Professional Documents
Culture Documents
Lab Manual
ME-313 Lab
Manufacturing Processes Lab
1
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment No.1 To make wood pattern for sand mold casting and to prepare sand mold.
PREFACE
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
It is well known that hands-on experience is the best way to learn. This lab manual is
designed to give the student hands-on laboratory experience to better reinforce their
knowledge about certain basic machines and their operations used for manufacturing.
Each experiment begins with a detailed discussion that provides all the information
needed to understand that lab. The discussion section is followed by a detailed stepby-
step procedure. Figures are provided as and where required. Each experiment
concludes with a detailed exercise to help the student interpret the results. It will be
highly appreciated receiving feedback for revisions from the instructors and students.
Pre-requisite(s): None
Credit Hours: 01
Course Objective:
This course is imperative for the Engineering undergrads to accrue their knowledge domain and to develop their
understanding regarding different Machines used for manufacturing as well as to develop their hands-on
experience on various tools and machines with ensuring safety measures. The course focuses and targets to
enhance their cognitive and psychomotor skills. At the end of this course, students will be able and understand to
use Machine Shop facility in their Engineering Projects.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
P3 04 Psychomotor
Sr.No CLOs
Lab Experiments
CLO-1 CLO-2
1 To make wood pattern for sand mold casting and to prepare sand √ √
mold.
5 √ √
To make a cone of thin sheet metal by riveting operation.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
5
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 01
To make wood pattern for sand mold casting and to prepare sand mold.
Experiment No. 01
Aim:-
To make wood pattern for sand mold casting and
To prepare sand mold so that pattern’s shape could be imprinted on it to form a mold cavity.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
5. Wood
Procedure:
1. First of all 13cm wood piece was cut from the sock with the help of a saw. The dimensions of the wood
pattern were kept slightly high due to the fact that metal shrinks when they cool down to room temperature.
If this fact was not kept in mind then the casted part would not have the desired dimensions.
2. With the help of T-square, the required dimensions were marked onto the wood work piece. In accordance
to those dimensions, the wood piece was cut so that it may be transferred from its basic form to final desired
shape.
3. The using rasp file, final finishing touches were given and measurement again done to ensure that proper
dimensions are achieved.
4. The for sand mold first sand was placed on a matt on which, binder was added in it. The binder was added
on that the sand particles may bind with one another to make a rigid structure. With the help of shovel the
sand was mixed properly till the time sand was hard enough and could retain shape.
5. The sand was then dumped into a mold box and it was totally filled with properly stamping tools the sand
was set properly so that no air is present inside the sand which can effect the shape of the mold cavity.
Another purpose of stamping was to force the sand to form a rigid structure. Then with the help of wood
piece the sand was properly levelled.
6. For sometimes, the sand was left so that it may properly set. Once the whole arrangement became rigid, the
wood pattern which was created in the previous experiment was placed into the sand so that the shape could
be imprinted on it. Nails were attached with the pattern so that to ensure proper removal of the pattern from
the mold box, leaving behind the cavity.
Safety Precautions:
1. Care must be taken while cutting the wood piece from the wood stock as teeth’s of the saw are shape
and may cause injury if it is mishandled.
2. As rasp file also has sharp points hence it should be used with care attention.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 02
EXPERIMENT No.02
AIM:-
To perform Aluminium casting.
Induction Furnace:
A type of furnace that uses alternating current that passes through a coil due to which a magnetic field is created
in the metal. This results in induced current that causes rapid heating and melting of the metal. Also the
electromagnetic force field causes a mixing action to occur in the liquid metal.
Procedure:
1. Scrap of aluminium was added in the induction furnace and then it was switched on. It was left for
sometime so that the furnace could acquire the respective temperature to melt aluminium. Water pump
was also switched on so that the coils through which current was passing could be cooled down.
2. In the mean time, gating system and sprue were made in the sand mold so that the molten metal maybe
guided to the mold cavity where it will cool and solidify into the shape of the cavity.
