MANUFACTURING & SERVICING AND

MAINTENANCE LAB PRACTICE MANUAL

DIPLOMA IN MECHANICAL ENGINEERING

ANURAG COLLEGE OF ENGINEERING

AUSHAPUR (V), GHATKESAR (M), MEDCHAL (D), HYDERABAD

TELANGANA-501301

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 ANURAG COLLEGE OF ENGINEERING

AUSHAPUR (V), GHATKESAR (M), MEDCHAL (D), HYDERABAD

MANUFACTURING&SERVICINGANDMAINTENANCE

LABPRACTICE

LIST OF EQUIPMENTS

S.NO LIST OF EQUIPMENTS

1. SLOTTING MACHINE.

2. MILLING MACHINE.

3. ARC/GAS WEILDING MACHINE

4. PLANNING MACHINES,

5. SHAPING MACHINE

6. 4-STROKE DIESEL ENGINE

LIST OF EXPERIMENTS

S.NO LIST OF EXPERIMENTS

1. KEY WAY CUTTING BY SLOTTING MACHINE.

2. INDEXING ON SLOTTING / MILLING MACHINE

3. T-SLOT CUTTING ON MILLING MACHINE.

4. BEVEL/HELICAL GEAR CUTTING ON MILLING MACHINE.

5. SERVICING OF MACHINE/ENGINE COMPONENTS

6. SERVICING OF SMALL COMPONENTS OF LATHE

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 EXPERIMENT –I

PRACTICE THE CUTTING OPERATION SLOTTER

INTRODUCTION:

The slotting machine is a reciprocating machine tool in which, the ram holding the tool
reciprocates in a vertical axis and the cutting action of the tool is only during the downward
stroke.

CONSTRUCTION:

The slotter can be considered as a vertical shaper and its main parts are:

1. Base, column and table

2. Ram and tool head assembly

3. Saddle and cross slide

4. Ram drive mechanism and feed mechanism.

Fig: slotting machine

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The base of the slotting machine is rigidly built to take up all the cutting forces. The front face of
the vertical column has guide ways for Tool the reciprocating ram. The ram supports the tool
head to which the tool is attached. The work piece is mounted on the table which can be given
longitudinal, cross and rotary feed motion.

The slotting machine is used for cutting grooves, keys and slots of various shapes making regular
and irregular surfaces both internal and external cutting internal and external gears and profiles
The slotter machine can be used on any type of work where vertical tool movement is considered
essential and advantageous.

The different types of slotting machines are:

1. Punch slotter: a heavy duty rigid machine designed for removing large amount of metal from
large forgings or castings

2. Tool room slotter: a heavy machine which is designed to operate at high speeds. This
machine takes light cuts and gives accurate finishing.

3. Production slotter: a heavy duty slotter consisting of heavy cast base and heavy frame, and is
generally made in two parts.

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 Fig; key way cutting slotting operation

KEY WAY CUTTING OPERATION SLOTTER

AIM:To Make Slot on given Work Piece.

MATERIAL REQUIRED: Mild Steel, Aluminum.

MACHINE REQUIRED: Slotting Machine.

MEASURING INSTRUMENTS: Vernier caliper, slip gauges.

CUTTING TOOL: HSS Tool Bit of Required Slot Size.

SEQUENCE OF OPERATION:

 Fix the specimen in 3 jaw check of the slotting machine

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  By giving the required feed and depth of cut the require a slot is being made
progressively

PROCEDURE:

 Fix the work piece in head stock check firmly

 Turning tool is fixed in tool post and entering is to be done
 Turn the job to get a diameter of required length
 Facing is to done one side of job
 Drill bit 8mm diameter is fixed on tail stock and entering of work piece
 Drill bit of 25mm diameter is fixed in tail stock and entering of work piece
 Drill bit of 25mm diameter is fixed in the tail stock
 Boring tool is fixed on tail stock to perform boring operation to get a hole of diameter
 Fit the job in reverse position in the chuck
 Drilled work piece is fixed on slotting machine
 A slot of required depth is made

PRECAUTIONS:

 Choose proper feed and depth of cut

 Feed should be controlled to avoid any damage to the cutting tool
 Care has to be taken so as to maintain the right feed of the material
 Work piece interface zone is to be flooded with coolant
 All the chips should be removed from the lathe

RESULT:

Required specimen obtain according to specified operation with given dimensions

EXPERIMENT –II

PRACTICE THE CUTTING OPERATION ON PLANER

INTRODUCTION:

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 The planer is a machine tool designed to produce plane and flat surface on a work piece
which is too large or too heavy. The work piece is securely fixed on a table called platen, and it
reciprocates horizontally against a single edged cutting tool. The surface machined may be
horizontal, vertical or at an angle.

OPERATIONS OF PLANER MACHINE:

The planer is used for:

1. Planing flat horizontal, vertical and curved surfaces.

2. Planing at an angle and machining dovetails.

3. Planing slots and grooves.

The planer are available in different types for doing different types and sizes of job; the most
common being the standard and double housing planer.

