MT II LAB MANUAL New

ST.
MOTHER THERESA ENGINEERING COLLEGE
THOOTHUKUDI – 628102.
DEPARTMENT OF MECHANICAL ENGINEERING
ME – 8462-MANUFACTURING TECHNOLOGY LABORATORY - II Manual
Name : .....................................................................................
Reg No : ......................................................................................
Branch : MECHANICAL ENGINEERING
Semester : IV
Subject : MANUFACTURING TECHNOLOGY LABORATORY-II
PREFACE
St .Mother Theresa Engineering College,

Department of Mechanical Engineering,
Manufacturing Technology Lab-II
The objective of Manufacturing Technology laboratory is to give an introductory to the
Mechanical engineering concepts. Basic Mechanical engineering is taught as an interdisciplinary
subject across various Engineering streams. This manual features ten exercises and covers the
syllabus framed by the Anna University of Chennai.
The content of this manual have been planned and presented in an organized manner to
meet the general academic requirement of all engineering students.
Manufacturing Technology lab - II practices have become important in the industrial

field to produce for the service of the customers. The knowledge of the manufacturing
technology is highly essential for all Engineering students. This manual have machine tool
concept and various machines working module can be explained clearly. Therefore, an attempt
has been made through this manual to present both the theoretical and practical knowledge to
the students.
College Vision and Mission

Vision:
To provide education in engineering with excellence and ethics and to reach the
unreached.
Mission:
To create innovative and vibrant young leaders and entrepreneurs in engineering and
technology for building India as a super knowledge power and blossom into a university of
excellence recognized globally.
QUALITY POLICY
We aim at continuous pursuit for excellence through
 Quality education tapped from National and International Resources

 Modular approach to channelize knowledge and programmed evaluation of
knowledge accumulated
 Continuous reviewable and renewal of quality systems leading to quality output
 Producing Engineers with strong ethical and moral background
The Vision of the Department is

The Department strives to be recognized globally for outstanding education & research leading
to well qualified engineers who provide to be move innovative entrepreneurial and successful in
advanced fields of engineering and research.
The Mission of the Department is
 To provide valued based education in engineering, technology and management.
 To inculcate dedication, hard work, sincerity, integrity and ethics to built up overall professional
personality in our student and faculty.
 To breed inquisitive and creative research culture to help in the development of new knowledge
and up gradation of existing knowledge using information and Management technology.
 To empower the students with current knowledge and ethics to meet the requirements of the
nation in an evolving knowledge based competitive world with an endless evolving knowledge.
Programme Educational Objectives (PEO’s)
S.No. PEOs Definition of PEOs
PEO 1 IMPARTING To impart intense knowledge in basic science and its

I
KNOWLEDGE applications in engineering.
PEO 2 MULTI - To integrate the knowledge on basic sciences and engineering

II DISCIPLINE concepts with industrial, social and environmental issues and
to innovate technologies for betterment.
PEO 3 SKILL To develop interpersonal skills to strengthen team work,

III DEVELOPMENT leadership quality and to promote awareness about continual
learning not limited to higher studies.
PEO 4 To enhance professionalism in problem solving through

IV PROFESSIONALIS decisiveness, moral and professional ethics to shoulder social
M responsibility.

Programme Outcomes (PO’s)
S.No. Programme Outcomes

Pa Engineering Knowledge: Apply knowledge of mathematics, science, engineering
fundamentals and an engineering specialization for building engineering models.
Pb Problem Analysis: Identify and solve engineering problems reaching conclusions
using mathematics and engineering sciences.
Pc Design/Development of Solutions: Design and develop solutions for engineering
problems that meet specified needs.
Pd Conduct Investigations of Complex Problems: Conduct investigations of complex
problems including design of experiments and analysis to provide valid solutions.
Pe Modern Tool Usage: Create and apply appropriate techniques, resources, and modern
engineering tools for executing engineering activities.
Pf The Engineer and Society: Apply reasoning of the societal, safety issues and the
consequent responsibilities relevant to engineering practice.
Pg Environment and Sustainability: Understand the impact of engineering solutions in
the environment and exhibit the knowledge for sustainable development.
Ph Ethics: Apply ethical principles and commit to professional ethics, responsibilities
and norms of engineering practice.
Pi Individual and Team Work: Function effectively as an individual, and as a member
or leader in diverse teams in multi-disciplinary settings.
Pj Communication: Communicate effectively to the engineering community and the
outside world and also to write effective reports.
Pk Project Management and Finance: Understand engineering and management
principles and apply them to handle projects in multi disciplinary environments.
Pl Life-Long Learning: Recognize the need for life-long learning and apply in the
context of technological change.

MANUFACTURING TECHNOLOGY LABORATORY -II
INTRODUCTION:
The three principal machining processes are classified as turning, drilling and milling. Other

operations falling into miscellaneous categories include shaping, planing, boring, broaching and
sawing.
 Turning operations are operations that rotate the workpiece as the primary method of
moving metal against the cutting tool. Lathes are the principal machine tool used in turning.
 Milling operations are operations in which the cutting tool rotates to bring cutting edges
to bear against the workpiece. Milling machines are the principal machine tool used in
milling.
 Drilling operations are operations in which holes are produced or refined by bringing a
rotating cutter with cutting edges at the lower extremity into contact with the workpiece.
Drilling operations are done primarily in drill presses but sometimes on lathes or mills.
 Miscellaneous operations are operations that strictly speaking may not be machining
operations in that they may not be swarfproducing operations but these operations are
performed at a typical machine tool. Burnishing is an example of a miscellaneous operation.
Burnishing produces no swarf but can be performed at a lathe, mill, or drill press.
OVERVIEW:
After completion of this course, the students should be able to:
1. Explain the concepts and understanding theory of machining and the usage of models in
different engineering applications.
2. Ability to use different machine tools for finishing operations
3. Ability to use different machine tools to manufacturing gears.
4. Ability to manufacture tools using cutter grinder
5. Explain the basic concepts of CNC programming and machining.
DOs and DON’T DOs in Laboratory:
1. Do not enter the laboratory without lab coat and shoes.

