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1. MANUFACTURING PROCESS LAB-III

2. FOUNDRY
1. Study of Foundry tools
2. Mould preparation using solid-
patterns
3. Mould preparation using split-
patterns
GEAR CUTTING
4. Study of gear hobbing machine
5. Helical gear hobbing
6. Spur gear Milling
LIST OF EXPERIMENTS
TOOL GRINDING
7. Study of tool and cutter grinder
8. Grinding of single point cutting tool
CNC PROGRAMMING
9. Study of CNC turning and milling
machines
10. Programming of CNC turning
11. Programming of CNC milling

3. What is Manufacturing?
Derived from the Latin word manufactus
–Manus=hand, factus= made(‘made by hand’)
– practical definition: process of converting or
processing raw materials into usable products.

4. Classification Of Manufacturing Process
Its classified as
 Primary shaping process
 Secondary shaping process

5. Primary Shaping Process
 It is the oldest manufacturing process.
 Its manufacture a product directly to its usable form.
Example : casting process
Products : channels, rods, I- section etc.,

6. Primary Shaping Process
Liquid state Solid state
• Forging
• Rolling
• Die forging
• Hot rolling
• Tube forming
• Upsetting
Metal casting process
• Sand mold casting
• Die casting
• Shell mold casting
• Continuous casting
Moulding process
• Injection moulding
• Compression
moulding
• Transfer moulding.

7. Secondary Shaping Process
• These process are carried out on the outcome of primary
shaping process like casting.
• In many cases the product from the primary forming process
are required to under go further refinement the shape and
size through various process of metal removal such as
turning and milling.
• Finishing process such as buffing, lapping are done for
surface finish on the product.

8. Secondary Shaping Process
solid state Super finishing
• Lapping
• Belt grinding
• Buffing
• Honing
• Cold working
• Bending
• Punching
• Rolling
• Cold extrusion
• Coining
• Thread rolling
• Spinning
• Stretch forming
Metal removal process

9. Foundry
• The place where the casting works to be carried out is called
“FOUNDRY SHOP”.
• Casting is the process of pouring the molten metal into the
refractory cavity of the shape to be mold, and allow them for
solidification.

10. Steps Involved In Casting Process
 Pattern making
 Mould making
 Casting.

11. Pattern and Pattern Making
Pattern is the model of the object to be mold with some
modification.
The following points should be considered while making the
pattern.
 Pattern material
 Types of pattern
 Pattern allowances

12. Types Of Pattern
The types of the pattern and the description of each are given
as under.
1. One piece or solid pattern
2. Two piece or split pattern
3. Cope and drag pattern
4. Three-piece or multi- piece pattern
5. Loose piece pattern

13. Single-piece Or Solid Pattern
Solid pattern is made of single piece without joints,
partings lines or loose pieces. It is the simplest form of the
pattern.

14. Two-piece Or Split Pattern
When solid pattern is difficult for withdrawal from the
mold cavity, then solid pattern is splited in two parts.
Split pattern is made in two pieces which are joined at
the parting line by means of dowel pins. The splitting at the
parting line is done to facilitate the withdrawal of the pattern.
Two piece pattern

15. Pattern Allowance
 Pattern are not made to the exact size of the casting to be
produced.
 It should be made little higher size than the required
castings.
 Extra size on the pattern given is called “Pattern
Allowances”

16. Various Tools Used In Foundry

17. CONT.,
1.SHOVEL
Shovel is a big tool used for mixing and transferring
moulding sand.
2. RIDDLE
It is metal sieve used for removing foreign materials such
as stones, nails etc., from the moulding sand.
3. RAMMER
It is a tool made of wood or cast iron used for packing or
ramming the moulding sand in the moulding box.
4. TROWELS

18. 6.VENT ROD
This rod is used for making vent holes in the sand mould so
that the molten gases released during pouring of molten
metal, can easily escape from mould.
7.SPRUE PIN
It is a tapered cylindrical wooden piece. It is used for making
a sprue hole in the mould, to facilitate pouring of metal
CONT.,

19. MOULD PREPARATION USING SOLID- PATTERN
AIM:
To make the mould for the given solid pattern (stepped cone pulley).
MATERIAL AND TOOLS REQUIRED:
• Riser pin
• Moulding box
• Sprue pin
• Green sand
• Rammer
• Trowel
• Lifter
• Riddle
• Draw spike
• Gate cutter
• Bellow
• Vent rod

20. Pattern Moulding process
MOULD PREPARATION USING SOLID- PATTERN

21. STEPS INVOLVED TO PREPARE SAND MOULDING
WITH SOLID PATTERN
• Place the Moulding board on a horizontal surface.
• The drag box is placed above the Moulding board. Now the pattern is
kept at center of drag.
• Now parting sand in sprinkled before we keep pattern.
• Facing sand is sprinkled over the pattern to a depth of 5mm. then green
sand is filled over it.
• Proper ramming is done on the green sand to get a air tight packing.
• Excess sand is removed by strike off bar.
• The drag box is inverted upside down.

