King Khalid University ‫جامعة الملك خالد‬

College of Engineering ‫كلية الهندسة‬

‫قسم الهندسة الميكانيكية‬
Dept. of Mechanical
Engineering

422ME-3 Production Engineering-3

LAB - MANUAL

NAME OF THE STUDENT: …………………………...……………………………………..………………

SECTION: ……………………. UNIVERSITY ID: ………………………….....……….

Instructors: Dr. E. Abhilash, Er. Syed Waheedullah Ghori

 GENERAL SHOP SAFETY

All tools are dangerous if used improperly or carelessly. Working safely is the first thing
the user or operator should learn because the safe way is the correct way. A person learning to
operate machine tools must first learn the safety regulations and precautions for each tool or
machine. Most accidents are caused by not following prescribed procedures. Develop safe work
habits rather than suffer the consequences of an accident. Most of the safety practices
mentioned in this section are general in nature. Safety precautions for specific tools and
machines are described in detail in the chapters along with the description of the equipment.
Study these carefully and be on the alert to apply them.

EYE PROTECTION

Using eye protection in the machine shop is the most important safety rule of all. Metal chips
and shavings can fly at great speeds and distances and cause serious eye injury. Safety glasses
must be worn when working with hand-cutting tools, since most hand-cutting tools are made of
hardened steel and can break or shatter when used improperly. Safety goggles should be worn
over prescription glasses.

HAZARDOUS NOISE PROTECTION

Noise hazards are very common in the machine shop. High intensity noise can cause
permanent loss of hearing. Although noise hazards cannot always be eliminated, hearing loss
is avoidable with ear muffs, ear plugs, or both.

FOOT PROTECTION

The floor in a machine shop is often covered with razor-sharp metal chips, and heavy stock
may be dropped on the feet. Therefore, safety shoes or a solid leather shoe must be worn at
all times.

ELECTRICAL SAFETY
Exposure to electrical hazard will be minimal unless the operator becomes involved with
machine repair. The machine operator is mostly concerned with the on and off switch on the
machine tool. However, if adjustments or repairs must be made, the power source should be
disconnected. If the machine tool is wired permanently, the circuit breaker should be switched
off and tagged with an appropriate warning statement. Most often the power source will not
be disconnected for routine adjustment such as changing machine speeds. However, if a
speed change involves a belt change, make sure that no other person is likely to turn on the
machine while the operator’s hands are in contact with belts and pulleys.

SAFETY RULES FOR MACHINE TOOLS

Since different cutting tools and machining procedures are used on various machine tools, the
safety precautions for each may vary. The following are general safety rules for any machine
tool:

1- Gears, pulleys, belts, couplings, ends of shafts having keyways, and other revolving or
reciprocating parts should be guarded to a height of 6 feet above the floor.
2- The guards should be removed only for repairing or adjusting the machine and must
be replaced before operating it. Safety setscrews should be used in collars and on all
revolving or reciprocating members of the machine tool or its equipment.
3- Do not operate any machine tool without proper lighting.
4- Never attempt to operate any machine tool until you fully understand how it
works and know how to stop it quickly.
5- Never wear loose or torn clothing and secure long hair, since these items can become
caught in revolving machine parts. Ties should be removed and shirt sleeves should be
rolled up above the elbow.
6- Gloves should never be worn when operating machinery except when absolutely
necessary. Always stop the machine before cleaning it or taking measurements of the
work piece.
7- Do not lubricate a machine while it is in motion. Injury to the operator and damage to
the machine may result from this practice.
8- Never remove metal chips, turnings, or shavings with your hands; they may cause a
serious cut. If the shavings are long, stop the machine and break them with pliers or a
 bent rod, and then brush hips off the machine. Remove cast-iron chips, which break
into small pieces, with a brush. Never wipe away chips when the machine is operating.
9- Always wear safety glasses or goggles while operating machine tools. Also, wear
respiratory protection if operation creates hazardous dust. All persons in the area where
power tools are being operated should also wear safety eye protection and respirators
as needed.

