Experiment-1:

Study of Bench Grinding and It’s Operations

The grinding process consists of removing material from the workpiece by the use of a rotating wheel that
has a surface composed of abrasive grains. Grinding is considered to be the most accurate of the existing
machining processes, Grinding processes are used when high accuracies, close dimensional tolerances,
and a fine surface finishes are required. Grinding processes also allow for high production rates. This
allows for a lowered cost of production. Hard materials can also be machined.

Fig: Surface grinding machine

Surface grinding is most common of the grinding operations. A rotating wheel is used in the grinding
of flat surfaces. Types of surface grinding are vertical spindle and rotary tables.

Internal grinding is used to grind the inside diameter of the workpiece. Tapered holes can be ground
with the use of internal grinders that can swivel ion the horizontal.
Cylindrical grinding is also called center-type grinding and is used in the removing the cylindrical
surfaces and shoulders of the workpiece. Both the tool and the workpiece are rotated by separate motors
and at different speeds. The axes of rotation tool can be adjusted to produce a variety if shapes.

Common Grinding Wheels: A grinding wheel is made of abrasive grains held together by a bond. These
grains cut like teeth when the wheel is revolved at high speed and is brought to bear against a work piece.
The properties of a wheel that determine how it acts are the kind and size of abrasive how closely the
grains are packed together and amount if the bonding material.
Experiment-2:
Study of Radial Drill and It’s Operations

A drill press is preferable to a hand drill when the location and orientation of the hole must be controlled
accurately. A drill press is composed of a base that supports a column, the column in turn supports a
table. Work can be supported on the table with a vise or hold down clamps or the table can be swiveled
out of the way to allow tall work to be supported directly on the base. Height of the table can be adjusted
with a table lift crank than locked I place with a table lock. The column also supports a head containing a
motor. The motor turns the spindle at a speed controlled by a variable speed control dial. The spindle
holds a drill chuck to hold the cutting tools (drill bits, center drills, deburring tools etc.)

Radial drilling machines: used on large workpieces, spindle mounts on radial arm allowing drilling
operations anywhere along the arm length.

Gang–drilling machines: independent columns each with different drilling operation work piece slide
from one column to next
 Radial drill machine Gang drill machine

Various operations that can be performed on a Drilling Machine

Experiment-3:
Study of Shaper Machine and It’s Operations

The shaper is a relatively simple machine. It is used fairly often in the tool room or for machining one or
two pieces for prototype work. Tooling is simple and shapers do not always require operator attention
while cutting. The horizontal shaper is the most common type and its principal components are shown
below and described as follows:

Ram: The ram slides back and forth in dovetail or square ways to transmit power to the cutter. The
starting point and the length of the stroke can be adjusted.

Toolhead: The toolhead is fastened to the ram on a circular plate so that it can be rotated for making
angular cuts. The toolhead can also be moved up or down by its hand crank for precise depth adjustments.

Shaping machine

Clapper Box: The clapper box is needed because the cutter drags over the work on the return stroke. The
clapper box is hinged so that the cutting tool will not dig in. Often this clapper box is automatically raised
by mechanical, air or hydraulic action.

Table: the table is moved left and right, usually by hand, to position the work under the cutter when
setting up. Then either by hand or more often automatically the table is moved sideways to feed the work
under the cutter at the end or beginning of each stroke.
Quick Return Mechanism

The shaping machine is used to machine is used to machine flat metal surfaces especially where a large
amount of metal has to be removed. Other machines such as milling machines are much more expensive
and are more suited to removing smaller amounts of metal very accurately.

The reciprocating motion of the mechanism inside the shaping machine can be seen in the diagram. As
the disc rotates the top of the machine moves forwards and backwards pushing a cutting tool. The
cutting tool removes the metal from work which is carefully bolted down.

Quick return mechanism

Various cutting operations that can be performed on a Shaping Machine

GROOVES T -SLOT

DOVETAILS FLATS and ANGLES

Experiment-4:
Study of Milling Machine and It’s Operations
Milling machine is one of the most versatile conventional machine tools with a wide range of metal
cutting capability. Many complicated operations such as indexing, gang milling, and straddle milling
etc. can be carried out on a milling machine. Milling machines are among the most versatile and useful
machine tools due to their capabilities to perform a variety of operations. Milling machines can be
classified as horizontal and vertical.
(A) Horizontal Milling Machine

Column: The column houses the spindle, the bearings, the gearbox, the clutches, the shafts, the pumps and the
shifting mechanisms for transmitting power from the electric motor to the spindle at a selected speed.

Knee: The knee mounted in front of the column is for up or down motion supporting the table and to
provide up and down motion along the Z axis.

Fig : Horizontal milling machine

Saddle : The saddle consists of two slide ways , one on the top and one at the bottom located at 90◦
to each other for providing motions in the X or Y axes by means of lead screws.
Table: The table is mounted on top of the saddle and can be moved along the X axis. On top of the table
are some T-slots for the mounting of workpiece or clamping fixtures.

Arbor: The arbor is an extension of the spindle for mounting cutters. Usually, the thread end of an arbor
is of left hand helix.

(B) Vertical Milling Machine

Column : The column houses the spindle, the bearings, the gearbox, the clutches, the shafts, the pumps and
the shifting mechanisms for transmitting power from the electric motor to the spindle at a selected speed.

Knee: the knee mounted in front of the column is for supporting the table and to provide an up or down
motion along the Z axis.

Saddle: The saddle consists of two slide ways, one on the top and one at the bottom located at 90◦to each
other, for providing motions in the X or Y axes by means of lead screws.

Table: The table is mounted on top of the saddle and can be moved along the X axis. On top of the table
are some T-slots for the mounting of workpiece or clamping fixtures.
Milling head : The milling head consisting the spindle, the motor and the feed control unit is mounted on
a swivel base such that it can be set at any angle to the table.

Ram: The ram on which the milling head is attached can be positioned forward and backward along the
slide ways on the top of the columns.

Various cutting operations that can be performed on milling machine

Peripheral Milling
a)slotting
b)slitting
c)slab milling
d)slitting
e)form milling
f) side milling
g) straddle milling
h) end milling
Face milling