EXPERIMENT NO:1
PREPARING “T” SECTION
AIM: To Prepare ‘T’ in fitting for given measurements of size 50 x50 x 10 mm
Tools & equipment required:
1) Steel rule
2) Scriber
3) Try square
4) File
5) Hacksaw
6) Benchvice
Sequence of Operations:
1) Marking
2) Measuring
3) Sawing
4) Filing
5) Finishing
Procedure:
1) Cut the work piece from the bar for required size.
2) File the work piece edges each to right angle
3) Mark the work piece for’T’ section
4) Fit the job in Bench vice
5) Cut the job with hacksaw to get ‘ T’ shape .
6) File inner side to right angle .
Precautions :
1) File the work piece on the sawing marks .
2) Use coolent while using hacksaw .
3) Inner side edges also checked with Try square for trueness of the job .
EXPERIMENT NO:2
PREPARING “L” SECTION
AIM: To Prepare ‘L’ in fitting for given measurements of size 50 x50 x 10 mm
Tools & equipment required:
1) Steel rule
2) Scriber
3) Try square
4) File
5) Hacksaw
6) Benchvice
Sequence of Operations:
1) Marking
2) Measuring
3) Sawing
4) Filing
5) Finishing
Procedure:
1) Cut the work piece from the bar for required size.
2) File the work piece edges each to right angle
3) Mark the work piece for’L’ section
4) Fit the job in Bench vice
5) Cut the job with hacksaw to get ‘ L’ shape .
6) File inner side to right angle .
Precautions :
1) File the work piece on the sawing marks .
2) Use coolent while using hacksaw .
3) Inner side edges also checked with Try square for trueness of the job .
EXPERIMENT NO:3
Aim: Make holes on given plate with given sizes.
Tools & Equipment
Drilling Machine, Steel rule, inside caliper, Drill bit
Procedure
1.Place the drill bit in the chuck.
2.Tighten the chuck with a chuck key then remove the chuck key and position the guard.
3.Clamp the work piece in a vice underneath the drill bit.
4.Switch the drill on.
5.Using the lever force the drill bit through the material.
6.Raise the lever.
7.Turn the drilling machine off.
8.Clean the workpiece.
Precautions
1. Work piece should be held firmly.
Result : Made holes on given plate with given sizes.
EXPERIMENT NO:4
PLAIN TURNING
Aim: To obtain required diameter of a cylindrical work piece with the given length
Tools & Equipment
Lathe machine. Mild steel bar, right hand cutting tool, box key or tool post key, chuck key, steel rule,
outside calipers or vernier calipers.
PLAIN TURNING
Theory
Facing is the operations of finishing the ends of work to make ends flat, smooth and to required length.
Rough turning operation is used where excessive stock is to be removed and surface finish is not critical.
For such a operation deep cuts with coarse feed are used. During rough machining, maximum metal is
removed and very little oversize dimension is left for finishing operation.
Procedure
1. The given work piece is held in the 3‐jawchuck of the lathe machine and tightened firmly with chuck key.
2. Right hand single point cutting tool is taken tightened firmly with the help of box key in the tool post.
3. Machine is switched on and the tool post is swiveled and the cutting point is adjusted such that it
positioned approximately for facing operation then the tool is fed into the work piece and the tool
post is given the transverse movement by rotating the hand wheel of the cross slide.
4. With this facing is completed and the tool post is swiveled and cutting point is made parallel to the
axis of work piece.
5. Depth of cut is given by cross slide to the tool post and the side hand wheel is rotated to give the
longitudinal movement for the tool post and job is turned to the required length and diameter.
6. After completion of the job it is inspected for the dimensions obtained with the help of steel rule
and outside caliper or vernier caliper.
Precautions
1. Work piece should be held firmly.
2. In rough turning operation do not over feed the tool, as it may damage the cutting point of the tool.
3. Exercise over hung of tool should be avoided as it results in chatter and causes rough machined surface.
4. It is important to ensure that during facing operation the cutting is performed from center point to
the outer diameter of the work piece.
Result The job is thus made according to the given dimensions.
EXPERIMENT NO:5
STEP TURNING
Aim: To obtain required diameters(steps) on a cylindrical work piece with the given lengths.
