DEPARTMENT OF MECHANICAL

ENGINEERING

ACADEMIC YEAR 2023-2024

III B.Tech. 2nd SEMESTER

MACHINE TOOLS LABORATORY

B V RAJU INSTITUTE OF TECHNOLOGY

(An UGC Autonomous Institution)
VISHNUPUR, NARSAPUR, MEDAK DISTRICT – 502 313
Phone No : 08458 – 222031, www.bvrit.ac.in

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VISION OF THE INSTITUTE
To create and nurture competent engineers and managers who would
be enterprise leaders throughout the world with a sound background in ethics
and societal responsibilities.

MISSION OF THE INSTITUTE

We are committed to providing a positive and professional learning
environment where all students are inspired to strive for excellence in
becoming competent engineers, technology innovators and leaders in a global
society through a cohesive network of parents, students, college staff and
industry.

VISION OF THE DEPARTMENT

The Mechanical Engineering Department strives to be recognized globally for
outstanding education and research leading to well-qualified engineers as well
as managers who are innovative/creative, entrepreneurial and successful in
advanced fields of engineering and research to take up social responsibilities
with ethics.

MISSION OF THE DEPARTMENT

1. To provide innovative technology solutions to solve a wide range of complex
scientific, technological and social problems in Mechanical Engineering field.
2. To provide opportunities supported by continuous industry– institute
interaction aimed at promoting employability, entrepreneurship, leadership
and research aptitude among students.
3. To prepare the students who are psychologically strong and emotionally
balanced imbibed with social consciousness and ethical values.

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PROGRAM OUTCOMES (POs)
1. Engineering knowledge: Apply the knowledge of mathematics, science,
engineering fundamentals, and an engineering specialization to the solution
of complex engineering problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze
complex engineering problems reaching substantiated conclusions using first
principles of mathematics, natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering
problems and design system components or processes that meet the specified
needs with appropriate consideration for the public health and safety, and the
cultural, societal, and environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge
and research methods including design of experiments, analysis and
interpretation of data, and synthesis of the information to provide valid
conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques,
resources, and modern engineering and IT tools including prediction and
modeling to complex engineering activities with an understanding of the
limitations.
6. The engineer and society: Apply reasoning informed by the contextual
knowledge to assess societal, health, safety, legal and cultural issues and the
consequent responsibilities relevant to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate
the knowledge of, and need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a
member or leader in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities
with the engineering community and with society at large, such as, being able
to comprehend and write effective reports and design

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documentation, make effective presentations, and give and receive clear
instructions.
11. Project management and finance: Demonstrate knowledge and understanding
of the engineering and management principles and apply these to one’s own
work, as a member and leader in a team, to manage projects and in
multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and
ability to engage in independent and life-long learning in the broadest context
of technological change

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PROGRAM SPECIFIC OUTCOMES (PSOs)

PSO 1: The graduate will be able to design, analyze, validate and fabricate different
types of automobiles by applying fundamental concepts, practical skills and
advanced tools in mechanical softwares.

PSO 2: To develop industry ready graduates with theoretical and practical skills
needed for the mechanical industry with necessary aptitude, communication and
ethics.

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

PEO 1: The nurture students with profound basic theoretical knowledge along with
practical skills in the core area of Mechanical Engineering viz. Design,
Manufacturing, Thermal, Industrial Engineering and management along with
modern analytical and computational tools.

PEO 2: To strengthen the students to be able to exhaust excellence in their field of

interest through engineering projects, industrial visits/ internships and take up
research assignment in societal context or entrepreneurial context.

COURSE OBJECTIVES:

1. Familiarize different machine tools used in production floor.

2. Impart hands on experience on lathe, milling, drilling, shaping, sloting,
grinding and tool and cutter grinding machine.

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PREFACE
The significance of the Machine Tools Lab is renewed in the various fields of
engineering applications. For a Mechanical Engineer, It is obligatory to have the
practical ideas about the Machine Tools Lab. By this perspective we have introduced
a Laboratory manual cum Observation for Machine Tools Lab.

The manual uses the plan, cogent and simple language to explain the
fundamental aspects of Machine Tools Lab in practical. The manual prepared very
carefully with our level best. It gives all the steps in executing an experiment.

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ACKNOWLEDGEMENT

It is one life’s simple pleasures to say thank you for all the help that
one has extended their support. I wish to acknowledge and appreciate
Asso. Professor Mr. M. Trivikrama Shankar, for their sincere efforts made
towards developing the Machine Tools Lab manual. I wish to thank
student for their suggestions which considered while preparing the lab
manual.

I am extremely indebted to Sri. Dr. Sanjay Dubey, Principal and

Professor, B. V. Raju Institute of Technology for his valuable inputs and
sincere support to complete the work.

Specifically, I am grateful to the Management for their constant

advocacy and incitement.
Finally, I would again like to thank faculty in the Department and
those people who directly or indirectly helped in successful completion
of this work.

HoD-Mech

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GUIDELINES TO WRITE YOUR OBSERVATION BOOK

1. Experimental title, Aim, Apparatus, Procedure should be on right side.

2. Diagrams, Observation table, Calculations should be left side.

3. Theoretical and model calculations can be any side as per your convenience.

4. Result should always be in the end of the experiment.

5. You all are advised to leave sufficient no of pages between experiments for
theoretical or model calculations purpose.

