Laboratory Manual: Department of Mechanical Engineering

LABORATORY MANUAL
DEPARTMENT OF MECHANICAL
ENGINEERING
WORKSHOP PRACTICE LAB

I / II SEMESTER (All Branches)
(2023-24)
Lloyd Institute of Management &

Technology,
Greater Noida, Uttar Pradesh
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Lloyd Institute of Management & Technology, Greater Noida
WORKSHOP PRACTICE LAB (BWS-151/251)

Objectives:
a) Use various engineering materials, tools, machines and measuring equipments.
b) Perform machine operations in lathe and CNC machine.
c) Perform manufacturing operations on components in fitting and carpentry shop.
d) Perform operations in welding, moulding, casting and gas cutting.
e) Fabricate a job by 3D printing manufacturing technique
S. No. MECHANICAL WORKSHOP LAB Duration

Introduction to Mechanical workshop material, tools and machines
To study layout, safety measures and different engineering materials (mild steel, medium
carbon steel, high carbon steel, high speed steel and cast iron etc) used in workshop.
1 To study and use of different types of tools, equipments, devices & machines used in 3 Hours
fitting, sheet metal and welding section.
To determine the least count of vernier caliper, vernier height gauge, micrometer (Screw
gauge) and take different reading over given metallicpieces using these instruments.
Machine shop
2 Demonstration of working, construction and accessories for Lathe machine 3 Hours
Perform operations on Lathe - Facing, Plane Turning, step turning, taper turning,
threading, knurling and parting.
Fitting shop
3 1. Practice marking operations. 3 Hours
2. Preparation of U or V -Shape Male Female Work piece which contains:Filing,
Sawing, Drilling, Grinding.
Carpentry Shop
4 Study of Carpentry Tools, Equipment and different joints. 3 Hours
Making of Cross Half lap joint, Half lap Dovetail joint and Mortise Tenon Joint
Welding Shop
5 Introduction to BI standards and reading of welding drawings. 6 Hours
Practice of Making following operations Butt Joint, Lap Joint TIG-MIG Welding
Moulding and Casting Shop
6 Introduction to Patterns, pattern allowances, ingredients of moulding sand and melting 6 Hours
furnaces. Foundry tools and their purposes, Demo of mould preparation and Aluminum
casting, Practice – Study and Preparation of Plastic mould
CNC Shop
7 Study of main features and working parts of CNC machine and accessoriesthat can be 6 Hours
used. Perform different operations on metal components using any CNC machines
8 To prepare a product using 3D printing 3 Hours
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EXPERIMENT NO: 1
WELDING SHOP
OBJECT: To make simple butt and lap welded joints through TIG welding in welding shop.
MATERIALS USED: Two pieces of mild steel strip of size100mm x 25mm x 25mm.
TOOLS USED: TIG welding machine, tungsten rod, filler rod, face shield, gloves and apron,
chipping hammer, wire brush/emery paper etc.
THEORY: TIG welding is a fusion welding process where fusion is obtained by heat produced
by an electric arc. The arc may be obtained by striking the electrode to workpiece. It is one of the
most versatile joining process and used for thickness below 6 mm.
First of all, a contact is made between two conductors of electricity i.e. anode and
cathode to create an electric circuit. The electrode become anode and workpiece cathode.
Electrons liberated from cathode moves toward anode. When they strike anode at high velocity a
large amount of heat is generated. In this about 10,0000C temperature is generated.
PROCEDURE:
1. First of all the required size of piece were cut from mild steel plate with the help of
hacksaw.
2. Edges of both pieces were prepared according to the given dimension.
3. Two pieces were placed in proper position on the welding table.
4. A proper arc were prepared at one end and moved to the other end at a proper speed for
completing the weld.
5. After welding, slag were removed from the welding joint by chipping hammer and
cleaned with the help of wire brush.
PRECAUTIONS:
1. The joints of the cable should not be loose.
2. Proper arc should be made for welding carefully.
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3. Produced arc should not be seen by naked eyes.
4. Apron, face shield and gloves should be used at the time of welding.
(A) TIG WELDING SETUP
(A) TYPES OF WELDING JIONTS
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EXPERIMENT NO: 2
CASTING(FOUNDRY) SHOP (A)
OBJECT: To study various tools and stages of Sand Casting Process in foundry shop.
TOOLS USED: Pattern, Sand, furnace, crucible, tong, sand container, shovel, hand riddle,
rammer, strike off bar, vent wire, trowel, draw spike, lifter.
1. Pattern: It is a true replica of the object to be prepared. Generally made up of wood, metal,
plastic, wax, plaster of paris etc.
2. Sand: It is a mixture of silica particles, clay and water/moisture.
3. Furnace: It is used to provide heat for melting the scrap metal.
4. Crucible: It is a ceramic container used to melt metallic scrap.
5. Tong: It is used to carry crucible from furnace to casting cavity.
6. Sand container: It is a hollow square container used to fill sand for cavity creation.
7. Shovel: It is used in mixing and conditioning of the moulding sand.
8. Hand riddle: It is used to remove foreign material from the sand.
9. Rammer: It is used for striking to pack sand uniformly in the moulding box.
10. Strike off bar: It is a flat bar, made of wood or iron. It is used to remove excess sand from
the top of a box after ramming.
11. Vent wire: It is used to make small holes in the cope portion. This hole is called vent and
this helps for the exit of gases and steams produced in the mould.
12. Trowel: It is used for finishing flat surfaces and joints in a mould.
13. Draw spike: It is used to draw pattern from the mould.
14. Lifter: It is used to repair and finish the sand mould cavity after withdrawal of pattern.
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Crucible Shovel Hand riddle Rammer
Strike off bar Vent wire Trowel
Draw spikes Lifter
THEORY:
Founding or casting is the process of producing metal/alloy component parts of desired