3. One sufficient melt was accumulated in the furnace, the mold box was brought. The furnace was filled
allowing the molten metal to flow from the crucible to the sprue from where it started to flow into the
mold cavity.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
4. Once the mold cavity was filled, it was left for sometime so that it may cool and solidify.
5. Once the metal was cooled enough, the mold was broken and the casting was removed. The additional
material other than the molded shape was cut out and proper finishing of the casting was done.
Safety Precautions:
1. When the furnace was switched on and sufficient molten melt was accumulated, safe distance during
paring of the metal should be kept. On contact it can cause a serious injury.
2. People who are operating the furnace should wear gloves and apron while the spectators should maintain a
safe distance.
3. Tilling of the furnace should be done slowly to avoid spattering of molten metal.
4. Avoid the contact of sand with eyes. If contact does take place, properly rinse it with cold water.
Experiment # 03
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
EXPERIMENT No. 3
AIM:
To perform Sheet Rolling Operation on Rolling Machine.
Procedure:
1. First of all get all the tool and equipment required.
2. Mark the sheet metal according to dimensions with the help of steel tape and scriber.
3. Cut the work piece in dimensions as required with the help of cutter.
4. According to drawing roll the work piece by inserting it between the two rollers.
5. Sheet Rolling is done.
Precautions:
1. Mark the sheet plate carefully.
2. When inserting the Metal Sheet, keep your hands away from Rollers.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 04
AIM:
To perform V-bending of sheet metal.
4. Steel tape
5. Scriber (for making)
Procedure:
1. First of all get all the tool and equipment required.
2. Mark the sheet metal according to dimensions with the help of steel tape and scriber. 3. Cut the
work piece in dimensions 13”*4” with the help of cutter.
4. According to drawing bend the work piece at 90° from four lines already marked.
5. V-Bending is done.
Precautions:
1. Mark the sheet plate carefully.
2. When making bend, keep your hands away from press.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 06
To perform blanking and punching operations on thin sheet metal using power press machine.
Experiment No. 6
Power Press
A power press is preferable to a hand drill when the location and orientation of the hole must be controlled
accurately. A power press is composed of a base that supports a column; the column in turn supports a table. Work
can be supported on the table with a vise or hold down clamps, or the table can be swiveled out of the way to allow
tall work to be supported directly on the base. Height of the table can be adjusted with a table lift crank than locked
in place with a table lock. The column also supports a head containing a motor. The motor turns the spindle at a
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
speed controlled by a variable speed control dial. The spindle holds a drill chuck to hold the cutting tools (drill bits,
center drills, deburring tools, etc.).The quill is moved up and down with a lever on the side.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 07
Experiment No. 7
Description:
Grinding is the process of removing material by the cutting action of the countless hard and sharp abrasive particles
of a revolving grinding wheel as they come in contact with the surface to be ground. Grinding machines are made
in a variety of types and sizes, depending upon the class of work for which they are to be used. The grinding wheels
are held between two flanged disks. A roughing or coarse grained wheel is usually mounted on one end of the
spindle and a fine wheel on the other. A tool rest is provided for each wheel so that tools may be held or steadied
while being ground.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Grinding wheels are made up of abrasive particles that are held together by a glue-like material called the bond.
Almost all grinding wheels made for pedestal grinders are made with artificial abrasives, namely silicon carbide
and aluminum oxide. Artificial abrasives have replaced natural materials, such as emery and corundum, because of
their superior hardness and durability.
Grinding wheels are made by mixing the abrasive grains with the bond, and molding this mixture into forms of
various shapes and sizes. The wheels are then baked in ovens or kilns to cause the bond to harden and cure. The
grinding wheels are then bushed with lead, plastic to reduce the hole size to the shaft. Lastly, the wheels are
accurately trued, balanced, and inspected prior to shipment.
Procedure:
1. Examine the grinder to see that the tool rest is set at the required height, is within 1/8 of an inch to the face
of the wheel, and is securely fastened in this position.
