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ICHAPTER INTRODUCTON OF M .1
11 MEASURINGTOOIS ,2
.3
VernierCa lpe.
vernier Ne sht Gause 11
Stee Ruer
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12 TOOISBTSCUTTING
1l oPERATTON N TATHE MACU Nt.......... ................. 2
14 OPERATION N MIIIING MACHINE,,,, ,,,,,,,,,,,,
15 OPERATION N BENCI] GRINDER .. ...10

N 5URIACE CRINOING 23
33
CHAPTER2:SEMESTER 1(DKM AND DTP )
ll I
2.1 FTTTTNG...... .....................

2.1.1 Diaeram............ .............
2.1.2 FittingPro.ess.,.......................
2.1.3 Asesment...............................

22 MACH1NNG....................................

2.2.2 MachlnngPro.ers..................

CHAPTER 3 : SEMESTER 2.......

31.1 Dracram................
112 lvachining Proces

2] MANUfACIUR N6,,

3 2.2 Ma.hi^i^g Pro.e$

CIAPTER 4 SEME5IER ],,,,,,, 62
41 I/ECHAN CAl........ . ---.72
4.12 Ma.hinlng Pro.e$

4.2.2

CHAPTER5 SEMESTER4

5 2 Ma.h n'nEPro.e*

1 1, Dagram M dometer..... ............. 2
1.2 Howto Read Mi.rometer 2
r-3r DaSramVerni€rCalper 3

14 Howto Read Vern er Ca ipe. I

r-5 DiaeramvernierHeiehtGaue€.... .12

16 r Oiasram 5ree Rurer I

r 7:cultn3. ....................... 12
L3
13: cuttinEToo 5hapes. ..... 13
14
19: Too BtGeometry ...

1 10: ToolBilAng e

11r: LatheMarhlne

112: Miling Mach ne

1.13 : Bench Grinding Ma.hine
1 14:5uda.e Grlndiig Marhine .......
1 15 : Cy indri.al 6rind nB Machine.

2 1 Taps thread ngtools.

2 2 DlesthreadinEtoos..
2 3 td.nEPrccest..........

23:SteppedTurninc.............,..............
2-9 : operat on Relat€ToTurning............
2-10: Kdur nE Pro.e$.......
2 11 : Knu.l n9Too1..........

2-12:(nurln3P t.rn.......

risure 3 3: Ihree and Four.law chu.ks 35
Ficure3.4 ParalelTurnns Z6

5Fsure3 Stepped Turnln3..... .. 33

Feure3 6: BorinE Proce$
rigure3 7:cuti^3Too M 1in8Ma.h]ne.......................
tiSure3 3: Mi ingMach ne Proce$ .
FisureS 9,Milingolcrooves..............
FlCure3.l0 SpurGear .
Frsure 3 11: Applicarlons ofspur Geat ..........................
F Sure 3.12: Advantages & DGadvantases OfSpurcear
tiCUre 1.13: ndexing olGear
fisureS 14 ErampeCa.uarronrndexinsof Gear.........

4-1r ChamlerCutt ns 63

4 2 ThreadCuttincToo 3t..................... 13
4 3 V 5hapedftread Curter..................... .....................................15
............................................76
4 4: Angle Thread Cutt ng Gauge Too
4.s : S.rew Pir.h GaugeThread.................
4 6: ExternalThread Curung

4.7 External and!nterna Thread Cutuns

4 3 Co^tourinSMil ncPro.e$.........
4 9 HelxGearProce$.............................

4 10 Typeof Gear....................................

Fguresl: nderpateandsedo

figure 5 2: SpurGear

cticure 5 r: App tat onsol spur

risure 5 4: Atlvantase5& Di5advantases of tpur Gear

tiSurp 5.s: rndex neofcear.............

fisure 5 6 Example Ca cu ation nderins ofGear ....