2. Do not use the tools and machines unnecessary manner.
3. Never run in the laboratory.
4. Follow the instructions given by the teacher.
5. The performance of unauthorized experiments is strictly forbidden.
6. Do not sit on laboratory benches
Instruction to Teachers:
 Prepare an outline (on the board) of the lab activities

 Do not hesitate to explain things more than once or answer questions that you may
consider simple
 Demonstrate new techniques to the class or small groups
 Check the students are in proper lab uniform.
 Visit with each student individually during the lab
 Ask specific questions of the students in order to monitor their progress during the lab
 Provide ample feedback to students during the lab
Instruction to students:
 Student should maintain discipline & silence inside the lab.

 Follow the instructions given by the teacher
 Students should bring their textbook, observation and record to the lab class and no other
materials are allowed.
 HEADINGS and DETAILS should be neatly written
 i. Aim of the experiment
 ii. Apparatus / Tools / Instruments required
 iii. Procedure / Theory / Algorithm / Program
 iv. Neat Diagram
 v. Result / discussions.
 Students should maintain the cleanliness of the lab.
 Be PATIENT, STEADY, SYSTEMATIC AND REGULAR.
Lab Code of Conduct:
 Students should enter the lab with proper Dress code (i.e. with I.D card, shoes & lab
coat)
 Breakdown of apparatus /Equipment should be immediately intimated to the staff In-
charge and proper entry should be made in the breakdown Register
 Students should switch off the machines and arrange the chairs before leaving the lab.

Major Lab Equipments with Specifications:
S.No Description Of Equipment Specifications
4 ½ Feet –‘V’bed
Bearing Type - Non Gears
1 Lathe Center Height-7 Inch
Center To Center -30 Inch
4 ½ Feet –‘V’bed
Capstan And Turret Lathe ‘V’belt Drive
2
Spindle Bore -1 ½ Inch
Drive-‘V’belt
Bed -12 Inch
Coloum -5 Inch
Radial Drilling Machine
3 Spindle Bore- Mt 3
Up And Down Movement-3 Feet
Motor-2 Hp
Drive- Hydraulic
Spindle Moment =12mm
Operation- Max.10 Mm
Gear Shaper
4 Motor- H- Pump 1 ½ Hp
Sp.Rotation -0.14 Kw
Table Rotation-0.14 Kw
3½ Feet –‘V’bed
Turret Lathe ‘V’belt Drive
5
Spindle Bore -1 1/4 Inch
Bed-2 ½ Feet
Drive- Manual
Cylindrical Grinder Wheel Size-12*1½ Inch
6
Motor-2 Hp
Sp Drive -1/2 Hp
Drive- Bed Movement 6 Inch

Wheel Size Grinder-14*4 Inch
Centerless Grinder
7 Wheel Size Rubber-9*4 Inch
Motor- 1 Hp,3hp

Spindle Drive- Gear Drive Max. Dia 10
Inch
Spindle- Rotating Table
Cutter- Gear Drive 4 Module
Gear Hobbing
8 Max Hight 10 Inch
Motor-2hp
Up And Down 0.5 Hp
Swivel Base Table-3 Feet Length

Drive-‘V’belt
Horizontal Milling Spindle Arbour- 11 Inch
9
Up And Down Height- Height 18 Inch
Motor-2hp
Swivel Base Table- 2 ½ Feet Length

Drive-Gear
Vertical Milling
10 Up And Down Height- Height 8 Inch
Motor-2hp

Drive- Direct
Surface Grinding
11 Wheel Size-8*3/4 Inch
Motor-1hp

Tool And Cutter Grinder Drive- Belt
12 Wheel Size-4 Inch Up Down Motor-1hp
5000rpm

Mapping Of Course Outcomes with Program outcomes
Ability to use different
tools using cutter grinder
programming Develop CNC part

Ability to manufacture
machine tools for
PEO
manufacturing gears
machine tools to
S.
No.
PO
finishing operations.
Pa Engineering Knowledge: Apply knowledge of
mathematics, science, engineering fundamentals H H H H
and an engineering specialization for building
engineering models.
Pb Problem Analysis: Identify and solve
engineering problems reaching conclusions using M
mathematics and engineering sciences.
Pc Design/Development of Solutions: Design and
develop solutions for engineering problems that H
meet specified needs.
Pd Conduct Investigations of Complex Problems:
Conduct investigations of complex problems M
including design of experiments and analysis to
provide valid solutions.
Pe Modern Tool Usage: Create and apply
appropriate techniques, resources, and modern H H H
engineering tools for executing engineering
Pf activities.
The Engineer and Society: Apply reasoning of
the societal, safety issues and the consequent H H
responsibilities relevant to engineering practice.
Pg Environment and Sustainability: Understand the
impact of engineering solutions in the environment
and exhibit the knowledge for sustainable
development.
Ph Ethics: Apply ethical principles and commit to
professional ethics, responsibilities and norms of
engineering practice.
Pi Individual and Team Work: Function effectively
as an individual, and as a member or leader in M M M M
diverse teams in multi-disciplinary settings.

tools using cutter grinder
programming Develop CNC part

Ability to manufacture
machine tools for
PEO
manufacturing gears
machine tools to
S.
No.
PO
finishing operations.
Pj Communication: Communicate effectively to the
engineering community and the outside world and M M M M
also to write effective reports.
Pk Project Management and Finance: Understand
engineering and management principles and apply H
them to handle projects in multi disciplinary
environments.
Pl Life-Long Learning: Recognize the need for life-
long learning and apply in the context of H H H H
technological change.

ANNA UNIVERSITY SYLLABUS
ME6411 MANUFACTURING TECHNOLOGY LABORATORY – II
(Regulation -2013) LTPC

0032
COURSE OBJECTIVES:
To Study and acquire knowledge on various basic machining operations in special purpose
machines and its applications in real life manufacture of components in the industry
LIST OF EXPERIMENTS
1.Contour milling using vertical milling machine
2.Spur gear cutting in milling machine
3.Helical Gear Cutting in milling machine
4.Gear generation in hobbing machine
5.Gear generation in gear shaping machine
6.Plain Surface grinding
7.Cylindrical grinding
8.Tool angle grinding with tool and Cutter Grinder
9.Measurement of cutting forces in Milling / Turning Process
10.CNC Part Programming.
TOTAL: 45 PERIODS
COURSE OUTCOMES
 Ability to use different machine tools to manufacturing gears.

