A Laboratory Manual for

Advanced Manufacturing Processes

Third year Diploma in Mechanical Engineering Group (ME,PG,PT)

Maharashtra State Board of Technical Education, Mumbai

CURRICULUM DEVELOPMENT CELL, MSBTE, MUMBAI.

LABORATORY MANUAL DEVELOPMENT PROJECT

Item Educational Consultant/ Regional Project Coordinator Project Institution Project Period Chief Project Coordinator Project Coordinator

Team for design

Team for restructuring

Dr. R.S. Mahashabde Dr. A. R. Thete, Technical Teachers' Training Asst. Director, Institute, Extension Centre, Pune Regional Office of Technical Education, Aurangabad. SBM Polytechnic, Mumbai April 2002 - March 2003 Principal, Shri A. C. Mehta Shri N. M. Joshi, Workshop Supdnt, SBM Polytechnic, Mumbai Shri. R. S. Patil, Lecturer SBM Polytechnic, Mumbai 1) Shri A. R. Patil, Consultant, Mumbai 2) Shri S. U. Pandit, LME Fr. Agnel Polytechnic, Vashi. 3) Shri N. M. Joshi, Workshop Supdnt, SBM Polytechnic, Mumbai Shri A. R. Patil, Consultant, Mumbai Govt. Polytechnic, Aurangabad July 2004 - Feb. 2005 Principal, Shri P. V. Sarode Shri R. D. Virdhe, HOD, Mechanical Engineering, Govt. Polytechnic,Aurangabad --1) Shri V. A. Kulkarni, Workshop Supdnt. Govt. Polytechnic Aurangabad 2) Shri D.D. Deore, LME Govt. Polytechnic Aurangabad 3) Shri P. T. Kale, LME, P. L. Govt. Polytechnic, Latur ---

Course Coordinator Subject Experts

Subject Editor

2004,Maharashtra State Board of Technical Education, 49,Kherwadi, Aliyawar Jung Road, Bandra (East), Mumbai-400051, Maharashtra State, India. No part of this Laboratory Manual may be reproduced, in any form or by any means, without permission in writing from MSBTE Mumbai.

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

Certificate
This is to certify that Mr. / Ms. Roll No. , of Third Year Diploma in has

completed the term work satisfactorily in Advanced Manufacturing Processes (1542) for the academic year 200 the curriculum. to 200 as prescribed in

Place : Date :

Enrolment No.: Exam. Seat No.:

Subject Teacher

Head of the Department

Principal

Seal of Institution

Advanced Manufacturing Processes

LEARNING OVERVIEW
IMPORTANCE OF THE SUBJECT
Advanced Manufacturing process in a core practice fin Mechanical and Production engineering field. It is concerned with the various types of chip forming processes. In an industrial organization, Production of components is achieved by various operations. Each operation is part of some manufacturing process. Selection of process should be done based on various factors so that expected level of accuracy can be achieved. Incorrect process selection and incorrect sequence may lead to production of inaccurate components. Experiences in Workshop for Advanced Manufacturing Processes will be useful to the Mechanical engineering Diploma holder in industries under various job situations such as, Selection of appropriate manufacturing process for given job Select attachments. Setting of attachments. Setting the workpiece. Selection of cutting tools. Setting the cutting tools. Operate the machines with accuracy Take care and maintenance of the machines. Determine the dimensional accuracy of jobs produced. Inculcate Quality mindedness at all levels of work.

This subject is related with other subjects as - Strength of Materials, Manufacturing Process, Metrology & Quality Control, Production Engineering, Tool Engineering, CAD/CAM Tool Design This laboratory manual covers areas of Milling, Gear cutting, Modern machining methods, Boring, Broaching, Grinding and CNC machines.