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LAB CODE

1. Students should report to the concerned labs as per the time table schedule
2. Student who turn up late to the labs will in no case be permit to perform the
experiment schedule for the day.
3. After completion of the experiment, certification of the concerned staff- in –
charge in the observation book is necessary.
4. Students should bring a note book of about 100 pages and should enter the
reading/observations into the note book while performing the experiment.
5. The record of observations along with the detailed experimental procedure of
the experiment the record of observations along with the detailed
experimental procedure of the experiment performed in the immediate last
session should be submitted and certified the staff member in –charge.
6. Not more than three students in a group are permitted to perform the
experiments on a setup.
7. The group- wise division made in the beginning should be adhered to, and no
mix up of student among different groups will be permitted later.
8. The components required pertaining to the experiment should be collected
from stores in –charge after duly filling in the requisition form.
9. When the experiment is completed, students should return all the
instruments/components taken for the purpose.
10. Any damage of the equipment will be viewed seriously either by putting
penalty or by dismissing the total group of student from the lab or the
semester/year.
11. Students should be present I the lab for the total scheduled duration
12.Students are required to prepare thoroughly to perform the experiment
before coming to the laboratory.
13.Procedure sheets/data sheets provided to the students group should be
maintained neatly and to be returned after the experiment.

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MACHINE TOOLS LABORATORY
III Year B.Tech. Mechanical 1st Semester L T/P/D C
3 2

LIST OF EXPERIMENTS
1. To perform plain turning and facing operations using Lathe Machine.
2. To perform step turning and taper turning using Lathe Machine.
3. To perform thread cutting and knurling using Lathe Machine.
4. To perform drilling and tapping using Radial Drilling Machine.
5. To perform V and square groove operation using Shaping Machines
6. To Machine a slot using Planning Machines

7. To produce key way in a bush using Slotting Machine.

8. To produce spur gear using Milling Machine.
9. To perform a plain surface using Surface Grinding Machine
10. To produce a single point cutting tool using Tool and Cutter Grinder

ADD ON EXPERIMENTS

1. To perform boring and internal taper using Lathe Machine.

2. To produce a cylindrical job using Cylindrical Grinding Machine.

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COURSE OUTCOMES:
After Completion of the course, the students will able to

1. Infer knowledge of different machine tools used in machine shop.

2. Produce step, taper turning, knurling and threading operations.
3. Plan and design stepped surface using shaper, keyway using slotting, hexagonal shape using
shaping, gear manufacture using milling machine and finishing using grinding Machine.

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COURSE INFORMATION SHEET

Machine Tools and Metrology

COURSE NAME/CODE LAB / A351K

DEGREE/BRANCH B.TECH. / MECHANICAL

YEAR/SEMESTER/SECTION
III / II

COURSE CREDIT 2

COURSE CATEGORY LABORATORY

COURSE INSTRUCTORS Dr. M. Sandeep Kumar

DEPARTMENT COORDINATOR

ACADEMIC YEAR 2023-24

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INDEX
S.NO NAME OF THE EXPERIMENT PAGE NO. GRADE SIGN
WITH
DATE
1
Introduction to machine tools lab

1 To perform facing, plain turning and step turning

operations using Lathe machine 4

To Perform Taper turning, grooving and Knurling 11

2 using lather machine

To perform thread cutting, grooving and knurling 14

3 operation using lathe machine

To prepare a Hexagonal Nut using drilling and 16

4 tapping operation using drilling machine
To perform V and square operations using shaping 18
5 machine
To machine a slot using planning machine 20
6

To produce a keyway in a bush using slotting 22

7 machine
To produce spur gear using milling machine 24
8

To produce a plain surface using surface grinding 26

9
machine
To produce single point cutting tool using 28
10 tool and cutter grinder

ADD ON EXPERIMENTS

To perform drilling, boring and internal taper 32

11 turning operation using lathe machine

To finish a cylindrical surface using cylindrical 34

12 grinding machine

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INTRODUCTION TO MACHINE TOOLS LAB
EXPERIMENT No.: DATE:

MACHINING PROCESSES
Machining is one of the processes of manufacturing in which the specified shape to the work piece is imparted
by removing surplus material. Conventionally this surplus material from the workpiece is removed in the
form of chips by interacting the workpiece with an appropriate tool. This mechanical generation of chips can
be carried out by single point or multi point tools or by abrasive operations these are summarized below:
Machining Processes
Single point tool operations Multi-point tool operations Abrasive operations
1. Turning 1. Milling 1. Grinding
2. Boring 2. Drilling 2. Lapping
3. Shaping 3. Tapping 3. Honing
4. Planing 4. Reaming 4. Super-finishing
5. Hobbing
6. Broaching
7. Sawing
The process of chip formation in metal cutting is affected by relative motion between the tool and the
workpiece achieved with the aid of a device called machine tool. This relative motion can be obtained by a
combination of rotary and translatory movements of either the tool or the workpiece or both. The kind of
surface that is produced by the operation depends on the shape of the tool and the path it traverses through
the materials. When the workpiece is rotated about an axis and the tool is traversed in a definite path relative
to the axis, a surface of revolution is generated. When the tool path is parallel to the axis, the surface generated
is a cylinder as in straight turning or boring operations. Similarly, planes may be generated by a series of
straight cuts without rotating the workpiece as in shaping and planning operations (Fig.3). In shaping
the tool is reciprocating and the work piece is moved crosswise at the end of each stroke. Planning is done
by reciprocating the workpiece and crosswise movement is provided to the tool.
Surface may be machined by the tools having a number of cutting edges that can cut successively through
the workpiece materials. In plane milling, the cutter revolves and moves over the work piece as shown
Fig. 4. The axis of the cutter is parallel to the surface generated. Similarly, in drilling, the drill may turn
and be fed into the workpiece of the workpiece may revolve while the drill is fed into it (Fig.5). The machine
tools, in general, provide two kinds of relative motions. The primary motion is responsible for the cutting
action and absorbs most of the power required to perform the machining action. The secondary motion of
the feed motion may proceed in steps or continuously and absorbs only a fraction of the total power
required for machining. When the secondary motion is added to the primary motion, machine surfaces of
desired geometric characteristics are produced.
Consider a situation where both the cutting motions as well as the feed motion (provided at the end of each
stroke) are rectilinear but perpendicular to each other. Here the machined surface produced is a plane. The
line generated by the primary motion (cutting motion) is called the generatrix, while the line representing the
secondary motion (feed motion) is called the directrix (Fig. 6a).
Depending upon the shapes of the generatrix and the directrix and their relative orientations. Various
geometries can be produced on the workpiece. Consider another case when the generatrix is a circle and the
directrix is a line perpendicular to the plane of the generatrix. It is clear that in this situation the surface
produced will be a cylinder (Fig.6b). A tapered surface can be produced by merely changing the

