MANUFACTURING ENGINEERING LAB

MANUAL
3rd Semester

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC MADHEPURA

PREPARED BY- PRAMANAND KUMAR MANDAL

MECH. LAB ASSISTANT G P MADHEPURA

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List of experiments
1. Arc welding (i) Lap Joint (ii) Butt Joint
(iii) T-Joint
2. Gas welding (i) Lap Joint (ii) Butt Joint
3. Spot we Grinding the Lathe Cutting
tools to the required angles
4. Turning Exercise (i) Step Turning (ii)
Taper Turning (iii) Groove Cutting (iv)
Knurling (v) Thread Cutting (vi) Drilling (vii)
Facing (viii) Chamfering
5. Study of Lathe,
6. Study of Shaper Machine
7. Study of Drilling machine

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 Experiment No 1
AIM:
Arc welding (i) Lap Joint (ii) Butt Joint (iii) T-Joint

Materials Required:
Mild Steel flat 100 mm X 50 mm X 5 mm.

Equipment Required:
Flat, rough file, try square, step down transformer electrode holder, electric
lugs, shield, goggles, gloves, electrode tongs.

Theory:
The welding in which the electric arc is produced to give heat for the purpose
of joining two Surfaces is called electric arc welding.
Arc welding is a welding process that is used to join metal to metal by
using electricity to create enough heat to melt metal, and the melted
metals, when cool, result in a binding of the metals. It is a type of
welding that uses a welding power supply to create an electric
arc between a metal stick ("electrode") and the base material to melt the
metals at the point of contact. Arc welders can use either direct (DC)
or alternating (AC) current, and consumable or non-consumable
electrodes.

Principle
Power supply is given to electrode and the work. A suitable gap is kept
between the work and electrode. A high current is passed through the circuit.
An arc is produced around the area to be welded. The electric energy is
converted into heat energy, producing a temperature of 3000°C to 4000°C.
This heat melts the edges to be welded and molten pool is formed. On
solidification the welding joint is obtained.

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Diagram of Arc Welding

Electric Power for Welding

AC current or DC current can be used for arc welding. For most purposes, DC
current is preferred. In D.C. welding, a D.C. generator or a solid state rectifier is
used. D.C. machines are made up to the capacity range of 600 amperes. The
voltage in open circuit is kept around 45 to 95 volts and in closed circuit it is
kept 17 to 25 volts. D.C. current can be given in two ways:
(a)Straight polarity welding.
(b)Reverse polarity welding.
In straight polarity welding work piece is made anode and the electrode is
made cathode as Shown in the fig Electrons flow from cathode to anode, thus,
heat is produced at the materials to Be welded.
In reverse polarity system the work is made cathode and the electrode is made
anode. This welding is done specially for thin section. AC welding has the
advantage of being cheap. Equipment used is simpler than DC welding. A
transformer is used to increase the current output at the electrode. The
current varies from 150 to 1000 amperes depending upon the type of work.

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Procedure:
1. Mild steel flat is taken and it is filed using flat rough file.
2. After filing the right angles arc checked by using try square.
3. The above two steps are repeated on another work piece also.
4. The two pieces are kept one above the other in lap position.

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5. Tags are made on either side of the work pieces, so that their positions are
disturbed during welding.
6. Welding is carried out, first on one side of the work pieces, allowing
sufficient amount of metal to fill the weld puddle by slowly moving the
electrode I wavy fashion.
7. After the welding is over, the slag which is formed on the top of the weld
head is removed by using chipping hammer.
8. The work pieces are reversed by holding them with tongs, and above two
steps are repeated.
9. The joint thus obtained is a lap joint.

Precautions:
1. Check the right angles of the work pieces properly using try square.
2. Tags should be made so that work pieces are not disturbed from their
position
3. Arc is struck by touching the work piece with the electrode and quick
removing the electrode away from the work piece. The electrode should be
kept at a distance of equal to electrode diameters for maintaining the arc.