10- Know where fire extinguishers are located in the shop area and how to use them.
Never wear jewelry while working around machine tools. Rings, watches, or
bracel ets maybe caught in a revolving part which could result in the hand being
pulled into the machine.
11- Avoid horseplay. Tools are very sharp and machines are made of hard steel. An accidental
slip or fall may cause a serious injury. Never use compressed air without a safety nozzle
to clean machines or clothing. It will blow sharp, dangerous metal chips a long distance.
12- Keep the floor around machines free of tools, stock, oil, grease, and metal chips.
Tripping over metal on the floor, especially round bars can cause dangerous falls. Wipe
up all oil, grease, and cutting fluid spills on the floor as soon as possible to prevent a fall.
Metal chips are very sharp and can easily become embedded in the soles of shoes,
making them very slippery, especially when walking on a concrete floor.
13- Never place tools or other materials on the machine table. Cluttering up a machine
with tools or materials creates unsafe working conditions. Always use a rag when
handling sharp cutters such as milling cutters and end mills.
14- Do not expose power tools to rain or use in damp or wet Remove adjusting keys and
wrenches. Form a habit of locations. Checking to see that keys and wrenches are
removed from tools before turning them on.
15- Always secure the work piece. Use clamps or a vise. It is safer than using your hands,
and it frees both hands to Do not operate any machine tool while under the operate the
tool influence of drugs, alcohol, or any medication that could cause drowsiness. Do not
abuse electrical cords.
16- Never carry a tool by its cord or yank it to disconnect it from a receptacle. Keep Electrical
cords away from heat, oil, and sharp edges. Have damaged or worn power cords and
strain relievers repaired or replaced immediately.
 TABLE OF CONTENTS

EXPERIMENT No: 1 Lathe Machine: Taper Turning & Knurling Page No: 6

EXPERIMENT No: 2 Lathe Machine: Grooving & Thread Cutting Page No: 14

EXPERIMENT No: 3 Shaping Machine: V- Groove Cutting Page No: 18

EXPERIMENT No: 4 Milling Machine: End milling Page No: 22

EXPERIMENT No: 5 Milling Machine: Making Spur Gear Page No: 25

EXPERIMENT No: 6 Drilling Machine: Drilling and Tapping Page No: 28

EXPERIMENT No: 7 Grinding Machine: Surface grinding Page No: 33

5
EXERCISE No: 1 Study on Lathe Machine 1 Week No:

Objectives
 To understand about lathe machine ,its different components and types
 To understand the specification of lathe
 To study about different operations which can be performed on lathe
 To study about different lathe accessories and attachments
 To study about the different lathe tools and its nomenclature
 To calculate the machining time in lathe operation
 To perform taper turning and knurling

6
Definition/Description:
Lathe is a machine tool that rotates the work piece against the tool which can be moved
longitudinal and traverse to obtain various profiles on cylindrical surfaces. The electric motor
driven spindle is rotated under variable speed through a system of belt drives and gear system.
The depth of cut and the feed is provided by controlling the motion of cross slide and carriage.

Basic Schematic Diagram:

Important parts:
1. The bed
2. Carriage
3. Head stock
4. Tail stock
5. Feed Mechanism
6. Screw Cutting Mechanism
7. Tool post
8. Compound rest

7
Types of Lathe Machine:
1. According to the use of lathe (Speed lathe):
a. Wood working lathe
b. Centering lathe
c. Polishing lathe
d. Spinning lathe
2. According to the method of transmitting power Engine lathe or Center lathe:
a. Belt driven
b. Individual motor driven
c. Gear head lathe
3. Bench lathe (for small and precision works)
4. Tool room lathe (for precision work on tools, die and gauges)
5. Capstan and turret lathe (for mass production of work by a setting up tools for a sequence
of operations on turret)
6. Special purpose lathe
a. Wheel lathe
b. Gap bed lathe
c. T-lathe
d. Duplicating lathe
7. Automatic lathe (Computer Numerical Controlled Lathes)

Specification:
1. The height of the centres
2. The swing diameter over bed
3. The swing diameter over carriage
4. The length between centres
5. The maximum bar diameter
6. The length of the bed
7. Power of main drive
8. Range of spindle speed
9. Range of feeds

Lathe accessories and attachments:

1. Lathe centres
2. Carriers (driving dogs) and catch plates
3. Chucks
4. Face plates
5. Angle plates
6. Mandrels

8
 7. Rests

Cutting tools in lathe:

Lathe Cutting Operations:

1. By holding the work piece between centres or by a chuck
a. Straight turning
b. Taper turning
c. Shoulder turning
d. Eccentric turning
e. Chamfering
f. Polishing
g. External thread cutting
h. Facing
i. Knurling
j. Filing
k. Forming
l. Spinning
m. Grooving

2. By holding the work piece by a chuck or face plate or an angle plate

a. Drilling
b. Reaming
c. Boring
d. Counter boring
e. Internal thread cutting
f. Taper boring
g. Under cutting
h. Tapping
i. Parting-off