CONSTRUCTION: The main parts of the double Housing Planer machine is Bed and table,
Housings, Cross rail, , Tool heads, Driving and feed mechanism.

Bed and table: The bed is a long heavy base and table made of cast iron. Its top surface is flat
and machined accurately. The flat top surface has slots in which the work piece can be securely
clamped. The work piece needs rigid fixing so that it does not shift out of its position. The
standard clamping devices used on planer machine are: Heavy duty vice, T-holders and clamps,
angle plate, planer jack, step blocks and stop. The table movement may be actuated by a variable
speed drive through a rack and pinion arrangement, or a hydraulic system.

Housings: The housings are the rigid and upright column like castings. These are located near
the Centre on each side of the base.

Cross rail: The cross rail is a horizontal member supported on the machined ways of the upright
columns. Guide ways are provided on vertical face of each column and that enables up and
vertical movement of the cross rail. The vertical movement of the cross rail allows to
accommodate work piece of different heights. Since the cross rail is supported at both the ends,
this type of planer machine is rigid in construction.

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 Fig: Planer Machine

Tool heads: Generally two tool heads are mounted in the horizontal cross rail and one on each of
the vertical housing. Tool heads may be swiveled so that angular cuts can be made.

Driving and feed mechanism: The tool heads may be fed either by hand or by power in
crosswise or vertical direction. The motor drive is usually at one side of the planer near the
Centre and drive mechanism is located under the table.

The size of the planer is specified by the maximum length of the stroke, and also by the size of
the largest rectangular solid that can be machined on it.

CUTTING OPERATION ON PLANER

AIM: To Make A Flat Horizontal, Vertical and Curved Surface On Given Surface

MATERIAL REQUIRED:Mild steel, aluminum

MEASURING INSTRUMENTS:VernierCaliper, slip gauges, height gauge

CUTTING TOOLS:HSS Tool bit

MACHINE REQUIRED: Planing Machine

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PROCEDURE:

 Measure the specimen

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  Fixing of the specimen in machine vice of planning machine
 Giving the correct depth for removing the surface and automatic feed for the machine flat
horizontal is to be made
 Next giving the correct depth and automatic feed for the slot is to be made
 Next giving the correct radius and the automatic feed for the curved surface is to be made
 Check the work piece of flat horizontal vertical curved surface with tools

PRECAURIONS:

 Choose the proper feed and depth of cut

 Feed should be controlled to avoid any damages to cutting tool
 Care has to be taken so as to maintain right feed of the material
 Work piece interface zone is to be flooded with coolant
 All chips should be removed from cutter

RESULT:

Thus work piece is obtained according to dimensions performing on the planer machine

EXPERIMENT –III

PERFORM THE CUTTING OPERATION ON MILLING MACHINE

INTRODUCTION TO MILLING MACHINE:

Milling machine is the main machining operations. In this process work piece is fed
besides turning cylindrical tool. Turning tool has of several cutting edges. Milling process is

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notable as of other machining operations on the foundation of direction between the tool axis
with the feed direction, though, in other operations similar to drilling, turning, and so on. The
tool is feeding way parallel to axis of rotation. Milling machine can also use for slotting, drilling,
make circular profile with gear cutting by having proper attachments.
Cutting tool use in milling operation is call milling cutter, which has of numerous edges
call teeth. Machine tool to make the milling operations by produce necessary relative movement
among work piece and tool is call milling machine. It gives necessary relative motion under
extremely controlled condition.
Generally, milling function creates plane face. Other geometries can too be formed
through milling machine. Milling process is consider an episodic cutting process teeth of milling
cutter go into and goes out the work through every revolution. This periodic cutting action
subjects teeth to a cycle of impact force with thermal shock on each rotation. Tool material and
cutter geometry have to be intended to bear the over stated situation.

WORKING PRINCIPLE

Milling is a basic machining process by which a surface is generated by progressive chip

removal. Thework piece is fed into a rotating cutting tool. Sometimes the workpiece remains
stationary, and the cutter is fed to the work. In nearly all cases, a multiple-tooth cutter is used so
that the material removal rate is high. Often the desired surface is obtained in a single pass of the
cutter or work and, because very good surface finish can be obtained, milling is particularly well
suited and widely used for mass-production work. Many types of milling machines are used,
ranging from relatively simple and versatile machines that are used for general-purpose
machining in job shops and tool and die work (these are NC or CNC machines) to highly

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 FIG: Vertical Milling Machine

Specialized machines for mass production. Unquestionably, more flat surfaces are produced by
milling than by any other machining process.

Vertical mill

In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle
and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered,
giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical
mills: the bed mill and the turret mill.