Tools & Equipment
Lathe machine. Mild steel bar, right hand cutting tool, box key or tool post key, chuck key, steel rule,
outside calipers or vernier calipers.
Theory
Step turning is the operation of creating various cylindrical cross sections on a metal blank. Rough
turning operation is used where excessive stock is to be removed and surface finish is not critical. For
such a operation deep cuts with coarse feed are used. During rough machining maximum metal is
removed and very little oversize dimension is left for finishing operation.
Sketch
STEP TURNING
Procedure
1. The given work piece is held in the 3‐jawchuck of the lathe machine and tightened firmly with chuck key.
2. Right hand single point cutting tool is taken tightened firmly with the help of box key in the tool post.
3. Machine is switched on and the tool post is swiveled and the cutting point is adjusted such that it
positioned approximately for facing operation then the tool is fed into the work piece and the tool
post is given the transverse movement by rotating the hand wheel of the cross slide.
4. With this facing is completed and the tool post is swiveled and cutting point is made parallel to the
axis of work piece.
5. Depth of cut is given by cross slide to the tool post and the side hand wheel is rotated to give the
longitudinal movement for the tool post and job is turned to the required length and diameters
according to the sketch shown in figure.
6. After completion of the job it is inspected for the dimensions obtained with the help of steel rule
and outside caliper or vernier caliper.
Precautions
1. Work piece should be held firmly.
2. In rough turning operation do not over feed the tool, as it may damage the cutting point of the tool.
3. Exercise over hung of tool should be avoided as it results in chatter and causes rough machined surface.
4. It is important to ensure that during facing operation the cutting is performed from center point to
the outer diameter of the work piece.
Result The job is thus made according to the given dimensions.
EXPERIMENT NO:6
AIM:
To make knurling operation on a given work piece by lathe
MATERIAL SUPPLIED:
Mild Steel round rod of size ____________________mm
TOOLS REQUIRED:
Single point cutting tool ,Vernier calliper ,Steel rule ,Outside calliper ,Marking gauge ,Knurling tool
SEQUENCE OF OPERATIONS:
Knurling
PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece.
3. Check the center of the job using marking gauge.
4. Fix the single point cutting tool in the tool post.
5. Select the corresponding spindle speed and feed the before starting the operation
6. Cutting tool is moved at an angle to the lathe axis
7. Now the tool will move in helical path on the work piece to form thread
8. Fix the knurling tool in the tool post
9. Then the tool is held in tool post and passed again checked
RESULT:
Thus the knurling operation of required dimensions was determined
EXPERIMENT NO:7
AIM: To perform thread cutting operation on a given work piece by lathe.
MATERIAL SUPPLIED: Mild Steel round rod of size ____________________mm
TOOLS REQUIRED: Single point cutting tool ,Vernier calliper ,Steel rule ,Outside calliper ,
Marking gauge Thread cutting tool ,Thread pitch gauge
SEQUENCE OF OPERATIONS: Thread cutting
CALCULATION:
Thread Cutting: (Driver teeth)/ (Driven teeth) = (Pitch of the work)/ (Pitch of the lead screw)
PROCEDURE:
1. The given work piece is checked for its dimensions by using measuring devices.
2. Loosen the jaws in the chuck using the chuck key to position the work piece.
3. Check the center of the job using marking gauge.
4. Fix the single point cutting tool in the tool post.
5. Select the corresponding spindle speed and feed the before starting the operation
6. Cutting tool is moved at an angle to the lathe axis
7. The gear ratio of no of teeth required on change gear are calculated
8. The current size of gears in the change gear train is fixed
9. Rotation of spindle should be sent out fourth of speed
10. The cutting tool height is set which is equal to the centre of work piece
11. The cross slide hand wheel is rotated tilled tool touches the work piece
12. The half nut is engaged when any one making on the dial coincides with reference mark on chasing dial
13. Now the tool will move in helical path on the work piece to form thread
14. Fix the knurling tool in the tool post
15. Then the tool is held in tool post and passed again checked
RESULT:
Thus the thread cutting operation of required dimensions was determined
EXPERIMENT NO:8
MAKING A ROUND BAR FROM A SQUARE BAR
AIM: To prepare round bar from given a square bar.
Tools & equipment required : 1) Anvil 2) Forge 3) Tong 4) Hammer etc.