 Ability to use different machine tools for finishing operations
 Ability to manufacture tools using cutter grinder
 Develop CNC part programming

LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS
S.No. NAME OF THE EQUIPMENT Qty.
1 Turret and Capstan Lathes 1 No each

2 Horizontal Milling Machine 2 No
3 Vertical Milling Machine 1 No
4 Surface Grinding Machine 1 No.
5 Cylinderical Grinding Machine 1 No.
6 Radial Drilling Machine 1 No.
7 lathe Tool Dynamometer 1 No
8 Milling Tool Dynamometer 1 No
9 Gear Hobbing Machine 1 No
10 Tool Makers Microscope 1 No
11 CNC Lathe 1 No
12 CNC Milling machine 1 No
13 Gear Shaping machine 1 No
14 Centerless grinding machine 1 No
15 Tool and cutter grinder 1 No

LIST OF EXPERIMENTS
Index
PAGE MARKS STAFF
EX.NO DATE EXERCISES NO AWARDED SIGNATURE
Contour milling using vertical milling

1 machine
Spur gear cutting in milling machine
2
Helical Gear Cutting in milling
machine
3
Gear generation in hobbing machine
4
Gear generation in gear shaping
machine
Plain Surface grinding

6
Cylindrical grinding
Tool angle grinding with tool and

Cutter Grinder
8
Measurement of cutting forces in

Milling / Turning Process
9
10
CNC Part Programming.
Mt-ii lab – exercises

INTRODUTION TO GEARS AND MACHINES
Bevel gears Bevel gears are used mostly in situations that require power to be
transmitted at right angles (or applications that are not parallel). Bevel
gears can have different angles of application but tend to be 90°
Helical gears Helical gears are very similar to spur gears except the teeth are not
perpendicular to the face. The teeth are at an angle to the face giving
helical gears more tooth contact in the same area.
Helical gears can also be used on non-parallel shafts to transmit motion.
Helical gears tend to run quieter and smoother than spur gears due to the
increased number of teeth in constant contact at any one period of time
Herringbone Herringbone gears resemble two helical gears that have been placed side
gears by side. They are often referred to as "double helicals".
One benefit of herringbone gears is that it helps to avoid issues related to

side thrust created with the use of helical gears
Worm Gears
Worm gears are used to transmit power at 90° and where high reductions
are required. The worm resembles a thread that rides in concaved or
helical teeth
Spur Gears Spur gears are by far the most common type of gear and with the
exceptions of the "cog" the type of gear that has been around the longest.
Spur gears have teeth that run perpendicular to the face of the gear
Internal Gears
Internal gears typically resemble inverted spur gears but are occasionally
cut as helical gears
Racks
A rack is basically a straight gear used to transmit power and motion in a

linear movement.
Face Gears

Face gears transmit power at (usually) right
angles in a circular motion. Face gears are not
very common in industrial application
Sproc
kets
Sprockets are used to run chains or belts.
They are typically used in conveyor systems

MILLING MACHINE
Milling is the process of removing metal by feeding the work piece through a rotating
multipoint cutter. Milling machine can be used for machining flat surfaces, complex and
irregular areas, surface of revolution, external and internal threads, gear cutting, helical
surface of cross sections.
1. Base
2.Column
3.Knee
4.Saddle
5.Table
6.Spindle
7.Arbor
2.1. BASE:
It is the foundation of the machine and is that part upon which all parts are mounted.
It gives the machine rigidity and strength.
2.2. COLUMN:
It is the main supporting frame. The motor and other driving mechanisms are
contained within it.
2.3 KNEE:
The knee projects from the column and slides up and down on its face. It supports
the saddle and table and partially supported by the elevating screw which adjusts its height.
2.4. SADDLE:
The saddle supports and carries the table and is adjustable transversely on ways on
top of the knee. It is provided with graduations for exact movement and operated by power
or hand.
2.5. TABLE:
The table rests on ways on the saddle and travels longitudinally in a horizontal
plane. It supports the works piece, fixtures and all other equipments.
2.6. SPINDLE:
The spindle obtains its power from the motor through motors. Cutters are mounted
directly in the spindle nose.
2.7. ARBOR:
The arbor is an accurately machined shaft for holding and driving the arbor cutter.
It is tapered at one end to fit the spindle nose and two slots to fit the nose keys for locating and
driving it

SHAPER
1. Table support
2. Table
3. Clapper box
4. Apron clamping bolts
5. Down feed hand wheel
6. Swivel base degree graduations
7. Position of stroke adjustment hand wheel
8. Ram block locking handle
9. Ram
10. Column
11. Driving pulley
12. Base
13. Feed disc
14. Pawl mechanism
15. Elevating screw
3. SHAPER
The shaper is a reciprocating type of machine tool intended primarily to produce flat
surfaces. These surfaces may be horizontal, vertical, or inclined.
The different parts of typical shaper are shown in fig (3.0).
The principal parts of a standard shaper are:
1. Base
2. Column
3. Cross rail
4. Saddle
5. Table
6. Ram
7. Tool head