2. Adjust safety glass shields on the grinder to permit clear vision of the part to be ground and still protect the
operator from flying particles.
3. Start the grinder.
4. Hold the work in one hand, and steady it with the other. Place the work on the tool rest; then guide it
against the face of the revolving wheel and apply enough pressure to grind, depending upon the hardness
of the material and the wheel itself.
5. Cool work in a water pot as it becomes heated from grinding, especially the small hardened tools which
would lose their temper if overheated. Twist drills should not be cooled by dipping in water, as it may
cause cracking.
6. Grind the job to the required shape or size by moving the work back and forth across the face of the wheel.
This will prevent wearing a groove into the wheel and will result in a flatter surface on the work.
7. Stop grinder.
Safety:
Always wear safety glasses when using a grinder.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Milling Machine
Introduction
Milling machine is one of the important machining operations. In this operation the workpiece is fed against a
rotating cylindrical tool. The rotating tool consists of multiple cutting edges (multipoint cutting tool). Normally
axis of rotation of feed given to the workpiece. Milling operation is distinguished from other machining
operations on the basis of orientation between the tool axis and the feed direction, however, in other operations
like drilling, turning, etc. the tool is fed in the direction parallel to axis of rotation.
The cutting tool used in milling operation is called milling cutter, which consists of multiple edges called teeth.
The machine tool that performs the milling operations by producing required relative motion between workpiece
and tool is called milling machine. It provides the required relative motion under very controlled conditions.
These conditions will be discussed later in this unit as milling speed, feed rate and depth of cut.
Types of Milling Machines
Milling machines can be classified into different categories depending upon their construction, specification and
operations. The choice of any particular machine is primarily determined by nature of the work to be done, its
size, geometry and operations to be performed. The typical classification of milling machines on the basis of its
construction is given below.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 8, 9 & 10
To perform conventional face and partial face milling operations on vertical milling machine. To
To perform conventional face and partial face milling operations on vertical milling machine.
3. T-slot cutter
4. Work piece
Procedure:
1. First of all get all the tools and equipments.
2. Hold the work piece in machine vice.
3. Mark the piece according to dimensions.
4. Make slot in the piece using end mill cutter to a specified depth.
5. Insert T-slot cutter in the machine.
6. Make T-slot in the machine.
7. Work piece is ready for finished work.
8. Then for pocket milling First get all the tools and equipment required for pocket milling.
9. Mark the work piece according to drawing.
10. Set the work piece in the holding machine vice.
11. Set the end mill cutter.
12. Give depth of cut
13. Give feed in X-direction and Y-direction of table in order to mark pocket inside the work piece.
14. Work piece is ready, pocket milling is done.
Precautions:
1. Give feed slowly so that cutter may not over heat.
2. Do not give too much depth of cut.
3. Give proper depth of cut.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 11 & 12
And
To perform the following operations on Universal Milling machine
Generally columns and knee type milling machine is considered as typical milling machine. Principal parts of a
typical milling machine are described as below.
Base
It provides rest for all parts of milling machine including column. It is made of grey iron by casting.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Column
It is a type of rigid vertical long box. It houses driving mechanism of spindle, table knee is also fixed to the guide
ways of column.
Knee
Knee can be adjusted at a height on the column. It houses the feed mechanism of the table and other controls.
Saddle
Saddle is placed at the top of the knee. Saddle provides guide ways for the movement of the table.
Table
Table rests on the saddle. It consists of „T‟ shaped slots for clamping the workpiece. Movements of the table
(feed motions) are given in very controlled manner be lead screw.
Overhanging Arm
Overhanging arm is mounted on the column and serves a bearing support for the arbor. This arm is adjustable so
that the bearing support may be provided near to the milling cutter. There can be more than one bearing supports
to the arbor.