Procedure:
1) Place the square bar in forge and heat it till it got red hot.
2) Pick up the red heated square bar with tong and place on the anvil and give blows.
3) Place the rod in the forge and then place it on the anvil and give blows with hammer till
square bar made into round.
4) Continue the process till full length of the bar is made in to round.
Precautions:
1) Always use hand gloves to protect hand from the heat.
2) Use correct tool.
3) Give blows continuesly with out gap.
4) If the job is not in red hot place it in the forge.
EXPERIMENT NO:9
RING
Aim: To make a ring from a given round rod, by following hand forging operation
Tools required: Smith’s forge, Anvil, sledge hammer, flatters, swage block, half round tongs and
pick up tongs.
Sequence of operations:
1.One end of the bar is heated to red hot condition in the smith’s forge for the required length
2. Using pick up tongs, the rod is taken from the forge and holding it with the half round tongs the
heated end is forged into a tapered pointed end.
3.The length of the rod required for ring is estimated and the excess portion is cut-off using a cold
chisel
4. One half of the rod towards the pointed end is heated in the forge to red hot condition and then
bent into circular shape as shown.
5. The other end of the rod is then heated and forged into a tapered pointed end.
6. The straight portion of the rod is finally heated and bent into circular shape as required.
7. Using the flatter ,the ring made as per given specification,is kept on the anvil and flattened so that
the shape of the ring is proper.
Precautions:
1.Hold the hot work downward close to the ground, while transferring from the hearth to anvil.
2. Use correct size and types of tongs to fit the work.
3. Care should be exercised in the use of the hammer.
4. Wear face shield when hammering hot metal.
5. Wear gloves when handling hot metal.
6. Wear steel-toed shoes.
7. Ensure that hammers are fitted with tight and wedged handles.
RESULT:
The ring is thus made from the given round rod, by following the stages mentioned above
EXPERIMENT NO:10
S-HOOK
Aim: To make a S-hook from a given round rod, by following hand forging operation
Tools required: Smith’s forge, Anvil, sledge hammer, flatters, swage block, half round tongs and
pick up tongs.
Sequence of operations:
1.One end of the bar is heated to red hot condition in the smith’s forge for the required length
2. Using pick up tongs, the rod is taken from the forge and holding it with the half round tongs the
heated end is forged into a tapered pointed end.
3.The length of the rod required for S-hook is estimated and the excess portion is cut-off using a
cold chisel
4. One half of the rod towards the pointed end is heated in the forge to red hot condition and then
bent into circular shape as shown.
5. The other end of the rod is then heated and forged into a tapered pointed end.
6. The straight portion of the rod is finally heated and bent into circular shape as required.
7. Using the flatter ,the S-hook made as per given specification,is kept on the anvil and flattened so
that the shape of the hook is proper.
Precautions:
1.Hold the hot work downward close to the ground, while transferring from the hearth to anvil.
2. Use correct size and types of tongs to fit the work.
3. Care should be exercised in the use of the hammer.
4. Wear face shield when hammering hot metal.
5. Wear gloves when handling hotmetal.
6.Wear steel-toed shoes.
7. Ensure that hammers are fitted with tight and wedged handles.
RESULT:
The S-hook is thus made from the given round rod, by following the stages mentioned above
EXPERIMENT NO:11
SHEET METAL TRAY
Aim: To make a rectangular tray from the given sheet metal.
Material Required:
G.I Sheet
Tools required
• Steel rule
• Mallet
• Scriber
• Divider
• Protractor
• Snips
• Stakes
• Ball peen hammer
Procedure
1. The size of the given sheet is checked for its dimension using steel rule.
2. Then the sheet is leveled on the leveling plate using a mallet.
3. The development procedure is followed the same as the square taper tray.
4. The dimensions are marked as shown in figure.
5. The sheet is cut as per the marked dimensions by straight snips.
6. Then a single hemming is made on the four sides of the tray as shown in figure.
7. The four sides of the tray bent to 90_ using the stakes anvil.
8. Finally all the corners of the tray are joined by riveting.
Result
Thus desired rectangular tray is made from the given sheet metal.
EXPERIMENT NO:12
AIM: To make a rectangular scoop, using the given sheetmetal.