CURRICULUM PHILOSOPHY
The Maharashtra State Board of Technical Education has conducted a survey of industries in Maharashtra to find out the job functions of the Mechanical Engineering Diploma Holders in the Industries. The curriculum document explicitly describes technical skills, social skills and attitudes to be developed in industries while designing this subject; the principles under theories of learning have been used. The link diagram and graphical structure is provided, which helps the students to learn systematically and also helps the teachers to use different strategies for teaching. The major important points to note for users of curriculum (as described in curriculum document of MSBTE) are : Job description and role of technician Curriculum objectives drawn from job analysis Personal development domain Social development Life Long Learner Industry related professional role Curriculum areas to develop / achieve curriculum objectives Graphical structure of the subject area Teaching learning process at curriculum level Approach student evaluation With development of technology, there are many improvements and advances in Manufacturing Processes and Equipments. As a part of these, conventional machine tools, processes have under gone metamorphic changes as per their construction, working and control by incorporating NC and CNC controls in virtually every wake this change is observed Diploma engineers being in direct contact with manufacturing should possess undertaking of advances in manufacturing areas and related equipments & processes. To make their working prominent in field, it is necessary to give basic inputs about these advances.

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Advanced Manufacturing Processes

LINK / BLOCK DIAGRAM SHOWING INTER RELATIONSHIP OF SUBJECT AREAS, CURRICULUM OBJECTIVES & JOB PROFILE.

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Advanced Manufacturing Processes

GRAPHICAL STRUCTURE OF SUBJECT AREA Third year- Mechanical Engineering

ADVANCED MANUFACTURING PROCESSES (1542)

Problems

To handle operate and routinely maintain advanced machine tools, processes with NC & CNC controls is industries / practical field with proper inputs of basic principles concepts and procedures of this area.

Procedure

To operate various machines in manufacturing like milling grinding boring, broaching etc. To maintain various machine tools, to select the proper toolings/ attachments for the above.

To operate NC/CNC machines. To design & write part program for various jobs on CNC lathe & milling machine. To select various types of tools for CNC machines

Principles

Principles of metal cutting, principle of indexing, multipoint cutting, metal finishing.

Principle of gear generation, principles of automation in machine tools, EDM, ECM, principles of port programming

Concepts

Cutting force, cutting speed, feed, depth of cut, machining plasma cutting, non-conventional machining using EDM, ECM.

Control system, computer controlled machines, coordinate systems, G & M codes, automatic tool changer, flexible tooling.

Facts

Milling machines, boring machines, grinding machines, gear manufacturing, machine tools & systems, EDM machining.

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Advanced Manufacturing Processes

DEVELOPMENT OF SKILLS
Intellectual Skills : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. To understand the principle of milling process. To know specification of milling machine. To study types of milling cutters and tools. Selection of milling cutter-shape and size. To select the attachment for the required operation. To understand the procedure of fitting the attachments on milling machine. To select the cutter for keyway milling. To understand the procedure of keyway milling. Selection of form cuter for cutting gear. To understand different Indexing processes. To select correct tool material and electrolyte. To select machine and machine tool. To decide sequence of operations. To select proper type of fit. To know the difference between absolute and incremental systems. To reduce programming time and efforts used for canned cycle. Use the codes, which are exclusively used for canned cycles. Knowledge of codes use in DO loops.

Motor Skills : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Mounting of cutters and tools in correct position & check it. To set the attachments on machine for holding work piece and cutter/tools in proper position. To set the attachments on the machine in proper position for the given cutters and tools To set the attachments on the machine in proper position for the given jobs. To confirm the setting of attachment for proper functioning. To set the work piece in correct position for keyway milling. To set the work piece and cutter in relative position. To cut the keyway. To check the milled keyway. To use of indexing head. Setting the machine, electrode and work in correct position. Assembly of different mating parts. Finishing of the job. To prepare part program using G & M codes. Writing program using canned cycle. Apply DO LOOPs in turning and milling operations. Writing program using DO loops.

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Advanced Manufacturing Processes

Following table gives grid of the experiments and related intellectual and motor skills. Teacher shall ensure for development of generic skills during the practicals. Students are expected to focus on acquiring specific skills mentioned therein.

