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1.0 STUDY OF DRILLING, MILLING, SHAPER, GRINDING AND GEAR HOBBING MACHINES

1. DRILLING MACHINE The drilling machine is one of the most important machine tools in a workshop. In a drilling machine holes may be drilled quickly and at a low cost. The hole is generated by the rotating edge of a cutting tool known as the drill, which exerts large force on the work clamped on the table. The different parts of a radial drilling machine have been illustrated in Fig (1.0). They are as follows: 1. Base, 2. Column, 3. Radial arm, 4. Drill head 5. Spindle speed and feed mechanism 1.1 BASE The base of a radial drilling machine is a large rectangular casting that is finished on its top to support a column on its one end and to hold the work table at the other end. In some machines T-slots are provided on the base for clamping work when it serves as a table. 1.2 COLUMN The column is a cylindrical casting that is mounted vertically at one end of the base. It supports the radial arm which may slide up or down on its face. An electric motor is mounted on the top of the column, which imparts vertical adjustment of the arm by rotating a screw passing through a nut attached to the arm. 1.3 RADIAL ARM The radial arm that is mounted on the column extends horizontally over the base. It is a massive casting with its front vertical face accurately machined to provide guide ways on which the drill head may be made to slide. The arm may be swung round the column. In some machines this movement is controlled by a separate motor.

1.4 DRILL HEAD The drill head is mounted on the radial arm and drives the drill spindle. It encloses all the mechanism for driving the drill at multiple speeds and at different speed. All the mechanisms and controls are housed within a small drill head, which may be made to slide on the guide ways of the arm for adjusting the position of drill spindle with respect to the work. 1.5 SPINDLE DRIVE AND FEED MECHANISM A constant speed motor is mounted at the extreme end of the radial arm, which drives a horizontal spindle, which runs along the length of the arm, and the motion is transmitted to the drill head through bevel gears. By train of gearing within the drill head, the speed of the spindle may be varied. Through another train of gearing within the drill head, different feeds of the spindle are obtained. In some machines, a vertical motor is fitted directly on the drill head and through gearbox multiple speed and the feed of the spindle can be obtained.

. Fig (1.0) Radial drilling machine 1.Base, 2.Column, 3.Radial arm, 4.Motor for elevating the arm, 5.Elevating screw, 6.Guide ways, 7.Motor for driving the drill

2. MILLING MACHINE Milling is the process of removing metal by feeding the work piece through a rotating multipoint cutter. Milling machine can be used for machining flat surfaces, complex and irregular areas, surface of revolution, external and internal threads, gear cutting, helical surface of cross sections. The different parts of a Milling machine have been illustrated in Fig (3.0). They are as follows: 1. Base 2.Column 3.Knee 4.Saddle 5.Table 6.Spindle 7.Arbor Fig (2) shows the parts of a standard Milling Machine. 2.1. BASE: It is the foundation of the machine and is that part upon which all parts are mounted. It gives the machine rigidity and strength. 2.2. COLUMN: It is the main supporting frame. The motor and other driving mechanisms are contained with in it. 2.3 KNEE: The knee projects from the column and slides up and down on its face. It supports the saddle and table and partially supported by the elevating screw which adjusts its height. 2.4. SADDLE: The saddle supports and carries the table and is adjustable transversely on ways on top of the knee. It is provided with graduations for exact movement and operated by power or hand. 2.5. TABLE: The table rests on ways on the saddle and travels longitudinally in a horizontal plane. It supports the works piece, fixtures and all other equipments. 2.6. SPINDLE: The spindle obtains its power from the motor through motors. Cutters are mounted directly in the spindle nose.