shape by pouring the molten metal/alloy into the mould cavity. Then allowing the
metal/alloy to cool and solidify. The solidified piece of metal/alloy is known as casting.
OPERATIONS :
1. Pattern making: Complete construction of pattern consists of two stages. The first
stage is to prepare a layout and the next is to shape the different parts.
2. Sand preparation: Select the sand and mix the sand grains uniformly with binding
agent. After preparing sand it is put into a container and packed uniformly with the help
of a rammer.
3. Mould cavity creation: With the help of pattern a cavity is created in sand by
hammering pattern in sand structure and removing pattern afterwards.
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4. Melting: Metal is melted in this process. For this purpose scrap metal is to be filled in
a melting container called crucible. After that crucible is put in melting furnace. Metal
liquefies in the container as the temperature in furnace rises above melting point.
5. Pouring and solidification: After melting the metal, crucible is drawn from furnace
with the help of a metallic tong and metal is poured into mould cavity for solidification at
room temperature.
6. Cleaning and finishing: After solidification metal is drawn from sand and cleaned
with the help of metallic brush. After cleaning product surface is finished with the help of
various machining processes to remove surface irregularity.
7. Testing and inspection: After Finishing various tests are performed on the specimen
to check the reliability of the product. If required heat treatment processes is also done to
reduce stresses in the product.
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EXPERIMENT NO: 3
CASTING(FOUNDRY) SHOP (B)
OBJECT: To prepare a sand mould for Sand Casting in foundry shop.
TOOLS AND MATERIALS USED:

Pattern, moulding flasks, moulding tools, sand riddle, sand, molasses/ bentonite, melting furnace,
pyrometer, hacksaw, file.
PROCEDURE :
1. Place the drag part of the pattern with parting surface down on ground or molding board
at the center of the drag (flask).
2. Riddle molding sand to a depth of about 2 cm in the drag and pack this sand carefully
around the pattern with fingers.
3. Heap more molding sand in the drag and ram with rammer carefully.
4. Strike off the excess sand using strike bar.
5. Make vent holes to within 1 cm of the pattern surface in the drag.
6. Turn this complete drag and place the cope portion (flask) over it.
7. Place the cope half of the pattern over the drag pattern matching the guide pins and apply
parting sand over the parting surface. Also place the sprue pin and riser pin in proper
positions.
8. Complete the cope half by repeating steps 2 to 5.
9. Remove the sprue and riser pins and make a pouring basin. Separate the cope and drag
halves, and place them with their parting faces up.
10. Moisten sand at the copes of the pattern and remove pattern halves are fully using draw
spikes.
11.Cut gate and runner in the drag. Repair and clean the cavities in the two mold halves.
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PRECAUTIONS:
1. Pattern preparation should be done properly according to layout.
2. Allowances should be considered according to metal used for casting during pattern
preparation to avoid dimensional loses.
3. Mould walls should not be disturbed during removal of pattern.
4. Pouring should be done properly to avoid turbulence due to flow.
5. Safety equipments should always be used during melting and pouring of molten metal.
V- block
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EXPERIMENT NO: 4
MACHINE SHOP(A)
OBJECT: To study tools and various parts of lathe machine in machine shop.
MATERIALS USED: Mild steel rod of size 25mm dia x 150mm length.
PRINCIPLE OF LATHE MACHINE: A lathe machine is power driven device used to