CHAPTER 1 : INTRODUCflON OF MACHINING

Themicrometercalperusualyca edthomi.roneter rthenon.ommonly
usedm.asuriiEii*rumentwhenaccuracv srequired

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IFCure r D.B dm M.rometer

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5.a7m r 1,.idtrc to ne rcsl onc-\undEdrh

Fisure 1 2: lowlo n€ad Micrometer

verniercalper are precision tools used to make accurate measurefrena to
within 0.02 mm or 0 001]n, depend n3 on wherherthey are metric or inch they
cons n ofan t-shaped bar and movabe jaw wh.h areEraduated on both 5d€,

one sde lor takng outside measurefrenr and the other sde for inide

Jaws (for measuing hner d,mension

Jaws (for measu ns oulerdimension)

tigure 1.3: Diagran Vern erCa iper

The reading hete is 15.8 mm or 7.58 cm.

Fisure 14: Howro R.adVernierCa ioer

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1.1,3 vemi€r Heisht cauge

The Verner he sht gauge is a pre.i5ion instrument used in too roomsand
nspeclion departments on layoutandjieand frture worklo mer5ure and mark

g8sc8 [ody-

mlcr0lnchln0 0cllng scr€ur

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mcosurttrfctsws ie

F gure 15I Dia€ramVernier He ght Gause

A ruler, sometimer a rite or ineEause, is an tnsrruhent used tn e.ometryi
technical drawing, print ry, a^s neering and bu tdine to measure d nan.e or to
rule(raight ines The ruler k a stra shtedge wh ch may a so contain.atibrated
lnes to measure dktance.

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FlSu/e 1 6 I 0 aeram sreel Ruler

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1,2 TOOts BIT5 CUTTING

Atoo bnis a non rotary curuB too used inmetaL Lathe5, shape6,

andpaneB. Soch cuttets are ako often refeii.d to by the ser phGse name
ofsnCle.pont cutung tooL, as dBtngush€d from other.urtng tool5 su(h a5
a saw orwatarjetcutler.Ihe cutrinSedge ksround torulla part cu a. ma.hi^inc
operation and may be resharp.ned or reshaped as needed. The sroundroolbt is
h€ d rgidlybya toolholder whie t i5.uttiry.

orgnally, altool biB were made olhlgh carbon too neeswth the

approprktehardennCaidtempernC since the introdudlons of h gh speed

stee (Hsi)(earLyyea6olthe 2oth centu ry), [email protected] dell930s), ceramicand
d amond.utter.those materD s have qradua!lv replacedtheearLler klnds oftool

neel n a mon al.urtB applicauons. Mosl toolbits todav are made ol Hss,

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Fisure r 3r colung Tool ShaPes

Tool Bit Geometrv

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Fisure 1 9 : Tool Bil Geometry

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Frcure 1 10 loo BitAig e

1,3 OPERATION IN TATHEMACHINE

Component Des. Ption

Fgure 1.11: lathe Ma.hlne
Explanat on of the standard cohponenkot most lathes:

usua v made ol.ast ron. Provdes a heaw r c d frame on whi.h al the ma n

compone^ts are mounted.

nner a^d outercuide raislhat are preck on machlned para le to a5sure
moonted ln a lixed orsiuon on the innerways, usua lvat the left end. usins a

chuck, rohterthework.
n5 de the head{o.k, providinc mu up e speeds wth a geometrc rauo bv

Ho e rhroush the headnock to whth bar *o.kcan be fed, which alows shalts
that are up to 2 timesthe length belween lathe cente6 lo be worked on one

I jaw (self@nttrhc)or4 Fw (independent) to . amp part bp nc harhiied

a lows the mounting oI dlffcu t wo*pieceslhat are not round, square or

F tson lhe innerwavsofthe bed and.an s idetowards anvposiuonthe
headstocItoJit the ensth olthe wor( piece. An optionaltaperurn nC
atta.hment would be mounted to it.

Nas a Mo6etaperto hold a lathe center, d lbitorothertoo

Moves on the outerways. used for mount ns and movidg monthecutt nC

Mounted on th.traveEe d d€ ofthe ca age, and uses a handwheeltoleed

To nou^t toolholdeG in which the cutlrnc bitsare clatrped.