2.7. ARBOR: The arbor is an accurately machined shaft for holding and driving the arbor cutter. It is tapered at one end to fit the spindle nose and two slots to fit the nose keys for locating and driving it.
1
2 3

5 6 7

1 0

Fig (2.0) MILLING MACHINE 1. Over arm 2.Arbor support 3.Arbor 4.Spindle 5.Table 6.Saddle 7. Knee 8. Elevating screw. 9. Column 10. Base

3. SHAPER The shaper is a reciprocating type of machine tool intended primarily to produce flat surfaces. These surfaces may be horizontal, vertical, or inclined. The different parts of typical shaper are shown in fig (4.0). The principal parts of a standard shaper are: 1. 2. 3. 4. 5. 6. 7. Base Column Cross rail Saddle Table Ram Tool head

3.1 BASE The base is the necessary bed or required for all machine tools. The base may be rigidly bolted to the floor of the shop or on the bench according to the size of the machine. It is so designed that it can take up the entire load of the machine and the forces set up by the cutting tool over the work. It is made of cast iron to resist vibration and take up high compressive load. 3.2 COLUMN The column is a box like casting mounted upon the base. It encloses the ram driving mechanism. Two accurately machined guide ways are provided on the top of the column on which the ram reciprocates. The front vertical face of the column, serves as the guide ways for the cross rail. The lid on the left side of the column may be opened for inspection and oiling of the internal mechanism. 3.3 CROSSRAIL The crossrail is mounted on the front vertical guide ways of the column. It has two parallel guide ways on its top in the vertical plane that is perpendicular to the ram axis. The table may be raised or lowered to accommodate different sizes of jobs by rotating elevating screw, which causes the cross rail to slide up and down on the vertical face of the column. A horizontal cross feed screw, which is fitted within the cross rail and parallel to the top guide ways of the cross rail actuates the table to move in a crosswise direction. 3.4 SADDLE The saddle is mounted on the crossrail, which holds the table firmly on its top. Crosswise movement of the saddle by rotating the cross feed screw by hand or power causes the table to move sideways. 3.5 TABLE The table is bolted to the saddle receives crosswise and vertical movements from the saddle and cross rail. It is a box like casting having T-slots both on the top and sides for clamping the work. In a universal shaper the table may be swiveled on a horizontal axis and the upper part of the table may be tilted up or down. 3.6 RAM The ram is the reciprocating member of the shaper. This is semi cylindrical in form and heavily ribbed inside to make it more rigid. It slides on the accurately machined dovetail guide ways on the top of the column and is connected to the

reciprocating mechanism contained within the column. It houses a screwed shaft for altering the position of the ram with respect to the work and holds the tool head at the extreme forward end. 3.7 TOOLHEAD The toolhead of a shaper holds the tool rigidly, provides vertical and angular feed movement of the tool and allows the tool to have an automatic relief during its return stroke. The vertical slide of the toolhead has a swivel base, which is held on a circular seat on the ram. The swivel base is graduated in degrees, so that the vertical slide is set perpendicular to the work or at any desired angle.

Fig (3.0) Shaper 1. Table support, 2. Table, 3. Clapper box 4. Apron clamping bolts 5. Down feed hand wheel 6. Swivel base degree graduations 7. Position of stroke adjustment hand wheel 8. Ram block locking handle 9. Ram 10. Column 11. Driving pulley 12. Base 13. Feed disc 14. Pawl mechanism 15. Elevating screw.

4. GRINDING MACHINE Grinding is metal cutting operation performed by means of a rotating abrasive wheel that acts as a tool. This is used to finish work pieces, which must show a high surface quality, accuracy of shape and dimension. 4.1 SURFACE GRINDER Surface grinding machines are employed to finish plane or flat surfaces. The different parts of a horizontal spindle reciprocating table surface grinder are shown in fig 4.0. The principal parts of a horizontal spindle reciprocating table surface grinder are: 1. 2. 3. Base Table Wheel head The base has a column at the back for supporting the wheel head. The base also contains the drive mechanisms. 4.1.2 TABLE The table is fitted to the saddle on carefully machined ways. It reciprocates along ways to provide the longitudinal feed. T- slots are provided in the table surface for clamping work pieces directly on the table or for clamping grinding fixtures or a magnetic chuck. 4.1.3 WHEEL HEAD The wheel head is mounted on the column secured to the base. It has ways for the vertical slide, which can be raised or lowered with the grinding wheel only manually by rotating a hand wheel to accommodate work pieces of different heights and to set the wheel for depth of cut. Horizontal, cross wise movement of the wheel slide with the wheel, actuated by hand or by hydraulic drive, accomplishes the cross feed of the wheel. The grinding wheel rotates at constant speed; it is powered by a special built- in motor.