GRID TABLE
No. 1 Experiment a) Study of different types of Milling Machines. b) Study of different types of Milling Cutters c) Study of milling attachments d) Milling keyways on shaft 2 3 4 5 Spur gear cutting using indexing head. Modern machining methods. To manufacture composite job Visit to industry to study/observe jig boring, broaching and grinding machines. a. Fundamentals of part programming b. Part programming using canned cycle c. Part programming using DO LOOPs NOTE : Idenditified Skills indicated by numbers. 15 16,17 18 14 16 17,18 Intellectual Skill 1,2 1,3,9 5,6 4,7 9,10 11,12 2,3,5,14 Motor Skill 1,2,5 4,5 5,6,7,8 7,10 11 1,12,13

STRATEGY FOR IMPLEMENTATION

It is suggested that 40 to 50% experiments shall be completed in first term and remaining experiments in the second term.

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GUIDELINES FOR TEACHERS

Teachers shall discuss the following points with students before start of practicals of the subject. 1) 2) 3) Learning Overview : To Develop better understanding of importance of the subject. To Know related skills to be developed such as intellectual skills and Motor Skills. Link / Block Diagram : Context of the subject in the form of link diagram showing interrelationship of various subject areas, curriculum objectives and job profile. Graphical structure : In this topics and sub topics are organized in systematic way so that ultimate purpose of learning the subject is achieved. This is arranged in the form of fact, concept, principle, procedure, application and problem. Know your Laboratory work : To understand the layout of laboratory, specifications of Equipment / Instruments/ Materials, procedure, working in groups, planning time etc. Also to know total amount of work to be done in the laboratory. Teacher shall ensure that required equipment are in working condition before start of experiment, also keep operating instruction manual available. Explain prior concepts to the students before starting of each experiment. Involve students activity at the time of conduct of each experiment. While taking reading/observation each student (from batch of 20 students) shall be given a chance to perform/observe the experiment. List of questions is given at the end of each experiment. Teacher shall instruct the students to attempt all questions given at the end each experiment / exercise. Teacher shall ensure that each student writes the answers to the allotted questions in the laboratory manual after performance is over. If the experimental setup has variations in the specifications of the equipment, the teachers are advised to make the necessary changes, wherever needed. Teacher shall assess the performance of students continuously as per norms prescribed by MSBTE. Teacher should ensure that the respective skills and competencies are developed in the students after the completion of the practical exercise. Teacher is expected to share the skills and competencies to be developed in the students. Teacher may provide additional knowledge and skills to the students even though not covered in the manual but are expected from the students by the industries. Teachers shall ensure that industrial visits recommended in the manual are covered. Teacher may suggest the students to refer additional related literature of the technical papers / reference books / Seminar Proceedings, etc. During assessment teacher is expected to ask questions to the students to tap their achievements regarding related knowledge and skills so that students can prepare while submitting record of the practicals. Focus should be given on development of enlisted skills rather than theoretical/codified knowledge. Teacher should enlist the skills to be developed in the students that are expected by the industry. Teacher should organised Group discussions / brain storming sessions/ Seminars to facilitate the exchange of knowledge amongst the students. Teacher should ensure that revised CIAAN-2004 norms are followed simultaneously and progressively. Teacher should give more focus on hands on skills and should actually share the same. Teacher shall also refer to the Circular No. MSBTE/D-50/Lab Mannual / 2005 / 3183 dated 5th May, 2005 for additional guidelines.