generate cylindrical surface. The principle of lathe machine is that it holds workpiece between
two strong supports called chuck. The cutting tool is rigidly supported in the tool post. The job
rotates in its axis and tool moves parallel along the longitudinal axis to generate cylindrical
surface.
VARIOUS PARTS OF LATHE MACHINE: The various parts of lathe machine are:
1. Head stock 2. Tail stock 3. Tool post 4. Cross slide
5. Live centre 6. Dead centre 7. Carriage 8. Lead screw
9. Bed 10. Tray 11. Compound rest 12. Feed rod
13. Half nut lever 14. Spindle 15. Chuck 16. V belt
17. Motor 18. Hand wheel 19.Cone pulley 20. Tail stock clamping bolt
etc.
Head stock: It supports the main spindle in the bearing. It is used to hold the workpiece.
Sometime it is called as live stock.
Tail stock: It is the movable part located opposite to the head stock. It is used to support the free
end of the workpiece. It is also known as dead stock.
Tool post: Cutting tool is mounted on the tool post.
Compound rest: Tool post is mounted on the compound rest. Also it used to set angle of taper
for taper turning operation.
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Carriage: It is located between head stock and tail stock. It contains five main parts i.e.
(a) Tool post (b) Compound rest (c) Apron (d) Cross-slide (e) Guide wheel.
Cross slide: It is used to give motion to the tool in radial direction.
Bed: Lathe bed is made up of cast iron. It supports the head stock, tail stock and carriage.
Leg: It supports the entire load of the lathe machine.
Chuck: Chuck is used to hold the workpiece in the head stock e.g. three jaw chuck, four jaw
chuck, magnetic chuck etc. Three jaw chuck is used to hold the job of symmetrical cross-section.
Three jaw chuck is also known as universal chuck. Four jaw chuck is used to hold
unsymmetrical cross-section, it is also known as independent chuck.
Cutting tool: Single point cutting tool made of high speed steel(HSS) is used in this machine.
OPERATIONS PERFORMED ON LATHE MACHINE:
1. Centering: Centering is the most frequently done operation so that the workpiece can be held
between centres. Centering offers seat on two ends of the workpiece for supporting it in the head
stock and tailstock centre.
2. Facing: It is an operation of making end surface flat. For this purpose tool moves in radial
direction.
3. Plain turning: It is an operation of generating cylindrical surface of uniform diameter. For

this purpose tool moves along the longitudinal axis of the job.
4. Taper turning: It is an operation of making surface uniformly tapered. Common methods of

taper turning are:
(a) Compound rest method: In this method, compound rest may be swivelled to any
desired angle with the workpiece and then tool is fed into the work by hand.
tanα=(D-d)/2L where, α= tapered angle,

D= Diameter at larger end,
d= diameter at smaller end,
L= tapered length
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(b) Form tool method: If the length of the taper is very short, use of form tool is very
useful. Form tool consists of cutting edge half the taper angle 'α'. During operation chattering
arises, therefore this type of tool is used specially when the machine have a rigid base.
5. Step turning: Step turning is a process of turning the workpiece in different diameter with the
help of single point cutting tool.
6. Threading: Threading is the operation of making thread on the cylindrical surface with the
help of threading tool.
7. Knurling: Knurling is an operation of making surface rough. This operation is performed for
better gripping purpose and tool used for this purpose is known as knurling tool.
8. Drilling: It is an operation of making hole in workpiece with the help of drilling tool held in
tail stock.
9. Boring: It is an operation of enlarging the diameter of drilled hole.
Jaw chuck Tail stock (dead centre)

