Open Ended Lab Report

Table of Contents
To make a V-shaped double ended threaded stud bolt

Introduction .................................................................................................................................................. 1
Objectives.................................................................................................................................................. 1
Apparatus and tools .................................................................................................................................. 1
Materials used........................................................................................................................................... 1
Theoretical Background ............................................................................................................................... 1
Center Lathe machine ............................................................................................................................... 1
Thread cutting operations ........................................................................................................................ 1
Threaded stud bolt .................................................................................................................................... 1
Terminologies used in thread cutting ....................................................................................................... 2
Calculations of the threaded stud bolt ........................................................................................................ 2
Procedure ..................................................................................................................................................... 3
Pre-setting of the machine ....................................................................................................................... 3
After pre-setting procedure ...................................................................................................................... 4
1. Chuck .............................................................................................................................................. 4
2. Facing operation ............................................................................................................................. 4
3. Center drill and countersink ........................................................................................................... 5
4. Plain turning ................................................................................................................................... 5
5. Setting feed and speed for different threads ................................................................................. 6
6. Thread cutting operation ............................................................................................................... 7
7. Parting operation ........................................................................................................................... 8
8. Thread cutting operation ............................................................................................................... 9
9. Surface finish .................................................................................................................................. 9

Final finished product ................................................................................................................................ 10

Chips and types of chips ............................................................................................................................. 11
Applications of double ended threaded stud bolt .................................................................................... 13
Problems we faced while operations ........................................................................................................ 13
Conclusions ................................................................................................................................................. 14
 To make a V-shape threaded Stud Bolt
Introduction:
The main objective of this open-ended lab is to manufacture any type of mechanical
assembly/part by performing various operations in machine shop. We have selected a machine
part called stud bolt and successfully manufactured it on lathe machine in machine shop. In this
lab report we will discuss all the operations step by step with figures used in manufacturing of
stud bolt.

Objectives:
● To manufacture any type of mechanical assembly/part by performing various operation
in machine shop,
● To have an understanding about the threading operations,
● To make a V-shape threaded Stud Bolt,
● To perform various operations required in making of stud bolt and to list a step-by-step
procedure.

Apparatus and tools:

● Center Lathe Machine, Three-jaw chuck, Chuck key, Vernier caliper, Single-point cutting
tool, compound rest method, center drill, chalk, thread gauge, threading tool bit, V-
shape single point cutting tool.
Material used:
● Aluminum cylindrical rod
Theoretical Background:
Center Lathe Machine:
A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform various
operations such as cutting, threading, sanding, knurling, drilling, deformation, facing, and
turning, with tools that are applied to the workpiece to create an object with symmetry about
that axis. Speed motion is given to the job and Feed motion is given to the cutting tool.
Thread cutting operation:
Thread cutting on lathe is a process that produces a helical ridge of uniform section on the work
piece. This is performed by taking successive cuts with a threading tool bit the same shape as
the thread form required.
Threaded stud bolt: Stud Bolts are externally threaded fasteners without a head, used with 2
nuts on either side, substituting a usual "bolt & nut" assembly. It is a type of bolt having threads
on both sides with same pitch or sometimes with different pitch threads.

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Terminologies used in thread cutting:

• Thread:
A helical structure/groove used to convert between rotational and linear movement or
force. It is used for the motion transmission.
• Pitch:
The distance between two consecutive crest or trough is called pitch
• Major diameter:
Larger diameter of thread on screw.
• Minor diameter:
Smallest diameter of thread on screw.
• Thread per inch (TPI):
TPI stands for thread per inch. In lathe machine there is complete table and gear
arrangement for specific TPI movements.
• Metric system:
It is a method of making threads using pitch given method. In the table proper feed
mechanism for specific pitch is given. For example. If we select to make a 2.5 pitch bolt,
we’ll put one lever on C and another one on number 3. So, we’ll get a 2.5 pitch bolt.
• Depth of cut:
The perpendicular distance measured from machined surface to uncut surface of the
work piece. The formula below will give us the single depth of cut for unified threads:

Depth of cut(d)= pitch x 0.6495

Calculations of the threaded Stud bolt:

Following are the specifications of the bolt that we made:
● Pitch: (The thread pitch is the distance between threads)

1. Pitch = 4 mm
2. Pitch = 2.5 mm

● For pitch = 4 mm
Depth of cut(d)= 4 x 0.6495
= 2.598 mm
For 2.598 mm we will set 52˚ depth of cut.

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 ● For pitch = 2.5 mm

Depth of cut(d)= 2.5 x 0.6495

= 1.6237 mm
For 1.6237 mm we will set 32˚ depth of cut.

● Total Length of the Bolt was found out to be 147.3 mm.