Arbor
It holds rotating milling cutters rigidly and mounted on the spindle. Sometimes arbor is supported at maximum
distance from support of overhanging arm like a cantilever, it is called stub arbor. Locking provisions are
provided in the arbor assembly to ensure its reliability.
Milling Front Brace
Front base is used to adjust the relative position of knee and overhanging arm. It is also an extra support fixed
between the knee and overhanging arm for rigidity.
Spindle
Spindle is projected from the column face and provided with a tapered hole to accommodate the arbor.
Performance of a milling machine depends on the accuracy, strength and rigidity of the spindle. Spindle also
transfer the motive power to arbor through belt or gear from column.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Hobbing cutter:
These cutters are a type of form tool and are used in hobbing machines to generate gears. A cross section of the
cutters tooth will generate the required shape on the workpiece, once set to the appropriate conditions (blank
size). A hobbing machine is a specialized milling machine.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Fly cutter:
A fly cutter is composed of a body into which one or two tool bits are inserted. As the entire unit rotates, the tool
bits take broad, shallow facing cuts
Woodruff cutter:
Woodruff cutters make the seat for woodruff keys. These keys retain pulleys on shafts and are shaped as shown in
the image.
Slot drill:
Slot drills are generally two (occasionally three or four) fluted cutters that are designed to drill straight down into
the material.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Knurling Tool:
A knurling tool is used to press a pattern onto a round section. The pattern is normally used as a grip for a handle.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Working of a milling machine is based on the fact that milling cutter is fed against workpiece. This is achieved by
developing relative motion with precise control between workpiece and rotating milling cutter. Feed motion is
generally given to the workpiece through its holding device. Cutting mechanism of the workpiece in milling
operations is same as that in turning operation on lathe. This cutting takes place due to plastic deformation of
metal by the cutting tool. Milling machine can also hold more than one cutter at a time. The holding device is
supported by mechanism that can offer a selective portion of the workpiece to milling cutter for its processing.
Indexing is one of the examples of this type of processing.
CUTTING PARAMETERS
There are three major cutting parameters to be controlled in any milling operation. These three parameters are
cutting, speed, feed rate and depth of cut. These parameters are described below.
Cutting Speed
Cutting speed of a milling cutter is its peripheral linear speed resulting from operation. It is expressed in
meters per minute. The cutting speed can be derived from the above formula. V=πd n/1000
where d = Diameter of milling cutter in mm, V =
Cutting speed (linear) in meter per minute, and n
= Cutter speed in revolution per minute.
Spindle speed of a milling machine is selected to give the desired peripheral speed of cutter.
Feed Rate
It is the rate with which the workpiece under process advances under the revolving milling cutter. It is known
that revolving cutter remains stationary and feed is given to the workpiece through worktable. Generally feed is
expressed in three ways. Feed per Tooth
It is the distance traveled by the workpiece (its advance) between engagement by the two successive teeth. It is
expressed as mm/tooth (ft).
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Depth of Cut
Depth of cut in milling operation is the measure of penetration of cutter into the workpiece. It is thickness of the
material removed in one pairs of cutter under process. One pairs of cutter means when cutter completes the
milling operation from one end of the workpiece to another end. In other words, it is the perpendicular distance
measured between the original and final surface of workpiece. It is measured in mm.
MILLING MACHINE OPERATIONS
Milling operations described earlier were based on major categorization of milling. These were differentiated on
the basis of relative position of milling cutter and workpiece. Their detailed description is given below. Following
different operations can be performed on a milling machine :
1. Plain milling operation
2. Face milling operation
3. Side milling operation
4. Straddle milling operation
5. Helical milling operation
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Milling machines are among the most versatile and useful machine tools due to their capabilities to perform a
variety of operations. They can be broadly classified into the following types:
3. Bed type
4. Rotary table
5. Tracer controlled
These are so named because of these two main structural elements- a column shaped main frame and a knee shaped
projection ,Used for general purpose milling operations, column and knee type milling machines are the most
common milling machines. The spindle to which the milling cutter is attached may be horizontal (slab milling) or
vertical (face and end milling).