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angle that the directrix makes with the plane of the generatrix. When the directrix is in the plane of the
circular generatrix (Fig. 6c), lines are generated which results in a plain surface when a number of
generatrices and directrices are placed side by side in the direction perpendicular to the plane of the
generatrix. In actual practice, the cutting is performed by cutting edge and not a point. Thus, a series of
generatrix directrix combinations are involved and the relative motion produces a surface rather than a line.
Basically, there are two methods of producing new surfaces, the tracing method and the generation method.
In the tracing method, the surface is obtained by direct tracing of the generatrices and when the surface
produced is the envelope of the generatrics the process is known as generation. Figs. 6(a) & 6{b), the plane
and the cylindrical surfaces are obtained by direct tracing, while in Fig. 6(c) the final surface geometry is the
envelope of the generatrices.

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3
INTRODUCTION OF GENERAL PURPOSE MACHINES -
LATHE, DRILLING MACHINE, MILLING MACHINE, SHAPER,
PLANING MACHINE, SLOTTING MACHINE, SURFACE
GRINDER AND TOOL AND CUTTER GRINDER
EXPERIMENT No.: DATE:

1. LATHE
1.1 INTRODUCTION
The lathe is one of the oldest machine tools. The main function of a lathe is to remove metal from a
piece of work to give it the required shape and size. This accomplished by holding the work securely and
rigidly on the machine and then turning it against cutting tool, which will remove, metal from the work in
the form of chips. To cut the material properly the tool should be harder than the material of the work piece,
should be rigidly held on the machine and should be fed or progressed in a definite way relative to the work.

1.2 MAIN PARTS OF A LATHE

Fig. 1. Block Diagram of Lathe Fig.2. Lathe sizes

1.3 SPECIFICATIONS
The size of a lathe is expressed or specified by the following items and illustrated in the given fig.2.
The height of the centres measured from the lathe bed.
The swing diameter over bed. This is the largest diameter of work that will revolve without
touching the bed and is twice the height of the centre measured from the bed of the lathe.
The length between centres. This is the maximum length of work that can be mounted between the
lathe centres.
The swing diameter over carriage. This is the largest diameter of work that will revolve over the
lathe saddle, and is always less than the swing diameter over bed.
The maximum bar diameter. This is the maximum diameter of bar stock that will pass through hole
of the headstock spindle.
The length of bed. This indicates the approximate floor space occupied by the lathe.

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2. DRILLING MACHINE
2.1 INTRODUCTION
The drilling machine is one of the most important machine tools in a workshop. As regards its
importance it is second only to the lathe. The hole is generated by the rotating edge of a cutting tool known
as the drill, which exerts large force on the work clamped on the table. As the machine tool exerts vertical
pressure to originate a hole it is loosely called a “drill press”.

2.2 MAIN PARTS OF A RADIAL DRILLING MACHINE

Fig.3. Radial Drilling machine.

2.3 SPECIFICATIONS
The size of a drilling machine varies with the type of machine being considered.
A portable drilling machine is specified by the maximum diameter of the drill that it can hold.
The sensitive and upright drilling machines are specified by the diameter of the largest piece that can
be centered under the spindle. Thus, in the case of a 600mm size upright drilling machine, the spindle
placed at a distance is slightly greater than 300 mm from the front face of the column.
To specify a fully further particular such as the maximum size of drill that the machine can operate,
table diameter, the maximum spindle travel, numbers of spindle speeds and feeds available, Morse
taper number of the drill spindle, power input floor space required, net weight of the machine etc. are
all needed.
The size of a radial drilling machine is specified by the diameter of the column and length of the arm.
Other particulars such as maximum drilling radius, minimum drilling radius, spindle speeds and feeds,
etc. should also be stated to specify the machine fully.

3. MILLING MACHINES

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3.1 INTRODUCTION
A milling machine is a machine tool that removes metal as the work fed against a
rotating multipoint cutter. The cutter rotates at a high speed and because of the multiple cutting edges it
removes metal at a very fast rate. The machine can also hold one or more cutters at a time. This is a why
a milling machine finds wide application in production work. This is superior to other machines as regards
accuracy and better surface finish, and is designed for machining a variety of tool room work.

3.2 MAIN PARTS OF A MILLING MACHINE

Fig.4. Vertical milling machine Fig.5. Horizontal milling machine

3.3 SPECIFICATIONS

1. Width and length of the table.

2. Maximum distance the knee can travel.
3. Maximum longitudinal movement and cross feed of the table.
4. Number of spindle speeds.
5. Power of the main drive motor.

