DAILY

WORKSHOP:DIARY
Machine Shop
GROUP MEMBERS:
12102029- Mukesh Kwatra
12102068- Aditya Aggarwal
12102070- Viresh Verma
12102083- Agam Sachdeva
12102084- Rajit Mehan

WORKSHOP COMMENCED: 28th May 2013

WORKSHOP ENDED: 19th June 2013
JOB: Multiple operations on a workpiece.

DAY-1
On the first day we were allotted our workshops.
Our group was allotted the machine shop. After
the allotment process got over, we went to the
shop. We interacted with other groups as well as
with the instructors. We were briefed about the
work in the shop and advised to be sincere,
disciplined and punctual.

DAY-2
On the second day, we were provided with the
sketch of the job to be made and we were all
required to have a copy of the sketch. The sketch
was complete in all respects and all the
operations to be performed were highlighted.
The operations were mentioned in order. The
estimated time required to perform each
operation was also mentioned.
Each group was required to make three jobs. We
cut out three pieces of length 175mm and
diameter 36mm from a long rod of mild steel.
This was done with the help of Power Hacksaw.
Power Hacksaw is used to cut metals in large
size, something which is not possible manually.
The blade of the Power Hacksaw is made of High
Speed Steel (HSS). The machine works on a
hydraulic mechanism. We also poured coolant on
the blades to avoid damage to the blade due to
prolonged heating due to the cutting of metal.

After this, we started with the facing of the cut

out pieces. Facing was done on lathe machine
with the help of single point cutting tool. For this
purpose, the job is held in a three-jaw chuck or
centring chuck. As the name suggests, this holds
the job exactly in centre. For proper facing, the
tool is taken from inside to the outside.

DAY-3
On the third day, we continued with the facing of
the jobs. We also performed drilling and countersunking on both the faces of the jobs. This is
required to hold the job properly in head stock
and tail stock.
We were also explained the step turning process.

DAY-4
For the step turning process, firstly marks were
made on the job with the help of a chalk and pen
to highlight the distinction between different

diameters. After this, we started with the step

turning process. The job is first fixed in the job
holder with the help of bench vice. Step turning
is done with a single point cutting tool which is
moved from right to left and job rotates
anticlockwise.

DAY-5
On this day we continued with the step turning
process.

DAY-6
We continued with the step turning process on
the three jobs. By the end of this day, we were
finished with step turning operation.

DAY-7
Due to one-sided cutting, the boundary between
two different diameters is tapered. On this day,
this taper was removed and edges were
straightened with the help of edge straightening

tool. We were also introduced to the milling

machine and explained about the milling
operation.
We were told about the various parts of the
milling machine-arm arbour, indexing plate,
bracket and also about different cutters like
involutes cutter, slab mill cutter, angular cutter
etc.

DAY-8
We did hexagonal milling. In this we use slab mill
cutter made of HSS is used which is of helical
shape. We did indexing by applying the formula
40/N were N is the number of sides required.
As in this case N = 6.

So the ratio 40/N becomes 6(2/3). This requires

us to rotate the hand wheel 6 times and
additional 2/3 turns. We compute 2/3 holes in the
following manner:
We multiply and divide by 7 to make 21 in the
denominator so the resultant becomes 14/21.
This takes us to the conclusion that we have to
rotate additional 14 holes to complete the
remaining 2/3 turns since in total the circle in
which we were rotating in the indexing plate had
21 holes.
During the milling operation, water in the form of
coolant was continuously supplied to counter the
heat produced due to metal cutting.
We were explained about the knurling and taper
turning processes.

DAY-9

We continued with the milling process. It was a

lengthy process and it took about three quarters
of an hour to complete one job.
Side by side, we also began with the knurling
process.
For the knurling process, knurling tool is fitted in
the lathe machine, job is rotated counterclockwise and the tool is hard-pressed against
the job to produce a criss-cross pattern. The tool
is moved both in forward and backwards
direction to produce the correct pattern.

DAY- 10
Today we continued with the milling and knurling
processes and these operations were done with.
Next we moved to the taper turning process.
First of all, we calculated the taper angle. The
formula for this is:
Tan A=(D-d)/2l
Substituting the values,
D=25mm
d=20mm
l=20mm
We found the angle is 7 degrees
approximately.We rotated the dial to 7 degree

and started taper turning.In this carriage wheel

is not rotated.Cross feed and compound wheel is
rotated.
We were also explained about the V-shaped
threading process, to be done at 6TPI.

DAY- 11
Today we did square threading on the job. We
were taught by our instructors about different
typex of threading like V-shaped threaing whose
tool angle is 55 degree, acme threads whose tool
angle is 29 degree etc. After threading we did
filing on our job to give it smooth finishing. TPI of
this thread is 6 , so the depth of the cut as
calculated by the formula
Depth of cut = 1/(TPI X diameter)
Which gives us 2 mm, so the depth of cut is 2
mm.

Coolant was poured continuously to avoid damge

to the job and tool due to over-heating.

DAY- 12
Today we did V-shaped threading on the job. To
accomplish this job, orthogonal tool was used .
The TPI required for square threading was 10, so
the depth of the cut using above formula is 4.18
mm. We used coolant to avoid damage to our job
and tool due to over heating . In this case also
filing was done to give smooth finishing.

DAY- 13
After finishing square threading, we moved on to
drilling and parting off of the hexagonal part of
our job. To accomplish this we held the job in the
3-jaw chuck. The drill of mearurment 16.5 mm
was used which was held still while our
workpiece was rotated. Coolant was poured to
reduce heat at the tool job interfrace and thus
acted as a coolant. Drill was taken inside up to
the sleeve part. After this, parting was done to
using a tool similar to square threading tool.
Clearance is kept double the width of the tool to
avoid the stucking of the tool. After this facing
was done with the help of facing tool to give
finishing.

DAY-14
On this day we performed internal threading
operation on the parted hexagonal part with the
help of tap. The job was held horizontally in the
bench vice. After this tap was inserted in the
drilled hole while the tap was held using tap
holder. The tap was first rotated clockwise for a
few turns and then turned anticlockwise so that
the generated chips may fall. All through this
procedure, lubricant oil was applied to the tap
for the smooth movement of the tap and
generation of threads.

DAY-15
On this day, first of all the knurled part of the job
was drilled using a 16.5mm diameter drill.
Following this, the knurled part was parted off
from the job. During the course of drilling and
parting off, constant coolant supply was provided
for. To enlarge the diameter to 18mm, boring tool
was used. The tool, moved with the help of
compound rest, was moved through the knurled

part so that uniform diameter on both the ends

could be obtained.
For internal tapering, dial on the tool post was
set to 7. The boring tool was moved forward
with the help of compound rest wheel throughout
the job to obtain taper on the internal side.

DAY-16
On this day, we did the facing of the job to
produce better surface finish of the ends of the
job. This was done on the lathe machine.

Day-17
On this day, we rubbed emery paper on the jobs
to remove the rust and to give a fine shiny
appearance to the jobs. Due to application of
water as a coolant rust had settled on the job.
To accomplish this, first of all machine oil was
applied on the jobs and emery paper was rub on
it.