Mount€d to rhe.ro$ dide, t pivoaaround the too po{.

attsched to thefront ofthe.aft a8p, it has the me.han sm and contro sfor
movnsthe carase and cro$ s ide

Ha5a keywa, w th two revere ns pin on sea6, eitheroiwhkh can be meshed
withthenati^gbeve Ceartoforwardorreveuerhe.araseusnsadutch

when. osed around the ead screw, the.arlase G drven along by d rect drive

Controkthe mov€menl ofthe carriage using eveE.

Clamped 1o the athe ways, it uses adiustable finge6 to contadrhe workpiece
and align it. can be u5ed i^ Olace oJtaistocIorin the m ddle to support long or

unstable pans being mach ned.

Bolted to the lathe cariaee,lt uses adlunable linge6ro bearagalnst the
workp e.e opposite the cuttinC tool to prevent de, edion,

l',lillng sa mechanical ma.hlne wh .h r used to frachi^ed unsydfret cal
lob t nwide y used ln too and die making ndustrles.lt is a versari. ma.hlne. L

canp.rforfr al operaridns ikerurnins,facns,drilns,shapnsan.l€rooving

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ticure112: Miling Mach ne

Exp anation ofthe nandard components ol most miling ha(h'nes:
tisfoundationpartof amilinsma.hine.Allotherpansarelointedonit ft camer

the entire load so nshou d have hgh compre$ve strencth so tis made by cast

iron lt a so works as resenoir of.uttinsfuid.
Column !anotherloundationpartof mitinEma.hine.tt smountanverticatyon
the base.lt supports the ltnee, tabe etc. Work as houstry for rhe atlthe other

driving nembei t s a holow m.mber whi.h .ontans drvng gearc and

sometimes motor for soi^d e and thetable.

Knee Bthef 6t mov ng part offrilins mach ne lf G mounted on th€ co umn and
moves alonS the s ideways situated overthe.olumn. t is made by can iron and

Imove5 vert ca yonsideways movesup and down on d dewavs whi.h chanFe

th€ dnan.e hetween tooi and workpe.e. rt G driven by me.hanicaty or

ttr oh.ed between tab e and the hee and workas nrermedate part betw€€n
them ltonmovestrarovecalvtothecoumnface jtdrdesoverthesuldewavs
whch G perpendkular to lhe rolLimn face The
p.ovided situated on the knee mouon in horronta dtect on to work pie'e
lL k
m:i nmdion of rt s to dovide

Tabre ssituatedoverthek^ee.ltkthepartof ma.hinewhi'hholdtheworkpie'e
whllemachlnng. tismadebycasiironandhaveTsorrutoverll Theworkprece
. amp over it by using clampin8 bots Theone end of c amping bolt flx into this
slol and other isllxtowork pLe.e which holdthe work piece lt can provide lhree

deeree olieedom lowo'i Plete.
I o.o, d.1,e,'i!a ro.io- ovnovnSrre ncctoanodo*-

i ltDrov,deshorzontalmotronbvlhefeedsnew

rt is stuareJm,tne coumn on horizontaL mi !inE mach ne t isoverhans over

theco umn surface and othersupport5the arbor' lt k made bvca* iron'

$ nl. r me md n om or r . .r ' s-, ora e n 'Pn{J
n l1p rd-'tr P rd Fod ' bor '_ ho' ro''alr'r 'g ndrr nr
whi.h kin rotarY mdion. Lt i5motor drven and drlvesthetool thasa sLotonthe

front end olit The cutllng looLiir inthat s ot.

rmtisiiimnsem.haa.nhi.ianlepatas(ofit^twedhocnhthseusspeinddaeswexhteenne5vloenrrpeaqrutoirlethdesprhnd'llde!lhnehtooro'onatnad

moves n n conect d re.rion

This is used to support arbor at right pla.e. One end ofrh s support sjointed al
the overhangins arm and another isro nted with arbor'

., .*",""" *"."r-,r.u-.,hnc ".o'''. ordP.d' \ nSToro'"ndorhq

RamkworkasoverhanBingarminvertcalmi inEma'hine on'endof thearm

< ata.hed to the coLumn and otherend rorhe miling head'

1.5 OPERATIONINBFN'HGRINDFA

Bench er nd€r, wh ch usua ly ha5rwo wheek ofdifferent grain snes for
rough ng and f nkhinC operat ons and is se.uredro a wort6en.h or ftoorqand
la u5e5 inc ud. shaplnc too b a orvartous too I that need ro be made or
repa red. Ben.h grndec are nanualV operated.