 A turret mill has a stationary spindle and the table is moved both perpendicular and parallel
to the spindle axis to accomplish cutting. The most common example of this type is the
Bridgeport, described below. Turret mills often have a quill which allows the milling cutter
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 to be raised and lowered in a manner similar to a drill press. This type of machine provides
two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by
moving the knee.
 In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the
spindle itself moves parallel to its own axis

KEY WAY CUTTING ON MILLING MACHINE

MATERIAL REQUIRED: M.S Specimen.

MEASURING INSTRUMENTS:Vernier Caliper

CUTTING TOOLS: Plane Milling Cutter

MATERIAL TOOL: Steel Rule, Scriber

1. Work Holding Fixture: Work Piece Supporting Fix Facer

2. Miscellaneous Tool: Hammer Or Brush, Allen Keys

PROCEDURE:

 The dimensions of the given rod are check of the steel rule
 The rule rod is fixed in the vice provided on the machine table such as a one end of it is
projected outside the jaws of vice
 A face milling cutter is mounted on the horizontal milling spindle and one end of the
rod is face milling by raising the table so that the end of the rod faces the cutter
 The rod is removed down the vice and filled in the lower position
 The outer end of rod is face milled such that the length of job is exactly 100mm
 The table is towards one the rod is removed from the vice and rather in the such that
the top face of the rod is projected from the vice jaws
 The face milling cutter is removed from the spindle and the ember mounted in the
spindle followed by fixing the plan milling cutter
 The top surface of the job is slab milled first giving rough outer followed by a finish cut

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  The job is removed from the vice and rectified in if such that the face opposite to
above comes to the top end projects above the vice jaws.
 The top surface of the job is milled in stages giving finish cuts towards the end such
that the job is exactly
 The bans if any along the edge are removed with the help of the flat file

Fig key way slot cutting on milling

PRECAURIONS:

 The milling machine must be stopper slotting up of removing a work piece cutter of the
accuracy

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  Never stop the feeding of job when the cutting operation is going on otherwise tool will
cut deeper at the point when feed is stopped
 All the chips should be removes from the cutter a wipping the cloth should be places on
the cutter to protect bench the cutter be rotated in the clock wise direction only reject
hand tools
 The work piece any cutter should be kept as low as possible
 The table surface should be protected with a wipping cloth
 Tool must be mounted as escape to the machine spindle as possible

RESULT:

The rectangular blows is obtained by following stages described above

EXPERIMENT-IV

PERFORM CUTTING OPERATION ON V-BLOCK ON SHAPING

MACHINE

INTRODUCTION:

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 The shaper is a machine tool used primarily for:

1. Producing a flat or plane surface which may be in a horizontal, a vertical or an angular plane.

2. Making slots, grooves and keyways

3. Producing contour of concave/convex or a combination of these

Fig: Shaping machine

CONSTRUCTION:

The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column), Cross rail,
Ram and tool head (Tool Post, Tool Slide, Clamper Box Block).

Base: The base is a heavy cast iron casting which is fixed to the shop floor. It supports the body
frame and the entire load of the machine. The base absorbs and withstands vibrations and other
forces which are likely to be induced during the shaping operations.

Body (Pillar, Frame, and Column): It is mounted on the base and houses the drive mechanism
compressing the main drives, the gear box and the quick return mechanism for the ram
movement. The top of the body provides guide ways for the ram and its front provides the guide
ways for the cross rail.

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Cross rail: The cross rail is mounted on the front of the body frame and can be moved up and
down. The vertical movement of the cross rail permits jobs of different heights to be
accommodated below the tool. Sliding along the cross rail is a saddle which carries the work
table.

Ram and tool head: The ram is driven back and forth in its slides by the slotted link
mechanism. The back and forth movement of ram is called stroke and it can be adjusted
according to the length of the work piece to be-machined.

Fig: V- Block on Shaper

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CUTTING OPERATION ON V-BLOCK ON SHAPING MACHINE:

AIM: To Perform V-Joint Cut and Given the Work Piece by Shaping Machine

MATERIAL REQUIRED: Mild Steel/Cast Iron/Cast Aluminum

MACHINE REQUIRED: shaping machine

MEASURING INSTRUMENT:vernier calipers, vernier height gauge, dial indicator, required

steel ball

CUTTING TOOLS: HSS Tool Bit, V Tool, Plan Tool, Grooving Tool

SEQUENCE OF OPERATION:

 Measuring of specimen
 Fixing of specimen in the machine vice of the shaping machine
 Giving the correct depth and automatic feed for the slot is to be made
 Check the slit which the vernier caliper and precision measurement by slip gauges at the
end

WORKING PRINCIPLE:

 The job is rigidly fixed on the machine table.

 The single point cutting tool held properly in the tool post is mounted on a reciprocating
ram.
 The reciprocating motion of the ram is obtained by a quick return motion mechanism.
 As the ram reciprocates, the tool cuts the material during its forward stroke.
 During return, there is no cutting action and this stroke is called the idle stroke.
 The forward and return strokes constitute one operating cycle of the shaper

PRECAUTIONS:

 The shaping machine must be stopped before setting up or removing the work piece.
 All the chips should be removed from the cutter.

