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LABORATORY MANUAL

MEC224

MECHANICAL ENGINEERING WORKSHOP

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TABLE OF CONTENTS

S. No. Title of the Experiment Page No.

1 To perform taper turning using tailstock offset method 3

2 To make a job of eccentric turning on lathe machine. 7

3 To make a job with drilling and boring operation on lathe machine 10

4 To prepare a job on Surface Grinder / Cylindrical Grinder and measure the various

parameters of the finished piece.

14

5 To make a job on lathe machine with internal threading and external threading 17

6 Exercise on milling machine to produce a spur gear 21

7 Graph plotting of variation in hardness at different zones of job after welding with TIG and MIG welding

24

8 To join two metal sheets of 1.5 mm thickness through the spot welding

27

3

JOB 1:- To perform taper turning using tailstock offset method.

MACHINES/EQUIPMENTS/TOOLS USED:-

MACHINE USED: - Lathe machine

MATERIAL USED: - M.S round bar 25mm diameter.

TOOLS USED: - Marking block, facing tool, steel rule, vernier calipers and out side caliper.

LEARNING OBJECTIVE: - To learn taper turning operation on lathe machine using tail stock offset

method

OUTLINE OF PROCEDURE:-

1. Take a circular bar of diameter 25mm and 65mm length and hold it in 4 jaw chuck.

2. Turn diameter as 22mm and according to dimensions given turn required diameters.

3. For taper turning set the tail stock off-center (adjusting the axis of rotation)

REQUIRED RESULTS:-

1. To know the nomenclature of single point cutting tool.

2. To analyze the turning operation on lathe machine.

4

CAUTIONS:-

1. Do not change the gear while running the machine.

2. Concentrate on job while machining.

3. Do not check the size of job while machine is running.

4. Set the speed as per required.

LEARNING OUTCOME:- to be written by the students in 50-70 words.

5

Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

6

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the procedure/apparatus. (process sheet)

20

2

Dimensional Accuracy, Finishing and Learning

Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

7

JOB 2:-To make a job of eccentric turning on lathe machine.

MACHINES/EQUIPMENTS/TOOLS USED:- Machine used: - Centre lathe

MATERIAL USED: - Mild steel

TOOL USED: - Surface gauge, steel foot rule, odd leg calliper, turning tool, smooth file, dot

punch

LEARNING OBJECTIVE: - To learn eccentric turning on lathe machine.

BEFORE MACHINING AFTER MACHINING

PROCEDURE:-

Take MS round piece of 32mm and cut the piece of 62mm. Face & turn the job 30mm &length 60

mm. Now mark the dot punch at the centre of the faced side and paste the chalk on that side and with the

help of divider make a circle of 15mm at side of chalk paste. Now hold the job in four jaw chuck lathe for

eccentric turning aligns it with help of surface gauge and scribe around the dotted circle. Now turn the

work piece at the centre of work piece i.e up to 30mm.

SCOPE OF RESULTS TO BE REPORTED:-

1. To know the operation of eccentric turning on lathe machine.

PRECAUTIONS

1. Align the job properly in the 4 jaw chuck.

2. Set the cutting tool in the centre height of job.

3. The depth of cut should be minimum; it should not be more than 0.5 mm.

4. Do not change gear while lathe is running.

5. Lock the compound slide for the threading operations.

6. Clean the machine after the completion of job.

LEARNING OUTCOME:- to be written by the students in 50-70 words.

8

Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

9

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the procedure/apparatus. (process sheet)

20

2

Dimensional Accuracy, Finishing and Learning

Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

10

JOB3:- To make a job with drilling and boring operation on lathe machine.

MACHINES/EQUIPMENTS/TOOLS USED: - Lathe machine

MATERIAL USED: - M.S round bar 25mm diameter.

TOOLS USED: - Marking block, facing tool, steel rule, vernier calipers, out side caliper, drill

(12.7mm), boring bar and depth gauge

LEARNING OBJECTIVE: - To learn about drilling and boring operation on lathe machine.