Tools required: Steel Rule,Try square, divider,scriber,s traight snip, mallet,cross peen hammer and
hatchet stake
Note:
1. All dimensions are in mm
2. Remove the crossed symbol portion
Sequence of operations:
1.
2.
3.
4.
5.
The size of the given sheet is checked with the steel rule
The layout of the scoop are marked on the given sheet
The layout of the scoop is cut by using the straight snip
The corners of the scoop are hemmed
The edges of the scoop can be riveted or soldered to ensure stability of the joints.
Precautions:
1. Mark the dimensions correctly
2. Cut the sheet carefully
3. Remove the chips with brush
Result:
The open scoop is thus made from the given sheet metal
EXPERIMENT NO:13
MAKING OF A FUNNEL
Aim: To make a funnel from the given sheet metal.
Material Required:
G.I Sheet
Tools required
• Steel rule
• Mallet
• Scriber
• Divider
• Protractor
• Snips
• Stakes
• Ball peen hammer
• Solder
Procedure
1. The size of the given sheet is checked for its dimension using steel rule.
2. The required development of surface is being made on the white paper which is
overlapped on the sheet metal.
3. The marking is done on the sheet metal as per the development being done on the paper.
4. Now using straight snips, unwanted material are removed.
5. Now fold and bend the workpiece to make the funnel shape and joint is made on the workpieces.
6. Then using a groove, a locked grooved joint is made for about 5mm. also; hemming
is done in the bottom of the funnel.
7. In between top face and bottom face, a butt joint is made using a solder.
8. Finally, trimming and finishing operations are carried out.
Result
Thus desired funnel is made from the given sheet metal.
EXPERIMENT NO:14
SQUARE BUTT JOINT
AIM:
Make a square butt joint with given work pieces by arc welding.
MATERIAL SUPPLIED:
Mild Steel Plate of size
TOOLS REQUIRED:
Welding transformer , Welding rods ,Safety gloves ,Goggle ,Tong ,Chipping hammer ,Flat file ,
Try square, etc.,
SEQUENCE OF OPERATIONS:
Edge preparation (Removal of rust, scale etc.,), Tacking, Welding, Cooling, Chipping, Cleaning.
PROCEDURE:
1. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint and
more strength.
2. The welding rod is held in the electrode holder and the ground clamp is clamped to the plate to be
welded.
3. The plates to be welded are positioned touching each other (butting) and tag weld is done on the
ends to avoid the movement of the plates during welding.
4. Now start welding from one end of the plates.
5. The electric arc produced melts the welding rod and joints the two metal plates. Maintain a gap of
3 mm between the plate and the welding rod.
6. The welding process is completed by removing slag using chipping hammer.
RESULT:
Thus the two metal plates were joined by square butt weld.
EXPERIMENT NO:15
T‐ JOINT
Aim:
To make a T‐ joint, using the given mild steel pieces and by arc welding.
Material used :Two mild steel pieces of 100X40X6 mm.
Tools and equipment used
Arc welding machine, Mild steel electrodes, Electrode holder, Ground clamp, flat nose Tong, Face shield,
Apron, Hand gloves, Metallic work Table, Bench vice, Rough flat file, Try square, Steel rule, Wire brush,
Ball peen hammer, Chipping hammer, Chisel and Grinding machine.
Sketch
Operations to be carried out
1. Cleaning the work pieces
2. tack welding
3. full welding
4. cooling
5. chipping
6. finishing
Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from rust, dust
particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table such that, the T shape is formed.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the pieces the arc is struck and
the work pieces are tack‐welded at both the ends.
7. The alignment of the T joint is checked and the tack‐welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the T joint as shown in the figure.
9. Remove the slag, spatters and clean the joint.
Result The Tee joint is thus made, using the tools and equipment as mentioned above.
EXPERIMENT NO:16
LAP JOINT
Aim: To join the given two work pieces as a lap joint by arc welding.
Material used:Mild Steel plates.
Tools required
• Welding power supply • Flat file
• Welding rod • Chipping hammer
• Electrode holder • Wire brush
• Gloves and apron • Earthing clamps
• Shield and goggles
Procedure
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
2. Then the given work pieces are placed on the table in such a way that one work piece
is placed on the other work piece like the LAP joint is formed.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Then the welding is carried out throughout the length.