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 Experiment No 2
AIM:
Gas welding (i) Butt Joint (ii) Lap Joint
Equipment Required:
Oxy-acetylene gas welding outfit
Tools Required:
Wire brush, Hand gloves, chipping hammer, Spark lighter
Material Required:
MS Sheets 100×50×5mm
Theory:
Gas Welding or Oxy-fuel gas welding is a general term used to describe any
welding process that uses a fuel gas combined with oxygen to produce a flame.
The most commonly used fuel is acetylene (C2H2) gas. The heat source is the
flame obtained by combustion of oxygen and acetylene. When mixed together
in correct proportions within a hand-held torch or blowpipe, a relatively hot
flame is produced with a temperature of about 3300ºC (6000ºF). The chemical
action of the oxyacetylene flame can be adjusted by changing the ratio of the
volume of oxygen to acetylene. The combustion of oxygen and acetylene (C2
H2) is a two-stage reaction. Chemical reactions are as follows:
Stage 1: In the first stage, the supplied oxygen and acetylene react to produce
Carbon Monoxide And Hydrogen. Approximately one-third of the total welding
heat is generated in this stage.
C2H2 + O2 = 2CO + H2 + heat
Stage 2: The second stage of the reaction involves the combustion of the CO
and H2. The Remaining two-third of the heat is generated in Stage 2. The
specific reactions of the second stage Are:
2CO + O2 = 2CO2 + heat
H2 + ½ O2 = H2O + heat

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Diagram of gas welding

Types of joint

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Types of flames:
Three different types of flames can be obtained by varying the oxygen–
acetylene (or oxygen–fuel gas) ratio.
Neutral Flame: When the ratio of oxygen-acetylene (or oxygen–fuel gas) is
between 1:1 and 1.15:1, all reactions are carried to completion and a neutral
flame is produced. As the supply of oxygen to the blowpipe is increased, the
flame contracts and the white cone become clearly defined, assuming a
definite rounded shape. This type of flame is the one most extensively used by
the welder, who should make himself thoroughly familiar with its appearance
and characteristics.
Oxidizing flame: A higher ratio of oxygen-acetylene (or oxygen–fuel gas), such
as 1.5:1, produces an oxidizing flame, which is hotter than the neutral flame
(about 3600°C or 6000°F). With the increase in oxygen supply, the inner cone
will become shorter and sharper, the flame will turn a deeper purple colour
and emit a characteristic slight "hiss". An oxidizing flame is only used for
special applications.
Carburizing flame: Excess fuel compared to oxygen produces a carburizing
flame. The excess fuel decomposes to carbon and hydrogen, and the flame
temperature is not as great (about 3050°C or 5500°F). This type of flame is
mainly used for hard surfacing and should not be employed for welding steel
as unconsumed carbon may be introduced into the weld and produce a hard,
brittle, deposit.

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Filler Metals & Flux
Filler metals are used to supply additional material to the weld zone during
welding. These consumable filler metals maybe bare or flux coated. The
purpose of flux is to retard oxidation of the surfaces of the parts being welded,
by generating a gaseous shield around the weld zone.

Gas Welding/Cutting Equipment

The apparatus used in gas welding consists basically of an oxygen source and a
fuel gas source, regulators, hoses, non-return valve, check valve and torches.

Regulator:
The regulator is used to control pressure from the tanks by regulating pressure
and flow rate of gas. It releases the gas at a constant rate from the cylinder
despite the pressure in the cylinder becoming less as the gas in the cylinder is
used.

Hoses:
The hose is usually a double-hose design i.e. there are two hose joined
together. The oxygen hose is green and the fuel hose is red.

Non-return valve:
Between the regulator and hose and ideally between hose and torch on both
oxygen and fuel lines, a non-return valve and/or flashback arrestor should be
installed to prevent flame/oxygen-fuel mixture being pushed back into either
cylinder and damaging the equipment.

Check valve:
A check valve lets gas flow in one direction only. Not to be confused with
flashback arrestor, a check valve is not designed to block a shockwave. A check
valve is usually a chamber containing ball that is pressed against on end by a
spring. Gas flow in a particular direction pushes the ball out of the way while
no flow or flow on the other way lets the spring push the ball into the inlet
thus blocking it.