4. PLANING MACHINES
4.1 INTRODUCTION
The planer like a shaper is a machine tool primarily intended to produce plane and flat surfaces by a single
point cutting tool. A planer is very large and massive compared to a shaper and capable of machining
heavy work piece which cannot be accommodated on a shaper table. The fundamental difference
between a shaper and a planer is that in a planer the work which is supported on the table reciprocates
past the stationary cutting tool and the feed is supplied by the lateral movement of the tool, whereas in
a shaper the tool which is mounted upon the ram reciprocates and the feed is given by the crosswise
movement of the table.

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4.2 PLANING MACHINE PARTS
A standard double housing planer is illustrated in the given figure. The principle parts of the planer are:

Fig.6. Main parts of Planner Machine

1. Bed
2. Table or platen
3. Tool head
4. Cross rail
5. Housing or column or upright
6. Driving and feed mechanism

4.3 SPECIFICATIONS
The size of the largest rectangular solid that can reciprocate under the tool.
The size of the largest solid is known by the distance between the two housings, the height from the
top of the table to the cross rail in its uppermost position, and the maximum length of table travel.
In addition to these basic dimensions, other particulars such as number of speeds and feeds available,
power input, floor space required, net weight of the machine, type of drive, etc. are required to be
stated in order to specify a planer fully.

5. SLOTTING MACHINES
5.1 INTRODUCTION
The slotting machine falls under the category of reciprocating type of machine tool similar to a
shaper or a planer. It operates almost on the same principle as that of a shaper. The major difference between
a slotter and shaper is that in a slotter the ram holding the tool reciprocates in a vertical axis, whereas in a
shaper the ram holding the tool reciprocates in a horizontal axis. A vertical shaper and a slotter are almost
similar to each other as regards to their construction, operation, and use. The only difference being, in the
case of a vertical shaper, the ram holding the tool may also reciprocate at an angle to the horizontal table in
addition to the vertical stroke. The ram can be swiveled not more than 5° to the vertical. The slotter is used
for cutting grooves, keyways and slots of various shapes, for making regular and irregular surface both
internal and external, for handling large and awkward work pieces, for

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cutting internal or external gears and many other operations which cannot be conveniently machined in any
other machine tool.
5.2 MAIN PARTS OF A SLOTTING MACHINE

Fig. 7. Main parts of a slotter.

5.3 SPECIFICATIONS
The size of a slotter like that of a shaper is specified by the maximum length of stroke of the ram,
expressed in “mm”. The size of a general purpose or precision slotter usually ranges from 80mm to 900mm.
To specify a slotter correctly the diameter of the table in mm, amount of cross and longitudinal travel of the
table expressed in mm, number of speeds and feeds available, h.p. of the motor, floor space required, etc.
should also be stated.

6. GRINDING MACHINES
6.1 INTRODUCTION
Grinding is metal cutting operation performed by means of a rotating abrasive when that
acts as a tool. This is used to finish work pieces, which must show a high surface quality, accuracy of
shape and dimension. Mostly grinding is the finishing operation because it removes comparatively little
metal, 0.25 to 0.50 mm in most operations and the accuracy in dimensions is in the order of 0.0000025
mm. Grinding is also done to machine materials which are too hard for other machining methods that
use cutting tools. Many different types of grinding machines have now been developed for handling
various kinds of work to which the grinding process is applicable.

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6.2 MAIN PARTS OF GRINDING MACHINES

Fig.8. Block diagram of a plain center-type grinder Fig.9. Principle of cylindrical grinding

Fig.10. Tool and cutter grinder

6.3 SPECIFICATIONS
➢ Grinding machine size is specified according to the size of the largest work piece that can be amounted
on the machine. The size of a cylindrical center type grinder is usually designated by the diameter and
length both expressed in mm of the largest work piece the machine can nominally accommodate
between centers. The diameter of the work piece should not exceed one half of the nominal capacity
of the machine.
➢ The size of the internal center type grinder is specified by the diameter of work piece that can be
swung and the maximum length of stroke of wheel, all expressed in mm.
➢ For all types of surface grinders, particularly for a reciprocating grinder, the size is generally expressed
in terms of table area and maximum height from table to wheel. The diameter of the chuck or table
usually specifies the size of a rotary surface grinder. In contrast to cylinder-type

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grinders the actual working capacity of surface grinders is approximately equal to the nominal
capacity.
➢ The same general rules apply to tool and cutter grinders whenever applicable. In some cases, where
the machines of not make use of tables, the size is specified by the maximum size of tool that can be
sharpened or dressed.
7. SHAPER
7.1 INTRODUCTION
Figure 11. shows a schematic diagram of a shaping machine. It is a versatile machine tool used to pro-
duce flat surfaces, grooves, T-slots, dovetails, etc. The workpiece is kept stationary and the cutting tool
is given a reciprocating motion. The feed motion is given to the workpiece. The forward stroke is the
cutting stroke and moves at a slower speed as compared to the backward stroke. The backward or the
reverse stroke is a non-cutting or idle stroke, therefore, is completed at a faster speed. This difference
in the speed is achieved by a special mechanism called a quick return mechanism. The shaping machine
is not generally used as a mass production tool because of its slow cutting speed and the unproductive
return stroke.
7.1 MAIN PARTS OF SHAPER

Fig.11. Shaping machine

7.2 SPECIFICATIONS
1. the maximum stroke length of the ram
2. the maximum travel of the table in vertical and horizontal directions.

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To perform facing, plain turning and step turning operations
using Lathe machine
EXPERIMENT No.: 01 DATE:

Aim: -

a) To study the Characteristic features of Lathe.

b) To perform plain turning and step turning operations on a given work piece to get the required
products.
Material / Tools required: -

M.S. round rod of 25mm diameter and 95mm long, Vernier caliper, Outside caliper, steel rule, tool
post spanner, chuck spanner, HSS single point tool.