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RESULT:

Required specimen obtain according to specified operations with given dimensions

EXPERIMENT –V

PRODUCE UTILITY ARTICLES SUCH AS SHOE RACK, GARDEN

CHAIR, WASH BASIN STOOLS BY WELDING OPERATION

AIM: Produce the Utility Article Shoe Rack by Welding Operation

MATERIAL REQUIRED: Switch box, Secondary terminals, Welding machine, Current

reading scale, Current regulating hand wheel, Leather apron, Asbestos hand gloves,Protective
glasses strap, Electrode holder, Hand shield, Channel for cable protection, Welding cable,
Chipping hammer, Wire brush, Earth clamp, Welding table (metallic).

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Fig: shoe rack

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 Fig : Garden Chair

PROCEDURE :

 Cut the given material as per the requirement for making shoe rack
 The wider part of the taper goes toward the bottom.
 Make sure rib on split sleeve is seated into a groove on the post.
 Mounting one set of 4 split sleeves at a time, followed by adjoining shelf, onto the post
groove location specified.
 Start with the bottommost location, and work from bottom to top
 Hook rod onto outside of top wire shelf.
 Make sure rod is parallel with posts of shelf unit.
 Slide tab notch onto rod.
 Push tab up and onto bottom of shelf truss.
 attaching tabs where rod intersects with adjacent wire shelves remaining
 Finally get The Required Shape

PRECAUTIONS:

 Keep children away

 Pacemaker wearers, consult your doctor first
 Have all installation, operation, maintenance and repair work performed only by qualified
people
RESULT :

Produced the Utility Article Shoe Rack by Welding Operation

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 EXPERIMENT –VI

UNDERSTAND VARIOUS OPERATION IN FOUNDARY

AIM : prepare and understand various opertaions of flange coupling , cupola and fit
furnace,metal casting of simple objects in aluminium by foundary

INTRODUCTION: - Foundry practice deals with the process of making casting in moulds,
formed in either sand or other material. This is found to be the cheapest method of metal
shaping. The process involves the operations of pattern making, sand preparation, molding,
melting of metals, pouring in moulds, cooling, shake out, fettling, heat treatment, finishing, and
inspection. Mould is a cavity in a molding core, formed by a pattern. It is similar in shape and

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size that of the actual casting plus some allowance for shrinkage, machining etc., molding is the
process of making molds.

MOULDS ARE CLASSIFIED AS: -

 Temporary moulds
 Permanent moulds
Temporary mould are made of sand and other binding materials and may be
produced either through hand molding (or) machine molding.
Permanent moulds are made of ferrous materials and alloys i.e., cast iron, steel
Molding Sand: - Sand is the principle material used in foundry. The principle
ingredients of molding sands are 1) Silicon sand 2) Clay 3) Sand
Clay imparts the necessary bonding strength to the molding sand, moisture when
added to correct preparation provides the bonding action to the clay sand can withstand
high temperature and doesn’t react with molten metal.
Natural molding sand is either available in river beds are dug from pits. It
possesses and appreciable amount of clay and are used as received with the addition of
water. Synthetic sands are prepared by adding clay. Water and other materials to silica
sand so that the desirable strength and banding properties are achieved.
Most of molding is done with green sand i.e.; sand containing 6 to 8%, moisture
and 10% clay content to give it sufficient bond. Green sand moulds are used for pouring
the molten metal – immediately after preparing the moulds. Green sand moulds are
cheaper and take less time to prepare. These are used for small and medium size casting.
Parting sand, which is clay tree, fence grained silica sand, is used to keep the
green sand from sticking to the pattern and also to prevent the cope and drug from
cleaning. Core sand is used for making cores. This is silica missed with core oil and other
oddities.

Pattern: - A pattern is the replica of the desired coasting, which when packed in a suitable
materials produces a cavity called mould. This cavity when filled with molten metals, produces
their desired coasting of the solidification.

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Types of pattern: - Wood are metal patterns are used in foundry practice, single piece, split
loose piece and cored patterns are some of the common types.

Tools and equipment: - The tools are equipment needed for molding are; -

Molding board: - It is wooden board with smooth surfaces. It supports the flasks and the
pattern, while the mould is being made.

Molding Flask: - It is a base, made of wood or metal, open at both ends. The sand is rammed in
after placing the pattern to produce a mould it is made of 2 parts; cope is the top half of the flask,
having guides for the aligning paints to enter. Drag is the bottom half of the flask having aligning
pins.

Shovel: - It is used for mixing and tempering molding sand and for transferring the sand in to
the flask. It is made of steel blade with a wooden handle.

Rammer: - It is used for pocking or ramming the sand, around the pattern one of its ends called
the peen end, is wedge shaped and is used for packing sand in spaces, pockets and corners in the
early stages of ramming. The other end called the But – end has a surface and is used for
computing the sand towards the end of molding.