Tool post
Head stock(live centre) Single point

cutting tool
Compound rest
Cross slide
Saddle
Lead
Screw
Bed
Carriage
Leg
LATHE MACHINE
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EXPERIMENT NO: 5
MACHINE SHOP(B)
OBJECT: To Prepare a job for turning, facing, knurling, taper turning, threading, grooving, step
turning, drilling, boring etc. in machine shop.
MATERIALS USED: Mild steel rod of size 25mm dia x 150mm length.
PRINCIPLE OF LATHE MACHINE: A lathe machine is power driven device used to

generate cylindrical surface. The principle of lathe machine is that it holds workpiece between
two strong supports called chuck. The cutting tool is rigidly supported in the tool post. The job
rotates in its axis and tool moves parallel along the longitudinal axis to generate cylindrical
surface.
PROCEDURE:
1. First of all, the job was held in the chuck and centering was done precisely.
2. A centre hole was drilled by combination drill to support the free end.
3. After that facing was done at the free end of workpiece.
4. After that turning was performed throughout the length of workpiece and get the required
dimensions.
5. Threading was done on 30mm length and 16mm diameter by setting the gear in the gear
box for metric thread M 16x2(2mm is the pitch for 16mm diameter metric thread).
6. Taper turning was done on 30mm length, making the diameter 22mm on one side and
14mm on the other side, by setting the taper angle. The taper angle was calculated as
follows:
tanα = (D-d)/2L
i.e. tanα = (22-14)/2x30,
taper angle, α = 7.590
7. After that turning, grooving and step turning operations are performed.
8. After that knurling is done with the help of knurling tool(knurling die).
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9. At the end of the thread, chamfering is done at angle 45 0.
10. Finally job was finished by removing the burrs.
PRECAUTIONS:
1. Job should be centered properly.
2. During operation job should not handled by naked hand.
3. Proper coolant should be applied during operation.
4. Feed rate should be selected according to material hardness.
5. Cutting tool should be sharpened properly.
Grooving Taper turning

Threading
Knurling
Facing
Plain turning
Step turning
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EXPERIMENT NO: 6
CARPENTRY SHOP(A)
OBJECT: To study of tools, operations and carpentry joints.
MATERIALS USED: Wooden workpiece (soft wood).
TOOLS USED: Iron jack planner, steel rule, file, carpentry vice, saw, pencil, try square, chisel,
marking guage etc.
1. Steel rule: It is made up of stainless steel and is marked with cm and inch scale.It is used
for measurement purpose.
2. Pencil: It is used for marking the job.
3. Try square: It is used to check squareness and flatness of the job and also used to check
the perpendicularity i.e. 900 of the surfaces.
4. Marking gauge: It is used to draw parallel lines. For this purpose, the movable portion
of the gauge is adjusted to suitable position and tightened on the stem.
5. Carpentry vice: It is used to hold the job in position.
6. Saw: Saw is a multipoint cutting tool made up of thin sheet attached with the wooden
handle. Various types of saw used in carpentry are rip saw, cross cut saw, tennon saw,
coping saw, compass saw, key hole saw etc.
7. Chisel: A chisel is strong cutting tool with a sharp bevelled edge at one end. Chisel are
made up of carbon steels. They are used to shape and fit parts. The common types of
chisel used in carpentry are firmer chisel, bevelled edge chisel, mortise chisel, gauge
chisel etc.
8. Iron jack planner: Iron jack planner is used for better surface finish. It is made up of
cast iron with a wooden handle at the back and a wooden knob at the front, so that it can
be held by both ends during operation.
THEORY: Carpentry involves cutting, shaping and fastening wood (and other materials)
together to produce an article. Carpentry deals with timber, various tools used and the art of
joining. Timber is an important engineering material finding many applications in our daily life.
Timber is prepared from matured trees. Joining deals with various joints required for making
wooden jobs such as doors, window, almirah and other furniture etc.
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OPERATIONS INVOLVED:
1. Measuring: In this operation workpiece is been measured with the help of steel rule, inch
tape or try square.
2. Marking: In this operation marking is done with the help of pencil and marking gauge.
Measuring and marking is a simultaneous process after each measurement.
3. Planning: In this operation initial roughness or smoothening of wooden workpiece is