a) Vertical Milling Machine: Vertical knee type milling machines have a vertical spindle. They may be either
of the fixed head, sliding head, swivel head type or it may be combination of last two. The vertical milling
machine is capable of performing milling, drilling, boring, and reaming operations. It differs from the
horizontal mill in that the spindle is normally in a vertical position. The spindle head swivels 90 deg. left or
right for machining at any angle. The ram, on which it is mounted, can be adjusted in and out.
b) Horizontal Milling Machine: The primary difference between vertical and the horizontal knee type milling
machine is the spindle is horizontal and in the same plane as the table. They are classified as plain horizontal
milling machine and universal horizontal milling machine depending on whether or not the table can be
swiveled in a horizontal plane. The table on universal milling machine can swivel up to 45 degree to the
right or left, making possible angular and helical milling
The ram-type milling machine is characterized by a spindle mounted to a movable housing on the column to
permit positioning the milling cutter forward or rearward in a horizontal plane parallel to the saddle movement
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
In bed type machines, the work table is mounted directly on the bed, which replaces the knee, and can move only
longitudinally. These machines have high stiffness and are used for high production work.
These machines are so called because of their structural resemblance to a planer. These are usually equipped with
one or two cutting heads on the overhead cross-rail. The overhead units can be positioned for angular cuts. Two
horizontal spindle heads one on each of the columns, move vertically on the columns. The table carrying the
workpiece moves back and forth between the columns.
3. Head, which contains the spindle and cutter holders. In vertical machines the head may be fixed or
vertically adjustable.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
4. The Column is a precision-machined and scraped section used to support and guide the knee when it is
moved vertically. It contain the spindle and its driving mechanism.
5. The Knee is attached to the column face and may be moved vertically on the column face either manually or
automatically. It houses the feed mechanism.
6. The Saddle is fitted on top of the knee and may be moved in or out manually by means of the cross feed
hand wheel or automatically by cross feed engaging lever.
7. The Swivel Table Housing, fastened to the saddle on a universal milling machine, enables the table to be
swivel 45 degree to either side of the centerline.
8. The Table rests on guide ways in the saddle and travels longitudinally in a horizontal plane. It supports the
vice and the work.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
9. The Cross Feed Hand Wheel is used to move the table toward or away from the column.
10. The Table HandWheel is used to move the table horizontally back and forth in front of the column.
12. The Spindle provides the drive for arbors, cutters, and attachments used on a milling machine.
13. The Spindle Speed Dial is set by a crank that is turned to regulate the spindle speed. On some milling
machines the spindle speed changes are made by means of two levers.
The indexing or dividing head is one of the most important attachments for the milling machine. It is used to divide
the circumference of a workpiece into equally spaced divisions when milling gears, splines, squares, and hexagons.
It may also be used to rotate the workpiece at a
predetermined ratio to the table feed rate to produce cams
and helical grooves on gears, drills, reamers, and other
parts.
Most units are made with a 40:1 reduction in the worm, such that 40 turns of the crank will rotate the spindle through
one full turn. The indexing plate (the disk with concentric circles of equally spaced holes behind the crank) provides
a handy positive index for positioning the crank at 1/n turns of the crank, where n equals the number of holes in the
disk. The plunger can be positioned along the arm of the crank to select which circle of holes you wish the indexing
pin to engage. These indexing plates are usually interchangeable to provide a wide variety of choices for n, so that
one turn of the spindle can be divided into a great variety of equal parts.
The crank is outfitted with a pair of sector arms which can be adjusted to indicate the correct number of holes for
any partial turn of the crank you must make. This eliminates the need to count holes on every subsequent advance
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
of the spindle.