Torches:
The torch is the part that the welder holds and manipulates to make the weld.
It has a

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connection and valve for Oxygen and also a connection and valve for Fuel, a
handle for grasp, amixing chamber for mixing of the fuel and oxygen, a tip
where the flame forms. A welding torch head is used to weld metals and can
be identified by having only two pipes running to the nozzle and no oxygen
blast trigger. A cutting torch heagd is used to cut metals and can be identified
by having three pipes that go to an around 900 nozzle and also by oxygen-blast
trigger that provides oxygen to blast away material while cutting.

Procedure:
1. Acetylene valve on the torch is opened slightly and lightened with the
help of spark Lighter.
2. Proper connection of hoses to the cylinders Is also an important factor in
safety.
3. Oxygen and acetylene has different threads, so that the hoses cannot be
connected to the wrong cylinders.
4. Gas cylinders should be anchored securely and should not be dropped or
mishandled.

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 Experiment No 3
AIM:
Spot welding (i) Butt Joint
Material Required:
GI Sheet of 50 x 50 mm--- 1 No’s
GI Sheet of 50 x 50 mm---- 1 No.
Apparatus Required:
Spot Welding Equipment, Snips and Gloves

Theory:
Spot welding is a resistance welding process in which overlapping sheets are
joined by local fusion at one or more spots by the heat generated by resistance
to the flow of electric current through work pieces that are held together
under force by two electrodes, one above and the other below the two
overlapping sheets as shown in fig.

In resistance welding (RW) a low voltage (typically IV) and very high current
(typically 15,000 A) is passed through the joint for a very short time (typically
0.25 s). This high amperage heats the joint, due to the contact resistance of the
joint and melts it. The pressure on the joint is continuously maintained and the

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metal fuses together under this pressure. The heat generated in resistance
welding can be expressed as

Where H = the total heat generated in the work, J

l = electric current, A
t = time for which the electric current is passing through the joint, s
r = the resistance of the joint, ohms
and k = a constant to account for the heat losses from the welded joint.
The resistance of the joint, R is a complex factor to know because it is
composed of
1. The resistance of the electrodes,
2. The contact resistance between the electrode and the work piece,
3. The contact resistance between the two work piece plates,
4. The resistance of the work piece plates.
The amount of heat released is directly proportional to the resistance. It is
likely to be released at all of the above-mentioned points, but the only place
where a large amount of heat is to be generated to have an effective fusion is
at the interface between the two work piece plates. Therefore, the rest of the
component resistances should be made as small as possible, since the heat
released at those places would not aid in the welding. Because of the squaring
in the above, equation, the current, i needs to be precisely controlled for any
proper joint. The main requirement of the process is the low voltage and high
current power supply.

Steps Involved In Spot Welding:

The job is clean, i.e. free from grease, dirt, scale, oxide etc. Electrode tip
surface is clean, since it has to conduct the current into the work with as little
loss as possible. Very fine emery cloth may be used for routine cleaning.
Proper welding current has been set on the current selector switch.

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Proper time has been set on the weld-timer.
Step I: Electrodes are brought together against the overlapping work pieces
and pressure applied so that the surfaces of the two work pieces under the
electrodes come in physical contact after breaking any unwanted film existing
on the work pieces.
Step II: welding current is switched on for a definite period of time. The
current may be of the order of 3000 to 100.000 A for a fraction of seconds
depending upon the nature of material and its thickness. As the current passes
through one electrode and the work pieces to the other electrode, a small area
where the work pieces are in contact is heated. The temperature of this weld
zone is approximately 8150C to 9300C. To achieve a satisfactory spot weld the
nugget of coalesced metal should form with no meeting of the material
between the faying surfaces.
Step III: at this stage, the welding current is cut off. Extra electrode force is
then applied or the original force is prolonged. This electrode force forges the
weld and holds it together while the metal cools down and gains strength.
Step IV: The electrode force is released to remove the spot welded work
pieces.

Procedure:
1. The two pieces to be joined by spot welding are placed between the two
electrodes in the required position.