Lathe Specifications: -

1. Admit between centers: 700mm

2. Length of the bed: 550mm
3. Centre height: 170mm
4. Swing over bed: 340mm
5. Swing on gap: 500mm
6. Spindle bore: 40mm
7. Number and range of speeds: 8, [65-100] rpm
8. Lead screw: 32mm with 4TPI
Sequence of Operations: -

1. Facing
2. Plain turning
3. Step turning
4. Chamfering
Procedure: -

Part -A
1. Run the machine at low speed and observe the motions i.e. cutting motion, feed motion, & depth of
cut given during Machining on lathe; which control the shapes of the surfaces produced. Record
these details (Table A).
2. Record the obtainable speed and feed values (Table B).
Part -B

1. The M.S. bar and HSS single point cutting tool are securely held in the 3-jaw chuck and tool post
respectively using chuck key and tool post spanner.
2. Adjust the machine to run the job to a required cutting speeds.
3. Fix the job such that 70mm is outside the chuck and perform the facing operation
4. Turn the bar to the required diameters with rough cuts.
5. Now Reverse the job (removing from the chuck and fixing the other side) such that 30mm is
outside the chuck and turn the bar to the required diameter with rough cuts.
6. Face the steps and finishes the diameters to the required sizes.
7. Finally perform chamfering on all sharp edges of the work piece.

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Table A
Speed given to Feed given to Type of Surface
Machine Type & Make Size
produced
Tool Work Tool Work

Lathe
Machine

Table B

Lathe
S.no.
Speed Feed

Fig. 1. raw material and final product of step turning

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Precautions:

1. The work piece should be held rigidly in the chuck before operating the Machine.
2. Tool should be properly ground, fixed at correct height and properly secured in tool post.
3. Before operating the machine see whether optimum machining conditions are set over the machine
and Maintained during process.
4. Chips should not be allowed to wound around a revolving job and cleaned as often as possible
5. Apply cutting fluids to the tool and work piece properly.

Result:

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To Perform Taper turning, grooving and Knurling using lather
machine
EXPERIMENT No.: 02 DATE:

Aim: -
To perform step turning, Taper turning and knurling operations on a given work piece to get the required
products.

Material / Tools required: -

M.S. round rod of 25mm diameter and 100mm long, Vernier caliper, Outside caliper,
steel rule, tool post spanner, chuck spanner, HSS single point tool.

Sequence of Operations: -

1. Facing
2. Plain turning
3. Step turning
4. Knurling
5. Chamfering
6. Taper turning

Procedure: -

1. Fix the job in chuck and HSS single point cutting tool in a tool holder of the Tool-post using chuck
key and tool-post spanner.
2. Adjust the machine to run the job at required revolutions and obtain usual cutting speeds for
specific tool or work piece.
3. Fix the job such that 40 mm is outside the chuck and perform the facing operation, now Turn the
bar 30 mm from the faced end to the required diameter with rough cuts.
4. Insert the Knurling tool in the tool post and perform the Knurling operation at very low speed.
5. Now Reverse the job (removing from the chuck and fixing the other side) such that 65mm protrudes
up outside and again surface is trued using surface gauge and perform the plain turning till the outer
diameter reaches 22mm.
6. Make a groove at 40mm from the outside end and perform step turning operation between the two
grooves allowing some allowance till diameter reaches 18 mm
7. Now, swivel the compound rest to a taper angle (half-cone angle) as 10.38° and perform the tapering
operation.
8. Perform chamfering on all sharp edges of the work piece.

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Fig. 1. Raw material and final product

Precautions: -

1. The work piece and the rod must be rigidly fixed.

2. The lathe should be started only after tightening the chuck with spanner and after removing it.
3. The center of the work piece should coincide with the axis of the lathe centers and the height of the
tip of tool should coincide with axis of lathe centers.
4. Optimum machining conditions should be maintained.
5. Knurling should be done at low speeds.

Result: -

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To perform thread cutting, grooving and knurling operation using
lathe machine
EXPERIMENT No.: 03 DATE:

Aim: -

To perform facing plain turning, step turning, right hand thread cutting, knurling operations on given
work piece to get the required product.

Material / Tools required: -

M.S. round rod of 25mm diameter and 100mm long, Vernier caliper, Outside caliper, steel rule,
tool post spanner, chuck spanner, HSS single point tool.

Sequence of Operations: -

1. Facing
2. Plain turning
3. Step turning
4. Knurling
5. Chamfering
6. Thread Cutting
Procedure: -

1. MS round rod of 25mm diameter and 95mm long is taken and loaded into the chuck in such a way
that 70mm projects out.
2. HSS single point tool is fixed to tool post (and) after centering the tool i.e. the tip of the tool is in
line with center of the axis of work piece and plain turning operation is done till 23mm diameter is
obtained.
3. The length of 40mm is marked on the length of job after facing operation is done; the knurling tool
is fixed to the tool post and in a slow manner performs the knurling operation.
4. After the lengths of 60mm,40mm are marked on the job, the step turning operation is done till a
diameter of 18mm in the 40m-60mm length of job. (At the 40mm and 60mm juncture both feeds are
given to get a tapered end which would later to face to get vertical plane).
5. Now the machine is adjusted for thread cutting, by engagement of half nut engagement lever. (Set
the cross-feed dial to 0-0 give the depth of cut. After one cut move to negative, bring back the tool
to reverse, again set the tool to 0-0, give more depth of cut than initial, repeat this procedure un till
the profile obtained matches with that on the screw pitch gauge).
6. Chamfering is done and job is removed from the chuck. (If a four-jaw chuck is used, the work piece
surface must first be turned).