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Fisurel.13 r Bench Grind n3 Ma.hine

1.6 OPERATION IN SIJRFA'IGRINDING

Surla.e gri^dlns is th. frosr common of the srind ng operations ft is a

finish ig processthar uses a rotating ab.as vewheetro sfrooth thefatsurfa.e of
meta i. or no^ meta lic matorals lo sive rhem a more rel ned ook by removing

the oxlde layer and lmpurities on wo* piece sudaces. rhis wlt a so attain a

des red surta.e lor a fun.tionat purpose.
Thesurfa.egrnder scomposedola.abrasivewheet,awo*hodinsdev.e

known as a chuck, and a recipro.atin8 or rotary tabl€. The chuck hods the

material in place whle tt is beiru worked on tt.an do thi5 one of rwo

ways: le.romagnet . pieces arc hed in ptace by a maenet. .huck, whte non.
fetromasneticandnoi metat cpecesarehetdtnpta.abyvacuumorme.hanicat

means. Ama.hne vke(made from Jetromasnetcstee or.a{ iron) pa.ed on

the masnetcchu.kcan be used to hod nonje(omasnetc workpie.es ilonty a
macneti..huck savailabe

FactoEto.onsderinsurfa.egrndingarethematerialof thes ndingwhee

and the materia ofthe pie.e be nSworked on
Ivpical workpie.e mat€ as inc ude cast kon and mld steel lhese two

maierlas donl tend to .oB the srnding wheel whie belng processed other
materaG are aluminium, staliles! neel, b'a* and some p a* e. wh€n Srindins
al hish temperatures, ihe materaliendi to become weakened a.d i5 mor€
n. ined to corode This.an also result n a lo$ ofmagnet sm in materakwhere

The grndins wheel s not limited to a .ylndr.a rhape and can have a

myriad oioptionrthatare usetulii transf.rine dillerentSeometriestotheobj€.t
beins worked on Straisht nhees can be dre$ed by the operabrlo produce
.u5tom geometres when surfacegrindingan object, one must keep n m nd that

rhe shape of the wheelwilbe tranefetred to the m eria of the obled ke a
Sro* outG a tern used whei preckion vauei are sought and ne6!

means untilthe sparks are our (no mo.e) lt i^voves ptrsins the workpece
under the wheel, w(hout r.sett ns the depth ol cut, hore than once and

gene.a ly mutiple rimes. ThG ensure! that anv inconsistpn. es in the ma.hine or
workp e.e a.e elimlnated.

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FiCure 1.14 Surfa.e Grindine Mach ne

1.? OPERAIION IN CYLINDRICAL CRINDING MACHINE

Wo* whth s to be I n shed on a.v indricalsrnder isAenera lv held

belween.entres, but nayalso bo he d in a.hu.k for certa n tYpes ofwork
There aretwotype5 of.y indri.al srinde6, the plain and the uiiveuai. The
univ€EalcyindftalSrnder smoreve6atle,sn.eboththewheeheadaid
headno.k mav be swiveled.

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Fgure 1 15: Cylindri.alcrndlneMach ne

Exp analion ofthe standard compone^ts of most grindinE fra.h nes:

to provtde rieidity. rhe top of th. base s

mach ned ro Iorm the ways for rhe table.

Mounted on a no$ s id. at the back ofrhe ma.hine. The lvays on whth it i5

mounted are at riShr ansles to the tabeways, permitring the wheethead ro
be fed towardsth€ tab e and the work, eitherautomatica y o. by hand.

Mounted on the ways, s drtven back and forth by hydrautc. The reveBa of
the tabe scontroled bytripdoss. Therabb G composed ofthe towertabe
which rests on the ways, and the upper tabt€ whi.h oay be swiveted tor

srind ngtape and alsnment Du.ooses

Un t G mounted on the reft end ofthe tabre and contains a frotorfoe rotating

the wo* Adead centreBmounred in the headsto.k spind e

Supports the riehr end ofthe work and Badjustabte atonethe lensth ot the

tabe. The dead cetrtre o^ which the wo* ir mounred, is sp.ine oaded lo

provde the propercentre tens on on the workpiece.