OUTLINE PROCEDURE:-

1. Hold the job in 4 jaw chuck and align it properly.

2. Set the facing tool and maintain the job length as 40mm.

3. Set the drill in tail stock and start drilling operation.

4. Make a hole throughout the job and set the boring tool and start boring operation.

5. Maintain size as per drawing.

REQUIRED RESULTS:-

1. To know the nomenclature of single point cutting tool.

2. To analyze the turning operation on lathe machine.

CAUTIONS:-

1. Do not change the gear while running the machine.

2. Concentrate on job while machining.

3. Do not check the size of job while machine is running.

4. Set the speed as per required.

LEARNING OUTCOME:-

To be written by the students in 50-70 words.

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12

Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

13

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the procedure/apparatus. (process sheet)

20

2

Dimensional Accuracy, Finishing and Learning

Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

14

JOB4: - To prepare a job on Surface Grinder / Cylindrical Grinder and measure the various

parameters of the finished piece.

MATERIAL USED: - M S sq. 65mm X 16mm X

16mm.

MACHINES/EQUIPMENT/TOOLS USED: - Surface grinder, Micrometer, diamond dresser,

vernier caliper.

LEARNING OBJECTIVES: - To perform different operations on surface grinder Machines,

cutting of specimen, measuring marking and product finishing on grinder Machines.

Sketch:-

OUTLINE PROCEDURE: - Hold the job in the center of magnetic chuck and take a sketch of the

specimen and work upon it by measuring the dimensions as per sketch. List down the steps of

operations and then used different tools as per the requirement.

SCOPE OF RESULT TO BE

REPORTED:-

i. Observed dimensions as per sketch.

ii. To know how to perform different operations on Machines.

PRECAUTI

ONS:- i. Clean the magnetic chuck before starting the operation.

ii. Set the job firmly in the center of the magnetic chuck.

iii. Depth of cut should be minimum 0.02mm.

iv. Sprinkle the coolant at tool and wok piece interface.

v. During working, never wear loose clothes.

LEARNING OUTCOME: - Student will know how to perform different operations on surface

grinder machines.

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Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

16

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the procedure/apparatus. (process sheet)

20

2

Dimensional Accuracy, Finishing and Learning

Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

17

JOB 5:- To make a job on lathe machine with internal threading and external threading. MACHINES/EQUIPMENTS/TOOLS USED:-Lathe machine

MATERIAL USED- M.S. pipe 50 mm, and M.S. round 25 mm

TOOL USED:- Surface gauge, facing tool, boring tool, threading tools, screw pitch gauge, steel foot

rule, and vernier calliper.

LEARNING OBJECTIVE: - To learn internal and external threading on lathe machine

BEFORE MACHINING AFTER MACHINING

PROCEDURE

Take a MS. pipe 2”*40 mm. Hold in 4 jaw chucks and align it properly with the help of surface gauge.

Set the boring tool and maintain the size …… mm. Set the threading tool and leaver of lead screw at

11 T.P.I (B.S.W). Set the depth of cut and threading is done until you get the required depth. Unload

the job. Reset the job from face side and mark of length 35mm. Face the job up to length 35mm.

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FOR EXTERNAL THREADS: -

PROCEDURE:-

Take a MS Round . 25mm*115 mm. Hold in 4 jaw chucks and align it properly with the help of

surface gauge. Set the turning and maintain the size as per drawing and set the drill chuck in tail stock

spindle and do centering operation . Set the threading tool and leaver of lead screw at 8 T.P.I (square).

Set the depth of cut and threading is done until you get the required depth. Unload the job.

SCOPE OF RESULTS TO BE REPORTED:-

1. To know geometry of boring tool.

2. To know internal and external threading operation on lathe machine

PRECAUTIONS

1. Align the job properly in the 4 jaw chuck.

2. Set the cutting tool in the centre height of job.

3. The depth of cut should be minimum; it should not be more than 0.5 mm.

4. Do not change gear while lathe is running.

5. Lock the compound slide for the threading operations.

6. Clean the machine after the completion of job.

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Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

20

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the procedure/apparatus. (process sheet)

20

2

Dimensional Accuracy, Finishing and Learning

Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

21

JOB-6 Exercise on milling machine to produce a spur gear. MATERIAL USED:- Cast iron.

MACHINES/EQUIPMENTS/TOOLS USED: Horizontal milling machine with dividing head,

Involute cutter 16 DP -o3, Vernier caliper, Dog carrier, Spanner set, Depth gauge.