Strike of edge / strike of bar: - It is a piece of metal or wood with straight edge. It is used
remove the excess sand from the mould after ramming to provide a level surface.

Spruce pin: - It is tapered wooden pin used to make a hole in the cope sand through which the
molten metal is poured into the mould.

Riser pin: - It is tapered wooden pin used to make a hole in the cope sand over the mould cavity
for the molten metal to rise and feed the casting to compassable the shrinkage that take place
during solidification.

Trowel: - It is used to smoothen the surface of the mould. It may also be used for reproducing
the damaged portion of the mould. A trowel is made in many different styles and sizes each one
recallable for a particular hole.

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 ONE STEPPED PATTERN

(SINGLE PIECE PATTERN)

Aim: - To prepare a sand mould cavity using One Stepped Shaft (single piece pattern).

Tools required: -

1. Molding board 2. Molding flask 3. Shovel 4. Riddle 5. Rammer 6.Strike-off bar or Strike Edge
7.Sprue pin 8. Riser pin 9. Trowel 10.Spike or Draw pin 11.Slick 12.Lifters 13.Gate cutter
14.Bellows 15.Vent rod

Material required: -

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1. Molding sand

2. Parting sand

3. Dum-Bell

Sequence of operation: - 1. Sand preparation

2. Sand mixing

3. Pouring

4. Finishing

Procedure: -

1. Place the pattern on the molding board, with its flat side on the board.

2. Place the drag over the board, after giving a clay wash inside.

3. Sprinkle the pattern and molding board, with parting sand.

4. Allow loose sand, preferably through a riddle over the pattern, unit it is covered to a depth of
2 to 3 cm.

5. Pack the molding sand around the pattern and into the corners of the flask, with fingers.

6. Place some more sand in the flask and pack the pattern with a rammer, using first the peen end
and then butt end.

7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.

8. Turn the drag upside down. 9. Blow-off the loose sand particles with the bellows and
smoothen the upper surface.

10. Place the cope on to the drag in position. Locate riser pin on the highest point of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side of the riser pin.

12. Sprinkle the upper surface with parting sand.

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13. Repeat steps 3 to 7, approximately.

14. Make holes with the vent rod to about 1 cm from the pattern.

15. Remove the sprue and riser pins by carefully drawing them out. Funnel shaped hole is made
at the top of the sprue hole, called the pouring cup.

16. Lift the cope and place it aside on its edge.

17. Insert the draw pin into the pattern. Wet the edges around the pattern. Loosen the pattern by
rapping. Then draw the pattern straight up.

18. Adjust and repair the mold by adding bits of sand, if necessary.

19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand particles in the
mold. 20. Close the mold by replacing the cope and placing weights on it.

Precautions:-

1. Do not get the sand too wet. Water is an enemy of molten metals.

2. Provide adequate ventilation to remove smoke and fumes.

3. Never stand near or look over the mold during the pouring because of the molten metal might
be too hot.

4. Do not shake out a casting too hastily, which may result in second and third degree burns.

Result: - A sand mold cavity is prepared by using one–Stepped Shaft.

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 DUM-BELL

(SPLIT PIECE PATTERN)

Aim: - To prepare a sand mould cavity using Dum-Bell (split piece pattern).

Tools required: - 1. Molding board 2.Molding flask 3. Shovel 4. Riddle 5. Rammer 6.Strike-off
bar or Strike Edge 7.Sprue pin 8. Riser pin 9. Trowel 10.Spike or Draw pin 11.Slick 12.Lifters
13.Gate cutter 14.Bellows 15.Vent rod

Material required: - 1. Molding sand 2.Parting sand 3. Dum-Bell

Sequence of operation: - 1. Sand preparation 2.Sand mixing 3.Pouring 4. Finishing

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Procedure: -

1. Place the pattern on the molding board, with its flat side on the board.

2. Place the drag over the board, after giving clay wash inside.

3. Sprinkle the pattern and molding board, with parting sand.

4. Allow loose sand, preferably through a riddle over the pattern, unit it is covered to a depth of 2
to 3 cm.

5. Pack the molding sand around the pattern and into the corners of the flask, with fingers.

6. Place some more sand in the flask and pack the pattern with a rammer, using first the peen end
and then butt end.

7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.

8. Turn the drag upside down.

9. Blow-off the loose sand particles with the bellows and smoothen the upper surface.

10. Place the cope on to the drag in position. Locate riser pin on the highest point of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side of the riser pin.

12. Sprinkle the upper surface with parting sand.

13. Repeat steps 3 to 7, approximately.

14. Make holes with the vent rod to about 1 cm from the pattern.

15. Remove the sprue and riser pins by carefully drawing them out. Funnel shaped hole is made
at the top of the sprue hole, called the pouring cup.

16. Lift the cope and place it aside on its edge.

17. Insert the draw pin into the pattern. Wet the edges around the pattern. Loosen the pattern by
rapping. Then draw the pattern straight up. 18. Adjust and repair the mold by adding bits of sand,
if necessary.