Dividing a circle into 40 equal parts is pretty straight forward since the worm wheel has 40 teeth - one full turn of
the crank equals one fortieth of a circle at the spindle. To divide a circle into 20 parts: two turns of the crank would
equal two 40ths, or one 20th of a circle. One fourth of a crank turn (or 6 holes in a 24 hole index circle) would equal
one 160th of a circle at the spindle. Here is the formula:
Reduce this fraction to its simplest form. Use any whole number to represent complete turns, and use the
denominator to determine the index plate to use. First a very simple example: we want to mill four flats on the side
of a shaft to make a square end to match the square hole in a garden hose Fawcett handle we found which we would
like to use as a declination clamp on an equatorial mount. So we must divide the circle of the shaft into 4 parts:
It doesn't matter which hole circle we use on the index plate since we have only complete revolutions of the crank
to make for each advance of the spindle.
Now multiply 9 by any whole number to get a number which is equal to the number of holes available on any row
of the index plate. If we have 34,40,54,60 holes of rows on index plate, so by multiplying and dividing 1/9 by 6 we
get 6/54 and 54 hole row is available on our index plate. Set the plunger to 54 hole row of index plate and for every
division advance the crank to 6 holes. Therefore, 6 holes in our 54 hole circle equals one ninth of a crank turn,
which equals one 360th of a circle at the spindle.
If we have to make a gear of 13 teeth. So to cut 13 teeth on the workpiece we have the following calculations.
Crank turns = 40 / 13
= 3 and 1/13.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Or in other words, 3 turn of the crank plus 1/13th of a turn per division. So to proceed, we set the plunger over 39
hole circle (3x13 = 39), Cut the first teeth, unclamp the spindle, turn the crank 3 full turns plus 3 holes in our 39
hole circle, clamp the spindle, cut the second teeth, unclamp, turn the crank 3 turns plus 3 holes, clamp, cut next
teeth, and similarly go on to complete the operation.
Classification of Milling
Peripheral Milling: In peripheral (or slab) milling, the milled surface is generated by teeth located on the
periphery of the cutter body. The axis of cutter rotation is generally in a plane parallel to the work piece surface to
be
machined.
Face Milling: In face milling, the cutter is mounted on a spindle having an axis of rotation perpendicular to the
work piece surface. The milled surface results from the action of cutting edges located on the periphery and face
of
the cutter.
End Milling: The cutter in end milling generally rotates on an axis vertical to the work piece. It can be tilted to
machine tapered surfaces. Cutting teeth are located on both the end face of the cutter and the periphery of the cutter
body.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Methods of Milling
Up Milling: Up milling is also referred to as conventional milling (A type of milling that feeds the cutter against
the cutter rotation. Conventional milling is typically used for
roughing the part). The direction of the cutter rotation opposes the feed motion. For example, if the cutter rotates
clock wise, the work piece is fed to the right in up milling.
Up milling
Down Milling: Down milling is also referred to as climb milling. The direction of cutter rotation is same as the
feed motion. For example, if the cutter rotates clockwise, the work piece is fed to the left in down milling.
Down milling
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
General procedure:
Properly installed the required cutter in the milling machine, and then mounted the job. Using the cross feed
adjustment screw and vertical feed adjustment screw; bring the cutter to touch the surface of the job at proper place.
Then switch ON the milling machine. And with the help of the vertical feed adjustment screw, set the depth of the
cut. The cutter will start cutting the job at specified speed.
The Coolant can also be used if we have job that is hard and is made up of high strength material, but can also be
avoided if we are working on a soft job.