● The threaded length came out to be 30.2mm.
● The unthreaded diameter came out to be 23.7 mm.
● The threaded diameter of 4 mm pitch found out to be 22 mm.
● The threaded diameter of 2.5 mm pitch was found out to be 20.9 mm.

We know that there is a setting of depth of cut in angles in lathe machine.

For 3 mm (which is maximum depth of cut), we will set angle to 60˚

For 1 mm = 20˚
For 2 mm = 40˚
For 3 mm = 60˚

Procedure:
Pre-setting of the Machine
● The capacity chart or tables of the machine is made available.
● The drawing of the finished hexagonal bolt is taken into consideration.
● Proper speeds and feeds for each operation are next calculated.
● Setting and machining operations are performed in the following order:
1. Chuck
2. Chamfering Tool
3. Facing Operation
4. Drill and Countersink
5. Plain turning
6. Setting feed and speed for different threads
7. Thread cutting operation
8. Cutting operation or parting operations
9. Thread cutting operation
10. Surface finishing

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After pre-setting, the following procedure is followed:
1. Chuck
First loosen the jaw in the chuck key to position the work piece, and then tighten
the jaws. Fix the cutting tool in the tool post.

Figure: Fixing the workpiece in chuck

2. Facing operation:
Facing on the lathe, uses a facing tool to cut a flat surface perpendicular to the work
piece's rotational axis. A facing tool is mounted into a tool holder that rests on the
carriage of the lathe. The tool will then feed perpendicularly across the part's
rotational axis as it spins in the jaws of the chuck. Then hand feed the machine while
facing the job. Facing will take the work piece down to its finished length very
accurately.

Figure: Facing operation

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3. Center Drill and countersink:
It is a small twist drill used to make centers in a piece of work about to be turned.
Replace the tailstock holder with center drill countersink to make a center hole in
work piece to hold it fixed for rest of the operations.

Fig. Center Drill and countersinking Process

4. Plain turning:
Plain turning is the operation of removing excess amount of material from the
surface of a cylindrical job. The workpiece is held on the chuck and it is made to
rotate about the axis, and the tool is fed parallel to the lathe axis. Plain turning was
done on our workpiece to a required diameter as per our calculations discussed
above.

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 Fig. Plain turning operation

Fig. Plain turning operation

5. Setting feed and speed for different threads:

After plain turning operation, set feed and speed for the thread cutting operations.
All this mechanism is performed in head stock of center lathe machine. Open the
head stock of lathe machine, a table for different feed is given. Select appropriate
settings for different pitches. For example, for 2.5 pitch, we select one lever on 1, by
moving straight on left side of pitch, as from the table, and other one on A, by
moving vertically straight above the pitch, as shown in table. Hence, feed is set for
our required pitch. Now, to set the speed of spindle we select the speed from the

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 table given. Also, we know that speed for thread cutting will be 1/4th of turning
operation. Similarly, for 4 pitch threads we did the similar settings for feed and
speed.

Fig. Table for setting of feed and speed

6. Thread cutting operation

Thread cutting on a lathe is a process that produces a helical ridge of uniform
section on the work piece. This is performed by taking successive cuts with a
threading tool bit i.e., single point cutting tool, the same shape as the thread form
required. Firstly, we set the feed and speed using the table on gearbox. Now set the
compound rest at the desired angle we calculated above. Then we set the tool bit
and at a right angle to the lathe center point. Then, we move the threading tool up
to part using both the compound and the cross feed. After that we engage the tool,
we take a scratch cut on the part. Disengage the half nut at the end of the cut. Stop
the lathe and backout the tool using the cross feed. Then, return the carriage to the
starting position. Using the screw pitch gage and check the thread per inch. We
performed this process automatically using the lead screw by setting the required

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 angle for the depth of cut. Repeat the process until our desired dimensions are not
achieved.

Fig. Thread cutting operation for 2.5-pitch

7. Cutting operation or parting operation

After success thread cutting operation on one side for 2.5 pitch threads. The thread
on the other side of the unthreaded length also required as we are going to make
double end stud bolt. Firstly, we cut the long workpiece to our required size using
the parting tool. We engage the parting tool perpendicular to the axis of rotation of
workpiece on a specified location to cut the piece into two parts.

Fig. Parting operation

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8. Thread cutting operation:
Now after parting operation, we need to make a different pitch or same pitch thread
up to our desired product. As we want to make 4 pitch threads on the other side of
work piece. We repeat the step 5 to make settings for feed and speed for the
required pitch. Now engaging the tool again to the starting point of thread and
repeat the step 6 to successfully cut the threads for the 4-pitch side. After the
process is done, we check the threads by using screw thread gauge. The threads was
successfully drawn on the workpiece.