3. By using special attachments

a. Grinding
b. Milling

9
Nomenclature of Right Hand Turning Tool:

10
 OPERATIONS ON LATHE: TAPER TURNING AND KNURLING

AIM:
To get the required shape as shown in figure by taper turning and knurling Operations on Lathes

EQUIPMENT:
Lathe machine

MATERIAL:
Mild Steel 50mm, General Tolerance: - ±0.2

TOOLS REQUIRED:
1. Measuring Tools: - Vernier Calliper
2. Cutting Tools: - Hss single point Cutting tool, knurling tool.
3. Hand Tools: - Chuck Key, Tool post key, spanner (12-13)

SEQUENCE OF OPERATIONS:

1. Holding the job

2. Alignment of tool to lathe axis
3. Facing
4. Plain Turning
5. Chamfering
6. Reverse the job
7. Knurling Operation
8. For next 35mm length reduce diameter to 21mm
9. Taper Turning: Calculate α

11
 i.e., Tan α = D-d/2L = 21-14/ 2(22)
a=9ͦ
Adjust the swivel base angle of 9 ͦ
Give the feed using cross feed and remove the material till the front diameter
Reduces to 14 mm.

10. Chamfering: Chamfer at both the ends to get 2×45 ͦ

PROCEDURE:

1. Facing is performed to get the final length 100 mm with the help of single point cutting tool.
2. Turn the stock from dia 24 to 22 mm over a length of 60 mm.
3. Swivel plate is turned through an angle 9.46 0 @ 9.50 for taper operation to be performed. Over a
length of 30 mm.
4. Tapering can be done by rotating the compound rest feed screw by applying load i.e. by turning
cross feed screw.
5. Reverse the work piece in the three jaw chuck.
6. Turn the stock dia. To 24 mm, over a length of 40 mm.
7. Chamfer the end, depth 2 mm x 450.
8. Knurling operation is done by doing with knurling tool the required shape is obtained as shown in
figure.
9. Knurling operation is done by pouring oil on wheels of tool to reduce friction and to avoid some
small pieces of mild steel attaching to the tool which doesn’t give perfect shape.

PRECAUTIONS:

1. Before starting any operation first set the tool nose to the centre axis of work piece.
2. Maintain the depth of cut.
3. Do not change the speed by shifting the gears knob near the head stock while the machine is
switched on.
4. Stop spindle before reversing.
5. Stop the machine before changing speeds.
6. Apply lubricating oil while knurling

RESULT:

12
The given job is machined as per the required dimensions and following dimensions are achieved
when compared to given dimensions.

L1 = d1 =
L2 = d2 =
L3 = d3 =
L4 =
L5 =

All dimensions are in mm.

13
EXERCISE No: # 2 Study on Lathe Machine 2 Week No:

Objectives
 To understand about lathe machine ,its different components and types
 To understand the specification of lathe
 To study about different operations which can be performed on lathe
 To study about different lathe accessories and attachments
 To study about the different lathe tools and its nomenclature
 To calculate the machining time in lathe operation
 To perform grooving and threading

14
 OPERATIONS ON LATHE: GROOVING AND THREAD CUTTING

AIM:

To get the required shape as shown in figure by grooving and thread cutting operations on lathe.

EQUIPMENT:

Lathe machine

MATERIAL:
Mild Steel 50mm, General Tolerance: - ±0.2

TOOLS REQUIRED:

1. Measuring Tools: - Vernier Caliper

2. Cutting Tools: - Hss single point Cutting tool, Grooving tool, Thread cutting tool.
3. Hand Tools: - Chuck Key, Tool post key, pitch gauge, Revolving center.

SEQUENCE OF OPERATIONS:

1. Holding the job

2. Alignment of tool to lathe axis
3. Facing
4. Plain Turning
5. Chamfering
6. Reverse the job
7. Facing
8. Plain Turning
9. Grooving
10. Chamfering
11. Threading

15
PROCEDURE:

1. Fix the work piece in a 3 jaw self centering chuck

2. Fix the tool in the tool post.
3. Alignment of tool with lathe axis: Align the cutting tool held in the tool post such that the cutting
point of the tool is in line with the axis of the machine.
4. Select an optimum speed for each operation while performing the same.
5. Facing: Job is machined at one end, by removing minimum amount of material depending upon
excess amount of material present on the job by facing operation.
6. Plain Turning: For a length of 33mm reduces the diameter reduce the diameter to 28mm by
turning.
7. Chamfering: Chamfer 2 mm x 45º by inclining the tool post at 45º.
8. Reverse the job and fix in the chuck.
9. Facing: Reduce the overall length to a dimension of 81mm.
10. Plain Turning: For next length of 48mm, reduce the diameter to 26.2mm
11. Grooving: Make a groove of 10mm width and maintaining 24mm diameter after 33mm length
from left using grooving tool.
12. Chamfering: Chamfer at the end 2 mm x 45º
13. Threading: Align the threading tool perpendicular to the work piece, select optimum speed and
adjust the gears to cut a pitch of 1.75mm.Lock the half nut and give a depth of cut of 0.5mm and
rotate the machine in forward direction. When the tool comes to the other end, switch off the
machine and rotate it in reverse direction.