22. • The cope box is placed over the drag box and locked.
• The riser pin sprue pin placed at right position and green sand is filled over the
pattern.
• Proper ramming is done on the green sand to get air tight packing with strike
off bar leaving is done.
• Now riser pin and sprue pin get removed from the green sand mould. The
pattern is removed by draw spike tool.
• Gate is prepared using gate cutter and core is placed vertically inside the cavity.
• The vent holes are made with vent rod and cope.
Result:
Thus the mould is created for given stepped cone pulley.
CONT.,

23. MOULD PREPARATION USING SPLIT- PATTERN
AIM:
To make the mould for the given Split pattern
MATERIAL AND TOOLS REQUIRED:
• Riser pin
• Moulding box
• Sprue pin
• Green sand
• Rammer
• Trowel
• Lifter
• Riddle
• Draw spike
• Gate cutter
• Bellow
• Vent rod

24. MOULD PREPARATION USING SPLIT-
PATTERN
Pattern Moulding process

25. STEPS INVOLVED TO PREPARE GREEN
SAND MOULDING WITH SPLIT PATTERN
• Place the Moulding board on a horizontal surface.
• The drag box is placed above the Moulding board. Now one piece of
pattern is kept at center of the drag as shown in figure.
• The parting sand is spread before we keep the pattern.
• Facing sand is sprinkled over the pattern to a depth of 2mm. then
greensand is filled over it.
• Proper ramming is done on the green sand to get a air free packing.
• Excess sand is remove with strike off bar.
• The drag box is inverted upside down.
• The cope box is place over the drag box.

26. • Now the parting sand is sprinkled over the parting surface.
• The other piece of pattern is placed over the drag box.
• Facing sand is riddled over the pattern to a depth of 5mm. Then riser is place over the
pattern and another sprue pin above parting surface.
• Now green sand is filled over it.
• Ramming operation is done to get an air tight packing.
• Excess sand is remove with strike off bar.
• Riser pin and sprue pin gets removed from the green sand.
• Pattern is removed gently now.
• Gate is provided by the use of gate cutter.
• The vent holes are made with vent rod on the cope box.
Result:
Thus the mould is created for the given split pattern.
CONT.,

27. MILLING
• Milling is the cutting operation that removes metal by feeding the
work against a rotating cutter having single or multiple cutting
edges.
• Flat or curved surfaces shapes can be machined by milling with
good finish and accuracy.
• A milling machine may also be used for drilling, slotting, making
a circular profile and gear cutting by having suitable attachments.

28. MILLING MACHINE

29. MILLING MACHINE
Table overall size : 1175x230mm
Longitudinal movement:
• Auto : 560mm
• Manual : 270mm
Transverse movement:
• Auto : 250mm
• Manual : 270mm
Vertical movement(Manual) : 340mm
• Table swivel to either side : 45
• Speed range : 40 to 2000 rpm
• Feed Range : 10 to 111 mm/min

30. SPUR GEAR MILLING
AIM:
To cut a spur gear in the milling machine as per the given diameter.
MATERIAL REQUIRED:
Mild steel of 50mm diameter and 25mm thick.
TOOLS REQUIRED:
1. Lathe 2. Milling
• Chuck key a) Milling cutter
• Tool post key b) Spanner
• Dead centre c) Sleeve
• Parallel Block d) Indexing head
• Vernier
• Centre drill
• Drill
• Reamer

31. SPUR GEAR MILLING

32. CALCULATION SPUR GEAR
Spur gear module = 2 module (Given)
Module = PCD/Z
No of teeth = 27 (Given)
Blank diameter = (Z+2) x module
= (27+2) x 2
= 58 mm
Teeth depth = 2.25 x module
= 2.25 x 2
= 4.5 mm
Index plate movement = 40 / Z
= 40 / 27
= 1 13/27
1= One revolution
13= No. of holes
27= Index plate number

33. STEPS INVOLVED TO MAKE SPUR GEAR MILLING
• The given work piece has been fixed on the chuck by the use of
center bit.
• With the help of tail stock the 10 mm hole has been made on the
work piece.
• Again 20 mm drill bit has been fixed on the tailstock to provide 20
mm hole on the work piece.
• By the use of boring tool 22mm hole has been made on the work
piece.
• The work piece has been fitted on the milling machine with the help
of mandrel.

34. CONT.,
• Fix the cutter in the arbor rigidly and check the index mechanism
before the operation.
• Fix the work piece and cutter to zero position by raising the table
upward for contact each other.
• Give the depth of cut as 4.5mm by raising the table towards the
cutter and fed the table longitudinal to form the gear tooth
• Repeat the process, for every indexing of gear tooth
• The above procedure is repeated for the gear operation.
• The work piece has been removed from the mandrel.

