ME 2207 - Manufacturing Technology 1 - Lab Manual

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Transcript of ME 2207 - Manufacturing Technology 1 - Lab Manual





Name of lab:Department :

Certify that this is a bonafide record of work done by of class in the .. Laboratory during the year 200 -200 .

Signature of Lab in Charge Head of The Dept

Submitted for the practical examination held on ..


A LIST OF BASIC SAFETY RULES1. When you handle chemicals wear eye protection (chemical splash goggles or full face shield). 2. When you work with furnaces for heat treatment procedures or other thermally activated equipment you should use special gloves to protect your hands. 3. Students should wear durable clothing that covers the arms, legs, torso and feet. (Note: sandals, shorts, tank tops etc. have no place in the lab. Students inappropriately dressed for lab, at the instructors discretion, be denied access)4. To protect clothing from chemical damage or other dirt, wear a lab apron or lab coat. Long hair should be tied back to keep it from coming into contact with lab chemicals or flames. 5. In case of injury (cut, burn, fire etc.) notify the instructor immediately. 6. In case of a fire or imminently dangerous situation, notify everyone who may be affected immediately; be sure the lab instructor is also notified. 7. If chemicals splash into someone's eyes act quickly and get them into the eye wash station, do not wait for the instructor. 8. In case of a serious cut, stop blood flow using direct pressure using a clean towel, notify the lab instructor immediately. 9. Eating, drinking and smoking are prohibited in the laboratory at all times. 10. Never work in the laboratory without proper supervision by an instructor. 11. Never carry out unauthorized experiments. Come to the laboratory prepared. If you are unsure about what to do, please ask the instructor.12. Always remember that HOT metal or ceramic pieces look exactly the same as COLD pieces are careful what you touch. 13. Know the location and operation of : Fire Alarm Boxes Exit Doors Telephones

LABARATORY CLASSES - INSTRUCTIONS TO STUDENTS1. Students must attend the lab classes with ID cards and in the prescribed uniform.1. Boys-shirts tucked in and wearing closed leather shoes. Girls students with cut shoes, overcoat, and plait incite the coat. Girls students should not wear loose garments.1. Students must check if the components, instruments and machinery are in working condition before setting up the experiment.1. Power supply to the experimental set up/ equipment/ machine must be switched on only after the faculty checks and gives approval for doing the experiment. Students must start to the experiment. Students must start doing the experiments only after getting permissions from the faculty.1. Any damage to any of the equipment/instrument/machine caused due to carelessness, the cost will be fully recovered from the individual (or) group of students. 1. Students may contact the lab in charge immediately for any unexpected incidents and emergency.1. The apparatus used for the experiments must be cleaned and returned to the technicians, safely without any damage.1. Make sure, while leaving the lab after the stipulated time, that all the power connections are switched off.1. EVALUATIONS:1. All students should go through the lab manual for the experiment to be carried out for that day and come fully prepared to complete the experiment within the prescribed periods. Student should complete the lab record work within the prescribed periods.1. Students must be fully aware of the core competencies to be gained by doing experiment/exercise/programs.1. Students should complete the lab record work within the prescribed periods.1. The following aspects will be assessed during every exercise, in every lab class and marks will be awarded accordingly:1. Preparedness, conducting experiment, observation, calculation, results, record presentation, basic understanding and answering for viva questions.1. In case of repetition/redo, 25% of marks to be reduced for the respective component.