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19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand particles in the
mold. 20. Close the mold by replacing the cope and placing weights on it.

Precautions:-

1. Do not get the sand too wet. Water is an enemy of molten metals.

2. Provide adequate ventilation to remove smoke and fumes.

3. Never stand near or look over the mold during the pouring because of the molten metal might
be too hot.

4. Do not shake out a casting too hastily, which may result in second and third degree burns.

Result: - A sand mold cavity is prepared by using Dum-Bell.

EXPERIMENT –VII

PRACTICE THE PRINCIPLE OF INDEXING OMN MILLING MACHINE

INTRODUCTION:

Milling is defined as the machining process for removing excess from the work piece by
feeding work against a rotating multipoint cutting tool. The rotating cutting tool called the
milling cutter is having the shape of a solid of revolution with a cutting teeth arranged either on
the periphery or on end face or on the both.

SIZE AND SPECIFICATIONS:

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  size of the milling machine usually denoted by dimensions (length &breadth ) of the table
of the machine
 number of spindle speeds
 .taper of the spindle nose
 .the maximum length of longitudinal, cross and vertical travel of the table

INDEXING :

The indexing is the operation of dividing the periphery of work into any number of equal
divisions by using special attachment known as dividing head or indexing head. It involves the
rotation of work through a required angle between two successive cuts so as to divide the
circumference into equally spaced divisions.

To facilitate indexing to fraction of a turn, index plates are used to cover practically all numbers.
Index plates with circles of holes patented by the Brown and sharp manufacturing company are
as follows :

Plate No:1-15,16,17,18,19,20

Plate No:2-21,23,27,29,31,33

PlateNo:3-37,39,41,43,47,49

These plates have also been accepted as standard index plates by the Indian standard machine
tool manufacturers. With the three index plates supplied, simple indexing can be used for all
divisions up-to 50,even numbers upto 100, except 96, and many others.

The index plate used on Cincinnati and Parkinson dividing heads is of larger diameter than
the brown and sharp index plates. The different series of holes are provided on each side of the
plate. The number of holes in each side of the plate are as follows:

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 First side: 24,25,28,30,34,37,38,39,41,42,43

Second side: 46,47,49,51,53,54,57,58,59,62,66

Result :

performed the indexing operation on milling /slotting machine

EXPERIMENT -VIII

HELICAL GEAR CUTTING IN MILLING MACHINE

AIM: To perform helical gear cutting using milling machine on a work piece.

INTRODUCTION :

helical or dry fixed gear offer a refinement over spur gears. The leading edges of the
teeth are not parallel to the axis of rotation, but are set at an angle. Since the gear is curved, this

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angling causes the tooth shape to be a segment of a helix.helical gears can be meshed in parallel
or crossed orientation.

MATERIAL USED :

 cast iron

TOOL REQUIRED :

 .vertical milling machine

 vernier caliper
 holding materials
 .milling tools

PROCEDURE :

 .the dividing head and the tail stock are bolted on the machine table. Their axis must be
set parallel to the machine table.
 the gear blank is held between the dividing head and tailstock using a mandrel. The
mandrel is connected with the spindle of dividing head by a carrier and catch plate.
 .the cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.
 set the speed and feed for machining.
 .for giving depth of cut, the table is raised till the periphery of the gear blank just touches
the cutter.
 the micrometer dial of vertical feed screw is set too zero in this position.
 then the table is raised further to give the required depth of cut.
 the machine is started and feed is given to the table to cut the first groove of the blank.

After the cut, the table is brought back to the starting position.

 .then the gear blank is indexed for the next tooth space.
 this is continued till all the gear teeth are cut.

DIAGRAM :

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RESULT :

The given workpiece as is subjected to gear generating operation to become a finished

workpiece

EXPERIMENT-IX

SERVICING AND MAINTENANCE OF ENGINE /MACHINE

COMPONENTS

A) CARBURETOR SERVICING:

AIM : dismantling assembling the carburetor

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EQUIPMENTS :

Key, vice, clear, cloth, screw driver, double and spanner set, kerosene, packing kit, required
super parts and grease.

PREPARATION :

 .vlean carburetor.
 .clean tray.
 .clean vice.

PROCEDURE :

 dismandle the carburetor

 disconnect able connection
 remove air cleaner
 remove carburetor from the engine inlet main fold.
 unscrew these studs on the float clam per cover.
 remove float cover assembly
 remove the float with toggle
 remove pump injectors, assembly with gas kit
 pedal accelerator pump connection rinks.
 remove the accelerator pump assembly
 remove the main jet holder
 unscrew the pump jet holder and remove pumplet

INSPECTION :

 toughly cleaned all parts in kerosene and ray out on a clean clothes
 check all components for wear and tears.
 wipe of all components and clean all circuits pets with compressed air.