done with the help of jack planner.
4. Cutting: In this operation workpiece takes its shape with the help of carpentry saw,
chisel and hammer by removing unwanted material marked.
5. Filling: Rasp file is used for removal of material to provide final symmetry of fit between
two components.
6. Finishing: In some of the carpentry operations sand paper is also used to provide final
finished surface by material removal.
7. Joining: In this operation two opposite wooden parts are joined to give a complete
structure with the help of glue and nails.
CARPENTRY JOINTS:
1. Edge joint 2. Butt joint 3. Rabbet joint 4. Dado joint 5. Mitre joint 6. Lap joint 7.
Dovetail joint 8. Mortise and tennon joint.
1. Edge joint
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2. Butt joint
3. Rabbet joint
4. Dado joint
5. Mitre joint
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5. Dovetail joint
6.Half lap corner joint
7. Mortise and Tennon joint
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EXPERIMENT NO:7
CARPENTRY SHOP(B)
OBJECT: To prepare cross half lap joint and half lap dovetail joint in carpentry shop.
MATERIALS USED: Wooden workpiece of 30.5mm x 45mm x 45mm.
TOOLS USED: Iron jack planner, steel rule, file, carpentry vice, saw, pencil, try square, chisel,
marking guage etc.
THEORY: Carpentry involves cutting, shaping and fastening wood (and other materials)
together to produce an article. Carpentry deals with timber, various tools used and the art of
joining. Timber is an important engineering material finding many applications in our daily life.
Timber is prepared from matured trees. Joining deals with various joints required for making
wooden jobs such as doors, window, almirah and other furniture etc.
PROCEDURE:
1. First of all, given piece of wood were measured and marked the required dimensions.
2. After that, job was held in carpentry vice and dimensions are reduced with the help of
iron jack planner.
3. Job was divided into two parts with the help of iron jack planner.
4. Again measuring and marking were done with the help of steel rule and pencil
respectively.
5. Unwanted portion were removed with the help of firmer chisel.
6. Smoothened the surface with the help of rasp file and sand papers.
7. After smoothening the two pieces were joined with the help of nails and glue. Finally we
get the half lap corner joint, mortise & tennon joint of required dimensions.
Precautions:
1. Jobs should be firmly held in carpentry vice.
2. Marking should be done accurately and precisely.
3. Planning should be done accurately.
4. Saw and files should be handled properly.
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Cross Half lap joint
Dovetail joint
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EXPERIMENT NO: 8
FITTING SHOP
OBJECT: To prepare perfect T and U shape workpiece in fitting shop.
MATERIALS USED: Iron workpiece of 60mm x 45mm x 10mm.
TOOLS USED: Steel rule, parallel jaw bench vice, scriber, hacksaw, try square, surface plate,
flat bastard file, triangular file, flat smooth file, centre punch, ball peen hammer, radial drilling
machine, drill bit etc.
THEORY: The work carried out by hand at bench vice is called bench work. Fitting is the
assembly of parts and sometimes removing the metal for assembling. In fitting shop the material
is removed with the help of hand tool and the person working in fitting shop is called fitter.
PROCEDURE:
1. First of all, it was made sure that given M.S. piece is sufficient to make desired
dimensions of job and then it was fitted in bench vice.
2. Given M.S. piece was measured and marked as per given dimensions using steel rule,
scriber, surface plate etc.
3. Permanent marking was made over the temporary marking with the help of centre punch
and ball peen hammer.
4. Two adjacent side of job were made perpendicular to each other with the help of filling
and comparing with try square.
5. After that the desired shape and size were achieved with the help of hackshaw, flat
bastard file, triangular file etc.
6. Finally a hole was drilled with the help of radial drilling machine.
PRECAUTIONS:
1. Job should be fixed properly in the jaw of parallel jaw bench vice.
2. Blade of the hacksaw should be firmly tightened and teeth of hacksaw should be in
forward direction.
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3. Sufficient margin should be taken for filling.
4. Dimensions should be checked regularly during the operation.
5. Drill bit should be well tightened in drill chuck.
6. Tap should remains straight during tapping operation.
(A) T-SHAPE (B) U-SHAPE
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EXPERIMENT NO: 9
INTRODUCTION
OBJECT: Introduction to Mechanical workshop material, tools and machines
1. To study layout, safety measures and different engineering materials (mild steel, medium
carbon steel, high carbon steel, high speed steel and cast iron etc) used in workshop.
2. To study and use of different types of tools, equipments, devices & machines used in
fitting, sheet metal and welding section.
3. To determine the least count of vernier caliper, vernier height gauge, micrometer (Screw
gauge) and take different reading over given metallicpieces using these instruments.
Workshop layout
Workshop layout is the way in which machines, work benches and storage in
a workshop are placed in relation to each other. Bad layout means that the product travels
and is handled too much during manufacture, and that people have to walk about too
much and effects on productivity.
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CARBON STEELS
Carbon steel is an iron-carbon alloy, which contains up to 2.1 wt. % carbon. For carbon
steels, there is no minimum specified content of other alloying elements, however, they
often contain manganese. The maximum manganese, silicon and copper content should be
less than 1.65 wt. % .
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EXPERIMENT NO: 10
CNC SHOP
OBJECT: Study of main features and working parts of CNC machine and accessoriesthat can be
used & Perform different operations on metal components using any CNC machines
CNC Technology
Numerical Control (NC) is a software-based machine tool control technique developed at
Massachusetts Institute of Technology (MIT) in early 1960s. It has now evolved into a mature
technology known as Computer Numerical Control (CNC). Although major applications of CNC
even today continue to be in machining, it finds applications in other processes such as sheet
metal working, non-traditional machining and inspection. Robots and Rapid Prototyping
machines are also CNC controlled. In fact, any process that can be visualized as a sequence of
motions and switching functions can be controlled by CNC. These motions and switching
functions are input in the form of alphanumeric instructions. CNC is the basis of flexible
automation which helps industries cut down time-to-market and enables launch of even low
volume products. Unlimited muscle power, unmanned operation, independent axes coordinated
through software, simplified generic tooling even for the most complex jobs and accurate
construction are some of the salient features of CNC.
CNC Machining
Automats and Special Purpose Machines (SPMs) require special
cams/ templates and clutch settings for each part. Manufacture of
these cams/ templates is costly and slow.
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Advantages of CNC
 Flexibility
 Accuracy
 Speed
 Simplified fixturing and generic cutting tools
 Storage of machining skill in NC programs
 Less skilled operators will do
 Less fatigue to the operators
G-codes
G-Code, or preparatory code or function, are functions in the Numerical control
programming language. The G-codes are the codes that position the tool and do
the actual work, as opposed to M-codes, that manages the machine; T for tool-
related codes. S and F are tool-Speed and tool-Feed, and finally D-codes for tool
compensation. The programming language of Numerical Control (NC) is
sometimes informally called G- code. But in actuality, G-codes are only a part of
the NC-programming language that controls NC and CNC machine tools.A basic
list of `G' operation codes is given below. These direct motion of the tools.
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1. G00 - Rapid move (not cutting)