7. As soon as the welding process is finished, switch off the current supply and allow the
work piece to cool.
8. Slag is removed by chipping process with the help of chipping hammer.
9. Finally using wire brush, welded portions are cleaned.
Result
Thus the given two work pieces are joined as a lap joint by arc welding.
EXPERIMENT NO:17
CORNER JOINT
Aim : To make a corner joint, using the given mild steel pieces and by arc welding.
Material used :Two mild steel pieces of 100X40X6 mm.
Tools and equipment used
Arc welding machine, Mild steel electrodes, Electrode holder, Ground clamp, flat nose Tong, Face shield,
Apron, Hand gloves, Metallic work Table, Bench vice, Rough flat file, Try square, Steel rule, Wire brush,
Ball peen hammer, Chipping hammer, Chisel and Grinding machine.
Sketch
Operations to be carried out
1. Cleaning the work pieces
2. tack welding
3. full welding
4. cooling
5. chipping
6. finishing
Procedure
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from rust, dust
particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table such that, the L shape is formed.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the pieces the arc is struck and
the work pieces are tack‐welded at both the ends.
7. The alignment of the corner joint is checked and the tack‐welded pieces are reset, if required.
8. Welding is then carried out throughout the length.
9. Remove the slag, spatters and clean the joint.
Result The Corner joint is thus made, using the tools and equipment as mentioned above.
EXPERIMENT NO:18
Aim: To write Part programme for plain turning for given work piece by using C.N.C lathe.
Tools & Equipment : CNC Lathe machine, Computer
Programme:
N5
N10
N15
N20
N25
N30
N35
N40
N45
N50
N55
N60
N65
N70
N75
N80
N85
N90
T1
MO3
GOO X 2.375 MO8
Z 0.1
GO1 Z-2.0 F0.015 (Feed to Z-2.0 F 0.015 mm/vav.)
GOO X 2.5 Z 0.1
X 2.25
GO1 Z-1.75 (Feed to Z-1.75 at same feed rate)
GOO X 2.375
Z 0.1
X 2.125
GO1 Z -1.5 (Feed to Z-1.75 at same feed rate)
GOO X 2.25 Z 0.1
X 1.875
GO1 X 2.125 Z -0.125 (Feed at same feed rate)
GOO X 4 MO9
Z3 MO5
M 30
Result: Wrote Part programme for plain turning for given work piece by using C.N.C lathe.
EXPERIMENT NO:19
Aim: To write part programme for step turning for given work piece by using C.N.C lathe.
.
Tools & Equipment : CNC Lathe machine, Computer
Programme:
N5
N10
N15
N20
N25
N30
N35
N45
N50
N55
G5A LF (setting wor zero)
G94
G90
LF (Feed mm./min)
T1
D1
LF
S500
M04
LF
GOO
X20
F100 LF
GO1
X20
F100 LF
Z-20
LF
Z-30
LF
GOO
X100 Z100 MO9 LF
M30
LF
Result: wrote part programme for step turning for given work piece by using C.N.C lathe
EXPERIMENT NO:20
Aim: To write a part programme for threading for given work piece by using C.N.C lathe.
Tools & Equipment : CNC Lathe machine, Computer
Programme:
N10
N20
N30
N40
N50
N60
N70
N80
N90
N100
N110
N120
N130
N140
N150
N160
N170
G90
GOO
T3
G54
GOO
GO1
GO2
GO1
GO2
GO1
x75
GO3
GO1
GOO
M30 LF
G95
GS3
D3
S3000
x 25
x 25
x 25
Z-3.75LF
x 50 z-50
x 62.5 LF
Z-62.5 LF
Z-75 LF
X100
X100
X 101LF
G53
G71
DO x 180
L
MO4
Z1
ZO
Z-25
(P4)
I 12.5
(P6)
(P7)
(P8)
Z-87.5 IO
Z-100 LF (P10)
(P11)
DO
Z300 LF
FOZLF
LF(P1)
LF(P2)
U12.5 K-12.5 LF(P3)
KO LF(P5)
K-12.5 LF(P9)
X 180 Z300 MO5 LF
Result: wrote a part programme for threading for given work piece by using C.N.C lathe.