3.1 BASE
The base is the necessary bed or required for all machine tools. The base may be
rigidly bolted to the floor of the shop or on the bench according to the size of the machine.
It is so designed that it can take up the entire load of the machine and the forces set up by
the cutting tool over the work. It is made of cast iron to resist vibration and take up high
compressive load.
3.2 COLUMN
The column is a box like casting mounted upon the base. It encloses the ram driving
mechanism. Two accurately machined guide ways are provided on the top of the column
on which the ram reciprocates. The front vertical face of the column, serves as the guide
ways for the cross rail. The lid on the left side of the column may be opened for inspection
and oiling of the internal mechanism.
3.3 CROSSRAIL
The crossrail is mounted on the front vertical guide ways of the column. It has two
parallel guide ways on its top in the vertical plane that is perpendicular to the ram axis. The
table may be raised or lowered to accommodate different sizes of jobs by rotating elevating
screw, which causes the cross rail to slide up and down on the vertical face of the column.
A horizontal cross feed screw, which is fitted within the cross rail and parallel to the top
guide ways of the cross rail actuates the table to move in a crosswise direction.
3.4 SADDLE
The saddle is mounted on the crossrail, which holds the table firmly on its top.
Crosswise movement of the saddle by rotating the cross feed screw by hand or power
causes the table to move sideways.
3.5 TABLE
The table is bolted to the saddle receives crosswise and vertical movements from the
saddle and cross rail. It is a box like casting having T-slots both on the top and sides for
clamping the work. In a universal shaper the table may be swiveled on a horizontal axis and
the upper part of the table may be tilted up or down.
3.6 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 and is connected to the reciprocating
mechanism contained within the column. It houses a screwed shaft for altering the position
of the ram with respect to the work and holds the tool head at the extreme forward end

Gear Hobbing Machining
GEAR HOBBING
Gear Hobbing is a technique that is employed to create gear teeth configurations that are ideal
for use in a wide range of machinery components. In cases where the gear hobbing takes place in a
mass producing environment, gear hobbing is accomplished through the use of precision gear
hobbing machines that ensure that the cut of each tooth on each gear produced meets the
specifications set by the producer.
Generally, a gear hobbing machine will make use of a series of customized bits that help to create
the specific types of cutting and shaping necessary to create gears those posses exactly the right
pitch and circle to work in various types of equipment. A customized bit is used for a particular size
and type of gear hobbing, which helps to ensure that the cuts that are made into the blank surface of
the circle of metal are relatively smooth and uniform.
CNC MACHINES

G-CODES AND M-CODES
G00 - Positioning at rapid speed; Milling and Turning
G01 - Linear interpolation (machining a straight line); Milling and Turning
G02 - Circular interpolation clockwise (machining arcs); Milling and Turning
G03 - Circular interpolation, counter clockwise; Milling and Turning
G04 - Milling and Turning, Dwell
G09 - Milling and Turning, Exact stop
G10 - Setting offsets in the program; Milling and Turning
G12 - Circular pocket milling, clockwise; Milling
G13 - Circular pocket milling, counterclockwise; Milling
G17 - X-Y plane for arc machining; Milling and Turning with live tooling
G18 - Z-X plane for arc machining; Milling and Turning with live tooling
G19 - Z-Y plane for arc machining; Milling and Turning with live tooling
G20 - Inch units; Milling and Turning
G21 - Metric units; Milling and Turning
G27 - Reference return check; Milling and Turning
G28 - Automatic return through reference point; Milling and Turning
G29 - Move to location through reference point; Milling and Turning (slightly
different for each machine)
G31 - Skip function; Milling and Turning
G32 - Thread cutting; Turning
G33 - Thread cutting; Milling
G40 - Cancel diameter offset; Milling. Cancel tool nose offset; Turning
G41 - Cutter compensation left; Milling. Tool nose radius compensation left; Turning
G42 - Cutter compensation right; Milling. Tool nose radius compensation right;
Turning
G43 - Tool length compensation; Milling
G44 - Tool length compensation cancel; Milling (sometimes G49)
G50 - Set coordinate system and maximum RPM; Turning
G52 - Local coordinate system setting; Milling and Turning
G53 - Machine coordinate system setting; Milling and Turning
G54~G59 - Workpiece coordinate system settings #1 t0 #6; Milling and Turning
G61 - Exact stop check; Milling and Turning
G65 - Custom macro call; Milling and Turning
G70 - Finish cycle; Turning
G71 - Rough turning cycle; Turning
G72 - Rough facing cycle; Turning
G73 - Irregular rough turning cycle; Turning
G73 - Chip break drilling cycle; Milling
G74 - Left hand tapping; Milling
G74 - Face grooving or chip break drilling; Turning
G75 - OD groove pecking; Turning
G76 - Fine boring cycle; Milling
G76 - Threading cycle; Turning
G80 - Cancel cycles; Milling and Turning
G81 - Drill cycle; Milling and Turning
G82 - Drill cycle with dwell; Milling
G83 - Peck drilling cycle; Milling
G84 - Tapping cycle; Milling and Turning
G85 - Bore in, bore out; Milling and Turning

G86 - Bore in, rapid out; Milling and Turning

G87 - Back boring cycle; Milling
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Milling
G92 - Thread cutting cycle; Turning
G94 - Per minute feed; Milling
G95 - Per revolution feed; Milling
G96 - Constant surface speed control; Turning
G97 - Constant surface speed cancel
G98 - Per minute feed; Turning
G99 - Per revolution feed; Turning CNC M
Codes
M00 - Program stop; Milling and Turning
M01 - Optional program stop; Turning and Milling
M02 - Program end; Turning and Milling
M03 - Spindle on clockwise; Turning and Milling
M04 - Spindle on counterclockwise; Turning and Milling
M05 - Spindle off; Turning and Milling
M06 - Toolchange; Milling
M08 - Coolant on; Turning and Milling
M09 - Coolant off; Turning and Milling
M10 - Chuck or rotary table clamp; Turning and Milling
M11 - Chuck or rotary table clamp off; Turning and Milling
M19 - Orient spindle; Turning and Milling
M30 - Program end, return to start; Turning and Milling
M97 - Local sub-routine call; Turning and Milling
M98 - Sub-program call; Turning and Milling
M99 - End of sub program; Turning and Milling

Ex. No: 01 CONTOUR MILLING USING VERTICAL
MILLING
DATE: MACHINE
Aim:
To study the contour milling using vertical milling machine on a
work piece
Introduction:
Machining of Irregular Parts and it is an outline especially of a

curving or irregular figure
Material used
Cast Iron
Surface contouring
The end mill, which is used in surface contouring has a
hemispherical end and is called ball-end mill. The ball-end mill is
fed back and forth across the work piece along a curvilinear path
at close intervals to produce complex three-dimensional surfaces.
Similar to profile milling, surface contouring require relatively
simple cutting tool but advanced, usually computer-controlled
feed control system.