NOTE 11. Preparation means coming to the lab classes with neatly drawn circuit diagram /experimental setup /written programs /flowchart, tabular columns, formula, model graphs etc in the observation notebook and must know the step by step procedure to conduct the experiment.1. Conducting experiment means making connection, preparing the experimental setup without any mistakes at the time of reporting to the faculty.1. Observation means taking correct readings in the proper order and tabulating the readings in the tabular columns.1. Calculation means calculating the required parameters using the approximate formula and readings.1. Result means correct value of the required parameters and getting the correct shape of the characteristics at the time of reporting of the faculty.1. Viva voice means answering all the questions given in the manual pertaining to the experiments.1. Full marks will be awarded if the students performs well in each case of the above component NOTE 21. Incompletion or repeat of experiments means not getting the correct value of the required parameters and not getting the correct shape of the characteristics of the first attempt. In such cases, it will be marked as IC in the red ink in the status column of the mark allocation table given at the end of every experiment. The students are expected to repeat the incomplete the experiment before coming to the next lab. Otherwise the marks for IC component will be reduced to zero.NOTE 31. Absenteeism due to genuine reasons will be considered for doing the missed experiments.1. In case of power failure, extra classes will be arranged for doing those experiments only and assessment of all other components preparedness; viva voice etc. will be completed in the regular class itself.NOTE 41. The end semester practical internal assessment marks will be based on the average of all the experiments.















Completed date: Average Mark: Staff - in - chargeA STUDY ON BASIC MACHINING

INTRODUCTIONMachining is the process of converting the given work piece into the required shape and size with help of a machine tool. The most widely used machine tool is lathe. In simple words machining is the process of removing certain material from the work piece.LATHELathe is the machine tool which is used to perform several operations on the work piece. Lathe is useful in making several parts which is further assembled to make new machine. Hence lathe is known as mother of machines.

BASIC WORKING PRINCIPLE OF LATHEIn lathe, the work piece is held in the chuck, a work holding device. The cutting tool is mounted in the tool post. The chuck is rotated by means of power. When the chuck rotates, the work piece also rotates. The tool is moved against the rotating work piece by giving small amount of depth of cut. The material is removed in the form of chips. Continuous feed and depth of cut is given until the required dimensions are obtained in the work piece.

TYPES OF LATHE MACHINESThere are different types of lathe machines, they are1. Centre lathe 2. Tool room lathe3. Bench lathe4. Capstan lathe5. Turret lathe6. Automatic latheDESCRIPTION OF LATHELathe is a machine which has several parts in it. They are1. BedIt is the base of the machine. On its left side, the head stock is mounted and on its right it has movable casting known as tailstock. Its legs have holes to bolt down on the ground.2. Head stockIt consists of spindles, gears and speed changing levers. It is used to transmit the motion to the job. It has two types one is the headstock driven by belt and the other one is the gear driven.3. CarriageCarriage is used to carry a tool to bring in contact with the rotating work piece or to with draw from such a contact. It operates on bed ways between the headstock and tail stock.4. SaddleIt is a H shaped part fitted on the lathe bed. There is a hand wheel to move it on the bed way. Cross slide, compound rest, tool post are fitted on this saddle.a) Cross slideIt is on the upper slide of saddle in the form of dove tail. A hand wheel is provided to drive the cross slide. It permits the cross wise movement of the tool (i.e.) movement of tool towards or away from the operator

b) Compound restIt is fitted over the cross slide on a turn table. It permits both parallel and angular movements to cutting tool.

c) Tool postIt is fitted on the top most part of the compound rest. Tool is mounted on this tool post. Cutting tool is fixed in it with the help of screws.

5. ApronIt is the hanging part in front of the carriage. It accommodates the mechanism of hand and power feed to the cutting tool for carrying out different operations.

6. Lead screwIt is a long screw with ACME threads. It is used for transmitting power for automatic feed or feed for thread cutting operation.

7. Tail stockIt is located at the right end of the lathe bed and it cn be positioned anywhere in the bed. It is used for supporting lengthy jobs and also carries tool to carry out operations such as tapping, drilling, reaming.

WORK HOLDING DEVICES1. Lathe centersThey are used to support work. It has two categories of centers. Live center is one which is fitted in the headstock spindle. Dead is another one which is fitted in the tail stock.2. ChuckIt is a device used to hold a job. It is easily fitted on the thread cut on the end of head stock spindle. Various types of chuck are a) Two jaw chuckb) three jaw chuckc) four jaw