1. Work must be clamped securely in a vise and vise clamped tightly to the table or work must be clamped
securely to the table.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
2. Do not take climb milling cuts on the shop’s mills unless instructed to do so.
3. Make sure cutter is rotating in the proper direction before cutting material.
4. Before running machine the spindle should be rotated by hand to make sure it is clear for cutting.
6. Always use the proper cutting fluid for the material being cut.
7. Never run the machine faster than the correct cutting speed.
8. Make sure that the machine is fully stopped before taking any measurements.
10. Don't place anything on the milling machine table such as wrenches, hammers, or tools.
12. Don't take too heavy a cut or use too rapid a feed.
13. Remove the collet tightening wrench immediately after using it.
14. If at all feasible rig a guard or shield to prevent chips from hitting other people.
15. Use the milling machine spindle brake to stop the spindle after the power has been turned off.
16. Before cleaning the mill remove cutting tools from the spindle to avoid cutting yourself.
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
Experiment # 14
To perform V-groove, square groove, T-slot and dovetail slot operations on shaper machine
Experiment No. 14
AIM:
To perform V-groove, square groove, T-slot and dovetail slot operations on shaper machine
1. Shaper machine
2. V-shape tool
3. Work piece
Procedure:
1. First of all get all the material equipments and tools required for V and square grooving.
2. Set the work piece in the work holding device.
3. Set the tool in the tool post.
4. Turn on the shaper machine.
5. Set feed and sheep of ram.
6. Cut the material with low feed rate and depth of cut should be adjusted.
7. Make sure that tool cutting edge is safe and working properly.
8. Now for T-slot and dovetail slot First get all the tools and equipments.
9. Hold the work piece in machine vice.
10. Mark the piece according to dimensions.
11. Make slot in the piece using end mill cutter to a specified depth.
12. Insert T-slot cutter in the machine.
13. Make T-slot in the machine.
14. Work piece is ready for finished work.
Precautions:
1. Do not give too much feed to tool.
2. Do not stand in the front of tool.
SHAPING MACHINE
A photographic view of general configuration of shaping machine is shown in Fig.1. The main functions of
shaping machines are to produce flat surfaces in different planes. Fig.3 shows the basic principle of generation of
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International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
flat surface by shaping machine.. The cutting motion provided by the linear forward motion of the reciprocating
tool and the intermittent feed motion provided by the slow transverse motion of the job along with the bed result
in producing a flat surface by gradual removal of excess material layer by layer in the form of chips. The vertical
infeed is given either by descending the tool holder or raising the bed or both. Straight grooves of various curved
sections are also made in shaping machines by using specific form tools. The single point straight or form tool is
clamped in the vertical slide which is mounted at the front face of the reciprocating ram whereas the workpiece is
directly or indirectly through a vice is mounted on the bed.
42
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
SHAPING MACHINE
The usual kinematic system provided in shaping machine for transmitting power and motion from the motor to
the tool and job at desired speeds and feeds is schematically shown in Fig.4.The central large bull gear receives its
rotation from the motor through the belt-pulley, clutch, speed gear box and then the pinion. The rotation of the
crank causes oscillation of the link and thereby reciprocation of the ram and hence the tool in straight path.
Cutting velocity which needs to be varied depending upon the tool-work materials, depends upon
• The stroke length, S mm
• Number of strokes per min., N and s
• The Quick return ratio, QRR (ratio of the durations of the forward stroke and the return
stroke)
43
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
It is already mentioned that shaping machines are neither productive nor versatile.
However, its limited applications include:
• Machining flat surfaces in different planes. Fig.5 shows how flat surfaces are produced in shaping
machines by single point cutting tools in (a) horizontal, (b) vertical and (c) inclined planes.
44
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
45
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
(d) Vee-block Fig.6 Machining (a) Slot, (b) Pocket (c) T-slot and (d) Vee-
block in Shaping machine
(a) Grooving (b) straight tooth cutting for spur gears Fig.7
Making grooves and gear teeth cutting in shaping machine by form tools.
However, due to very low productivity, less versatility and poor process capability, shaping machines are not
employed for lot and even batch production. Such low cost primitive machine tools may be reasonably used only
for little or few machining work on one or few pieces required for repair and maintenance work in small machine
shops.
Shaper machine:
A shaper is a type of machine tool that uses linear relative motion between the work piece and a single-
point cutting tool to machine a linear tool path.
46
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
47
International Islamic University, Islamabad
Faculty of Engineering and Technology
Department of Mechanical Engineering
48