35. STUDY OF HOBBING MACHINE
• Hobbing is a Machining process for making gears, splines, and sprockets on
a hobbing machine, which is a special type of milling machine.
• Compared to other gear forming processes it is relatively inexpensive but
still quite accurate.
• It is the most widely used gear cutting process for creating spur and helical
gears and more gears are cut by hobbing than any other process since it is
relatively quick and inexpensive.

36. HOBBING MACHINE

37. GEAR HOBBING MACHINE
SPECIFICATION
• Maximum module : 4 modules
• Maximum diameter of gear : 350mm
• Diameter of work table : 340mm
• Hob speed range (RPM) :60/75/90/115/150/190
• Maximum with cut of spur gear : 250mm
• Maximum with cut of helical gear : 200mm

38. HOB
• The hob is the cutter used to cut the teeth into the work piece.
• It is cylindrical in shape with Helical cutting teeth.
• Most hobs are single-thread hobs, but double and triple-thread hobs
increase production rates. The downside is that they are not as accurate
as single-thread hobs.

39. HELICAL GEAR HOBBING
AIM:
To machine a helical gear on the hobbing machine as per the
required dimensions.
TOOLS REQUIRED:
• Chuck key
• Tool post keys
• Mandrel single point cutting tool
• Drill bit
MATERIALS REQUIRED:
Cast iron block of diameter 63 mm and thickness 25 mm
• Centre drill and reamer
• Mandrel
• Helical gear hob.
• Spanner

40. HELICAL GEAR HOBBING

41. STEPS INVOLVED TO MAKE HELICAL GEAR HOBBING
• The given work piece has been fixed on the chuck by the use of center
bit.
• With the help of tail stock the 10 mm hole has been made on the
work piece.
• Again 20 mm drill bit has been fixed on the tailstock to provide 20
mm hole on the work piece.
• By the use of boring tool 25mm hole has been made on the work
piece,
• With the help of mandrel the work piece has been fitted on the
hobbing machine.

42. CONT.,
• The hob is adjusted till to touch the center of the work piece.
• Zero setting has been done by the use of hob.
• The hob has been lifted up by the way rapid motion.
• The feed has been given as 2.25 mm for three times by the use of automatic lever.
• The finished work piece has been removed for the mandrel.
Result:
Thus the helical gear was machined on the hobbing machine as per required
dimensions.

43. CNC MACHINE
• Computer Numerical Control (CNC) is one in which the functions
and motions of a machine tool are controlled by means of a
prepared program containing coded alphanumeric data.
• A CNC system consists of three basic elements
1. Part program (set of commands )
2. Machine Control Unit (MCU)
3. Machine tool (lathe, drill press, milling machine etc)

44. CNC MILLING

45. CNC MILLING MACHINE
SPECIFICATION
• XYZ travels : 762x305x406mm
• Table size : 1213x268mm
• Spindle speed : 4000 rpm
• Spindle : BT 40 taper
• Tool changer : 10 station automatic

46. CNC LATHE

47. CNC LATHE MACHINE
SPECIFICATION
• Cutting capacity : 406x1219mm
• XY travels : 203x1219mm
• Maximum swing : 483mm
• Spindle speed : 2000RPM
• Chuck 3 jaws 10 inch

48. GENERAL FORMAT OF A MANUAL CNC PROGRAM
The CNC program block generally contains the following format
N-G-X-Y-Z-A-B-C-F-S-T-M
Where,
• N – Sequence number of instructions
• G- Preparatory function
• X, Y, Z, A, B, C Co -ordinate and angular data
• F- Feed
• S- Spindle speed
• T-Tool code
• M- Miscellaneous function.

49. STUDY OF CNC CODES (M AND G CODES)
Miscellaneous Function (M - Code):
Miscellaneous function or "M-Codes," control the working
components that activate and deactivate coolant flow, spindle rotation,
the direction of the spindle rotation and similar activities.
• M00 Program stop
• M01 optional stop
• M02 End of program
• M03 Spindle clockwise
• M04 Spindle counterclockwise
• M05 Spindle stop
M06 Tool change (see Note below)
M08 coolant ON
M09 coolant OFF
M30 End of program
M98 Subprogram Call

50. STUDY OF CNC CODES (M AND G CODES
Preparatory Function (G - Code):
• Preparatory functions are G codes. G codes are designated by the letter G and a
two digit numeric value.
• These codes are the most important functions in CNC programming because they
direct the CNC system to process the coordinate data in a particular manner.
 G00 Rapid traverse
 G01 Linear interpolation with federate
 G02 Circular interpolation (clockwise)
 G03 Circular interpolation (counter clockwise)
 G17 Selection of the X, Y plane G18 Selection of the Z, X plane
 G19 Selection of the Y, Z plane G20 Selection of a freely definable

51. CONT.,
• G42 Path compensation right of the work piece contour
• G43 Path compensation left of the work piece contour with
altered approach
• G50 Scaling
• G54 Work coordinate systems
• G70 Inch format active
• G71 Metric format active
• G80 canned cycle "off"
G90 Absolute programming
G91 Incremental programming G92
Position preset
G94 Feed in mm / min
G95 Feed per revolution (mm / rev).

