MACHINING OF HEXAGON IN SHAPING MACHINE Aim : To machine a hexagon in the given workpiece to the dimensions as shown in the figureusing Shaping Machine. Tools Required : w 1. 2. 3. 4. 5. 6. w Shaping Machine, Scriber, Divider, Steel Rule, Chalk piece, Bevel Protractor. Procedure : The given workpiece is measured for its initial dimensions. With the help of scriber, mark the hexagon dimensions in the workpiece. Fix the workpiece in the vice of the shaping machine. After fixing the workpiece and the shaping tool, allow the ram to reciprocate. Start the shaping process by giving the required depth by lowering the tool. Slowly increase the depth of cut and repeat the procedure to make the hexagon shape. w .k in in di a. co m The workpiece is now checked for final dimensions.7.k in in di a. a hexagon is machined in the given workpiece to the dimensions as shown in the figure using Shaping Machine. Result : Thus. w w w . co m . Vernier caliper. Their axis must be set parallel to the machine table.5708 m where. The dividing head and the tail stock are bolted on the machine table. w Blank diameter =(Z+2)m Tooth depth = 2. TOOLS AND EQUIPMENTS REQUIRED : Milling machine. Calculate the gear tooth proportions. Mandrel. Z = Number of teeth required m = module w .25 m Tooth width = 1. co m .k in in di a. w 2.SPUR GEAR MILLING AIM : To machine a spur gear to the given module and number of teeth in the given workpiece. Indexing calculation Index crank movement = 40 / Z 3. PROCEDURE : 1. the table is raised till the periphery of the gear blank just touches the cutter.k in = 2 mm = (Z + 2) m = (23 + 2) 2 = 50 mm = 2. 9.5 mm = 40 / Z = 40 / 23 = 1 17/23 in 13. of teeth m = module = 23 Blank Diameter w w Tooth Depth Indexing Calculation w RESULT :Thus the required gear is machined using the milling machine to the required number of teeth. m 7. After the cut. .4. di a. Then the gear blank is indexed for the next tooth space. The cutter is centred accurately with the gear blank. The micrometer dial of vertical feed screw is set to zero in this position. This is continued till all the gear teeth are cut. co 8. For giving depth of cut.25 m = 2. 5. the table is brought back to the starting position. Set the speed and feed for machining. 12. The gear blank is held between the dividing head and tailstock using a mandrel.25 * 2 = 4. 10. 11. Then the table is raised further to give the required depth of cut. The mandrel is connected with the spindle of dividing head by a carrier and catch plate. 6. CALCULATION : Z = No. . The cutter is mounted on the arbor. The machine is started and feed is given to the table to cut the first groove of the blank. counter sink bit. drill bit. 3. Prepare the tooling layout for the given workpiece. The workpiece is chucked and checked for the rotation. turning tool. w w . drill chuck.CAPSTAN LATHE AIM : To machine the workpiece to the given dimensions using capstan lathe. Vernier Caliper. TOOLS AND EQUIPMENTS REQUIRED : Capstan Lathe. PROCEDURE : w 1.k in in di a. Stopper. co m . parting off tool. Set the tools in their respective positions of the tool stations. 2. co m . w w w . 5. RESULT : Thus the given workpiece is machined to the given dimensions using capstan lathe.k in in di a. The adjustment to the length of feed for each tool is adjusted by rotating the adjustment screws. Feed the tools in the required sequence to machine the given workpiece.4. k in in di a. Drill set.ASSEMBLY OF FLANGE COUPLING (ASSEMBLY – III) AIM : To machine and assemble the Flange Coupling as shown in the figure using required machines. Thus a Flange Coupling assembly is made using required machines. The center of the workpieces are marked and the Pitch Circle Diameter is marked in both the workpieces. Both the workpieces are mated together by using bolts and nuts. The first workpiece is drilled and tapped to the dimensions as shown in the figure. The given workpieces are checked for its initial dimensions. 2. 4. Vernier Caliper. co m . PROCEDURE : 1. The second workpiece is drilled to the dimensions as shown in the figure. TOOLS AND EQUIPMENTS REQUIRED : Drilling machine. 3. RESULT : Thus. Tap set. w w . w 5. a Flange Coupling is machined as per the given dimensions and assembled using the required machines. 6. Bolts & Nuts. The workpiece is chucked in lathe and machined to the projection dimensions as given in the figure. co m . 