Aero Manufacturing Tech Lab

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DEPARTMENT OF AERONAUTICAL

ENGINEERING

Lab Manual

Of

U4AEA14, Aircraft Manufacturing

Technology Lab

Prepared byM. Amala Justus Selvam

Professor, VTU.


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VEL TECH Dr. RR & Dr.SR TECHNICAL UNIVERSITY

DEPARTMENT OF AERONAUTICAL ENGINEERING

U4AEA14 AIRCRAFT MANUFACTURING TECHNOLOGY

LAB

LIST OF EXPERIMENTS

1. Step and Taper turning2. Thread cutting.3. Making of a Groove and Key way.4. Drilling 4 or 6 holes at a given pitch circle on a plate5. Plain Milling Exercises6. Cylindrical Grinding Exercises7. Fabrication of Airfoil


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SAFTY PRECAUTIONS IN LATHE WORKSHOP

While working in lathe machine, the following safety precautions should be followed

1. A full understanding of the nature of all risks involved in the machine and operation is

essential.

2. The correct setting up of the lathe driving mechanism is essential.

3. The use and correct adjustment of all guards are necessary for safe operations.

4. No tools should be left on the way of movement of slides, carriage, ect.

5. Work holding and tool holding methods are reviewed before making cut.

6. The machine power should be in off position, while removing the job from work holding

device and removing the chuck or face plate from spindle.

7. No attempt should be made to adjust the tool or for measurement when the machine is

running.

8. Gear should be never changed, when the machine is running.

9. Strips of sand paper should never be used for polishing work in lathe.

10. Chuck key, tool post or other tools should be removed from the chuck before switching on

machine.

11. All stock bars must be adequately arranged for the whole of their length.

12. The correct location and working of the feed rod and its attachment should be ensured.

13. Adequate clearance should be checked and ways kept clear of materials and tools.

14. While changing the belt drive, take more care.

15. Wear proper cloth, shoe and goggles.

16. Check the earth connection before switching ON the machine tool.

17. Whenever there is power failure, put-off the power supply to the lathe, in order to prevent

spontaneous recovery.

18. Provide proper ventilation.

19. The floor must de dry.

20. The hand tools should be clear and sharp.


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1. STEP TURNING AND TAPER TURNING

AIM

To perform facing, plain turning step turning and tapper turning on a cylindrical work

piece.

TOOLS REQUIRED

Lathe, chuck key, vernier caliper, box spanner, grooving tool, and single point cutting

tool

WORKPIECE REQUIRED

Mild Steel Rod

PROCEDURE (Step Turning)

1. First, loosen the jaws in the chuck using the chuck key to position the workpiece and then tighten the jaws.

2. Fix the cutting tool in the tool post.

3. Switch on the lathe and move the carriage near the work piece and give a smallcross- feed, and then move the carriage longitudinally to the required length

slowly

4. Bring the carriage to the original position, give a small cross feed, and move the

carriage longitudinally. Repeat this step until the required diameter is obtained. It

is good practice to check the diameter of the work piece regularly using a vernier

caliper.

5. To get smooth surface, give very small feed when the diameter is nearing the

required value.

6. To face the end surface of the work piece, move the carriage to make the tool

touch the end surface of the work piece.

7. Give a small feed in longitudinal direction, and then move the tool towards the

axis of the work piece using the cross-slide to complete facing.


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PROCEDURE (Tapper Turning)

1. First, loosen the jaw in the chuck using the chuck key to position the work piece and then

tighten the jaws.

2. Fix the cutting tool in the tool post.

3. Perform the facing and turning operation to get the required larger diameter (D)

and the required length (L).

4. Do grooving operation with grooving tool as per the figure.

5. After grooving switch off the machine and swivel the compound rest base after

loosening the nuts using box spanner. Set the swiveling angle ,of compound rest

using the formula,

Taper angle, = tan-1

(Dd) / 2L

Where, D = Larger diameter of taper in mm

d = Smaller diameter of taper in mm

L = Taper length in mm

6. Perform taper turning operation by given a small feed then move the tool using

the cross slide. Repeat this step to complete the taper.

RESULT

Thus in the given work piece facing, plain turning step turning and tapper tauring

are performed for given dimensions.


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STEP TURNING

301040

30

18

Chamfer 45 x 2

M 25.4 x 3.75

STEP AND TAPER TURNING

ALL DIMENSTIONS ARE IN mm


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2. THREAD CUTTINGAIM:

To turn and make single and multi-start V thread & to make diamonded knurl on the

given work piece.