2. G01 - Linear move
3. G02 - Clockwise circular motion
4. G03 - Counterclockwise circular motion
5. G04 - Dwell
6. G05 - Pause (for operator intervention)
7. G08 - Acceleration
8. G09 - Deceleration
9. G17 - x-y plane for circular interpolation
10. G18 - z-x plane for circular interpolation
11. G19 - y-z plane for circular interpolation
12. G20 - turning cycle or inch data specification
13. G21 - thread cutting cycle or metric data specification
14. G24 - face turning cycle
15. G25 - wait for input #1 to go low (Prolight Mill)
16. G26 - wait for input #1 to go high (Prolight Mill)
17. G28 - return to reference point
18. G29 - return from reference point
19. G31 - Stop on input (INROB1 is high) (Prolight Mill)
20. G33-35 - thread cutting functions (Emco Lathe)
21. G35 - wait for input #2 to go low (Prolight Mill)
22. G36 - wait for input #2 to go high (Prolight Mill)
23. G40 - cutter compensation cancel
24. G41 - cutter compensation to the left
25. G42 - cutter compensation to the right
26. G43 - tool length compensation, positive
27. G44 - tool length compensation, negative
28. G50 - Preset position
29. G70 - set inch based units or finishing cycle
30. G71 - set metric units or stock removal
31. G72 - indicate finishing cycle (EMCO Lathe)
32. G72 - 3D circular interpolation clockwise (Prolight Mill)
33. G73 - turning cycle contour (EMCO Lathe)
34. G73 - 3D circular interpolation counter clockwise (Prolight
Mill)
35. G74 - facing cycle contour (Emco Lathe)
36. G74.1 - disable 360 deg arcs (Prolight Mill)
37. G75 - pattern repeating (Emco Lathe)
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38. G75.1 - enable 360 degree arcs (Prolight Mill)