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2. Set the timer for which the current flows through the electrodes with
reference to the thickness of the plates
3. Press the foot lever, so that the movable electrode moves towards the fixed
electrode.
4. This causes to develop a pressure of about 200-1000 Kg / cm2 on the sheets.
5. A low voltage and very high current is passed through the joint for a very
short time. The duration of the current flow is for about 2 sec (This high
amperage heats the joint, due to contact resistance at the joint and melts it).
6. Then the metal under electrodes pressure is squeezed and welded
7. The pressure is then released and the process is repeated until the job is
completed.

Precautions:
1. Proper pressure should be applied on the electrodes.
2. Correct electrode diameter needs to be chosen depending on the material
thickness to be joined.
3. Proper weld time should be selected for welding.
4. Use Gloves while doing operation.

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 Experiment No 4
AIM:
Turning Exercise (i) Step Turning (ii) Taper Turning (iii) Groove Cutting
(iv) Knurling (v) Thread Cutting (vi) Drilling (vii) Facing (viii) Chamfering
THEORY:
TURNING: Turning is the most common lathe machining operation. During the
turning process, a cutting tool removes material from the outer diameter of a
rotating workpiece. The main objective of turning is to reduce the workpiece
diameter to the desired dimension.

Step Turning: Step turning creates two surfaces with an abrupt change in diameters
between them. The final feature resembles a step.

TAPER TURNING
Taper turning produces a ramp transition between the two surfaces with
different diameters due to the angled motion between the workpiece and a
cutting tool.

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CHAMFER TURNING: Similar to the step turning, chamfer turning
creates angled transition of an otherwise square edge between two
surfaces with different turned diameters.

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CONTOUR TURNING
In contour turning operation, the cutting tool axially follows the path with a
predefined geometry. Multiple passes of a contouring tool are necessary to
create desired contours in the workpiece. However, form tools can produce
the same contour shape is a single pass.

FACING
During the machining, the length of the workpieces is slightly longer
than the final part should be. Facing is an operation of machining the
end of a workpiece that is perpendicular to the rotating axis. During
the facing, the tool moves along the radius of the workpiece to
produce the desired part length and a smooth face surface by
removing a thin layer of material.

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GROOVING
Grooving is a turning operation that creates a narrow cut, a “groove” in the
workpiece. The size of the cut depends on the width of a cutting tool. Multiple
tool passes are necessary to machine wider grooves. There are two types of
grooving operations, external and face grooving. In external grooving, a tool
moves radially into the side of the workpiece and removes the material along
the cutting direction. In face grooving, the tool machines groove in the face of
the workpiece.

Knurling
KNURLING
Knurling operation produces serrated patterns on the surface of a
part. Knurling increases the gripping friction and the visual outlook of
the machined part. This machining process utilizes a unique tool that
consists of a single or multiple cylindrical wheels (knurls) which can
rotate inside the tool holders. The knurls contain teeth that are rolled
against the surface of the workpiece to form serrated patterns. The
most common knurling pastern is a diamond pattern.

THREADING
Threading is a turning operation in which a tool moves along the side
of the workpiece, cutting threads in the outer surface. A thread is a

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uniform helical groove of specified length and pitch. Deeper threads
need multiple passes of a tool.

DRILLING
Drilling operation removes the material from the inside of a
workpiece. The result of drilling is a hole with a diameter equal to the
size of the utilized drill bit. Drill bits are usually positioned either on a
tailstoc k or a lathe tool holder.

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 Experiment No 5
AIM:
Study of Lathe, drilling machine, shaping machine and slotting machine.
LATHE MACHINE:
A lathe Is a machine tool, which holds the workpiece between two rigid and
strong supports called centers or in a chuck or faceplate which revolves. The
cutting tool is rigidly held and supported in a tool post, which is held against
the revolving work. The normal cutting operations are performed with the
cutting tool fed either parallel or at right angles to the axis of the work.
Diagram of Lathe Machine and its Components

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1.Bed
The bed is a heavy, rugged casting and it carries the headstock and
tailstock for supporting the workpiece and provides a base for the
movement of the carriage assembly, which carries the tool.