TOOLS REQUIRED:

Lathe, chuck key, vernier caliper, box spanner, grooving tool, single point cutting tool and

thread cutting tool.

WORKPIECE REQUIRED:

Mild Steel Rod

PROCEDURE:

1. First, loosen the jaw in the chuck using the chuck key to position the work piece and

then tighten the jaws.

2. Perform facing, turning and chamfering operations to get the required diameters for

knurling and thread cutting operations.

3. Replace the turning tool by thread cutting tool in the tool post.

4. Calculate the depth for thread and pitch required.

Pitch = 1/N. where N= No. of Teeth per unit area.

5. Change the gears to obtain required speed for threadcutting using the back gear

mechanism.

6. Switch on the lathe, move the carriage near the work piece, and give a small cross feed.

7. Move the carriage outward and the move it longitudinally, and give a small cross feed.

Repeat this step until thread cutting of required length is obtained.

8. Use the half-nut engaging lever for automatic speed.


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9. Give small cross feed and repeat step 7 to complete the threading for required depth.

10. Now replace the thread cutting tool with knurling tool

11. Disengage halfnut lever and change the gears.

12. Switch on the lathe, move the carriage near the work piece, and give a small cross feed.

13. Move the carriage outward, and then move it longitudinally, and give a small cross feed.

Repeat this step until Knurling of required length is obtained.

RESULT:

Thus, thread cutting and knurling is performed in the given work piece.


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EXTERNAL SINGLE STRAT V THREAD



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Lathe Machine


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3. MAKING OF A GROOVE AND KEY WAY

AIM:

To make groove and key way in the given mild steel work piece as per given dimensions

by using shaping and slotting machines.

TOOLS REQUIRED:

1. Round nose tool2. Parting tool3. Vernier height gauge4. Tri square5. Punch6. Hammer7. Vernier Caliper

PROCEDURE FOR KEYWAY BY USING SLOTTER MACHINE:

1. The given work piece dimensions are measured. By knowing the machining allowances,marking is carried out using vernier caliper.

2. To identify the marking, the marked lines are punched.3. The work piece is hold in the machine table using self centering three jaw chuck.4. The tool is hold in the tool head in correct position.5. The stroke length and initial cutting positions are corrected by adjusting ram and table

manually.

6. The slotter machine is switched on. Tool moves inside the work piece. The material isremoved from the work piece by the tool cutting force.

7. By giving cross feed movement to the table, the total length of the work is machined.8. After completion of groove key way machining work the work piece is removed from the

chuck.

9. Again the work piece is clamped in the chuck. Correct feed and depth of cut are selected.10.Both sides are machined by altering the tool position.11.After machining the slot, the work piece is removed from the table, cleaned and an

inspection is carried out.


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PROCEDURE FOR GROOVING BY USING SHAPER MACHINE:

1. The given work piece dimensions are measured. By knowing the groove machiningallowances, marking is carried out using vernier caliper.

2. To identify the marking, the marked lines are punched.3. The work piece is hold in the machine table using self centering three jaw chuck.4. The tool is hold in the machine table using machine vice.5. The stroke length and initial cutting positions are corrected by adjusting ram and table

manually.

6. The shaper machine is switched on. Tool moves over the work piece.7. By giving depth of cut to the tool post and cross feed movement to the table.8. The material is removed from the work piece by the tool cutting force.9. After completion of groove machining work the work piece is removed from the chuck.

RESULT:

The groove and key way are machined in the given work piece as per given drawing.


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GROOVE CUTTING BY USING SHAPER

X



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INTERNAL KEYWAY BY USING SLOTTER

X



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Shaper Machine


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Slotter Machine


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4. DRILLING 4 OR 6 HOLES AT A GIVEN PITCH CIRCLE ONA PLATE

AIM:

To make 4 or 6 holes at a given pitch circle on a plate by using drilling machine.

TOOLS REQUARED:

1. Drill bit2. Coolant3. Steel Rule4. Compass5. Punch6. Divider7. Vernier Caliper

FORMULA USED:

Pitch Distance = 2 R / N

N = Number of holes

R = Radius of pitch circle

PROCEDURE:

1. Based on the diameter of the given pitch circle, a center is chosen on the given workpiece to accommodate pitch circle.

2. Based on the number of holes (4 or 6) to be drilled on the circumference of the pitchcircle of the work piece required pitch distance between each drill centre has been

chosen.

3. By using compass, pitch circle has been drawn with the given dimensions.4. By using pitch, centre of holes (4 or 6) that has to be drilled on the circumference of

pitch circle has been marked according to the above calculated pitch distance.