Fig. Thread cutting operation for 4-pitch

9. Surface finishing:
Lastly, we use foil to finish the ends of double end stud bolt. Fit the stud bolt in vice
bench. Use foil to finish the ends of the double end stud bolt to get the required
finished product, Double ended stud bolt.

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Final finished Product:

Fig. Final threaded stud bolt

Chips and types of chips:

The various types of chips produced in metal cutting are:
1) Continuous Chips:
If the metal chips formed during machining is without segments i.e., without breakage,
then it is called as continuous types of chips. Continuous chips are formed when the
ductile material is machined with high cutting speed and minimum friction between the
chip and tool face.

The conditions which are responsible for the formation of continuous types of chips are:
(i) Ductile material like mild steel is used.
(ii) Bigger rake angle of the tool.
(iii) High cutting speed.
(iv) Minimum friction between the chip and tool interface.
(v) Small depth of cut.

Advantages: The formation of continuous chips during machining process has the following
advantages:

• Better surface finish to the ductile material.

• Less heat generation due to minimum friction between the tool face and chip.

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• Low power consumption.
• Long tool life due to less wear and tear.

Discontinuous Chips

If the chips formed during machining process is not continuous i.e. formed with breakage is
called discontinuous chips.

Discontinuous types of chips are formed when hard and brittle metals like brass, bronze and
cast iron is machined.
Conditions which are responsible for the formation of discontinuous chips are:

(i) High feed rate.

(ii) Small rake angle of the tool.
(iii) Low cutting speed.
(iv) High friction forces at the chip tool interface.
(v) Too much depth of cut.

Advantages: The formation of discontinuous types of chips in brittle materials provides good
surface finish, increases the tool life and reduces the consumption of power.

Disadvantages: When discontinuous chips are formed in the ductile materials, the workpiece
result in poor surface finish and excessive wear and tear of the tool takes place.

Fig. Continuous chips

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 Fig. Dis-continuous chips

In our case the chips produced were continuous because of the material we used is very soft
material, i.e., Aluminum

Fig. Continuous chips

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Applications of double ended threaded stud bolt:
Stud Bolts are externally threaded fasteners without a head, used with 2 nuts on either side,
substituting a usual "bolt & nut" assembly. Stud bolts are prominently used in flange
connections. These are used mainly to connect flanges.

Following are the some of the applications of double ended threaded stud bolt;

I. On the main body of large equipment, accessories such as sight glass, mechanical seal,
deceleration frame, etc. need to be installed. At this time, using studs, one end of the
screw is on the main body, and the other end is fitted with a nut after the attachment is
installed, because the attachment is often removed, and the main body and the
attachment are directly bolted. Worn or damaged, it is very convenient to use stud
replacement.
II. When the thickness of the connector is large and the bolt length is very long, use stud
bolts. The purpose of the bolt connection: in actual work, external load vibration,
change, material temperature creep, etc. will cause the friction force to decrease, the
positive pressure in the thread pair disappears instantly, and the friction force is zero,
thereby loosening the thread connection Such as repeated action, the threaded
connection will relax and fail. Therefore, it must be loose, otherwise it will affect normal
work and cause accidents.
III. Stud bolts are also used in chuck in lathe machine.
IV. They are also used in large piping systems in industries, flanges, piping, etc.
V. They are also used to assemble the poles with ground plates.

Problems we faced in manufacturing of stud bolt:

Following are the problems we faced while doing open ended lab, i.e., to make a stud bolt:
• Firstly, the material was soft that is Aluminum, produced the continuous chips which
stuck the single point cutting tool again and again. Due to which the finishing of threads
was not good.
• Secondly, when we make the threads on one side and after the parting operation. It was
hard to make the threads on the other side because the material was soft and if we fit it
in the chuck the threads were going to destroyed. That’s why we fit the unthreaded
region of stud in the chuck to make threads on the other required side.
• Due to above problem, another problem occurred was that, the threaded region for the
side we were going to make threads, was not covering all because the cutting tool was
going to touch the chuck and that would make more problems. That’s why we finished
our process without making threads on the required threaded length.

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Conclusions:
In this experiment, we learned about different things related to manufacturing. We learned
how handle an open-ended lab. We learned how to select a project, we learned how to do
group work on a project. We learned how to complete the project successfully. In this open-
ended lab, we select a double ended thread stud bolt and to manufacture it in machine shop
using different machines and operations. We used 2-3 different machines and 10-11 different
operations on a single product that we learned in our manufacturing processes lab course. And
we successfully implement them on manufacturing of a real-life product that are used in
different applications. We successfully completed our open-ended lab.

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