2.Headstock:

The headstock is provided on the left-hand side of the bed and it serves
as housing for the driving pulleys, back gears, headstock spindle, live
center, and the feed reverse gear. The headstock spindle is a hollow
cylindrical shaft that provides a drive from the motor to work holding
devices.

3.Gear Box:
The quick-change gearbox is placed below the headstock and contains several different
sized gears.
4.Carriage:
The carriage is located between the headstock and tailstock and serves the purpose of
supporting, guiding, and feeding the tool against the job during operation.
Parts of Carriage
A. saddle: The saddle is an H-shaped casting mounted on the top of lathe ways. It
provides support to the cross-slide, compound rest, and tool post.

B. Cross Slide: The cross Slide is mounted on the top of the saddle, and it provides a
mounted or automatic cross-movement for the cutting tool.
C. Compound Rest: Compound Rest is fitted on the top of the cross slide and is used to
support the tool post and the cutting tool.

D. Apron: Apron is fastened to the saddle and it houses the gears, clutches, and levers
required to move the carriage or cross slide. The engagement of split nut lever and the
automatic feed lever at the same time is prevented she carriage along the lathe bed.
5. Tailstock:

The tailstock is a movable casting located opposite the headstock on the ways of the bed.
The tailstock can slide along the bed to accommodate different lengths of the workpiece
between the centers. A tailstock clamp is provided to lock the tailstock at any desired
position.
6.Leadscrew:

A lead screw also known as a power screw is a screw, moves the carriage by a precise
increment for every rotation of the screw. The lead screw is made with square, acme, or
buttress type threads.

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TYPES OF LATHE MACHINE

1. Engine or Center lathe:

• It is a general-purpose lathe and is widely used in workshops.

• The main parts of engine lathe are the bed, headstock, tailstock,
carriage, lead screw, and feed change gearbox.
• It differs from a speed lathe that it has an additional mechanism
for controlling the spindle speed and for supporting and
controlling the feed of fixed cutting tool.
• The cutting tool may be fed both in cross and longitudinal
direction concerning the lathe axis with the help of a carriage.
• The engine lathe, depending upon the design of the headstock for
receiving power, may be classified as belt-driven lathe, motor-
driven lathe, and geared head lathe.
• In Belt driven lathe, Power from the motor is transmitted to the
spindle by belt drive, In Geared head lathe power from the motor
is transmitted to the spindle by the gear drive.
• The speed changes in belt drive are obtained by shifting the belt
to different steps of a cone pulley.
• In geared-Head lathe the gear ratio (Spindle speed to motor
speed) is changed by Speed- Lever.
• Usage: It is used for producing cylindrical components. By using
the attachments and accessories, other operations such as taper
turning, Drilling, milling, and grinding may also be performed.
2. BENCH LATHE:

The bench lathe is so small that it can be mounted on a bench.

• All the types of operation can be performed on this lathe that

may be done on an ordinary speed or engine lathe.
• This is used for small work usually requiring considerable
accuracy such as in the production of gauges, punches, and beds
for press tools.
3. TRACER LATHE:

A lathe that can follow a template to copy a shape or contour.

4. Automatic Lathe:
The lathe in which the workpiece is automatically fed and removed without the use of an
operator. Cutting operations are automatically controlled by a sequencer of some form.

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The automatic lathes are so designed that the tools are automatically fed to the work and
withdrawn after all the operations are completed to finish the work. Since the entire
operation is automatic, these lathes require little attention from the operator. These lathes
are used for mass production of identical parts.
5.CAPSTAN AND TURRET LATHE:
• The lathes which have multiple tools mounted on turret either attached to the tailstock or
the cross-slide, which allows for quick changes in tooling and cutting operations.

•The capstan and turret lathes are the modification of engine lathe and is particularly used
for mass production of identical parts in a minimum time.
• The advantage of capstan and turret lathe is that several different types of operation can
be performed on a workpiece without resetting of the work or tools.