4.1.1 BASE

FIG 4.0. Horizontal spindle surface grinder

1. Column, 2. Wheel head 3. Table 4. Wheel 5. Saddle 6. Base 4.2. CYLINDRICAL CENTRE- TYPE GRINDER Cylindrical centre- type grinders are intended primarily for grinding Plain cylindrical parts, although they can also be used for grinding contoured cylinders, fillets and even cams and crank shafts. The different parts of a cylindrical centre- type grinder are shown in fig 5.1. The principal parts of a cylindrical centre- type grinder are: 1. 2. 3. 4. 5. 6. Base Tables Head stock Tailstock Wheel head Cross-feed

4.2.1 BASE The base or bed is the main casting that rests on the floor and supports the parts mounted on it. On the top of the base are precision horizontal ways set at right angles for the table to slide on. The base also houses the table- drive mechanism. 4.2.2 TABLES There are two tables lower table and upper table. The lower table slides on ways on the bed provides traverse of the work past the grinding wheel. It can be moved by hand or power within desired limits. The upper table that is provided at its center is mounted on the top of the sliding table. It has T- Slots for securing the headstock and tailstock and can be positioned along the table to suit the length of the work. The upper table can be swiveled and clamped in position to provide adjustment for grinding straight or tapered work as desired.

4.2.3 HEADSTOCK The headstock supports the work piece by means of a dead center and drives it by means of a dog, or it may hold and drive the work piece in a chuck. 4.2.4 TAILSTOCK The tailstock can be adjusted and clamped in various positions to accommodate different lengths of work pieces. 4.2.5 WHEEL HEAD The wheel head carries a grinding wheel and its driving motor is mounted on a slide at the top and rear of the base. The wheel head may be moved perpendicularly to the table ways, by hand or power, to feed the wheel to the work.] 4.2.6 CROSS-FEED The grinding wheel is fed to the work by hand or power as determined by the engagement of the cross feed control lever.

FIG 4.2 Cylindrical centre- type grinder 1. Headstock, 2. Grinding wheel 3. Wheel head 4. Tailstock 5. Upper table 6. Lower table 7. Base.

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4.3 CENTRELESS GRINDER Centreless grinding is a method of grinding exterior cylindrical, tapered and formed surfaces on work pieces that are not held and rotated between centers. The principal elements of an external centreless grinder are the grinding wheel, regulating wheel and the work rest. Both the wheels are rotated in the same direction. The work rest is located between the wheels. The work is placed upon the work rest, and the latter, together with the regulating wheel, is fed forward, forcing the work against the grinding wheel. 5.0 GEAR HOBBING Gear Hobbing is a technique that is employed to create gear teeth configurations that are ideal for use in a wide range of machinery components. In cases where the gear hobbing takes place in a mass producing environment, gear hobbing is accomplished through the use of precision gear hobbing machines that ensure that the cut of each tooth on each gear produced meets the specifications set by the producer. Generally, a gear hobbing machine will make use of a series of customized bits that help to create the specific types of cutting and shaping necessary to create gears that posses exactly the right pitch and circle to work in various types of equipment. A customized bit is used for a particular size and type of gear hobbing, which helps to ensure that the cuts that are made into the blank surface of the circle of metal are relatively smooth and uniform.