16
Fig. 1. raw material and final product

Precautions: -

1. The work piece surface should be fixed using a surface gauge and the tool tip must coincide with
axis of work piece.
2. Optimum working conditions should be maintained and chamfering done wherever required.
3. Knurling and threading operations should be done at low speeds.

Result: -

17
To prepare a Hexagonal Nut using drilling and tapping operation
using drilling machine
EXPERIMENT No.: 04 DATE:

Aim: -

To obtain a M16x2 hexagonal nut from the given work piece.

Material / Tools required: -

M.S Hexagonal bar of 30 mm diameter and thickness 15 mm, Spring divider, steel rule, dot punch,
rough file, finish cut file, Center punch, ball peen hammer, drill bit of 3mm diameter,10mm HSS twist
drill, M16 tap set with handle.

Sequence of Operations: -

1. Marking
2. Punching
3. Filling
4. Pilot hole drilling
5. Drilling
6. Hand tapping
7. Chamfering

Procedure: -

1. The two faces of a M.S bar smoothened by filing, are marked with the help of a spring divider and
dot punch.
2. The indentations are made at the points where the holes are to be drilled using center punch and
ball peen hammer.
3. The Work piece is firmly fixed in the vice on a drilling machine and the hole of required
dimensions are then drilled at the center of the hexagonally filed work using a drilling machine.
4. Threading inside the hole are obtained using the hand taps of suitable diameter.
5. Finally, chamfering is done to round off sharp edges as a final finishing operation.

18
Fig. 1. raw material and final product

Precautions: -

1. Marking should be done accurately.

2. Centre punching should be done before drilling.
3. Suitable machining conditions during drilling must be maintained.

Result: -

19
To perform V and square operations using shaping machine
EXPERIMENT No.: 05 DATE:

Aim: -

To prepare a V-groove and square groove on a square block of side 40 mm from a given block using
shaping Machine.

Material / Tools required: -

Square block of side 40mm x 40 mm x 40mm, steel rule, Dot punch, spring divider, surface
gauge, round nose HSS tool, shaping machine.

Sequence of Operations: -

1. Marking
2. Setting the work
3. Adjustment of stroke length
4. Adjustment of stroke position
5. Shaping

Procedure: -

1. The job is fixed tightly in the vice. The surface of the given M.S. block is first smoothened by shaping
with a small depth of cut.
2. The required width of the V-groove is marked on the top of the block.
3. The unwanted material (as much as possible) is removed by giving the depth of cut slowly reducing
the cross feed both of about the center.
4. The tool post is rotated by 45 degrees (i.e. the v makes with the base) and machining performed to
smoothen the inclined sides of the v groove. This is repeated by rotating 45 degrees to opposite side
also.
5. Finishing is done i.e. any bit of filing work at the V-groove vertex is done and the job removed.
6. The shaping of the job is done giving suitable depth of cut. After one side is finished, the jobs
related and the process repeated for all the remaining 5 sides.
7. Rotate the w/p and clam it the vice.
8. The required width of the square -groove is marked on the top of the block.
9. The unwanted material (as much as possible) is removed by giving the depth of cut slowly
reducing the cross feed both of about the center.
10. Finishing is done i.e. any bit or filing work at the groove vertex is done and the job removed.

20
Fig. 1. raw material and final product
Precautions: -

1. Marking should be done accurately.

2. Working piece should be positioned correctly in the vice, such that the side of hexagon is parallel
to the vice, using a surface gauge.
3. Work piece should be held rigidly in the vice.
4. The cross feed and depth of cut should be uniform.

Result: -

21
To machine a slot using planning machine
EXPERIMENT No.: 06 DATE:

Aim: -

To produce a slot on given mild steel plate using Planer Machine.

Material / Tools required: -

Mild Steel plate (250 x250 x 50 mm), Steel rule, spanner, M16 T–bolt, clamps, and single point
cutting tools.

Sequence of Operations: -

1. Marking
2. Job setting
3. Adjustment of Table
4. operating
Procedure: -

1. Job Set up: Place the job on work table which is provided with T-slots for mounting work piece,
slides in the guide ways of the machine bed past the stationary tool head.
2. check flatness of the job using spirit level if any error is observed the shims of sheet metal
(shim=thin strip of material used to align).
3. Job is clamped with the help of T-bolts, nut and clamps on the work table.
4. Machine Set–up: give an idle stroke for the machine without any depth of cut.
5. Set the table in position for the required cut. After arranging the above the machine is started with
the following steps:
6. By switching on the planing machine, the table holding the job reciprocates the tool holder holding
square nose planing tool, feeds vertically for machining key slot operation Both roughing and
finishing operations are done with proper cutting conditions.
7. The tool head holding the tool machines, during the forward or cutting stroke of the worktable.
8. During the cutting stroke the tool remains stationary, and no feed is given only machining takes
place.
9. The horizontal feed is given during return or backward stroke of the worktable Measuring and
checking the work piece are necessary with proper inspecting tool.

22
Fig. 1. raw material and final product
Precautions:

5. The work piece should be held rigidly.

6. Do not operate the Machine without proper work setup.

Result:

23
To produce a keyway in a bush using slotting machine
EXPERIMENT No.: 07 DATE:

Aim: -

To prepare a Key way on the given work-piece using the slotting machine.

Material / Tools required: -

M.S round block 50mm diameter and 10 mm long, previously turned on lathe, Steel rule, dot
punch, surface gauge, and HSS single point tool, hammer (ball peen), Ø 25mm drill, center drill.