Using Codes
G00 - Positioning at rapid speed; Milling and Turning
G01 - Linear interpolation (machining a straight line); Milling and Turning
G02 - Circular interpolation clockwise (machining arcs); Milling and Turning
G03 - Circular interpolation, counter clockwise; Milling and Turning
G04 - Milling and Turning, Dwell
G09 - Milling and Turning, Exact stop
G10 - Setting offsets in the program; Milling and
Turning G12 - Circular pocket milling, clockwise;
Milling
G13 - Circular pocket milling, counterclockwise; Milling
G17 - X-Y plane for arc machining; Milling and Turning with live tooling
G18 - Z-X plane for arc machining; Milling and Turning with live tooling
G19 - Z-Y plane for arc machining; Milling and Turning with live tooling
G20 - Inch units; Milling and Turning
G21 - Metric units; Milling and Turning
G27 - Reference return check; Milling and Turning
G28 - Automatic return through reference point; Milling and Turning
G29 - Move to location through reference point; Milling and Turning (slightly
different for each machine)
M00 - Program stop; Milling and Turning
M01 - Optional program stop; Turning and Milling
M02 - Program end; Turning and Milling
M03 - Spindle on clockwise; Turning and Milling
M04 - Spindle on counterclockwise; Turning and Milling
M05 - Spindle off; Turning and Milling
M06 - Toolchange; Milling
M08 - Coolant on; Turning and Milling
M09 - Coolant off; Turning and Milling
M10 - Chuck or rotary table clamp; Turning and Milling
M11 - Chuck or rotary table clamp off; Turning and Milling
M19 - Orient spindle; Turning and Milling
M30 - Program end, return to start; Turning and Milling
M97 - Local sub-routine call; Turning and Milling M98
- Sub-program call; Turning and Milling
M99 - End of sub program; Turning and Milling
Results
Thus the contour milling using vertical milling machine is studied .

Ex. No: 02 SPUR GEAR CUTTING IN MILLING MACHINE
DATE:
Aim:
To perform spur gear cutting using vertical milling machine on a work
piece.
Introduction:
Spur gears or straight-cut gears are the simplest type of gear. They consist of a
cylinder or disk with the teeth projecting radially, and although they are not straight-
sided in form (they are usually of special form to achieve constant drive ratio, mainly
in volute), the edge of each tooth is straight and aligned parallel to the axis of rotation.
These gears can be meshed together correctly only if they are fitted to parallel shafts.
Material used
Cast iron blank
Tools required
1. Vertical Milling machine

2. vernier caliper
3. Holding Materials
4. Milling Tools
5. Mandrel
Calculation:
Z = No. of teeth = 23
m = module = 2 mm
Blank Diameter = (Z + 2) m
= (23 + 2) 2 = 50 mm
Tooth Depth = 2.25 m
= 2.25 * 2 = 4.5 mm
Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23

Spur Gear
Fig 01 Before Gear cutting Fig 02After Gear cutting

 PROCEDURE:
1. Calculate the gear tooth proportions.

Blank diameter =(Z+2)m
Tooth depth = 2.25 m
Tooth width = 1.5708 m where,
Z = Number of teeth required
m = module Indexing calculation Index crank movement
= 40 / 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 blank is held between the dividing head and tailstock using a mandrel.
4. The mandrel is connected with the spindle of dividing head by a carrier and catch
plate.
5. The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.
6. Set the speed and feed for machining.
7. For giving depth of cut, the table is raised till the periphery of the gear blank just
touches the cutter.
8. The micrometer dial of vertical feed screw is set to zero in this position.
9. Then the table is raised further to give the required depth of cut.
10.The machine is started and feed is given to the table to cut the first groove of the
blank.
11.After the cut, the table is brought back to the starting position. Then the gear
blank is indexed for the next tooth space.
12.This is continued till all the gear teeth are cut.

RESULT:
The given work piece as is subjected to gear generating operation to become a

finished work piece

Ex No: 3 HELICAL GEAR CUTTING IN MILLING MACHINE
DATE:

Aim:
To perform Helical Gear Cutting using milling machine on a work piece.

Introduction:
Helical or "dry fixed" gears offer a refinement over spur gears. The leading edges
of the teeth are not parallel to the axis of rotation, but are set at an angle. Since the
gear is curved, this angling causes the tooth shape to be a segment of a helix.
Helical gears can be meshed
in parallel or crossed orientations.

Material used
Cast iron
 Tools required
1. Vertical Milling machine
2. vernier caliper
3. Holding Materials
4. Milling Tools
 Diagram


HELICAL GEAR FORMULAS
To Obtain Having Formula
Transverse Diametral Pitch Number of Teeth (N) & Pitch p = N/D
(P) Diameter (D)
Normal Diametral Pitch (Pa) P = PNCOSw
Helix Angle (w )
Pitch Diameter (D Number of Teeth (N) & D=N/P
Transverse Diametral Pitch
(P)
Normal Transverse Diametral Pitch PN = P / COS
Diametral Pitch (PN) (P) & Helix Angle
Normal Circular Tooth Normal Diametral Pitch (PN) = 1.5708/PN
Thickness (t)
Transverse Circular Pitch (pt) Diametral Pitch (P) Pt = /P
(Transverse
Normal Transverse Circular Pitch (p) Pn = pt Cos
Circular Pitch (pn)
Lead (L) Pitch Diameter and Pitch L= D/ Tan
Helix Angle
 PROCEDURE:
 The dividing head and the tail stock are bolted on the machine table.
 Their axis must be set parallel to the machine table.
 The gear blank is held between the dividing head and tailstock using a
mandrel. The mandrel is connected with the spindle of dividing head by a
carrier and catch plate.

The cutter is mounted on the arbor. The cutter is centred accurately with the
gear blank.