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2.1 MACHINING A WORK PIECE BY DRILLING AND REAMING USING A DRILLING MACHINE
AIM: To machine a wok piece by drilling, reaming and tapping operations using a drilling machine. MATERIALS REQUIRED: Cast iron circular plate 100 X 10 mm TOOLS REQUIRED: 1. 2. 3. 4. 5. 6. 7. 8. Drilling machine Steel Rule Drills Center punch Reamers Scriber Tap sets Hammer

GIVEN WORK PIECE (FIG: 1)

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FINISHED WORK PIECE (FIG: 2)

PROCEDURE: 1. The given work piece is marked and punched as per the given drawing. 2. Then the work piece is held firmly on the machine vice. 3. The drill bit of required drill size is held in drill spindle. 4. The machine is switched on and the drilling operation is done at the punched positions. 5. Like drilling operation the reaming operation is done at already drilled holes by using reamer. 6. The machine is switched off. 7. The work piece is measured and checked for all the dimensions as per the given drawing.

RESULT: The given work piece as shown in fig(1) is subjected to drilling and reaming operations to become a finished work piece as shown in fig (2).

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2.2 MACHINING V- BLOCK USING A SHAPER

AIM: To machine V- block using a shaper MATERIALS REQUIRED: Cast iron cube 78 X 78 X 78 mm TOOLS REQUIRED: 1. 2. 3. 4. 5. 6. 7. 8. Shaper Hammer Shaping tool Steel Rule Scriber Try Square Center punch Spanner

GIVEN WORK PIECE (FIG: 1)

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FINISHED WORK PIECE (FIG: 2)

PROCEDURE: 1. 2. 3. 4. 5. 6. 7. 8. 9. The given work piece is held firmly in a shaper vice. The shaping tool is set firmly on a tool head. After adjusting the length of stroke and position of stroke the machine is switched on. By giving cross feed to the work piece through the table the shaping operation is done on all the work surfaces. The machine is switched off and the work piece is removed from the vice. The work piece is marked and punched as per the given drawing. Again the work piece is held on the vice and the machine is switched on. By giving angular feed to the tool through the tool slide the V- shape is machined. The machine is switched off. per the given drawing. 10. The work piece is removed and is measured & checked for all the dimensions as

RESULT: The given work piece as shown in fig(1) is subjected to shaping operations to become a finished work piece as shown in fig (2).

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2.3 MACHINING THE DOVE-TAIL SLOT ON A WORK PIECE USING A SHAPER

AIM: To machine a work piece and provide a Dove - Tail slot using a shaper MATERIALS REQUIRED: Cast iron cube 80 X 80 X 80 mm TOOLS REQUIRED: 1. 2. 3. 4. 5. 6. 7. 8. Shaper Hammer Shaping tool Steel Rule Scriber Try Square Center punch Spanner

80

80

GIVEN WORK PIECE FIG (1)

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FINISHED WORK PIECE FIG (2) PROCEDURE: 1. The given work piece is held firmly in a shaper vice. 2. The shaping tool is set firmly on a tool head. 3. After adjusting the length of stroke and position of stroke of the ram, machine is switched on. 4. By giving cross feed and longitudinal feed to the tool head the all sides of work piece is machined as per the given drawing. 5. The machine is switched off and the work piece is removed from the vice. 6. The work piece is marked and punched as per the given drawing. 7. Again the work piece is held on the vice and the machine is switched on. 8. By giving angular feed to the tool through the tool slide the Dove-tail shape is machined. 9. The machine is switched off. 10. The work piece is removed and is measured & checked for all the dimensions as per the given drawing.

RESULT: The shaping operation was done on the given work piece as shown in fig (1) and Dove Tail slot was provided as per the dimensions shown in fig (2).

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2.4 MACHINING A HEXAGONAL SHAPE FROM A ROUND C.I.WORK PIECE USING A MILLING MACHINE
AIM: To machine a hexagonal shape from a round C.I. work piece using a milling machine. MATERIALS REQUIRED: Cast iron round blank 80 X 50 X 50 mm TOOLS REQUIRED: 1. Milling machine 2. Plain milling cutter 3. Dividing head 4. Vernier caliper 5. Spanners

GIVEN WORKPIECE (FIG: 1)

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FINISHED WORK PIECE (FIG: 2) CALCULATION: Index crank movement =

40 N

where N= Number of sides PROCEDURE: 1. 2. 3. 4. 5. 6. 7. 8. The selected speed and feed of the machine is set. The dividing head and the tailstock are bolted on the table after setting their axis The plain milling cutter is mounted on the arbor. The work piece is mounted between the two centers by a mandrel. The proper index plate is bolted on the dividing head and the positions of the The table is raised to give a required depth of cut. The machine is started and the feed is applied to finish the first surface of the After the end of the cut the table is brought to starting position and then the

exactly perpendicular to the machine spindle.

crank pin and the sector arms are adjusted.

blank. blank is indexed for the next surface.

