King Saud University
Mechanical Engineering Department
Lab Notes
Manufacturing Processes ME-311
By
Dr. Magdy El-Rayes Dr. Adel Taha Abbas
Associate Professor Associate Professor
1
King Saud University
Mechanical Engineering Department
Lab Notes
Manufacturing Processes
ME-311
Student Name:………………………………………………………………..
Student ID……………………………………………………………………
Academic Year…………………………………………………………………
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Table of Contents
Manufacturing Processes ME-311 Lab
Week # Contents
Dr. Adel Taha Abbas
1 Metal Cutting Workshop Overview
2 Measurements (V.Calipers + Micrometers)
3 Marking and Benching Operations
4 Turning Machines
5 Milling Machines
6 Drilling Machines
7 Grinding Machines
Mid-Semester
Dr.Magdy El Rayes
8 Metal Forming,Casting and Welding Overview
9 Metal Forming Measurements
10 Layout
11 Extrusion
12 Rolling
13 Sand Casting
14 Welding
Appendex
Exam
3
Lab Report #1
Metal Cutting Workshop Overview
Recognize the main machines in metal cutting workshop
# Machine Name Type Sketch
1 Turning Center
Machine Lathe
2 Milling Vertical
Machine Milling
Machine
3 Milling Horzental
Machine Milling
Machine
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4 Milling Universal
Machine Milling
Machine
5 Drilling Bench
Machine Drilling
Machine
6 Drilling Radial
Machine Drilling
Machine
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7 Grinding Surface
Machine Grinding
8 Grinding Cylindrical
Machine Grinding
9 Grinding Hand
Machine Grinder
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10 Reciprecoating Shaper
Machine Machine
11 Reciprecoating Slotting
Machine Machine
12 Reciprecoating
Machine
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Lab Report # 2
Measurements
Measurement means to compare something with standard.
E.g. measuring length of a wire, diameter of a cylinder, depth of any object.
Measurement Units:
Meter and its sub-multiple
Measuring Tools:
Meter Tape
Steel Scale
Vernier Calipers
Micrometers
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Vernier Caliper:
Vernier caliper is a measuring device used to measure precise increments between two
points.
Function:
To measure smaller distances.
Can measure up to 0.01 mm.
Features:
Larger, lower jaws are designed to measure outer points e.g. diameter of a rod.
Top jaws are designed to measure inside points e.g. size of a hole.
A rod extends from the rear of the caliper and can be used to measure the depth.
Structure of the Caliper
Parts of a Vernier caliper:
1. Outside jaws: used to measure external diameter or width of an object
2. Inside jaws: used to measure internal diameter of an object
3. Depth probe: used to measure depths of an object or a hole
4. Main scale: scale marked every mm
5. Main scale: scale marked in inches and fractions
6. Vernier scale gives interpolated measurements to 0.1 mm or better
7. Vernier scale gives interpolated measurements in fractions of an inch
8. Retainer: used to block movable part to allow the easy transferring of a measurement
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Dial caliper
Digital Caliper
Accuracy of the Veriener Caliper:
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How to Use the Veriner Caliper :
Examples:
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Recognize and revise the main parts of Veriner Caliper and try to
take some measurements from the available workpieces:
# Dimension Drawing
Workpiece-1
1
2
3
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Workpiece-2
1
2
3
4
5
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Micrometrs:
A micrometer is a device incorporating a calibrated screw used widely for precise measurement
of small distances in mechanical engineering and machining.
Types of Micrometers
Outside micrometer, typically used to measure wires, spheres, shafts and blocks.
Inside micrometer, used to measure the diameter of holes.
Depth micrometer, measures depths of slots and steps.
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Construction of Micrometer:
A micrometer is composed of:
Frame: The C-shaped body that holds the anvil and barrel in constant relation to each other.
Anvil: The shiny part that the spindle moves toward, and that the sample rests against.
Sleeve: The stationary round part with the linear scale on it.
Lock nut: The knurled part (or lever) that one can tighten to hold the spindle stationary, such as
when momentarily holding a measurement.
Screw (not seen): The heart of the micrometer. It is inside the barrel.
Spindle: The shiny cylindrical part that the thimble causes to move toward the anvil.
Thimble: The part that one's thumb turns. Graduated markings
Ratchet stop: (not shown in illustration)
Device on end of handle that limits applied pressure by slipping at a calibrated torque
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How to Use the Micrometer :
Reading 5.78 mm
Examples:
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Recognize and revise the main parts of Micrometer and try to take
some measurements from the available workpieces:
# Dimension Drawing
Workpiece-1
1
2
3
4
5
6
7
8
9
10
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Workpiece-2
1
2
3
4
5
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Lab Report # 3
Marking and Benching Operations
Recognize on the marking tools available in the workshop
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Exercise-1
Mark the block as shown below
Use the Bench drill to create holes as specified in the Design Drawing
Use the Tap Set to create thread in the holes as specified in the Design Drawing.
Check the Thread Size
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Exercise-2
Recognize the Die Thread Construction
Use the Die Thread M12X1.75 to create thread on the bar according to design drawing
Check the Thread size
Remark:
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Lab Report # 4
Turning Machine
Construction, Turing Operations, Turning Tools and Threading
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Recognize the main parts in the Turning Machine
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Define the type of cutting tool and operation name for the following Turning Operations
# Drawing Cutting Tool Operation Name
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# Drawing Cutting Tool Operation Name
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# Drawing Cutting Tool Operation
Name
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11
12
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# Drawing Cutting Tool Operation
Name
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Remarks:
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State the available spindle speed (rpm) in your Turning Machine
# N = RPM # N = RPM
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
State the available Feed rate (mm/rev) in your Turning Machine
# Feed rate (mm/rev) # Feed rate (mm/rev)
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
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State the available Pitch (mm) in your Turning Machine
# Pitch (mm) # Pitch (mm)
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
Study the effect of Feed Rate on the surface finish – Demonstrate this relation by some
experimental values.
# Feed mm/rev Value of Surface Finish Ra
1 0.1
2 0.2
3 0.3
4 0.4
Remark:
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Lab Report # 5
Milling Machines
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1- Recognize the main parts of milling machines
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2- State the different types of milling machines
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3- Recognize and draw some tools are be used with milling machines
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4- Draw the construction features of vertical milling machine
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5- Draw some operations can be done on vertical milling machine
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6- Draw the construction features of horizontal milling machine
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7- Draw some operations can be done on horizontal milling machine
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Lab Report # 6
Radial Drilling Machine
36
1- Recognize the main parts of radial drilling machines
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State the available spindle speed (rpm) in your Radial Drilling Machine
# N = RPM # N = RPM
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
State the available Feed rate (mm/rev) in your Radial Drilling Machine
# Feed rate (mm/rev) # Feed rate (mm/rev)
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
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2- Recognize and draw some tools are be used with drilling machines
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3- Draw the construction features of radial drilling machine
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4- Draw some operations can be done on radial drilling machine
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Lab Report # 7
Grinding Machines
42
1- State the different types of grinding machines.
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2- Draw the construction features of cylinderical grinding machine
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3- Draw the construction features of surface grinding machine
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4- Draw the different shapes of grinding wheels which are be used with grinding
machines
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5- State the different types of abrasive materials
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6- Draw the dressing system for grinding wheels
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