Sequence of Operations: -

1. Marking
2. Job setting
3. Adjustment of stroke
4. Adjustment of position of stroke
5. Slotting

Procedure: -

1. The job is fixed tightly in the vice.

2. The required width of the groove is marked on the top of the block.
3. The unwanted material (as much as possible) is removed by giving the depth of cut slowly
reducing the cross feed both of about the center.
4. The tool head is feed and machining performed to smoothen the sides of the Key-way.
5. Finishing is done i.e. any bit of filing work at the Key –way vertex is done and the job removed.

Fig. 1. raw material and final product

24
Precautions: -

1. The job should be fixed rigidly.

2. Marking should be accurate and depth of cut and cross feed should be uniformly incremented.

Result: -

25
To produce spur gear using milling machine
EXPERIMENT No.: 08 DATE:

Aim: -

To cut a spur gear with involute tooth profile 10 mm thick with 2 mm module having 20 teeth.

Gear Blank Calculations: -

1. Addendum = 1m= 1*(2 mm) = 2 mm

2. Dedendum = 1.25m = 1.25*(2 mm) = 2.5 mm
3. Gear tooth depth (h) = 4.5 mm
4. Gear blank dia = m (T+2) = 2(20+2) = 44mm

Material / Tools required: -

Gear blank 42mm dia and 10mm thickness, Involute form gear cutter No:6 with 2mm module,
Universal dividing head with its accessories

Procedure: -

1. The dividing head and the tail stock are bolted on the table after setting their axes perpendicular to
the machine spindle.
2. The cutter is mounted on the arbor and centered accurately with the dividing head spindle by
adjusting position of spindle in transverse direction.
3. The work is held rigidly with the help of toe and dog against the dividing head and is supported
from tail stock another end also.
4. The index plate with suitable number of holes is selected and bolted to the dividing head. The
positions of the crank pin and sector arms are adjusted.
5. Setting the Depth of Cut: First the table is raised so that the cutter touches the periphery of the gear
blank. The work (gear blank) is then raised to a height equal to the tooth depth.
6. The machine is started and the required longitudinal feed is given, to cut first tooth space of gear.
7. At the end of the cut, the table is brought back, longitudinally to its original position.
8. The work is indexed for milling the next tooth space i.e. the index crank is rotated by 2 rev.
9. The above 5 steps (5, 6, 8) are repeated till the gear is cut i.e. all the teeth are cut.

26
Fig. 1. raw material and final product

Precautions: -

1. Job must be secured tightly between the centers of indexing device.

2. Suitable machining conditions (longitudinal feed etc.) must be maintained.
3. Index crank must be rotated by exact number of holes.

Result: -

27
To produce a plain surface using surface grinding machine
EXPERIMENT No.: 09 DATE:

Aim: -

To Prepare a key on a given Square bar of side 6 mm from a given bar using the surface Grinding
Machine.

Material / Tools required: -

Mild Steel Bar (8 x 8 x 50 mm), Steel rule, Venire, Grinding wheel,

Sequence of Operations: -

1. Marking
2. Job setting
3. Adjustment of Table
4. operating

Procedure: -

1. Job Set up: Hold the job on a rectangular Magnetic chuck and check job is held rigidly on chuck.
2. Machine Set –up: Give longitudinal feed & cross feed to know the Flatness of the Work piece,
after examining the work piece. set the tool an approach length of 10 mm.
3. Turn on the Machine,
4. Operate the Machine: Give Depth of cut of 0.1mm by rotating hand wheel for wheel head (in feed.)
5. Give feed by rotate the hand wheel for work table (longitudinal feed) , and hand wheel for moving
the Saddle (cross–feed ) such that entire job crosses the Grinding wheel, repeat the step until desired
dimension and flatness is achieved

28
Fig. 1. raw material and final product

Precautions: -

1. The work piece should be held rigidly.

2. Do not operate the Machine without proper work set up

Result: -

29
To produce single point cutting tool using tool and cutter grinder
EXPERIMENT No.: 10 DATE:

Aim: -
To grind a single point cutting tool from a given work-piece using tool and cutter grinder
machine.

Material / Tools required: -

Mild Steel Bar (8 x 8x 150 mm), Venire Caliper, Bevel venire, cup-shaped wheel,

Procedure: -
1. Use cup-shaped wheel, universal vise to hold the work.
2. Set wheel head and table at zero.
3. Clamp the work in universal vise.
4. Swivel the vice to the required clearance angles (see table below).
5. Set wheel head center to the approximate height of tool cutting edge; position and secure
wheel guard.
Recommended HSS cutting tool angles for various

30
Precautions: -
1. The work piece should be held rigidly in the vice before operating the Machine.
2. Before operating the machine see whether optimum machining conditions are set over the
machine and Maintained during process
3. Apply cutting fluids to the tool and work piece properly.
Result: -

31
To perform drilling, boring and internal taper turning operation
using lathe machine
EXPERIMENT No.: 11 DATE:

Aim: -

To perform plain turning, drilling, boring and internal taper turning operations on the given work-
piece to get the required shape to the finished product.

Material / Tools required: -

MS round rod of 50mm diameter and 35mm long, Vernier caliper, Outside calipers, steel rule, tool
post spanner, chuck spanner, HSS single point tool, pilot drill, ½ “drill, 3/4 “drill, 1” drill, boring bar with tool,
drill chuck with key.

