Course Outcomes:

• Understanding the tools and equipment used in the practice.
• Enhancing the skills in machining operations like drilling, turning, milling.

Course Syllabus:

Module 1: Safety Practice (3 hours)

Theory:

Prevention of self, people present near and machines in machine floor, Safety rules to follow inside machine shop, Use of safety gears while working, prevent work pieces and fragments from being thrown out of the working area of the machine.

Demonstration and Practice:

• Demonstration of Personal safety, Professional safety and machine safety.
• Demonstration of uses of Personal Protective Equipment.
• Demonstration of uses of Emergency stop, Instant break  electrical and fire safety

Module 2: Introduction to conventional machines and machining processes (3 hours)

Theory:

Introduction to different machines, their parts, working of the parts and different operations performed by the machines.

• Drilling Machine
• Lathe Machine
• Milling Machine

Demonstration and Practice:

• Demonstration on conventional machines, types of machines.
• Demonstration of different parts of different machines and their work.

Module 3: Interpretation of different mechanical drawings related to jobs and parts (6 hours)

Theory:

Principle of Engineering Drawing/Graphics, Various Drawing Instruments, Conventions in Drawing, Principles of Orthographic Projections (First and Third Angle projections), Projections of planes, Plane parallel, perpendicular and inclined to one reference plane, Plane inclined to both the reference, Planes, Sections and sectional views, Right Regular Solids, Prism, Cylinder, Pyramid, Cone. Use of Auxiliary views.

Practice:

• Studying and understanding different mechanical drawings which are related to job production or different parts.
• Practicing of drafting for different drawings of different operations with shape, scale and dimensions.

Module 4: Measuring and Quality control (6 hours)

Theory:

Introduction to Tolerance, limits and fits, Linear measurement, Angular measurement, Gauges and gauge measurement

Demonstration and practice:

• Using different measuring tools while working on machine.
• Different quality checking processes like flatness, angle, go-no go.

Module 5: Drilling Operations (12 hours)

Theory:

Understanding the various types of holes that are used in manufactured parts, Know the various types of twist drills geometry as well as types of drills used in industry, Understanding the variety of machine tools and their construction

Demonstration and practice:

Different drilling processes;

• Reaming
• Counter sinking.
• Counter boring.
• Boring
• Tapping

Module 6: Lathe Operations (21 hours)

Theory:

Introduction to different types of lathes, their parts, choosing various aids used to locate and support work piece in lathe, selecting the large variety of cutting tools used in lathe machine, Knowing variety of common operations performed in lathe.

Demonstration and practice:

Practicing different lathe machining processes like;

• Facing
• Turning
• Step turning
• Taper turning
• Thread cutting
• Knurling

Module 7: Milling Operations (21 hours)

Theory:

Types of milling machines and about their parts. Characteristic feature of milling process, milling cutters based on application, Indexing possibilities of parts

Demonstration and practice:

Practice of different milling machine operations like;

• Face milling
• End milling
• Profile milling
• Pocket milling

Session Plan

Session: 01

Lecture: 01

Safety Practice in workshop

Safety in workshop

Assignment: 01

List out the safety rules used while working in workshop.

Session: 02 & 03

Practice: 01

Demonstration of Personal safety, Professional safety and machine safety.

https://www.youtube.com/watch?v=QI6mOu9OB3k

Session: 04 & 05

Practice: 02

Demonstration of uses of Personal Protective Equipment.

Session: 06 & 07

Practice: 03

Demonstration of uses of Emergency stop : Instant break, electrical and fire safety.

Emergency stop: https://www.youtube.com/watch?v=oIGMTsPyQwQ

Fire safety: https://www.youtube.com/watch?v=UlKS_A7Xg1E

Electrical hazards and safety: https://www.youtube.com/watch?v=c93eJtFR6H8

Session: 08

Lecture: 02

Introduction to conventional Machines

Conventional machines

Assignment: 02

To find the difference between conventional machines and non-conventional machines

Session: 09

Practice: 04

Demonstration of different parts of Drilling Machine and their work.