2. The given workpieces are checked for its initial dimensions. PROCEDURE : 1.k in in di a.ASSEMBLY OF DIE & PUNCH (ASSEMBLY – II) AIM : To machine and assemble a Die & Punch to the given dimensions using required machines. a Die & Punch assembly is machined as per the given dimensions and assembled using the required machines. 4. The other workpiece is machined for recess dimensions as given in the figure. Mate both the workpieces. . TOOLS AND EQUIPMENTS REQUIRED : Lathe. w w RESULT : Thus. Vernier caliper. w 3. 4. The workpiece is chucked and turned for the required dimensions. Check for the mating of internal and external threads formed. PROCEDURE : 2. Turning tool. Vernier caliper. TOOLS AND EQUIPMENTS REQUIRED : co m . 5. The external thread is made on the workpiece. 3. w w RESULT : Thus. The given workpiece is checked for its initial dimensions. a Bolt & Nut assembly is machined as per the given dimensions and assembled using the required machines. Threading tool.k in 1. Parting tool. w . Lathe.NUT (ASSEMBLY – I) AIM : To machine and assemble a Bolt & Nut to the given dimensions using required machines. in di a. The internal thread is made on another workpiece. Divider. Procedure : 1. 7. After fixing the workpiece and the slotting tool. allow the ram to vertically reciprocate. Steel Rule. 3.MACHINING AN INTERNAL KEYWAY USING SLOTTING MACHINE Aim : To machine an internal keyway in the given workpiece to the dimensions as shown in the figure using Slotting Machine. w Result : Thus. The workpiece is now checked for final dimensions. co m . Slowly increase the depth of cut and repeat the procedure to make the required shape. w The given workpiece is measured for its initial dimensions. w .k in in Tools Required : di a. Slotting Machine. internal keyway is machined in the given workpiece to the dimensions as shown in the figure using Slotting Machine. 2. Fix the workpiece in the vice of the slotting machine. 5. Start the slotting process by giving the required depth by horizontally moving the vice. 6. 4. With the help of scriber mark the keyway dimensions in the workpiece. Scriber. Finally. Surface Grinding machine.EXERCISE NO. The required depth of cut is given by raising the table. The permanent magnet worktable is cleaned thoroughly. Keep the workpiece over the worktable and push the lever to “ON” position to hold the workpiece. 6. Micrometer. The given workpiece is checked for its initial dimensions. w 3.k in in di a. co m TOO LS AND EQU IPM ENT S REQ UIR ED : . w 4. 2. . the finished workpiece is checked for the given dimensions. PROCEDURE : 1. RESULT : Thus the given workpiece is ground to the given tolerance using surface grinding machine. 3 SURFACE GRINDING AIM : To grind the workpiece to the given tolerance using surface grinding machine. The reciprocating and cross feed is given to grind the required length and width of the workpiece respectively. w 5. PROCEDURE : 1. TOOLS AND EQUIPMENTS REQUIRED : Lathe. Calculate the chip thickness ratio.SHEAR ANGLE MEASUREMENT AIM : To measure the shear angle to the given conditions. Repeat the same procedure to get few more readings and calculate the mean shear angle. Find the mean chip thickness. 3. The chip is taken for thickness inspection. .rc sinα where. 4. t1). The known depth of cut is given (uncut chip thickness. Micrometer. NOTE : co m .rake angle. in di a. Single point turning tool. t2. Repeat the experiment for different depth of cuts w w w 1.k in 5. rc cosα tan φ = ----------1 . α . rc = t1 / t2 2. Calculate the shear angle for the given rake angle of the tool. 2. The workpiece is held in the chuck. 50 0. 3. 2.25 0.k in in 1 2 3 4 0. more force is required to remove the chip.25 co m . THICKNESS RATIO SHEAR ANGLE 1 2 3 4 1 2 3 4 t1 (mm) 0. tool geometry. less force is required to remove the chip.25 0.50 0. Hence.50 di a.50 0.25 0.25 0. LC = Least Count DEPTH PITCH SCALE HEAD SCALE HEAD SCALE CHIP SL.1.25 4 0. t1 (mm) (PSR) (HSC) HSR = HSC*LC t2 = PSR + HSR 1 0. CHIP THICKNESS : SHEAR ANGLE : w w UNCUT CHIP CHIP SHEAR ANGLE CHIP THICKNESS THICKNESS AVERAGE SL.50 0. tool material and work material.50 t2 (mm) rc = t1 / t2 w . NO.25 2 0. If the Shear angle is small.25 3 0.50 0. The value of Shear angle depends on the cutting conditions.50 0. the plane of shear will be shorter and the chip is thin. the plane of the shear is large. If the shear angle is large. the chip is thicker. OF CUT READING COINCIDENCE READING THICKNESS NO. RESULT : Thus the shear angle is found for different depth of cuts.k in in di a. co m . w w w .