52. ADVANTAGES AND LIMITATIONS
• The benefits of CNC are
(1) High accuracy in manufacturing,
(2) Short production time,
(3) Greater manufacturing flexibility,
(4) Simpler fixturing,
(5) Contour machining (2 to 5 –axis machining),
(6) Reduced human error.
The drawbacks include high cost, maintenance, and the requirement of
skilled part programmer.

53. STEP TURNING

54. PROGRAMMING OF CNC TURNING
AIM:
To write a Manual part program to the given drawing and execute in
CNC lathe
MATERIAL REQUIRED:
Material : Aluminium
Size : Diameter 30 mm and length 100mm.
PROGRAM:
O00002 (Step Turning)
G28 U0 W0;
T101;
G97 S1000 M03;
G00 X30 Z10;
G00 Z2, M08;
G72 W0.5 R0.5;
G72 P10 Q20 F0.15;
N10 G00 Z0;
N20 G01 X-1;
N30 G00 Z2;

55. CONT.,G71 0.05 R0.5;
G71 P10 Q20 F0.15
N10 G01 X20
G01 Z0;
G01 X20 Z-30;
G01 X25 Z-30;
G01 X25 Z-60;
Result :
Thus the manual part program for the given drawing has been
executed in CNC Turning.
G01 X30 Z-100;
N20 G01X30;
G00 Z10;
M05;
M09;
G28 U0 W0;
M30;

56. CNC MILLING USING LINEAR INTERPOLATION

57. PROGRAMMING OF CNC MILLING
AIM:
To write a Manual part program to the given drawing and execute in CNC
Milling.
MATERIAL REQUIRED:
Material : Aluminium
Size : Square block 50mm x 50mm.
PROGRAM:
O00001 BILLET 50X50;
G00 G90 G54 G17 G49;
G91 G28 Z0.;
N1 T1(LINEAR);
M06;
G006 G90 G54 X0. Y0.;
G43 Z50 H01;
M03 S1000;
Z5.;

58. CONT.,
G01 G90 Z0. F500.;
G01 G91 Z0.25. F100.
G01 G90 G42 X-10 Y0.D01 F200.;
G01 X-10. Y10.;
X10. Y10.;
X10. Y1-0.;
X-10. Y-10.;
Result :
Thus the manual part program for the given drawing has been
executed in CNC milling
X-10. Y0.;
G01 G40 X0.Y0.;
G00 G90 Z50.;
M05;
G91 G28 Z0.Y0.;
M30;

59. STUDY OF TOOL AND CUTTER GRINDER
• A tool and cutter grinder is used to sharpen milling cutter and tool
bits along with a host of other cutting tools.
• It is an extremely versatile machine used to perform a variety of
grinding operations: surface, cylindrical, or complex shapes.
• The operation of this machine (in particular, the manually operated
variety) requires a high level of skill

60. TOOL AND CUTTER GRINDER
SPECIFICATION
• Vertical Movement Of wheel : 100 mm
• Longitudinal table Movement: 220 mm
• Transverse movement : 120mm
• Wheel tilting angle : 450
• Tool post tilting angle : 3600
• Rotating of wheel :clockwise and anticlockwise

61. TOOL AND CUTTER GRINDER
1. Base
2. Motor
3. Cup wheel
4. Tool post
5. Cross feed handle
6. Longitudinal table
7. Motor up and down
wheel
8. Stopper
9. Wheel guard
10. Wheel tilting angle

62. GRINDING OF SINGLE POINT CUTTING TOOL
AIM:
To perform a single point cutting tool by grinding operation using a tool
and cutter grinder machine as per given dimensions.
Tools Required:
• Bevel protractor
• Allen key
Material Required:
Mild steel bar 12 x 12 x 100 mm

63. SINGLE POINT CUTTING TOOL

64. STEPS INVOLVED TO MAKE SINGLE POINT
CUTTING TOOL
• The work piece is held in the tool post, which can be related about two axes
simultaneously.
• The depth of cut is given by rotating the vertical feed hand wheel by giving
to and fro motion and longitudinal movement of work table.
• The motor has been tilted to 5 degree clockwise to obtain the front
clearance angle.
• To rotate the tools post 20 degree clockwise to obtain the side cutting angle.

65. THANK YOU