RESULT: The given work piece as shown in fig (1) is subjected to milling operation to become a finished work piece as shown in fig (2).

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2.5 CONTOUR MILLING OPERATION ON A WORK PIECE USING A MILLING MACHINE

AIM: To perform a contour milling operation on the given work piece using a milling machine MATERIALS REQUIRED: Square aluminum plate-100x80x10 TOOLS REQUIRED: 1. Vertical Milling machine 2. Contour milling cutter 3. Outside Caliper 4. Steel Rule 5. Vernier Caliper

80

10 0

GIVEN WORK PIECE FIG (1):

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3 0

9.5 4 0 2 6

100

7 3 0 3 0 2 0 2 0

100

FINISHED WORK PIECE FIG (2) PROCEDURE: 1. 2. 3. 4. The given work piece is fixed in a table. The form milling cutters are used for contoured milling. The machine is switched on to revolve the cutter at the selected speed. By giving Cross feed and longitudinal feed to the work table, the contour

operations are done respectively. The profile of the cutter coincides with that of the work piece. 5. 6. After the work piece is milled as per the given drawing machine is switched off. The work piece is removed from the work table and all the dimensions are

measured and checked.

RESULT: The contour milling operation was done on the given work piece as shown in fig (1) as per dimensions shown in fig (2).

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2.6 MACHINING A WORK PIECE USING A SURFACE GRINDING MACHINE

AIM: To machine a work piece using a surface grinding machine. MATERIALS REQUIRED: Mild steel Flat - 80 X 50 X 10 mm TOOLS REQUIRED: 1. 2. Surface grinding machine Vernier Caliper

GIVEN WORKPIECE (FIG: 1)

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FINISHED WORK PIECE (FIG: 2)

PROCEDURE: 1. The given work piece is held firmly on a magnetic chuck of a surface grinder. 2. The machine is started and the grinding wheel is allowed to revolve at a selected speed. 3. After giving a depth of cut, the work piece is made to reciprocate under the grinding wheel. dimension is

4. The table is fed axially between passes to produce a fine flat surface. 5. The process is repeated for grinding another side until the desired achieved. 6. The dimensions are checked for its given dimensions using a vernier caliper.

RESULT: The given work piece as shown in fig (1) is subjected to surface grinding operation to become a finished work piece as shown in fig (2).

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2.7 MACHINING A WORK PIECE USING A CENTRE TYPE CYLINDRICAL GRINDING MACHINE
AIM: To machine a work piece using a cylindrical grinding machine. MATERIALS REQUIRED: Mild steel polished round rod - 25 X 150 mm TOOLS REQUIRED: 1. Centre type cylindrical grinder 2. Vernier Caliper 3. Spanners

GIVEN WORKPIECE: (FIG 1)

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FINISHED WORK PIECE: (FIG 2)

PROCEDURE: 1. 2. 3. 4. The given work piece is held between centers. The machine is switched on and the grinding wheel is allowed to selected speed. By giving longitudinal and cross feeds the work piece is ground for the required dimensions. The work piece is removed from the machine and is checked for the given dimensions. revolve at a

RESULT: The given work piece as shown in fig (1) is subjected to external cylindrical grinding operation by centre type cylindrical grinder to become a finished work piece as shown in fig (2).