4)

5) 6) 7) 8) 9)

10) 11) 12) 13) 14) 15) 16) 17)

18) 19) 20) 21) 22)

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INSTRUCTIONS FOR STUDENTS

Students shall read the points given below for understanding the theoretical concepts & practical applications. 1) Listen carefully to the lecture given by teacher about importance of subject, curriculum philosophy, graphical structure, skills to be developed, information about equipment, instruments, procedure, method of continuous assessment, tentative plan of work in laboratory and total amount of work to be done in a year. Students shall undergo study visit of the laboratory for types of equipment, instruments, material to be used, before performing experiments. Read the write up of each experiment to be performed, a day in advance. Organize the work in the group and make a record of all observations. Understand the purpose of experiment and its practical implications. Write the answers of the questions allotted by the teacher during practical hours if possible or afterwards, but immediately. Student should not hesitate to ask any difficulty faced during conduct of practical / exercise. The student shall study all the questions given in the laboratory manual and practice to write the answers to these questions Student shall visit the recommended industries and should study the knowhow of the shop floor practices and the operations of machines. Student shall develop maintenance skills as expected by the industries. Student should develop the habit of pocket discussion / group discussion related to the experiments / exercises so that exchanges of knowledge / skills could take place. Student shall attempt to develop related hands-on-skills and gain confidence. Student shall focus on development of skills rather than theoretical or codified knowledge. Student shall visit the nearby workshops, workstation, industries, laboratories, technical exhibitions, trade fair etc. even not included in the Lab Manual. In short, students should have exposure to the area of work right in the student hood. Student shall insist for the completion of recommended Laboratory Work, industrial visits, answers to the given questions, etc. Student shall develop the habit of evolving more ideas, innovations, skills etc. than included in the scope of the manual. Student shall refer technical magazines, proceedings of the Seminars, refer websites related to the scope of the subjects and update their knowledge and skills. Student should develop the habit of not to depend totally on teachers but to develop self learning techniques. Student should develop the habit to react with the teacher without hesitation with respect to the academics involved. Student should develop habit to submit the practicals exercise continuously and progressively on the scheduled dates and should get the assessment done. Student should be well prepared while submitting the write up of the exercise. This will develop the continuity of the studies and he will not be over loaded at the end of the term.

2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14)

15) 16) 17) 18) 19) 20) 21)

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Advanced Manufacturing Processes

KNOW YOUR WORKSHOP The workshop is like backbone of all technologies. It is a special space created for conversion of ideas into models and mechanisms. Many machines are made available for transforming raw material into the physical object one has designed. The student entering into this shops must be aware of this and should decide to learn many things and upkeep himself by getting hands on skills on manufacturing processes. Know what are the disciplinary measures to be adopted by you when you enter into the workshop. What are the dos and don'ts in the workshop? List them, follow them. The workshop is equipped with many machines such as: Lathe, Shaping Machine, Drilling machines, grinding machines, planning machine, horizontal milling machine, vertical milling machines and many other. List the types of machines. Know where the job is mounted, how it is mounted, how a tool/ cutter is mounted. Know the functions of wheels provided on every machine. What happen when the wheels are rotated in clockwise direction and anticlockwise direction? There are various levers provided on machines try to know there settings. Many times these levers are meant for changing speeds, feeds, clamping, decamping and many other purposes Before coming to practical, ask your teacher about the experiment to be conducted next week/ turn. Read it at home. Refer textbooks related to the experiment. Get clarified with the concepts of the experiment.

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List of Experiments & Record of Progressive Assessment

Sr. No. Name of the Experiments Page No Date of Performance Date of submi ssion AssessSign. of ment teacher & Max. Remarks Marks 15

1.

Milling Machines 1-a) Study of Milling Machines 1-b) Study of Milling Cutters 1-c) Study of Milling Attachment 1-d) Cutting Key way on shaft. 1 6 13 17 20 27 30 33 34 38 42

2. 3. 4. 5.

Gear Cutting on Milling Machine Modern Machining Methods Manufacture of Composite Job Industrial Visit 5-a) Study of Boring Machine 5-b) Study of Broaching Machine 5-c) Study of Grinding Machine

6.

CNC Machines 6-a) Fundamental of Part Programming-1 6-b) Fundamental of Part Programming-2 6-c) Fundamental of Part Programming-1 46

49

52

Total Marks . Average Marks out of 15. *

* To be transferred to proforma of CIAAN- 2004 (Proforma -I-1)

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