6.TOOL ROOM LATHE:

The tool room lathe is similar to an engine lathe and is equipped with all the accessories
needed for accurate tool work.It has an individually driven-geared headstock with a wide
range of spindle speeds. Since this lathe is used for precision work on tools, gauges, dies,
jigs, and other small parts, therefore greater skill is needed to operate the lathe.

7.SPEED LATHE:
It Is driven by power and consists of a bed, a headstock, a tailstock, and an adjustable slide
for supporting the tool.It has no gearbox, lead Screw, and Carriage. Headstock may have a
step-cone pulley arrangement or may be equipped with a Variable Speed Motor.Various
speeds are obtained by Cone pulley. Since the tool is fed into the work by hand and cuts are
very small, therefore this type of lathe is driven at high speeds usually from 1200 to 3600
rpm.
Usage: It is mainly used for woodworking, centering, metal spinning, polishing, etc.

8.COMPUTER CONTROLLED LATHE:

Highly automated lathes, where cutting, loading, tool changing, and part unloading are
automatically controlled by computer coding. (Computer Numerical Control) is the general
term used for a system that controls the functions of a machine tool using coded
instructions processed by a computer.
Under CNC Machining, machine tools function through numerical control. A computer
program is customized for an object and the machines are programmed with CNC machining
language (called G-code) that essentially controls all features like feed rate, coordination,
location, and speeds.

ADVANTAGES
• High Repeatability and Precision Aircraft parts.
• Volume of production is very high.

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• Complex contours/surfaces need to be machined.etc.
•Flexibility in job change, automatic tool settings, less crap.
•More safe, higher productivity, better quality.

• Less Paperwork faster prototype production, reduction in lead times.

DISADVANTAGES
• Costly setup, skilled operators
• Computers, programming knowledge required

• Maintenance is difficult

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 Experiment No 6
AIM:
Study of Shaper Machine

INTRODUCTION
Shaper Machine is used to remove the material from the surface of the workpiece by the
usage of reciprocating single-point cutting tools basically on horizontal, vertical, and Inclined
surfaces. The workpiece is fixed in the machine vice whereas the tool reciprocates on the
workpiece by means of ram.
Parts of Shaper Machine with their functions:
1. The base of the shaper
2. Ram
3. Worktable
4. Column
5. Cross-rail
6. Clapper box
7. Saddle
8. Tool head

1. base of the shaper:

This is the strongest part of any type of machine that has the ability to absorb the vibrations
produced during machining. So Cast Iron is a suitable material to absorb all the vibrations
induced during various types of operations.
2.RAM:

Ram carries the Single point cutting tool head and reciprocates on the column
guideways.The tool head is in the clapper box and the forward stroke is the cutting stroke
and the backward stroke is the idle stroke.

3.Worktable:
This is generally used to hold the machine vice where the workpiece will be held properly
for various types of machining operations.
4.Column:

It is a box like structure which is mounted on the base. Guideways are provided on the top
of the column surface for smooth movement of Ram for foraward and return strokes. Inside
the column, a driving mechanism was present which is used for the running of a machine.
5.Cross Rail: It is mounted on the vertical.

6.Clapper Box: Clapperbox holds the tool firmly during its cutting stroke and idle stroke.
7.Saddle: Saddle is mounted on the cross rail and its cross wise movement can be controlled
by the crossfeed screw.

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8.Tool Head: A tool head holds the cutting tool and make its movement in vertical and
Angular directions.A tool head consists of apron and clapper box.The Apron consists of a
clapper box and it houses the clapper block through a hinge pin.

Diagram of Shaper Machine

Working Principle of Shaper Machine:

Shaping is the operation of removing a layer of material from the flat surface of the
workpiece using a reciprocating single-point cutting tool. In shaping machine, the forward
stroke of the tool will be considered as the cutting Stroke in which material removal is
taking place from the workpiece and return stroke will be taking as an Idle stroke so that
tool is simply moving in backward direction to take the position of the tool.

The mechanism used in Shaper Machine is Whitworth Quick Return Mechanism. The
explanation for this concept was presented under types of Shaper machines.
Types of Shaper Machine:
1. Crank Type (Mechanism involved is Whitworth Quick Return Mechanism)
2. Clapperbox with Rocker Arm
3. Ratchet and Pawl mechanism.