Provides suppo for long, send.r work and prev.nts n from springry.

iOotward and downward movement otthe wodpiece s prevented bv means

oi od J.r.b d,,poorlr r onr o, ano be ow rhc 4o4p pi e

Which re5embles a lathe steadyrest, may be mounted at anv ponls on the

table. t 5 us€d to support the rlght end olthework when.rternalSr nding is

conlined tothe end of the workplece.

Mount€d on lhe whee head on most machi^es for inlernal grindins lt is
usuallYdrlven bya sepamte moto.

C amoed to the tab e to dre* the grlndins wheelas requted. on sametypes
ofBrnde6, d amond dressetsmaybepermanent y moumed on the footsto.k.

k buit intoalLcylindricalgrinde6lo prov dedustcontroL,temperaturecontrol
and a b€tter sudace I nish on rheworkp ece.

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CHAPTER 2 :SEMESTER 1( DKM AND DTP )

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Taos are culuns took used to .ut nternrthreads.Ihevare madcfrom
hiChqua tytoo deel, hardener andEround

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Flgur€ 2'1 Taps threadinstool5
Th.eadins dies are used to rut €xterna threads on round. The most

common threadlry des are the sold, adjustabe sp t and the adiusrable and

removab e screw p ate dles.

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F gure 2 2: Dias threadinslooG

Pdd G ra+ (2)-PLO4,cror
Ptudc rasr (6enericstrrs 1)lLD5)-PLos, cLo2
Pradkal Task (ceneric skil s 2 XtD3) PLo3,cto3

. Fo ow salety procedures in fitting workshop.
t Measore workpiece usinC:

d. Verilerhe shtgaoge

Mark out paral eli vert .a a^d dtJlerent anCutar ines on a wo*p ece using

. lse the cored fiLes to torm surfa.es
. Remove materialusinsvar oustypes of.hBel5 and hack saw
. Mark ourand dr llholes usin8 a hen.h dr tnsma.hine.
. Produce lnternal and external Metric V'th/eadsus ng

Measur.f nished product usingapprop ateneasurement nnruments
Keep the workshop .lean and 5afe.

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when fa. ng, the compound rest nav be set 3oo (to the .ros eLlde) rhe

side movemsnt of the cuttingrool s always haft the amount of the compound

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ticure 2 3: FacinE Proce$

Centredrlllns wo.kto beturned betweenthe on a lath' mu* have
cenrres ro ent'ee,n.trAecohhinarion drilland
noLJ,,l"i *a r",,r. tarhe
" " "r.r. 'Pdarentred1i r\r ro .L Fope "rior

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fisure 2 4: centre DriLlPro.e$

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CENTPE DP,II'I

FiSure 2.s : centre DrilTool

UNIVERSAL CHUCK TAILSTOCK
SFINDLE

DRILL CHUCK

U l/Y0Rl(

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CENTERDRILL

Fisure 2 6: Centrc DrillatheMach ne

Work is Een€ral y machined o^ a athefortwo reai.n: to rut t to sne
and to produce atrue diameter. Workthat musl be cutto s zeand havethe same

d ameter along rhe ent re ength of the workpie.e nvoves the opeGtion of

I

frBUre z 7. PaGle Turnine

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Figure 2 3 r StePPedTur^ing

c I ons

Contour turftng Chamferinq

1 InI '*

nqFac Taper turnrnq Form turnlng

1 Knuiing

Cutoff Thrcading Boring Drilling

F sure 2'9: operat on Re ateToTurnins

lGurinC is a proce$ of mpressinc a.tkmond rhaped or nraighr ine
pattern into rhe surface ofthe wo*pie.eto improve itsappearan.e orto provide