FITTING NEW PARTS:

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 Check for fitting of parts

RE ASSEMBLING :

 tighten the pump jet holder and get in proper place.

 fit main jet and it's holder
 install the started cover and tighter the screw
 instial the accelerator connection to throttle and pump
 install the injector assembly with new gasket
 tight the carburetor on the inlet main fold with new gasket
 give connection to accelerate links vacuum advance unit.
 installed air cleaner
 tune the carburetor

RESULT :

Inspecting and reassembling the carburetor

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B) PISTON ASSEMBLY :

OBJECT : assembly the piston

CLEANING AND REMOVAL OF PISTON

Remove the piston and connecting rod assembly as follows :

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  drain the engine cooling system
 drain the engine oil and remove the oil pan
 remove the cylinder head
 .use an Emery cloth to remove any carbon deposits from the upper surface of the cylinder
liner.
 remove the bearing cap and lower bearing she'll from the connecting rod

PISTON ASSEMBLY DIAGRAM

ASSEMBLYOF THE PISTON AND CONNECTING ROD

 .discard used piston pin bolts and replace with new bolts
 for specifications on reusing piston assembly components.
 the pin bore and bearing backs should be wiped clean prior to installation of the bushings
in the piston dome.

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  installing piston pin bearings requires the upper bearing piece to be inserted through the
end of the pin bore and dropped over the retaining pin

 the lower bearing pieces are inserted flat side in by tilting the bearing at approximately a
30 angle from the vertical away from the dome ear.
 .lubricant the piston pin bearing with clean engine oil
 check piston pin for foreign matter in the Bolt holes
 apply a small amount of international compound. Or equivalent. To the Bolt threads and
Bolt head contact surface and both ends of the spacers

C) CLUTCH ASSEMBLY

AIM:to study dismantle, inspect and assemble the given clutch assembly

TOOL REQUIRED :

Hammer, tool set, screw driver, clutching ring

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STUDY:

The mechanism that transmits engine power to the rear wheels or to the front wheels, or to all
the four wheels is known as a transmission system. It comprises of the following main units.

 Clutch
 gear box, transfer box
 Propeller shaft, universal joints
 final drive, differential gear assembly
 rear Axles, wheel

DIAGRAM :

INSPECTION :

 .visually check the fly wheel, ring gear and pressure for crankshaft
 .check the flatness of friction faces of the pressure plate with straight edge
 .if flatness is not found within the specific limit without the pressure plate and flywheel
can ground so not ground below the minimum specific thicknesses

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  check the free length and tension of pressure spring
 check the pressure plate tension usually for any damage. Replace the clutch plate if any
torsion spring found damaged
 measure the thickness of clutch lever. Release if thickness of clutch lever is less than
minimum specified.

ASSEMBLING :

 place the clutch finger Bush in the clutch fingers.

 fit the clutch bracket with eccentric pin.
 hand tighter mounting set screw of clutch bracket.
 align The marks of clutch plate and pressure plate and place the clutch over the pressure
plate.
 compress the spring with clutch finger.
 place the pressure pad on the pressure plate and tighten the pad mounting set screws.
 release the load from the spring and remove clutch cover assembly from the clutch kit.
 place the withdrawn plate, retaining plate on the clutch kit finger, tighten mounting set
screws of the withdrawn plate.

RESULT :Thus the given clutch assembly is disconnected, inspected and assembled.

D) GEAR BOX ASSEMBLY

AIM: To Study, Dismantle, Inspect and Assemble the Given Gear Box Assembly

TOOLS REQUIRED:

Hammer, Tool Set, Screw Driver, Sockets, Spanner Set, Pullers

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PRINCIPLE:

 Gear Box Contain Gearing Arrangement To Get Different Speeds

 Gears Are Used To Get More Than One Speed Ratios.
 When Both Mating Gears Have Same Number Of Teeth, Both Will Rotate At The Same
Number Speed.
 In Atypical Car, There May Be Six Gears Including One Reverse Gear.
 Gears Are Engaged And Disengaged By As haft Lever

DIAGRAM:

INSPECTION:

 Clean All the Components

 Check the Parts Visually For Damages Due To Wear
 Measure the Clearance between the Bushes and Their Respective Gears and Placed
By Bushed Gear

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  If the Clearance Found Is More Than Specific limit, measure the clearance found
more than projection of the bush & above the gear

ASSEMBLING:

 place the oil seal in the rear end cover place the drift on the drift on the oil seal
 press the oil seal in the cover by drift & fix it
 clamp the lay shaft in its position temporarily
 .fix the lever idler gears along with the shaft& level it
 .fix the bearing on the rear and bearing drive shaft & fit a cir clip.
 Fix the drive shaft by mallet and rotate by hand to ensure pilot in the drive shaft
bore.
 fix all the bearing covers along with gasket on the rear casting
 Place the drive flange on the main shaft & lock it by engaging the two gears.