39. G76 - deep hole drilling, cut cycle in z-axis
40. G77 - cut-in cycle in x-axis
41. G78 - multiple threading cycle
42. G80 - fixed cycle cancel
43. G81-89 - fixed cycles specified by machine tool
manufacturers
44. G81 - drilling cycle (Prolight Mill)
45. G82 - straight drilling cycle with dwell (Prolight Mill)
46. G83 - drilling cycle (EMCO Lathe)
47. G83 - peck drilling cycle (Prolight Mill)
48. G84 - taping cycle (EMCO Lathe)
49. G85 - reaming cycle (EMCO Lathe)
50. G85 - boring cycle (Prolight mill)
51. G86 - boring with spindle off and dwell cycle (Prolight
Mill)
52. G89 - boring cycle with dwell (Prolight Mill)
53. G90 - absolute dimension program
54. G91 - incremental dimensions
55. G92 - Spindle speed limit
56. G93 - Coordinate system setting
57. G94 - Feed rate in ipm (EMCO Lathe)
58. G95 - Feed rate in ipr (EMCO Lathe)
59. G96 - Surface cutting speed (EMCO Lathe)
60. G97 - Rotational speed rpm (EMCO Lathe)
61. G98 - withdraw the tool to the starting point or feed per
minute
62. G99 - withdraw the tool to a safe plane or feed per
revolution
63. G101 - Spline interpolation (Prolight Mill)
M-Codes
M-Codes control machine functions and these include,
1. M00 - program stop
2. M01 - optional stop using stop button
3. M02 - end of program
4. M03 - spindle on CW
5. M04 - spindle on CCW
6. M05 - spindle off
7. M06 - tool change
8. M07 - flood with coolant
9. M08 - mist with coolant
10. M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill)
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11. M09 - coolant off

12. M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill)
13. M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill)
14. M11 - turn off accessory #2 (120VAC
outlet) (Prolight Mill) or tool change
15. M17 - subroutine end
16. M20 - tailstock back (EMCO Lathe)
17. M20 - Chain to next program (Prolight Mill)
18. M21 - tailstock forward (EMCO Lathe)
19. M22 - Write current position to data file (Prolight Mill)
20. M25 - open chuck (EMCO Lathe)
21. M25 - set output #1 off (Prolight Mill)
22. M26 - close chuck (EMCO Lathe)
23. M26 - set output #1 on (Prolight Mill)
24. M30 - end of tape (rewind)
25. M35 - set output #2 off (Prolight Mill)
26. M36 - set output #2 on (Prolight Mill)
27. M38 - put stepper motors on low power standby (Prolight
Mill)
28. M47 - restart a program continuously,
or a fixed number of times (Prolight
Mill)
29. M71 - puff blowing on (EMCO Lathe)
30. M72 - puff blowing off (EMCO Lathe)
31. M96 - compensate for rounded external curves
32. M97 - compensate for sharp external curves
33. M98 - subprogram call
34. M99 - return from subprogram, jump instruction
35. M101 - move x-axis home (Prolight Mill)
36. M102 - move y-axis home (Prolight Mill)
37. M103 - move z-axis home (Prolight Mill
Page 34
CNC PROGRAMMING
 The coordinates are almost exclusively cartesian and the origin is on the
workpiece.
 For a lathe, the infeed/radial axis is the x-axis, the

carriage/length axis is the z- axis. There is no need for a y-
axis because the tool moves in a plane through the
rotational center of the work. Coordinates on the work
piece shown below are relative to the work.
CNC lathe / CNC turning center
CNC lathes are rapidly replacing the older production lathes (multispindle,
etc) due to their ease of setting and operation. They are designed to use
modern carbide tooling and fully utilize modern processes. The part may be
designed and the tool paths programmed by the CAD/CAM process, and
the resulting file uploaded to the machine, and once set and trailed the
machine will continue to turn out parts under the occasional supervision of
an operator.The machine is controlled electronically via a computer menu
style interface; the program may be modified and displayed at the machine,
along with a simulated view of the process. The setter/operator needs a high
level of skill to perform the process, however the knowledge base is
broader compared to the older production machines where intimate
knowledge of each machine was considered essential. These machines are
often set and operated by the same person, where the operator will
supervise a small number of machines (cell).
Page 35
Experiment Practice
PLAIN TURNING AND FACING OPERATION
AIM:
To write the part program for component shown in Fig. 01. Assuming the work piece is
Aluminum and the speed is 1200 rpm, feed 20 mm/min and maximum depth of cut is
1mm.
MATERIAL REQUIRED: Aluminum Rod of 30 mm diameter and 80 mm length.
PART DRAWING:
FIGURE: 01
Page 36
PART PROGRAM:
N 00 G 21 G 90 <EOB>
N 01 M 03 S <EOB>
1200
N 02 G 00 X 30 Z 1 <EOB>
N 03 G 01 Z –1 F 20 <EOB>
N 04 G 01 X 00 F 20 <EOB>
N 05 G 00 X 30 Z 00 <EOB>
N 06 G 01 Z –2 F 20 <EOB>
N 07 G 01 X 00 F 20 <EOB>
N 08 G 00 X 30 Z 00 <EOB>
N 09 G 01 Z –3 F 20 <EOB>
N 10 G 01 X 00 F 20 <EOB>
N 11 G 00 X 30 Z 00 <EOB>
N 12 G 01 Z -50 F 20 <EOB>
N 13 G 01 X 28 F 20 <EOB>
N 14 G 00 X 30 Z 00 <EO
B
N 15 G 01 Z -50 F 20 <EOB>
N 16 G 01 X 26 F 20 <EOB>
N 17 G 00 X 30 Z 00 <EO
B
N 18 G 01 Z -50 F 20 <EOB>
N 19 G 01 X 24 F 20 <EOB>
N 20 G 00 X 50 Z 10 <EO
B
N 21 M 30 <EOB>
Page 37
Page 38