Now repeat the operation with increase depth of cut by 0.2mm until the desire depth is obtained on
work piece.
Keep checking with gauge that the pitch required is obtained or not.

PRECAUTIONS:

1. Before starting any operation first set the tool nose to centre of work piece.
2. Stop spindle before reversing.
3. Stop the machine before changing speeds.
4. Use lubricant while performing thread cutting for higher surface finish.

16
RESULT:

The given job is machined as per the required dimensions and following dimensions are achieved
when compared to given dimensions.

L1 = d1 =
L2 = d2 =
L3 =

Thread dimensions:

Pitch:

Lead:

Angle of thread:

Depth of thread:

Major Diameter:

Minor Diameter:

All dimensions are in mm.

17
EXERCISE No: 3 Study on Shaping Machine Week No:

Objectives
 To understand about shaping machine and its different parts
 To understand the specification of shaping machine
 To study about different shaping operations
 To study about the different shaping tools and its nomenclature
 To calculate the machining time in shaping operation

18
Definition/Description:
A shaper is a type of machine tool that uses linear relative motion between the workpiece and a
single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe,
except that it is linear instead of helical.

Basic Schematic Diagram:

Cutting tools in shaping:

19
20
AIM: To make V- grooves on the workpiece with the help of shaping machine

TOOLS REQUIRED:

1. HSS V-shaping Tool

2. Tool Holder
3. Mild Steel Workpiece
4. Vernier Calliper
5. Adjustable Spanner
6. Brush
7. Coolant

PROCEDURE:

1. The work piece is held tightly between the two jaws of Machine Vice.
2. The tool is set in tool post such that the nose of the tool just touches the surface of work piece.
3. The surface of work piece is undergone to shaping operation removing the topmost layer of the
work piece by giving feed motion to the work piece table.
4. The machine is operated at a speed of 12 m/min.
5. The dimensions of the groove are marked on work piece.
6. A groove of dimensions of 10x5mm is made giving approximate feed.
7. Remove the chips from the workpiece using a brush at the end of operation.

PRECAUTIONS:

1. Always wear safety glasses while working on shaper.

2. Marking should be done without parallax error.
3. Maximum depth of cut should not increase 2mm.

21
EXERCISE No: 4 Study on Milling Machine 1 Week No:

Objectives
 To understand about milling machine and its different parts
 To understand the specification of milling machine
 To study about the different milling tools and its nomenclature
 To calculate the machining time in milling operation
 To use an end mill cutter to machine a work piece

22
Definition/Description:
Milling is the machining process of using rotary cutters to remove material from a workpiece by
advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety
of different operations and machines, on scales from small individual parts to large, heavy-duty
gang milling operations. It is one of the most commonly used processes in industry and machine
shops today for machining parts to precise sizes and shapes.

Basic Schematic Diagram:

23
AIM:
To make a workpiece of given shape and dimensions with the help of Universal Milling Machine

TOOLS REQUIRED:
1. End Mill cutter
2. Adjustable tool holder (Collet)
3. Mild Steel Workpiece
4. Vernier Calliper
5. C- Hook Wrench
6. Brush
7. Coolant

PROCEDURE:
1. The work piece is held tightly between the two jaws of Machine Vice.
2. The tool is fixed in collet such that the nose of the tool just touches the surface of work piece.
3. The surface of work piece is undergone to milling operation removing the topmost layer of the
work piece by giving feed motion to the table.
4. The machine is operated at a speed of 180 rpm
5. The dimensions are marked on work piece.
6. Milling is done on the workpiece to the required dimensions by giving approximate feed.
7. Remove the chips from the workpiece using a brush at the end of operation.

PRECAUTIONS:
Always wear safety glasses while working on milling machine.
Use coolant continuously during the machining operation.
Maximum depth of cut should not increase 2mm.