LEARNING OBJECTIVES:-To produce gear teeth using milling machine

OUTLINE PROCEDURE:- Hold the job in mandrel and adjust the table in the centre of slotting cutter then set the depth of cut, feed the job against rotating cutter and take a sketch of the specimen

and work upon it by measuring the dimensions as per sketch. List down the steps of operations and then used different tools as per the requirement.

SCOPE OF RESULT TO BE REPORTED:-

� Observed dimensions as per sketch. � To know how to perform different operations on milling m/c.

PRECAUTIONS:- � Do not carry tool in your pockets.

� Follow the operative instructions given strictly. � Always remove chips by brush, Do not remove by hand.

� During working, never wear loose clothes. Always wear fitting clothes. � Always use correct speed & feed.

LEARNING OUTCOME:- To perform gear cutting operation on milling machine.

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Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

23

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the procedure/apparatus. (process sheet)

20

2

Dimensional Accuracy, Finishing and Learning

Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

24

JOB 7:- Graph plotting of variation in hardness at different zones of job after welding with TIG and

MIG welding

EQUIPMENT REQUIRED: MIG and TIG welding machines, Hardness tester

MATERIAL REQUIRED: M.S flat

LEARNING OBJECTIVES: The objective of this work is to identify the part of a weld joint that

exhibited irradiated weld joint tensile specimen and investigate the mechanisms occurring by analyzing

the corresponding microstructure.

PROCEDURE AND OUTLINES

a First of all we will take the mild steel pieces and weld the mild steel pieces with the

TIG and MIG welding.

b The various effects will be read out with welding in the different zones.

c Then take the readings at different zones.

d Then again check the regions after the welding.their are various HAZ after welding with TIG and MIG we check the hardness at various regions.

e Then plot the variations of hardness at different zones.

SCOPE OF THE RESULTS TO BE REPORTED: To understand the working of various operations by TIG and MIG and analyze the hardness at various

levels.

CAUTIONS:

a Always wear shoes while performing the practical.

b Do not wear bangles, bracelets, rings, chains, and even neck tie.

c Turn off all equipment when not in use.

d Do not drape cables over your body.

LEARNING OUTCOMS:

To be written by the students in 50-70 words.

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Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

26

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the procedure/apparatus. (process sheet)

20

2

Dimensional Accuracy, Finishing and Learning

Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

27

JOB 8:- To join two metal sheets of 1.5 mm thickness through the spot welding

MACHINES/EQUIPMENTS:- Spot welding machine.

MATERIAL USED: - Two metal sheet of thickness 1.5 mm and length 100 mm.

TOOLS USED: - Marking block, Hammer, Chisel, , and sand paper

LEARNING OBJECTIVE: - To learn spot welding a sheet metal

OUTLINE OF PROCEDURE:-

1. Initially cut two mild steel sheets of length 100 mm each using a hammer and chisel.

2. Clean using a hammer and chisel.

3. The face surface of the sheet are being finally rubbed with a sand paper.

4. Then the welding parameters according to the thickness of the sheet are calculated.

5. Then the two sheets are made to overlap up to correct length and finally the overlap region is

placed between the electrodes.

6. As the electrodes are being pressed with the help of paddle the circuit gets completed and a nugget

is ground due to heat offered due to resistance between the sheets.

REQUIRED RESULTS:-

The mild steel sheets have been perfectly joined by the spot welding process.

CAUTIONS:-

1. Welding parameters play an important role in deciding the quality of weld, so must be calculated

properly.

2. The paddle faces at the sheet must be properly cleaned with the help of sand paper

3. The paddle must be kept pressed until whole of the nugget formation takes place.

LEARNING OUTCOME:- to be written by the students in 50-70 words.

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Process Sheet

Workshop Name: Date:

Name of Student: Section:

Roll No.: Registration No.:

Job:

Drawing:

S.

No.

Job

Specification

/ Dimension

Operations Tools Used Equipment/Machine

Used

Remark

5

29

Learning Outcome:

To be filled in by Faculty

S.No.

Parameter (Scale from 1-10, 1 for very poor and

10

excellent)

Marks

obtained

Max. Marks

1 Understanding of the student about the

procedure/apparatus. (process sheet) 20

2

Dimensional Accuracy, Finishing and Learning Outcome.

20

3 Completion of experiment/job, Discipline and Cleanliness

10

Signature of Faculty Total marks

obtained

30