Laboratory Manual: Department of Mechanical Engineering

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Laboratory Manual: Department of Mechanical Engineering

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LABORATORY MANUAL

WORKSHOP PRACTICE LAB

Lloyd Institute of Management &

WORKSHOP PRACTICE LAB (BWS-151/251)

S. No. MECHANICAL WORKSHOP LAB Duration

8 To prepare a product using 3D printing 3 Hours

2. Edges of both pieces were prepared according to the given dimension.

3. Two pieces were placed in proper position on the welding table.

1. The joints of the cable should not be loose.

2. Proper arc should be made for welding carefully.

3. Produced arc should not be seen by naked eyes.

(A) TIG WELDING SETUP

(A) TYPES OF WELDING JIONTS

2. Sand: It is a mixture of silica particles, clay and water/moisture.

3. Furnace: It is used to provide heat for melting the scrap metal.

4. Crucible: It is a ceramic container used to melt metallic scrap.

5. Tong: It is used to carry crucible from furnace to casting cavity.

7. Shovel: It is used in mixing and conditioning of the moulding sand.

8. Hand riddle: It is used to remove foreign material from the sand.

13. Draw spike: It is used to draw pattern from the mould.

Crucible Shovel Hand riddle Rammer

Strike off bar Vent wire Trowel

Draw spikes Lifter

Founding or casting is the process of producing metal/alloy component parts of desired

OBJECT: To prepare a sand mould for Sand Casting in foundry shop.

TOOLS AND MATERIALS USED:

4. Strike off the excess sand using strike bar.

5. Make vent holes to within 1 cm of the pattern surface in the drag.

8. Complete the cope half by repeating steps 2 to 5.

1. Pattern preparation should be done properly according to layout.

3. Mould walls should not be disturbed during removal of pattern.

4. Pouring should be done properly to avoid turbulence due to flow.

PRINCIPLE OF LATHE MACHINE: A lathe machine is power driven device used to

1. Head stock 2. Tail stock 3. Tool post 4. Cross slide

5. Live centre 6. Dead centre 7. Carriage 8. Lead screw

9. Bed 10. Tray 11. Compound rest 12. Feed rod

Tool post: Cutting tool is mounted on the tool post.

Cross slide: It is used to give motion to the tool in radial direction.

Leg: It supports the entire load of the lathe machine.

OPERATIONS PERFORMED ON LATHE MACHINE:

3. Plain turning: It is an operation of generating cylindrical surface of uniform diameter. For

4. Taper turning: It is an operation of making surface uniformly tapered. Common methods of

tanα=(D-d)/2L where, α= tapered angle,

d= diameter at smaller end,

9. Boring: It is an operation of enlarging the diameter of drilled hole.

Jaw chuck Tail stock (dead centre)

Head stock(live centre) Single point

PRINCIPLE OF LATHE MACHINE: A lathe machine is power driven device used to

3. After that facing was done at the free end of workpiece.

i.e. tanα = (22-14)/2x30,

taper angle, α = 7.590

9. At the end of the thread, chamfering is done at angle 45 0.

10. Finally job was finished by removing the burrs.

1. Job should be centered properly.

2. During operation job should not handled by naked hand.

3. Proper coolant should be applied during operation.

4. Feed rate should be selected according to material hardness.

5. Cutting tool should be sharpened properly.

Grooving Taper turning