 R1 M08

G71 P1 Q5 U0.1 W0.1 F40

G01 X10 Z1

G01 X20 Z-30

G01 X20 Z-60

G01 X23 Z-100

G70 P1 Q5

G01 X25

G00 Z1

G28 U0 W0

M05

M09

M30
Result:

 Thus the part program for given Lathe operations was done and verified.
Ex. No : 12 EXERCISE IN LINEAR, CIRCULAR INTERPOLATION AND
POCKETING
Date :

Aim:

To study and evaluate a part programming which consists of linear, circular

interpolation and pocketing operations are performed and validate by using
NC-Milling machine.

Tools Required:

 Machine vice.
 Steel rule.
Materials Used:
 Aluminum Plate [80mm x 80mm x 10mm]
Procedure:
1. Given dimension of job was analyzed.
2. Operation sequence for programming the given job in NC-Milling
machine was framed.
3. By using G-Codes and M-Codes was framed the CNC-Program as given.
4. Work piece was clamped in vice as same as the clamping done in
conventional lathe.
5. The program was given as input to the machine by the way of computer
system.
6. Check the predefining manufacture modal layout.
7. After verification machine was start operation whether there is no need
for any damage in modal layout.
8. After finished the operation, work piece removed from the vice and
verify the dimensions.
Program:

G21 G94 G91

G28 X0 Y0 Z0

M03 S1500

G00 G90 X0 Y0 Z5

G00 X-35 Y-35

G01 Z-1 F60

G01 X-35 Y30

G02 X-30 Y35 R5

G01X25 Y35

G01 X35 Y25

G01 X35 Y-30

G03 Y-35 R5

G01 X-35 Y-35

G00 G90 Z5

G28 G91 X0 Y0 Z0

M03 S1000

G90 G00 X0 Y0 Z5

G85 X0 Y0 Z-6 Q3 R1 F60

G80 G00 Z5

G28 X0 Y0 Z0

M05

M30
Result:

 Thus the part program for given Milling operations was done and
verified.
GEAR CUTTING USING GEAR HOBBING MACHINE
Ex. No : 13
GEAR CUTTING USING GEAR HOBBING MACHINE
Date :

Aim:

To machine a helical gear to the given module and number of teeth in the
given work piece.

Tools Required:

 Gear Hobbing machine

 Vernier caliper
 Mandrel
Procedure:

1. Calculate the helical gear angle.

Blank diameter = 70mm.
Number of teeth (Z) = 14.
Module (mn) = 4.095mm.
β = cos-1 [(mn/d) x Z].
2. The dividing head and the tail stock are bolted on the machine table. Their
axis must be set parallel to the machine table.
3. The gear hobbing tool is held in the dividing head held work piece in a
mandrel. The mandrel is connected with the spindle of dividing head by a
carrier and catch plate.
4. The cutter is mounted on the arbor. The cutter is centered accurately with the
gear blank.
5. Set the speed and feed for machining.
6. For giving depth of cut, the gear blank just touches the cutter.
 7. The micrometer dial of tool indexed mandrel is set to the required helix
angle.
8. The machine is started and feed is given to the work piece to cut the first
groove of the blank.
9. After the cut, the table is brought back to the starting position.
10. This is continued till all the gear teeth are cut.

Calculation:

Z = No. of teeth = 14

m = module = 4.095 mm.

Blank Diameter = 70mm.

Helical gear angle (β) = cos-1 [(mn/d) x Z].

= cos-1 [(4.095/70) x 14].

= 35.015 ~ 35

Helical gear angle (β) = 350

Result:

 Thus the required gear is machined using the gear hobbing machine to
the required number of teeth.
Ex. No : 14
CUTTING A SLOT USING PLANNER MACHINE
Date :

Aim:

To make a metal as per the given dimensions from the given cast iron block
in the size of 50 x 100 x 300 mm by using planner machine.
Tools Required:
 Steel rule.
 Try Square.
 Rod Holder with a single point cutting tool.
 Parting tool and dove tail cutting tool.
Procedure:
1. The single point cutting tool is set in the tool holder of the planner machine.
2. The work piece is fitted in the machine vice.
3. Then the ram position stroke length and speed is adjusted.
4. The upper surface of the work piece is machined.
5. Then it is turned to the other side and machined.
6. Then the try square is used to check whether the work piece is properly
machined.
7. Then the work piece is fitted on the machine and “V” – Shape was marked
and machined as per the given dimensions.

Result:
Thus the required “V” – Slot machined in the given work piece to the
dimensions as shown in the figure using planner machine.