RESULT: thus the given gearbox assembly is dismantled, inspected and assembled

E) PROPELLER SHAFT AND UNIVERSAL JOINT

AIM: to study, dismantle, inspect and assemble the given propeller shaft unit

TOOLS REQUIRED:

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Hammer spanner, screwdriver,sockets, and puller

DIAGRAM:

INSPECTION:

 Check up the straightness if bent, straighten it.

 Checkup universal joint crosses and bearings, if broken or worn replace them
 Checkup propeller shaft supporting mounting, if loose tighten it.
 Check up the universal joint bolt nuts. If loose tighten it.
 Checkup alignment of splines at sliding joint. If properly aligned them with the
help of arrows.
 Check the parts visually for damages due to improper lubrication and rectify.

ASSEMBLING:

 Insert the sleeve, place the bearing, top the bearing seat, replace the bearing
rubber, and fit the bracket on the shaft
 Tighten the lock nut to the specified torque and lock nut

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  Connect the propeller shaft and pinion flange, shaft flange and universal joints.

RESULT:

Thus the given propeller shaft unit is dismantled, inspected and assembled

F) ASSEMBLE THE DIFFERENTIAL UNIT:

AIM: to study, dismantle, inspect and assemble the given differential unit

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TOOLS REQUIRED:

Hammer, socket, extension rod, racket, leverage rod, strain driver

DISMANTLING:

 Remove output shaft/drive flange

 Pulling off tapered roller bearing inner race
 Remove tapered roller bearing outer race
 Remove bearing body for tapered roller bearing
 Remove differential
 Remove O-ring
 Remove the adjusting ring for tapered roller bearing
 Remove output shaft/drive flange
 Remove tapered roller bearing outer race
 Remove the small bevel gears, large bevel gears.

INSPECTION:

 Visually check the final drive gear. It is riveted onto differential housing and then
machined. If differential or final drive gear is damaged, replace differential
housing along with riveted final drive gear.
 Visually check all the spare parts and replace required parts .replace o rings
always

ASSEMBLING:

 Place, position, install, press and assemble all the spare parts as needed in the
reverse order of dismantling.

DIAGRAM:

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RESULT:

Thus the given differential unit is dismantled, inspected and assembled

EXPERIMENT-X

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 ASSEMBLY OF SMALL COMPONENTS SUCH AS, TAIL STOCK,
CHUCKS OF LATHES, 3-JAW CHUCK
4-JAW CHUCKS

A) TAIL STOCK:

OBJECT:

The spindle and screw are lubricated by 4 oiler located on top of the spindle
housing, the tailstock lock is lubricated with one oiler located on the front face. The bed
ways on which the tail stock slides should be cleaned and oiled frequently

DIAGRAM:

MANUAL TAILSTOCK:

 The tailstock spindle is extended and retracted through the use of the
hand wheel. The tailstock has 2.52” (64mm) of travel
 The spindle of the tailstock accepts 3 Morse taper tooling
 A grease fitting connection is provided for periodic lubrication

TAILSTOCK ALIGNMENT:

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  Once the rotary table indexer table information is recorded, align the tailstock
so that approximately one inch of travel will engage the work piece
 Indicate the height of the tailstock spindle centerline and compare with the
rotary table indexer. Centerline height should be within 0.001” (0.0254mm).
ifgreater than 0.001” (0.0254mm). shims are required either under the rotary
table indexer or tailstock

DIAGRAM:

REMOVAL:

To remove the live center in the manual tailstock, retract the spindle into the body
and the lead screw will force the center out. To remove the live center in the pneumatic
tailstock, wedge an aluminum bar between the face of the spindle and the rear surface of
the live centers flange and lightly tap with a brass until free

B) CHUCKS:

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  Work Pieces of short length, large diameter and irregular shapes.
 Which cannot be mounted between centers , are held quickly and rigidly
in
 Chuck there are different types of chucks namely , there jaw universal
 Chuck, four jaw independent chuck, Colet chuck and combination chuck.

THREE JAW SELF –CANTERING CHUCK:

The three jaws fitted in the three slots may be made to slide at the same time by an equal
amount by rotating any one of the three pinions by a v chuck key. This type of chuck is suitable

50
for holding and rotating regular shaped work pieces like round or hexagonal rods about the axis
of the lathe. Work pieces of irregular shapes cannot be held by this chuck

FOUR JAW INDEPENDENT CHUCK:

There are four jaws in this chuck each jaw is moved independent by rotating a screw with
the help of a chuck key. A particular jaw may be moved according to the shape of the work.
Hence this type of chuck can hold works of irregular shapes. But it requires more time to set the
work aligned with the lathe axis. Experienced turners can set the work. About the axis quickly,
concentric circles are inscribed on the face of the chuck to enable quick cantering of the work.

Once you are sure that the parts are true, tighten the chuck as tight as necessary to hold
the part without damaging the clamping surface. This is done by placing the “chuck key” in the
key receptacle on the side of the chuck and turning it clockwise

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