5. Drill bit of required diameter is hold to the drilling machine.


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6. Work piece is adjusted on the work table of drilling machine and drilling has beenperformed in the places of punch marks.

RESULT:

The work piece with the given dimensions of pitch circle and holes has been done.


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PITCH CIRCLE DRILLING



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RADIAL DRILLING MACHINE


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5. PLAIN MILLING MACHINEAIM :

To machine a given hexagonal surface in a given work piece using milling machine.

TOOLS AND EQUIPMENTS REQUIRED:

Milling Machine, Vernier caliper, Steel rule, Adaptor type end mill, Compass, Divider,

Center punch.

PROCEDURE :

1. The given work piece is checked for its dimensions.2. The width across the flat is first determined ( Across flat = 1.5 S + 3 mm )3. A universal dividing head is mounted on the table with its spindle swiveled to the horizontal

position.

4. The work piece is mounted at the nose of the dividing head spindle by the help of a suitablechuck.

5. The work piece is centered below the cutter and the first cut is taken.6. The work piece is rotated through one sixth of a revolution by using the indexing mechanism

and then the second cut is taken. It is to be repeated for six number of times to finish six

faces of the work piece.


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FORMULA USED:

Pitch Distance = 2 R / N

N = Number of Side

R = Radius of cylindrical work piece

RESULT :

Thus the required hexagonal surface is machined using the milling machine to the

given dimensions.


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HEXAGONAL PLAIN MILLING


S=20


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6. CYLINDRICAL GRINDING MACHINE

AIM:

To grind the cylindrical surface work piece to the required dimensions using

cylindrical grinding machine.

MATERIALS REQUIRED:

Mild steel iron rod

TOOLS AND EQUIPMENTS REQUIRED:

1. Cylindrical Grinding machine.2. Micrometer.3. Turning tool.4. Grinding wheel.5. Center drill bit.6. Vernier caliper.

PROCEDURE:

1. The given work piece is checked for its initial dimensions.2. Initially facing and turning is done on the work piece in lathe machine.3. The permanent magnet worktable is cleaned thoroughly.4. Keep the work piece over the worktable and push the lever to ON position to hold

the work piece.

5. The required depth of cut is adjusted and feed is given to the work piece by two handmotion.


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6. The reciprocating and cross feed is given to grind the required length and width of thework piece respectively.

7. The friction developed between the work piece and grinding wheel is reduced byusing the coolant.

8. Finally, the finished work piece is checked for the given dimensions.

RESULT:

Thus the given cylindrical work piece is grind to the required dimension using

cylindrical grinding machine.

70

50

70

50

10 90.01


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Plane Surface machine


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7. FABRICATION OF AEROFOILAIM:

To make aircraft wing with aerofoil shape by using Aluminum sheet.

TOOLS REQUIRED:

1. Aluminum Sheet2. Scriber3. Pencil4. 2.5 mm blind rivets5. 3mm drill bit6. Hand drill machine7. Mallet8. Smooth files9. Hand shear cutter

THEORY

Airfoil Nomenclature

1. C- chord lengthlength from the LE to the TE of a wing cross section that is parallel

to the vertical axis of symmetry

2. MCL - Mean camber lineline halfway between the upper and lower surfaces

3. LE -leading edge is the front most point on the mean camber line, trailing edge (TE)

is the most rearward point on mean camber line.

4. CB - cambermaximum distance between the mean camber line and the chord line,

measured perpendicular to the chord line.

5. UCB - camber or uncambered means the airfoil is symmetric above and below the

chord line

6. T- thicknessdistance between upper surface and lower surface measured

perpendicular to the mean camber line


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PROCEDURE:

1. Auto Cad drawing of aero foil with the given coordinates in three numbers are taken onwhite paper and pasted to the no 1 Aluminum sheet which are having 6mm thickness.

2. By using the scriber markings are made on the aluminum sheet with respect to the shape ofthe aero foils.

3. By using the hand shear cutter, aluminum sheets are cut in the shape of aero foils ( two webplates and one scroll plate).


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4. By using the scriber and dot punch marking the pitch dimensions around the edges of theaero foil web plate and scroll plates.

5. All the marked pitch distances are drilled with 4mm diameter drill bit.6. The scroll plate is wrapped around the web plates by using mallet.7. Now the blind riveting is done on the scroll and web plates and to form as wing shape.RESULT:

The aircraft wings aero foil has been made with given dimensions.


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AEROFOIL SCROLL PLATE LAYOUT



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AEROFOIL WEB PLATE LAYOUT



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