Sequence of Operations: -

1. Facing
2. Plain turning
3. Drilling
4. Boring
5. Internal taper turning
6. Chamfering
Procedure: -

1. Hold the job in the chuck and select HSS single point cutting tool and fix it in tool post.
2. Adjust the machine to run at required revolutions for the operation intended at that speed ie slow
for initial and fast for finishing operation.
3. Fix the job such that 20mm is outside the chuck and perform the facing operation, perform plain
turning till 48mm dia.
4. Now reverse the job and fix it such that 20mm is outside and perform facing till 30mm length is
reached (mark that length and face till that mark).
5. Using a pilot drill, drill a hole at center of the faced side then perform the drilling operations with
½ “,3/4”,1” drill bits in order given.
6. Swivel the compound rest to the required taper angle and using the boring bar with tool perform
the internal taper turning operation.
7. Perform the chamfering operation.

32
Fig. 1. raw material and final product

Precautions: -

1. The work piece should be held rigidly

2. Finishing cuts should be with small depth of cuts with higher speeds.

Result: -

33
To finish a cylindrical surface using cylindrical grinding machine
EXPERIMENT No.: 12 DATE:

Aim:

To grind the given work-piece to a tolerance of +/- 0.05 mm using cylindrical grinding machine.

Work Material Required: -

MS round rod of 25mm diameter and 95 mm long and turned on lathe.

Tools Required: -

Venire Caliper, Micrometer, Center Drill BS4, Grinding wheel, Spanner

Procedure: -

1. The given rod should be turned to the required diameter in the lathe as given below.
2. After facing operation is performed to get the required length of the job, a counter sunk is
produced on both ends of the job in the centre lathe.
3. Then the turning tool is fixed on the tool post and one end is step turned to a diameter of 15 mm to
a length of 25 mm.
4. Another turning operation for diameter of 20 mm to a length of 25 mm is done.
5. Another end is step turned to a diameter of 15 mm to a length of 25 mm.
6. After turning operation is completed an undercut for required dimensions is made at a distance of
45 mm from one end.
7. Under cut is done to a diameter of 15 mm for 5 mm width.
8. Finally chamfering operation is performed on both ends of the job.
9. Then the job is mounted between centers of the cylindrical grinder using dog and carrier.
10. The job is then ground at the required portion in length wise direction.
11. Care should be taken that the ground portion should be within the tolerance of +/- 0.05 mm from
the given dimension.

34
Precautions:

1. The work piece should be held rigidly in the chuck before operating the Machine.
2. Tool should be properly ground, fixed at correct height and properly Secured in tool post.
3. Before operating the machine see whether optimum machining conditions are set over the machine
and Maintained during process
4. Chips should not be allowed to wound around a revolving job and cleared as often as possible
5. Apply cutting fluids to the tool and work piece properly.
RESULT: -

35
Question Bank for laboratory quiz
All answers must be brief and to the point. Sketches must be neat and self-explanatory.
1. What are the units of cutting speed and feed on machine tools?
2. What is the use of back gear arrangement in a lathe headstock?
3. How is the rotation imparted to a part, which is to be turned between centers?
4. What are the different ways of mounting the work on a lathe?
5. What is the use of Center drilling?
6. What is the function of chasing dial?
7. What is the difference between the lead and the pitch of a multi-start thread?
8. Calculate the gear ratio between the spindle and the lead screw for cutting a screw with X threads per mm. The
lead screw pitch is mm.
9. Why is the main spindle of a lathe hollow?
10. List the type of surfaces produced by turning.
11. Sketch the plan/top view of different types of cutting tools you have used during the lathe exercise and indicate
their respective names.
12. What are the instruments for measuring the diameters of turned shafts?
13. What is the instrument normally used for-measuring lengths of various parts?
14. Explain how you can determine the taper angle of a taper pin.
15. Calculate the time required for single pass straight turning of a cylindrical bar (diameter D1 length L) at a
spindle speed of N rpm and feed f in appropriate units.
16. Main scale of a Venire has 10 divisions/cm and the least count of the instrument is 0.01mm. What should
be
the length of each division on the Venire scale?
17. How are the spindle speeds changed?
18. What is the relation between spindle speed and cutting speed?
19. What is the relation between feed rate (mm/rev.) and spindle speed?
20. Are the back gears used to get lower or higher spindle speeds?
21. Draw figures of left hand and right hand turning tools.
22. How is the size of lathe specified?
23. Why are follow-rest and steady-test used?
24. What is Live Center and Dead center of the lathe?
25. Name different parts of lathe?
26.Name Different Types of Lathe?
27.Where we use gap bed lathe?
28. Where we use reliving lathe?
29. Why we call center lathe as engine lathe? or when we call lathe a center lathe? 30.What
are different types of gear box used on lathe? with infinite speeds 31.What are different
types of guide ways used on lathe bed? give three functions 32.What is difference between
static friction and kinetic friction? explain with graph
33. What type of lubrication is observed between Lathe bed (or) guide ways and carriage? (Design of machine
Members BY S.K. Basu)
34. What are different structures observed in bed of lathe? Refer RK Jain -Production technology.
35.Name some operations of lathe Machine?
36.Give some work holding devices used on lathe machine? 37.What is
the application of mandrel? Different Types of Mandrel. 38.Where we
use collets?
39. Can we machine glass?
40. What are different types of tool post?
41.Types of single point Cutting tool?
42.Name 6 type of tool Material and composition?
43.Different methods of taper turning?
44.What is Morse taper, brown and sharp taper, metric taper? Refer rk jain
45.Different methods of thread cutting?
46. What are different parts of lathe used in thread cutting? Or explain how threads are cut on lathe.

36
47. What is different attachment used on lathe?
48.Where are box tools used?
49. Name some single purpose Machine tools of lathe?
50. Cutting motion is motion given to _ on Lathe. (rotary/translator) (tool/job)
51.Feed motion is given to on lathe. (rotary/translator) (tool/job)

37