Set the speed and feed for machining.

For giving depth of cut, the table is raised till the periphery of the gear blank
just touches the cutter.

The micrometer dial of vertical feed screw is set to zero in this position.

Then the table is raised further to give the required depth of cut.

The machine is started and feed is given to the table to cut the first groove of
the blank.

After the cut, the table is brought back to the starting position. Then
the gear blank is indexed for the next tooth space.
 This is continued till all the gear teeth are cut.
 RESULT:
The given work piece as is subjected to gear generating operation to become a
finished work piece

Ex No: 04 GEAR GENERATION IN HOBBING MACHINE
DATE :

INTRODUCTION
Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets
on a hobbing machine, which is a special type of milling machine. The teeth or splines
are progressively cut into the work piece by a series of cuts made by a cutting tool
called a hob. Compared to other gear forming processes it is relatively inexpensive but
still quite accurate, thus it is used for a broad range of parts and quantities.

AIM:
To machine a Spur Gear using a gear Hobbing machine.

MATERIALS REQUIRED:
Cast iron blank

TOOLS REQUIRED:
1. Gear Hobbing machine

2. Hob
3. Gear tooth vernier
4. Spanners

CALCULATION:
m = module = 2 mm
= (23 + 2) * 2 = 50 mm
Tooth Depth = 2.25 m
= 2.25 * 2 = 4.5 mm

Gear Hobbing
Fig 01 Before Gear cutting
Fig 02After Gear cutting
St .Mother Theresa
Engineering College,
Department of Mechanical
Engineering,
Manufacturing Technology
Lab-II

PROCEDURE:
 The given work piece is held firmly on the spindle of the gear
hobbing machine
 The Hob is set at an angle to he hob helix angle for cutting spur gear.
 The change gears are set for the desired speed of work piece and
Hob and feed of the Hob.
 The machine is switched on.
 The work piece and Hob are allowed to rotate at the desired
speed.
 The hob or work piece is given full deph of cut equals to the tooth
depth.
 The cutter is given feed for the full width of the work.
 After machining all gear teeth on the blank the machine is
switched off.
 The gear teeth are checked using a gear tooth vernier.
 RESULT:
The given work piece as shown in fig (1) is subjected to gear generating operation
to become a finished work piece as shown in fig (2). In gear Hobbing machine

Ex. No: 05 GEAR GENERATION IN SHAPING MACHINE
DATE:

AIM:
To machine a Spur Gear using a gear Hobbing machine.

MATERIALS REQUIRED:
Cast iron blank

TOOLS REQUIRED:
1. Gear Shaping machine
2. Gear tooth vernier
3. Spanners
PROCEDURE:

The given work piece is held firmly on the spindle of the gear shapping
machine

The workipice is set at an angle to shaping tool angle for cutting spur gear.

The change gears are set for the desired speed of work piece and The
machine is switched on.

The work piece and Shaper are allowed to remove the metal at the desired
speed.

The work piece is given full deph of cut equals to the tooth depth.

The cutter is given feed for the full width of the work.

After machining all gear teeth on the blank the machine is switched off.

The gear teeth are checked using a gear tooth vernier.
CALCULATION:
m = module = 2 mm
= (23 + 2) * 2 = 50 mm
Tooth Depth = 2.25 m = 2.25 * 2 = 4.5 mm

Fig 01 Before Gear cutting
Fig 02After Gear cutting
RESULT:
The given work piece as shown in fig (1) is subjected to gear generating operation to
become a finished work piece as shown in fig (2). In gear Shaping Machine.

Ex. No: 06 PLAIN SURFACE GRINDING
DATE:
 AIM:
To perform a Plain surface grinding operation on the given work piece for the given
dimensions .
 PRINCIPLE:
The principle involved in this process is to make flat surface on the given work piece.
The cutter is moved perpendicular to the work piece and the grinding is done.
 REQUIREMENTS
1. Grinding Machine
2. Work Piece 100x50x6 mm MS Plate
3. Grinding Wheel
 PROCEDURE:
o At first work piece is placed in the magnetic chuck.
o The work piece should be light weight so that it cannot be removed
from the magnetic chuck easily.
o Various arrangements regarding the positions of work piece is
done.
o Grinding wheel and grinding spindle are kept in position with the
work piece.
o Before switching on the motor, necessary steps should taken. For
proper grinding process wheel speed, work speed, transverse speed
of the wheel in feed, area of contact is to be noted.
o While running the area of contact is adjusted accordingly to the
spindle in order to remove the surface.
o It is done slowly to remove the materials on the both sides.
o In surface grinding the stock removal rate is given by Q = bdy
Where d =depth of cut (m) b =width of cut (m) y =work velocity
(m/s) q =rate of stroke (m3/s)

BEFORE GRINDING
AFTER GRINDING

RESULT:
Thus the surface grinding is done for the given dimensions.

Ex.No: 07 CYLINDRICAL GRINDING
DATE:
 AIM:
To grind the cylindrical surface of the given materials as per the given dimensions
 REQUIREMENTS:
1. Grinding Machine
2. Grinding Wheel
3. Work Piece
4. Steel rule.
5. Outside calipers.
6. Cutting tool.
 PROCEDURE:
 The given work piece is first fitted in the chuck of the lathe.
 By fitting the tool in tool post the work piece will be reduced to given
dimensions.
 First reduce the diameter to 23mm size then reduced the diameter to
15mm and 18mm at the middle.
 By facing the work piece to the tool work piece is reduced to 70mm.
 After the preliminary lathe operation, the work piece is held in the ends
of the cylindrical grinder.
 The grinding wheel is turned on and it is moved towards the work
piece such that the surfaces of the cylindrical position are grinded to +-
0.2mm.

BEFORE GRINDING
AFTER GRINDING

RESULT:
Thus the required dimension of cylindrical surface is obtained.