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2.8 MACHINING A WORK PIECE USING A CENTRELESS GRINDING MACHINE

AIM: To machine a work piece using a centreless grinding machine. MATERIALS REQUIRED: Mild steel polished round rod - 25 X 150 mm TOOLS REQUIRED: 1.Centreless grinder 2. Vernier Caliper 3. Spanners

GIVEN WORKPIECE: (FIG 1)

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FINISHED WORK PIECE: (FIG 2)

PROCEDURE: 1. The given work piece is held between grinding wheel and regulating wheel and supported on work rest. 2. The machine is switched on. 3. The grinding wheel and the regulating wheel are allowed to revolve at a selected speed. 4. The work is fed forward and the grinding operation is done. 5. The work piece is removed from the machine and is checked for the given dimensions.

RESULT: The given work piece as shown in fig (1) is subjected to external cylindrical grinding operation by centre less grinder to become a finished work piece as shown in fig (2).

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2.9 MACHINING A COMPONENTS FOR CLEARENCE FIT ASSEMBLY

AIM: To machine the components for clearance fit assembly using lathe. MATERIALS REQUIRED: Mild steel polished round rod - 30 X 110 mm TOOLS REQUIRED: 1.Turning tool 2. Parting off tool 3. Drill bit 4. Vernier caliper 5. Outside caliper 6. Inside caliper

GIVEN WORKPIECE: (FIG 1)

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FINISHED WORK PIECE: (FIG 2) PROCEDURE: 1. The given work piece is held between rigidly in the chuck. 2. The single point cutting tool is set on the tool post. 3. The machine is switched on. 4. The straight turning and facing operation are done on the one half of the work piece as per the given dimensions. 5. Then the drill bit of required drill size is held in tailstock and drilling is done for the required depth in the work piece. 6. After finishing the one half of the work piece then another half is also finished as per the drawing. 7. The machine is switched off. 8. The parting tool is fixed and by parting off operation the work piece is cut in to two parts as per the dimensions. 9. The two parts are assembled for getting a clearance fit assembly.

RESULT: The given work piece as shown in fig (1) is subjected to machining operations to become a finished work piece as shown in fig (2).

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2.10 MACHINING THE COMPONENTS FOR INTERFERENCE FIT ASSEMBLY

AIM: To machine the components for interference fit assembly using lathe and drilling machine. MATERIALS REQUIRED: 1. Mild steel polished round rod - 30 X 110 mm 2. Mild steel plate 50 X 50 X 10 mm TOOLS REQUIRED: 1. Lathe machine 2. Drilling machine 3.Turning tool 4. Drill bit 5. Parting tool 6. Vernier caliper

GIVEN WORKPIECE: (FIG 1)

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FINISHED WORK PIECE: (FIG 2)

PROCEDURE: 1. 2. 3. The component 1 is machined by straight turning and facing operations as per the dimensions using a lathe. The component 2 is machined by drilling operation as per the dimensions using a drilling machine. After that both the components are assembled to get an interference fit assembly.

RESULT: The given work piece as shown in fig (1) is subjected to turing and drilling operations to become a finished work piece as shown in fig (2).

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2.11 MACHINING A SPUR GEAR USING A GEAR HOBBING MACHINE

AIM: To machine a Spur Gear using a gear Hobbing machine. MATERIALS REQUIRED: 1. Cast iron blank - 86 X 25 X 20 mm TOOLS REQUIRED: 1. Gear Hobbing machine 2. Hob 3. Gear tooth vernier 4. Spanners

GIVEN WORKPIECE: (FIG 1)

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FINISHED WORK PIECE: (FIG 2)

PROCEDURE: 1. The given work piece is held firmly on the spindle of the gear hobbing machine. 2. The Hob is set at an angle to he hob helix angle for cutting spur gear. 3. 4. 5. 6. depth. 7. 8. off. 9. The gear teeth are checked using a gear tooth vernier. The cutter is given feed for the full width of the work. After machining all gear teeth on the blank the machine is switched The change gears are set for the desired speed of work piece and Hob and feed of the Hob. The machine is switched on. The work piece and Hob are allowed to rotate at the desired speed. The hob or work piece is given full deph of cut equals to the tooth

RESULT:

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The given work piece as shown in fig (1) is subjected to gear generating operation to become a finished work piece as shown in fig (2).