abetrersrppinCsu a.e Straghtknuninsisoit€nusedto ncreasetheworkptece

d am€t€r when a press fit is required

Kn u rlin g

Fgure210 (nur nC pro.e$

Flgure2 11 (nurinBTool

5IRA16HI AN6UTAR 0rAi0N0
PATIERN
PAIITRN PATTERN

tiCure 2 L2I (nurli^gPattern

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Piactft ra((2) PLo4,cro1

Pract.a rask(cene .skls 1)lLDs) Plos,cto2

Pract ca rask (ceneric sk I s 2 )(toS) Pto8, cto3

t tollow the saJety procedores in machtneshop.
. Grindtoo bits(ofi handBrnding)a.cordiistothe required geometri.
. Ope.atethe athemachne,seect5piidespeedsandfeedr
. Op.rate aihe mach nelor:

d. Taperturniru centre drlling

Measu.e workpie.e by usingthe fo low ns instruments:

Keep the workshop . ean and safe

Pradt:lr:!k 1- Tool Bit

SCBEME]RUBRIC PRACTICAL TA

IE@r@EEE I I III III
I
rrrrr I III
I
I I II I I II

IIII II rIrIII I

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PE.ticalIas* 2 Proi.(t/ RePon

scHEME]RUBRlcPRrcncALTA
srudent Name & Matri. No:

1)
z)

r)

I I I3

Re@ ods s! relod {trm. r rut d

8!!e4

rte l.over aisienment bue.olour)

Lathe Ma.hlne and advantages

Name in.0de pictures ofequipment
51 usrneaooe e wh le operat€s the machine
52

wear nBapproprDteartre

tu ldes(npt on of the pro.r$

Each 5tep ofwork!hould be ln.luded w th

r.dudenBuF/pdure/d'asram

Meetthe sDec ficallon and toleran.e
Moer the n€eds ol rhe obi€(t vPs
student ab e 1o op.rares lathe machine
Commenron safetypro.edurcs

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CHAPTER3:SEMEST€R2

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+( ('+ al)

:i (-)

L^

Groov.s{andoihertorh cutrinEproce$€risoneorthemore.ompi.ated

operat ons performed on the engtne tathe. The c,u,ffteingeto,f groovej often requnes

high evek ol pre.son, and a lor the machine.

Ahhough theory di.trtes a frerhod oJ seeclion of rhe.ored speed and feed,
!eanoc{oP, 6.
.onFriac! p.ar

Agroovekthe ocalionofan ndentaton in the paft.Ths ndentarion.an

Jwb"'hoe,nor€r.a.on"oo.trh.oeorr.p"oado'1f' .at'Cs sno.totddth1i.5pra-rt4.c.ocov-ebsoa-troO,p.,.rronovSi.nd[eoa.oreLdtgide.lodtoonFtbh!e",b...ad"cktp,sLod,ee

ofa thread wherethe thread rerm nates

l*{

.1.

Fsure3 1, CutGroove Procp$

I[

7

,/

t

FiEure 3 2: BoreHole Proces
Three.jaw.hucks,of thesamegeneia typeusedtoholdbtsinmostpower
drllk, are aho .ommon equpment on metaworkins lathes. Thoueh it is not
nece$a.ly$, three.jaw chucksare so commonlyofthe self.enter nSvariety, in
whi.hthejawsare not ndependent yadlostable,that'telt'.enterins" isseiera ly

assumed from the rerm "three jaw chuck.'l

But there are dEtin.t advsntases to uslng a four-jaw.hock (which sgeneraly
a*omed, contrarwGe, 10 have independently adiustable jawr, and thouSh a
three lawchu.kis niceto have forcoiven en.eand for use wirh hexagona stock,

no{ ma.hinists find the rourjaw chuck to b€ more vemtle and usefu nthe

I 0Fronl [,lounu.q Sfioll Ch!cks

-:- llll

d tO6r r-

tigure 3 3: Three and FoLrlaw chu.ks

I

Practicalrask 12) Ptoa, cLol
Pra(t(a rarr l6ener.sr c) (LD3) - PLo3, ctos

Po orm ma.hining workson lathe

Applysafetyprocedures n the machine workshop
Cutgrooveand bor. hole uslngthe athe
Use ofthree andlourjaw chucksol athe
Use measurinEandtestiiBequipmentstocheckstraieht^e$and

Keep the workshop c ean and safe