Sec-A Common Syllabus - MP Polytechnic

MACHINE SHOP

Machine Shop: Introduction to machine tools viz. lathe, drilling machine, shaper and planer, simple line

and block diagram of components and their functions. Brief concept of NC and CNC machines

Sec-A Common Syllabus

Familiarity with the Use of Various Tools Used in Mechanical Engineering Workshop:

Marking and Measuring: Steel rule, surface gauge, marking block, protractor, trysquare, scriber,

punches, divider and callipers, surface plate, V. block, gauges (screw, pitch, radius, feeler), Vernier

calipers, Micrometer Vernier height and depth gauge, use of dial gauge.

Holding Tools: Vices (Bench, leg and hand vice), clamps, tongs, pliers.

Cutting Tools: Hack saw (Fixed and adjustable frame), chisels-flat, cross cut, diamond, round nose.

Files: According to section-Knife edge, Flat, Triangular, Round, Square, Half round.

According to grade-Rough, Bastard, Second cut, Smooth and Dead Smooth.

Drills and Allied Tools : Parallel and taper shank twist drill

Thread Cutting Tools: Taps and Dies.

Miscellaneous Tools: Wrenches, Keys, Spanners, Pliers, Screw drivers, their specification and many

others which have not been named for use in various shop. They should be shown physically to each

student for familiarity.

Sec- B TOOLS AND TOOL MATERIALS

Introduction Principle of Machining.

1.2.1 Classifications of Machining Processes

1.2.2 Relative Motion Generation

1.2.3 Cutting Tools

Tool Geometry

1.3.1 Nomenclature of a Single Points and Tool

1.3.2 Tool Angles 1.3.3 Cutting Tools Signature

Heat Produced During Cutting and its Effect

1.4.1 Speed, Feed and Depth of Cut

1.4.2 Total Geometry

Tool Materials

Desirable Properties of Tool Materials

Types of Tool Materials

Study of Various Cutting Tool Materials

Theory QuestionsTURNING (LATHE)

IntroductionPrinciple of Turning

Main Parts of a Centre Lathe

Classification of Types of Lathe

2.4.1 Speed Lathe

2.4.2 Engine (Centre) Lathe

2.4.3 Bench Lathe

2.4.4 Tool Room Lathe

2.4.5 Capston and Turret Lathe

2.4.6 Special Purpose Lathe

2.4.7 Automatic Lathe

Drives (Flow of Power)

2.5.1 Cone Pulley Drive

2.5.2 All-Gear Drive

Feed Mechanism (Transmission of Motion)