Ex.No: 08 TOOL ANGLE GRINDING WITH TOOL AND CUTTER GRINDER
DATE:
 AIM:
To Study about the angle grinding with tool and cutter grinder on the given work
piece for the given dimensions.
 INTRODUCTION
An angle grinder, also known as a side grinder or disc grinder, is a handheld power
tool used for cutting, grinding and polishing. Angle grinders can be powered by
an electric motor, petrol engine or compressed air. The motor drives a geared head at
a right-angle on which is mounted an abrasive disc or a thinner cut-off disc, either of
which can be replaced when worn. Angle grinders typically have an adjustable guard
and a side-handle for two-handed operation. Certain angle grinders, depending on
their speed range, can be used assanders, employing a sanding disc with a backing pad
or disc. The backing system is typically made of hard plastic, phenolic resin, or
medium-hard rubber depending on the amount of flexibility desired.
REQUIREMENTS
Grinding Machine
Work Piece
Grinding Wheel


PROCEDURE:
 At first work piece is placed in the magnetic chuck.

 The work piece should be light weight so that it cannot be removed
from the magnetic chuck easily.
 Various arrangements regarding the positions of work piece is done.
 Grinding wheel and grinding spindle are kept in position with the work
piece.
 Before switching on the motor, necessary steps should taken. For
proper grinding process wheel speed, work speed, transverse speed of
the wheel in feed, area of contact is to be noted.
 While running the area of contact is adjusted accordingly to the spindle
in order to remove the surface.
 It is done slowly to remove the materials on all surface of the work
piece

RESULT:
To Study about the angle grinding with tool and cutter grinder on the given work
piece for the given dimensions.

Ex.No: 09 MEASUREMENT OF CUTTING FORCES IN MILLING /
DATE: TURNING PROCESS


AIM:
To measure the cutting forces for the given cutting conditions .

TOOLS AND EQUIPMENTS REQUIRED :
Lathe , Milling
Tool Dynamometer

PROCEDURE :
 The Lathe Tool Dynamometer is initially set to zero reading.
 The known depth of cut is given and take the readings of Px and Pz force components
from the Lathe Tool Dynamometer.
 Calculate the resultant cutting force

o P = Sqrt (Px2 + Pz2)
 Repeat the same procedure to get few more readings and calculate the mean cutting
force.
 Repeat the same procedure for different depth of cuts.
 RESULT :
Thus the cutting forces are measured for different depth of cuts.

Ex.No: 10 CNC PART PROGRAMMING
DATE:

AIM:
To Study about the cnc part programming

INTRODUCTION
A Part program is a set of instructions given to a Computerized numerical control
(CNC) machine.
If the complex-shaped component requires calculations to produce the component are
done by the programming software contained in the computer. The programmer
communicates with this system through the system language, which is based on words.
There are various programming languages developed in the recent past, such as APT
(Automatically Programmed Tools), ADAPT, AUTOSPOT, COMPAT-II, 2CL,
ROMANCE, SPLIT is used for writing a computer programme, which has English like
statements. A translator known as compiler program is used to translate it in a form
acceptable to MCU.
The programmer has to do only following things :

(a) Define the work part geometry.
(b) Defining the repetition work.
(c) Specifying the operation sequence.

STANDARD G AND M CODES
The most common codes used when programming NC machines tools are G-codes
(preparatory functions), and M codes (miscellaneous functions). Other codes such as F, S,
D, and T are used for machine functions such as feed, speed, cutter diameter offset, tool
number, etc. G-codes are sometimes called cycle codes because they refer to some action
occurring on the X, Y, and/or Z-axis of a machine tool. The G-codes are grouped into
categories such as Group 01, containing codes G00, G01, G02, G03, which cause some
movement of the machine table or head. Group 03 includes either absolute or incremental
programming. A G00 code rapidly positions the cutting tool while it is above the
workpiece from one point to another point on a job. During the rapid traverse movement,
either the X or Y-axis can be moved individually or both axes can be moved at the same
time. The rate of rapid travel varies from machine to machine.
G-Codes (Preparatory Functions)

Code Function
G00 Rapid positioning
G01 Linear interpolation
G02 Circular interpolation clockwise (CW)
G03 Circular interpolation counterclockwise (CCW)
G20 Inch input (in.)
G21 Metric input (mm)
G24 Radius programming
G28 Return to reference point
G29 Return from reference point
G32 Thread cutting
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation positive (+) direction
G44 Tool length compensation minus (-) direction
G49 Tool length compensation cancels
G 53 Zero offset or M/c reference
G54 Settable zero offset
G84 canned turn cycle
G90 Absolute programming
G91 Incremental programming

M-Codes (Miscellaneous Functions)
M or miscellaneous codes are used to either turn ON or OFF different functions, which control
certain machine tool operations. M-codes are not grouped into categories, although several codes
may control the same type of operations such as M03, M04, and M05, which control the
machine tool spindle. Some of important codes are given as under with their function s:
Code Function M00
Program stop
M02 End of program
M03 Spindle start (forward CW)
M04 Spindle start (reverse CCW)
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Chuck - clamping
M11 Chuck - unclamping
M12 Tailstock spindle out
M13 Tailstock spindle in
M18 Tool post rotation reverse
M30 End of tape and rewind or main program end M98 Transfer
to subprogram
M99 End of subprogram
Note : On some machines and controls, some may be differ.

RESULTS
Thus the Study about the cnc part programming has been completed
46
Francis Xavier Engineering College,
Manufacturing Technology Lab-II-Manual
VIVA VOCE QUESTIONS AND ANSWERS
1.What is ment by drilling?
Drilling is the process of producing hole on the work piece by using a rotating cutter
called drill
2.What is gang -drilling machine?
When a number of single spindles with essential speed & feed are mounted side by side
on one base and have common worktable is known as gang –drilling machine
3.Mention any four specification of drilling machine?
1. Maximum size of the drill in mm that the machine can operate
2. Table size of maximum dimensions of a job can mount on a table in square meter
3. Maximum spindle travel in mm
4. Number of spindle speed & range of spindle speeds in r.p.m.
4.List any four machining operations that can be performed on a drilling machine?
1. Drilling
2. Counter sinking
3. Tapping
4. Trepanning
5.What are the different ways to mount the drilling tool?
1. Fitting directly in the spindle
2. By using a sleeve
3. By using a socket
4. By means of chucks
47
6.what is broaching?
Broaching is a process of machining a surface with a special multipoint cutting tool