Definition of Drilling

Session: 10

Practice: 05

Demonstration of different parts of Milling Machine and their work.

Definition and Applications of Milling Machine

Session: 11 & 12

Practice: 06

Demonstration of different parts of Lathe Machine and their work.

Definition and Applications of Lathe

Session: 13

Lecture: 03

Engineering drawing and its interpretations

Assignment: 03

Write the difference between first and Third angle projection.

Session: 14 & 15

Practice: 07

Draw the orthographic projections of a U-channel and Cylinder block (first and third angle projections)

Projections

Session: 16 & 17

Practice: 08

Draw an isometric view of a  V-block

Isometric View

Session: 18 & 19

Practice: 09

Draw an orthographic views of a Flange coupling and Show half sectional views of it.

Sectional View

Session: 20

Lecture: 04

Introduction to measuring instruments and quality control

Assignment: 04

Draw and explain the parts of Vernier caliper and micrometer.

Session: 21 & 22

Practice: 10

Use of Vernier caliper and Micrometer and find the accuracy.

Session: 23 & 24

Practice: 11

Different quality checking processes like flat ness, straightness, Angle measurement(by using Bevel protector).

Session: 25 & 26

Lecture: 05 & 06

Definition of drilling

Assignment: 05

Draw and explain different drilling operations.

Session: 27 & 28

Practice: 12

Perform Reaming operation on a workpiece of 100mm x 50mm x 10mm.

Reaming Operation

Session: 29 & 30

Practice: 13

Perform Counter-sinking and Counter-boring operation on a workpiece of 100mm x 50mm x 10mm.

Counter-Sinking operation

Counter-boring operation

Session: 31 & 32

Practice: 14

Perform Boring operation on a workpiece of 100mm x 50mm x 10mm.

Boring operation

Session: 33 & 34

Practice: 15

Perform Tapping operation on a workpiece of 100mm x 50mm x 10mm.

Tapping operation

Session: 35 & 36

Lecture: 07 & 08

Introduction to Lathe Machine and its operations

Definition and Applications of Lathe

Assignment: 06

Draw and explain each operations performed in Lathe machine.

Session: 37 & 38

Practice: 16

Facing operation for a cylindrical job of Diameter 40mm.

Facing operation

Session: 39-41

Practice: 17

Plane Turning for a cylindrical job of Diameter 40mm(Reduce the diameter to 20mm)

Turning operation

Session: 42-45

Practice: 18

Step Turning for a cylindrical job (drawing will be given)

Step turning operation

Session: 46-51

Practice: 19

Taper Turning for a cylindrical job (drawing will be given)

Tailstock Set Over Method

Compound Rest Method

Taper Turning Attachment Method

Session: 52-55

Practice: 20

Thread cutting for a cylindrical job (drawing will be given)

Thread cutting operation

Session: 56,57

Practice: 21

Perform knurling operation on a cylindrical job.

Knurling operation

Session: 58,59

Lecture: 09 & 10

Definition and Applications of Milling Machine

Assignment: 06

Draw and explain each operations performed in milling machine.

Session: 60-63

Practice: 22

Face Milling for a slab of 80mm X 60mm X 30mm

Face Milling operation

Session: 64,65

Practice: 23

End Milling for a slab of 80mm X 60mm X 30mm

End milling operation

Session: 66-69

Practice: 24

Make a specific type of profile on workpiece using different Milling cutters (Drawing will be given).

Profile milling

Session: 70-72

Practice: 25

Perform pocket milling operation on a workpiece (Drawing will be given)

Pocket milling operation

Projects

1. Hand vice

2. C-Clamp

3. Screw Jack

4. Spur Gear

5. Different hand tools, Jigs and Fixture production using all machining activities