24
EXERCISE No: 5 Study on Milling Machine 2 Week No:

Objectives
 To understand about milling machine and its different parts
 To understand the specification of milling machine
 To study about the different milling tools and its nomenclature
 To calculate the machining time in milling operation
 To perform a spur gear milling operation

25
Definition/Description:
Milling is the machining process of using rotary cutters to remove material from a workpiece by
advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety
of different operations and machines, on scales from small individual parts to large, heavy-duty
gang milling operations. It is one of the most commonly used processes in industry and machine
shops today for machining parts to precise sizes and shapes.

Basic Schematic Diagram:

26
AIM:
To perform a spur gear milling operation in Milling Machine

TOOLS REQUIRED:
1. Milling cutter
2. Adjustable tool holder (Collet)
3. Aluminium rod
4. Steel rule
5. Spanner
6. Mandrel
7. Dog carrier

PROCEDURE:
1. Fix the gear blank in milling mandrel between supporting center and indexing head center.
2. Fix the milling cutter in Arbor.
3. Calculate the indexing for given blank diameter and find out the number of teeth.
4. Bring the cutter near the blank and it should touch the workpiece.
5. Give depth of cut by knee elevating handle according to the calculations.
6. Continue this indexing procedure for the required number of teeth and complete the model.

PRECAUTIONS:
Always wear safety glasses while working on milling machine.
Use coolant continuously during the machining operation.
Maximum depth of cut should not increase 2mm.

27
EXERCISE No: 6 Study on Drilling Machine Week No:

Objectives
 To understand about drilling machine and its different parts
 To understand the specification of drilling machine
 To study about different hole making operations
 To calculate the machining time in drilling operation
 To perform drilling and tapping operation

28
Definition/Description:
A drill is a tool fitted with a cutting tool attachment or driving tool attachment, usually a drill
bit or driver bit, used for boring holes in various materials or fastening various materials together
with the use of fasteners. The attachment is gripped by a chuck at one end of the drill and rotated
while pressed against the target material. The tip, and sometimes edges, of the cutting tool does
the work of cutting into the target material.

Basic Schematic Diagram:

Hole Making Operations

29
Standard Geometry of Twist Drill

Angular Geometrical Features

1. Point angle : (118o - 135o)

2. Lip relief angle: (7o - 15o)
3. Chisel edge angle: (125o - 135o)
4. Helix angle: (15o - 30o)

Linear Geometrical Features

1. Diameter of drill bit

2. Flute length
3. Shank length
4. Back taper (longitudinal clearance)

30
AIM:

To perform the drilling and tapping operations on a mild steel specimen.

TOOLS REQUIRED:

1. Drill Bit
2. Drill Chuck key
3. Vernier Height Gauge
4. Tapping tools
5. Brush
6. Spanner
7. Coolant

PROCEDURE:

1. First take the mild steel specimen and grid it properly on all edges.
2. Then apply wet chock on it.
3. Using Vernier Height Gauge mark the dimensions as shown in fig.
4. First fix the specimen on the base &adjust the drill bit to its center &drill it.
5. Similarly drill the other 4 points.
6. Then tapping is done at the center hole as shown by using tapping tools.

PRECAUTIONS:

1. Use the coolant during drilling operation.

2. Adjust the tool nose to the point exactly on work piece
3. While tapping internal threads apply cutting oil on it & the tapping operation must be done
perpendicular to the work piece.

31
EXERCISE No: 7 Study on Grinding Machine Week No:

Objectives
 To understand about surface grinding machine and its different parts
 To understand the specification of grinding machine
 To study about different grinding operations
 To study about the different grinding wheels and its specification
 To calculate the machining time in grinding operation
 To understand the surface roughness after surface grinding

32
Definition/Description:

Grinding machine is a power operated machine tool where, the work piece is fed
against a constantly rotating abrasive wheel (Grinding wheel) to remove very thin
layer of material to obtain high accuracy along with very good surface finish on the
work-piece.

Basic Schematic Diagram:

33
AIM: To perform surface grinding operation on the surface grinding machine.

Tools Required:

1. Screw gauge

2. HSS block

3. Vernier caliper

4. Coolant

PROCEDURE:

1. A rectangular work piece is taken to perform the grinding operation.

2. The dimensions of the job are measured using a screw gauge.
3. Firstly, the grinding tool is sharpened using a diamond point.
4. A feed of 0.1 mm is given is steps, till the required dimensions are obtained.
5. The surface on which the job is place is moved back and forth between 2 slopes.
6. The axle is rotated in clockwise direction for the movement of tool over the surface of work
piece.
7. Cooing is to be provided throughout the operation.

PRECAUTIONS:

1. Feed is to be provided within limits to avoid breakage of grinder.

2. Screw gauge readings must be taken without parallax error.

34
35