called broach which has successfully higher cutting edges in a fixed path
7.Indicate any two specification of a broaching machine?
1. Maximum length of stroke in mm
2. Maximum force developed by the slide in tones
8. What are the advantages and limitation of broaching?
Advantages:
1. Roughing, semi finishing & finishing cuts are completed in one pass of the broach
2. Broaching can be used for either external or internal surface finish
Limitation:
1. High initial cost of the broach tool compare to other tools
2. Job work or batch work is not advisable due to the high tool cost.
9.What are the different operations that can be performed on a broaching machine?
1. Broaching splines
2. Broaching a key way
10.What is boring?
Boring is a process of enlarging &locating previously drilled holes with a single point
cutting tool
11.What are the application of boring?
The boring machine is designed for machining large &heavy work piece in mass
production work of engine frame, cylinder, machine housing etc
48
12.Specify the importance of jig boring machine?
1. A jig boring machine is a precision boring machine used for boring accurate holes at
proper center to center distances.
2. The machining accuracy of holes produce by this machine tool lies with in a range of
0.0025mm.
13.State the purpose of grinding?
1. To remove small amount of metal from work pieces & finish then to close tolerances.
2. To obtain the better surface finish.
14.What is the function of cutting fluids?
1. It is used to cool the cutting tool & the work piece.
2. It improves the surface finish as stated earlier.
3. It causes the chips to break up into small parts.
4. It protects the finish surface from corrosion.
5. It prevents the corrosion of work & machine.
15.What are the properties of cutting fluid?
1. High heat absorbing capacities.
2. It should have good lubricant properties.
3. High flash point.
4. It should be odourless.
5. It should be non-corrosive to work & tool.
16.What are causes of wear?
The tool is subjected to three important factors such as force, temperature and sliding
action due to relative motion between tool and the work piece. So the tool is wear easily.
49
17.What are the specifications of the milling machine?
1. The table length &width.
2. Number of spindle speeds &feeds.
3. Power of driving motor.
18.Mention the various movements of universal milling machine table?
1. Vertical movement-through the knee.
2. Cross vise movement-through the saddle.
19.State any two comparisons between plain &universal milling machine?
1. In plain milling machine the table is provided with three movements, longitudinal,
cross&vertical. In universal milling machine in addition to these three movements, there is a
forth movement to the table. The table can be swiveled horizontally & can be fed at angles to the
milling machine spindle.
2. The universal milling machine is provided with auxiliaries such as dividing head,
vertical milling attachment, rotary table etc. Hence it is possible to make spiral, bevel gears, twist
drills, reamers etc on universal milling machine.
20.What are the cutter holding devices?
1. Arbors
2. Adaptors
3. Collets
21.List the various type of milling attachment?
1. Vertical milling
2. Universal milling
3. High speed milling
4. Rotary
5. Slotting
50
22. Write any ten nomenclature of plain milling cutter?
Body of cutter, cutting edge, face, fillet, gash, lead, land, outside dia, root dia, cutter
angles.
23. What is rake angle? What is the effect of nose radius in tools?
The angle between the tool face and the line parallel to the base of the tool is known as side rake
angle. It is used to control chip flow.
24.What is tool?
The various angles of tools are mentioned in a numerical number in particular order. That is
known as tool signature.
25. What are the causes of wear?
The tool is subjected to three important factors such as force, temperature and sliding action due
tool.
51

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ST.

MOTHER THERESA ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

ME – 8462-MANUFACTURING TECHNOLOGY LABORATORY - II Manual

Branch : MECHANICAL ENGINEERING

Subject : MANUFACTURING TECHNOLOGY LABORATORY-II

St .Mother Theresa Engineering College,

Manufacturing Technology lab - II practices have become important in the industrial

College Vision and Mission

St .Mother Theresa Engineering College,

We aim at continuous pursuit for excellence through

 Quality education tapped from National and International Resources

The Vision of the Department is

 To provide valued based education in engineering, technology and management.

Programme Educational Objectives (PEO’s)

S.No. PEOs Definition of PEOs

PEO 1 IMPARTING To impart intense knowledge in basic science and its

PEO 2 MULTI - To integrate the knowledge on basic sciences and engineering

PEO 3 SKILL To develop interpersonal skills to strengthen team work,

PEO 4 To enhance professionalism in problem solving through

St .Mother Theresa Engineering College,

S.No. Programme Outcomes

St .Mother Theresa Engineering College,

The three principal machining processes are classified as turning, drilling and milling. Other

After completion of this course, the students should be able to:

DOs and DON’T DOs in Laboratory:

1. Do not enter the laboratory without lab coat and shoes.

 Prepare an outline (on the board) of the lab activities

 Student should maintain discipline & silence inside the lab.

Lab Code of Conduct:

St .Mother Theresa Engineering College,

S.No Description Of Equipment Specifications

Drive- Bed Movement 6 Inch

St .Mother Theresa Engineering College,

Swivel Base Table-3 Feet Length

Swivel Base Table- 2 ½ Feet Length

Swivel Base Table-2 Feet Length

Swivel Base Table-2 Feet Length

St .Mother Theresa Engineering College,

Ability to use different

tools using cutter grinder

programming Develop CNC part

St .Mother Theresa Engineering College,

tools using cutter grinder

programming Develop CNC part

St .Mother Theresa Engineering College,

(Regulation -2013) LTPC

 Ability to use different machine tools to manufacturing gears.

St .Mother Theresa Engineering College,

S.No. NAME OF THE EQUIPMENT Qty.

1 Turret and Capstan Lathes 1 No each

St .Mother Theresa Engineering College,

Contour milling using vertical milling

Spur gear cutting in milling machine

Plain Surface grinding

Tool angle grinding with tool and

Measurement of cutting forces in

St .Mother Theresa Engineering College,

One benefit of herringbone gears is that it helps to avoid issues related to