2.6.1 End of Bed Gearing

2.6.2 Feed Gear Box

2.6.3 Feed Rod and Lead Screw

2.6.4 Apron Mechanism

Work Holding Devices

2.7.1 Chucks

2.7.2 Centres

2.7.3 Carriers and Catch Plates

2.7.4 Mandrels

2.7.5 Steady Rest

2.7.6 Follower Rest

Lathe Tools

2.8.1 Types of Lathe Tools

2.8.2 Tool Nomenclature

2.8.3 Tool Angles and Tool Signature

2.8.4 Systems of Cutting Tool Nomenclature

2.8.5 Application of Tool Angles

Lathe Operations

2.9.1 Plane Turning

2.9.2 Step Turning

2.9.3 Taper Turning

2.9.4 Thread Cutting

Sec C Cutting Parameters

2.10.1 Turning and Boring

2.10.2 Cylindrical Turning

2.10.3 Facing and Groove Cutting

2.10.4 Boring2.10.5 Parting Operation

2.10.6 External Threading

Speed Ratio

2.11.1 Speed Ratio for Belt Drive

2.11.2 Speed Ratio for Gear Drive

Lathe Accessories and Attachments

2.12.1 Working Holding Devices

2.12.2 Total Holding Devices

2.12.3 Attachments

Capstan and Turret Lathe

2.13.1 Principle Parts

2.13.2 Advantage of Capstan and Turret Lathe

Comparison of Capstan and Turret Lathes

Work Holding Devices in Capstan and Turret Lathe

2.15.1 Jaw Chucks

2.15.2 Collet Chucks

2.15.3 Fixture

Tool Guiding Devices in Capstan and Turret Lathe

Theory Questions

Objective Type Questions DRILLING

Introduction

Classification of Drilling Machines

3.2.1 Portable Drilling Machine

3.2.2 Sensitive Bench Drilling Machine

3.2.3 Upright Drilling Machines

3.2.4 Radial Driling Machine

3.2.5 Gang Drilling Machine

3.2.6 Multi-Spindle Drilling Machine

3.2.7 Automatic Production Drilling Machine

3.2.8 Deep Hole Drilling Machine

Drilling Operations 3.3.1 Drilling

3.2.2 Spot Facing

3.3.3 Reaming

3.3.4 Boring

3.3.5 Counter Boring

3.3.6 Counter Sinking

3.3.7 Hole Milling

3.3.8 Tapping

Speeds and Feeds and Drilling Time

3.4.1 Cutting Speed3.4.2 Feed

3.4.3 Depth of Cut 3.4.4 Machining Time in Drilling

Types of Drills

EE

EE

EE

E/E

EIE

} EE

EE{E

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E

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rill Ma

Boring Tools

Boring Bars and Boring Heads

4.7.1 Boring Bars

4.7.2 Boring Head or Cutter Head

4.7.3 Facing Head

Alignment of Bores and its Importance

Theory Questions

Objective Type Questions

SHAPING, PLANING AND SLOTTINGG

Introduction

Working Principles of a Shaper

Types of Shaper

5.3.1 Mechanism for Reciprocating Motion of Ram

5.3.2 Position and Travel of Ram

5.3.3 Design of Work Table

5.3.4 Cutting Stroke

Quick Return Mechanism

5.4.1 Crank and Slotted Link Mechanism

5.4.2 Whitworth Quick Return Mechanism

5.4.3 Hydraulic Shaper Mechanism

Work Holding Devices

5.5.1 Shaper Vises

5.5.2 Table Clamp5.5.3 Angle Plate

5.5.4 V-block

5.5.5 Index Centres

Shaper Tools

Specifications of a shaper

5.7.1 Principal Parts

5.7.2 Shaper size

5.7.3 Specifications

Sec- E Machining Parameters

Cutting speed5.8.1

5.8.2 Feed (f)

5.8.3 Depth of Cut () 5.8.4 Machining Time

Theory Questions

Objective Type questions

Working Principle of SlottingMachine

Types of Slotting Machines

5.10.1 Puncher Slotter

5.10.2 Precision Slotter

Specifications of a Slotter

5.11.1 Principal Parts of a Slotter 5.11.2 Size of Slotter

5.11.3 Specifications

Quick Return Mechanism Work Holding Devices

Slotter tools

Machining Parameters

Theory Questions Objective Type Questions Working Principle of Planing

Types of Planers

5.17.1 Double Housing Planer

5.17.2 Open Side Planer

5.17.3 Pit Planer

5.17.4 Plate Planer

5.17.5 Divided Table Planer

Planer Specifications

5.18.1 Principal Parts of a Planer

5.18.2 Planer size

5.18.3 Specifications

Machining Parameters

Work Holding Devices

5.20.1 Standard Clamping Devices

5.20.2 Special Fixtures

Planer Tools

Quick Return Mechanism

5.22.1 Open and Cross Belt Drive

5.22.2 Reversible Motor Drive

5.22.3 Hydraulic Drive

Comparison Between a Planer and a shaper

Theory Questions

Objective Type Questions

BROACHING

Introduction

Broaching Machines

6.2.1 Horizontal Broaching Machine

6.2.2 Vertical Broaching Machines

6.2.3 Continuous Broaching Machines

Broach Tools

6.3.1 Elements and Nomenclature of Broaching Tool

6.3.2 Broach Tooth Details

6.3.3 Tool Materials

6.3.4 Types of Broaches

Theory Questions

Objective Type Questions

IGS AND FIXTURES

Introduction

Design and Use of Jigs and Fixtures

Principle of Location

7.3.1 Six-Point Location of a Rectangular Block

7.3.2 Six-point Location of a Three Legged Object

Location of a Cylinder on a V-block7.3.3

Sec F Locating Devices

7.4.1 Flat Locators

7.4.2 Cylindrical Locators

7.4.3 Conical Locator

.4.4 Pin Locators

7.4.5 Sliding Pin Locators and Adjustable Pin Locator

7.4.6 V-locators

7.4.7 Flattened Locators

Clamping Devices

7.8.1 Screw Clamps

7.8.2 Button Clamps

7.8.3 Plate Strap Clamps

7.8.4 Hook Bolt Clamps

7.8.5 Edge Clamps

7.8.6 Cam Clamps

7.8.7 Equalising ClampsLatch-Type Clamps

7.8.9 Two-way Clamp

7.8.8

7.8.10 Toggle Clamp

7.8.11 Power Operated Clamping Devices.

Types of Jigs

Template Jig 7.9.2 Channel Jig

7.9.1

7.9.3 Plate Jig

7.9.4 Leaf Jig

Drill Jig Bushes

7.10.1 Fixed Bush

7.10.2 Liner Bush

7.10.3 Slip Bush

7.10.4 Renewable Bush

7.10.5 Screw Bush

Fixtures for Milling

Welding Fixtures Advantages of ligs and Fixtures

Theory Questions Objective Type Questions

Sec-G CUTTING FLUIDS AND LUBRICANTS Introduction

Beneficial and Harmful Effects of Cutting Fluids

8.2.1 Beneficial Effects

8.2.2 Harmful Effects

Desirable Properties

Categories of Cutting Fluids

Composition of Cutting Fluids

The Action of Cutting Fluids

8.2.1 Cooling Action

8.2.2 Lubrication Action

Selection of Cutting Fluids

Application of Culling Fluids

8.8.1 Manual Application

8.8.2 Flood Application

8.8.3 Jet Application

8.8.4 Mist Application

8.8.5 Through-the-tool Application Maintenance and Disposal of Cutting Fluids

8.9.1 Disposal of Cutting Fluids

Theory Questions