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1.Crank Type or Whitworth Quick Return Mechanism: In shaping machine, the half
revolution of crank produces forward stroke and another half revolution of the crank
produces return stroke. As per the requirement of a shaper machine, the velocity of forward
and return strokes must be different. To get the different velocities of Ram, it is not
possible to have different velocities of the crank in two different half revolutions of the
crank.

To get the variable velocity of Ram even though the crank is rotating at uniform
velocity, a mechanism is used between the Ram and the crank called Whitworth’s
quick return mechanism which is one of the inversions of single slider-crank
mechanism.
2. Clapperbox with Rocker Arm:
To do this job, a mechanism called a clapper box with the Rocker ARM will be used to
minimize the tool wear.
3.Ratchet and Pawl Mechanism:
The automatic feed required for shapping operation will be given to the workpiece only as
an intermittent feed. The ratchet and pawl mechanism will be used for obtaining the
intermittent-feed in shaping operation.

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Based on the Table Design
1. Universal Shaper
Here in this shaper, you can give the feed in all directions like horizontally, vertically, or an
inclined plane. The table can also swivel in its own axis. The universal feature of the machine
enables various operations to be performed on it.
2. Standard Shaper
It is the most commonly used shaper in the industries as well as educational institutions in
which the forward stroke is the cutting stroke and the backward stroke is the idle stroke.
The return stroke is guided by the Whitworth Quick return motion mechanism.
Based on the Ram Travel:
1.Vertical Shaper:

The workpiece is placed on the machine vice which Is fixed on the work table. The
workpiece can be movable in longitudinal, cross, and rotational movement. It is essentially
the same thing as of slotting machine. It is widely used for key holes, grooves, and cutting
slots.
2.Horizontal Shaper:

The horizontal shaper Is generally used for the production of key-ways, flat surfaces,
external grooves, etc. This is the detailed explanation the Types of Shaper Machine. Let’s
discuss the operations performed on it.
Operations Performed in Shaper Machine:

1. Horizontal Cutting
2. Vertical Cutting
3. Angular Cutting
4. Irregular Cutting

Specifications of Shaper Machine:

1. Feed to be given to the workpiece
2. Weight of the machine
3. The ratio of forward stroke to return stroke
4. Angular movement of the work table.
5. Power inpit given to the machine.
6. Floor space required to setup the machine.
7. Types of driving mechanisms involved.
Applications of Shaper Machine:

• Mostly it will be used to remove the material from the wood or metal workMachine .
• This machine is used for the manufacturing of gear.

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• This machine is used to make keyways in gears or pulleys.
• It Is used for machining of dies, punches, etc.
Advantages of Shaper Machine:

1. The shaper machine can be very easy to operate.

2. The tooling cost will be low.
3. The lead time between the components is low.
4. The workpiece and the tool can be held in the machine very easily.

Disadvantages of Shaper Machine:

1. The cutting speed is low in the case of shaper.
2. Only one cutting tool is used in this machine and there is no space for the installation
of another tool.
3. It can shape change only one workpiece at a time.
4. Applicable only for those workpieces(stock) whose length is more than 25cms.

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 Experiment No 7
AIM:
Study of Drilling machine

INTRODUCTION
A drilling machine is a type of machine in which the holes are being made on the workpiece
by making use of a rotating tool called drill bit or the twist drill. Drilling is basically a
technology of creating holes. Drilling operations can also be performed on Lathe machines.
In the lathe machine, the workpiece rotates and the drilling tool is held stationary in the
tailstock.
Drilling Machine working principle:
Drilling Machine has based upon the principle that the rotating edge of the tool exerts a
large force on the workpiece and holes are being created in the workpiece. The material is
removed from the workpiece by the shearing and extrusion process.

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Drilling Machine Parts:
Drilling Machine consists of the following Main Parts:
1. Bed
2. Pillar
3. Swivel table
4. Motor
5. Steeped pulley
6. Spindle
7. Chuck
8. Drill Bit and
9. Hand-wheel.

Drilling Machine Operation:

1. Drilling Operation
2. Boring Operation
3. Reaming Operation
4. Counter boring Operation
5. Countersinking Operation
6. Tapping Operation
7. Spot Facing Operation
8. Trepanning Operation and
9. Honing Operation.
1. Drilling Operations: Drilling is the process of creating circular holes on the job(workpiece)
using a drill.
2.Boring Operation: Boring is the process of enlarging a hole by means of an adjustable
cutting tool with only one cutting edge.
3.Reaming Operation: It is basically a type of finishing operation. It is a process of sizing and
finishing a hole by means of a reamer having several cutting edges.
4.Counter Boring Operation: Counter boring is a type of operation in which it is used to
enlarge a particular portion of the hole.
5.Countersinking Operation: Counter boring is a type of operation in which it is used to
enlarge a particular portion of the hole.
6.Tapping Operation: Tapping is the process of creating internal threads by means of a tool
called the tap.

7.Spot Facing Operation: Operation of removing the chip present on the surface of the hole
for proper seating of head nuts etc. This can be done by an end mill cutter with drill
machines.

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8.Trepanning Operation: It is the operation used for producing large size holes without
drilling. This operation is mostly used for holes that are more than 50mm in diameter. It
cannot be used for blind holes.

9.Honing Operation: Honing is the process of producing very smooth holes. In honing
operation, the tool will reciprocate and rotate about its axis. It is mainly used for finishing
the IC engine cylinder.

Drilling Machine Types:

The different types of Drilling Machine are:

1. Portable Drilling Machine

2. Sensitive Drilling Machine
3. Upright or Column Drill Machine
4. Radial Drilling Machine
5. Gang Drilling
6. Multi-Spindle Drilling
7. Vertical Turret Type Drilling
8. Automatic Drilling Machine
9. Deep hole Drilling
10.Turret Drilling
11.Automatics Drilling Machine.

1.Portable Drilling Machine: Portable Drilling Machine is the type of machine which
consists of a small electric Motor which gives power for rotation of the drill bit. Hand
Drill is the best example of the portable hand Drill.

2.Sensitive Drilling Machine : A sensitive Drilling machine is a machine that is hand-fed

and operates on the principle of rack and pinion drive.

3. Upright or Column Drilling Machine: Upright or column drill is similar to the sensitive
drill machine the only difference is that the power feeding mechanism is used for the
rotation of the drill.

4. Radial Drilling Machine: A radial drill machine is the most advanced form of the drill
machine. It is the most versatile drill machine. Best suited for drilling a large number of
holes.

5. Gang Drilling Machine: Gang Drilling Machines of two or more dill heads mounted on
the same table. These can run simultaneously or in sequence. The number of spindles
that can be mounted is unlimited but mostly four spindles are used.

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6. Multi-spindle Drilling Machine: A multi-spindle drill Machine is developed for
the purpose of drilling several holes simultaneously.
7. Vertical turret type drilling Machine: Vertical turret type drill machine consists
of a turret that houses various tools such as drill, ream, spot-face, counterbore,
tap in any desired sequence.
8. Automatic Drilling Machine: An automatic drill machine is used mostly in places
of higher Production work. They consist of a number of unit heads with single or
multiple spindles in angular, vertical or horizontal positions on various
combinations on a special case.
9. Deep-hole Drilling Machine: Deep hole Drilling machines are used for drilling
such holes whose length exceeds three times the drill size.

The precautions which should be followed while using the drilling machine are as follows:
i) The machine tool should be strong enough to drill a hole in the workpiece,
otherwise, the parts may be deformed due to the cutting force generated. Drill
feeding arrangement must be directionally stable.

ii) To avoid any kind of error it must make sure that the Axis of the spindle,
adapter, and tool must coincide.

iii) Accurately ground drills should be used so that the uniform chips are
produced by both cutting edges, otherwise, unbalanced forces may deflect the
tool during machining.

iv) The workpiece must be held rigidly otherwise it can lead to:

• Error in Shape.
• Burrs and
• Error in hole location.

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