Computer Workshop Technology

Bharati Vidyapeeth
(Deemed to be University)

College of Engineering, Pune

Department of Mechanical Engineering

LAB MANUAL
COMPUTER WORKSHOP TECHNOLOGY

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page i

 Computer Workshop Technology

CONTENTS

Page No.
[Link]. NAME OF THE EXPERIMENT
Introduction of different tools used in workshop technology for Computer 03-07
1 engineering.

Resistance welding processes (Spot Welding) 08-10

2

3 Soldering Processes on electronics components. 11-14

4 Practical demonstration on Sheet Metal Working Operation 15-20

5 Sheet Metal Working (Cabinet Box) 21-24

25-27
6 Practical demonstration on plastic molding machine
Practical demonstration on 3 D printing machine 28-31
7
Practical demonstration on Fastner Manufacturing on Lathe Machine 32-36
8

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 2

 Computer Workshop Technology

Experiment No: 1
Introduction of different tools used in workshop technology for Computer
engineering.

Aim: To understand the different tools used in workshop technology for computer engineering.

Health and Safety in Workshop

• Never adopt a casual attitude in the workshop and always be conscious of the potential hazards.
• Ensure that personal clothing is suitable to the workshop conditions, e.g. Safety footwear. Thongs or
open footwear should not be worn in the workshop area.
• Always wear eye protection when using power operated hand or machine tools, or while performing
physical tests that could lead to eye damage.
• Do not handle, store or consume food or drink in the workshop.
• Keep your work area tidy.
• Keep the tools at their proper place after use.

Types of Workshop Tools

[Link] Tools
[Link] Tools

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 3

 Computer Workshop Technology

[Link] Tools

Hand Tools:

[Link] Tools Description

Hacksaw Hacksaw frames are used in carpentry for sawing purposes. They
1.
Handle are made to take 8-,10- or 12- inch blades.

Pliers are common hand tools found in almost every household.

2. Pliers They help to hold objects firmly, bend other materials, and remove
unwanted elements.

A file is a tool used to remove fine amounts of material from a

3. File workpiece. It is common in woodworking, metalworking, and other
similar trade and hobby tasks.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 4

 Computer Workshop Technology

In order to hold the work piece in place, the bench vise is used. It
4. Bench Vise prevents the movement of the work piece while working on it and
makes the handler’s job very easy.

A C-clamp or G-clamp is a type of clamp device typically used to

5. G Clamp hold a wood or metal workpiece, and often used in, but are not
limited to, carpentry and welding.

A mallet is a kind of hammer, often made of rubber or sometimes

6. Mallet wood, that is smaller than a maul or beetle, and usually has a
relatively large head.

These are designed to deliver high force on a small area. Hammers

7. Hammer are made from a good grade of tool steel. This tool steel is hardened
and drawn to a blue colour at the eye and dark straw.

A coping saw is a type of bow saw used to cut intricate external

8. Coping Saw shapes and interior cut-outs in woodworking or carpentry. It is
widely used to cut moldings to create coped rather than mitre joints.

A wrench or spanner is a tool used to provide grip and mechanical

9. Spanner advantage in applying torque to turn objects—usually rotary
fasteners, such as nuts and bolts—or keep them from turning.

Screw drivers are of several kinds. Each is unique for its own
10. Screw Driver purpose. Therefore it is necessary for a tool maker to have a set of
screw drivers for all requirements.

An implement used to check and mark right angles in constructional

11. Try Square work. A try square is a woodworking tool used for marking and
measuring a piece of wood.

A tape measure or measuring tape is a flexible ruler and used to

Measuring measure distance. Its design allows for a measure of great length to
12.
Tape be easily carried in pocket or toolkit and permits one to measure
around curves or corners.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 5

 Computer Workshop Technology

[Link] Tools

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 6

 Computer Workshop Technology

Power Tools:

[Link] Tools Description

Angle grinders are also labelled as side grinders or disc grinders, and they’re a
Angle
1. handheld power tool that grind, cut, and polish various objects and materials. They
Grinder
can be powered by compressed air, an electric motor or petrol engine.

A chop saw is a power tool that used to make straight cuts in wood. It may have
2. Chop Saw
features that allow it to cut angles, which makes it a miter saw

A drill is a tool primarily used for making round holes or driving fasteners. It is fitted
3. Drills with a bit, either a drill or driver, depending on application, secured by a chuck. Some
powered drills also include a hammer function.

Bench The bench drill is a smaller version of the pillar drill. This type of machine drill is
4.
Drill used for drilling light weight pieces of material.

A bench grinder is a benchtop type of grinding machine used to drive abrasive wheels.
Bench
5. A pedestal grinder is a similar or larger version of grinder that is mounted on a
Grinder
pedestal, which may be bolted to the floor or may sit on rubber feet.

A table saw is a woodworking tool, consisting of a circular saw blade, mounted on an

6. Table Saw arbor, that is driven by an electric motor. The blade protrudes through the top of a
table, which provides support for the material, usually wood, being cut.

A sander is a power tool used to smooth surfaces by abrasion with sandpaper. Sanders
7. Sander have a means to attach the sandpaper and a mechanism to move it rapidly contained
within a housing with means to hand-hold it or fix it to a workbench.

It is a powerful tool designed for making cuts at quite a few different angles. Also
Milter
8. known as “compound miter saws”, these work by having a blade mounted to a swing
Saw
arm that can pivot either right or left to create cuts that are angled.

The planer is a power tool that helps woodworkers create parallel pieces of wood for
9. Planer various projects. They’re used to make a board of wood that has already been jointed
(hence the frequent comparison to jointers) flat into equal end-to-end thickness

Power Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting
10.
Hacksaw diameters of more than 10/15mm is very hard work with a normal hand held hacksaw.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 7

 Computer Workshop Technology

Experiment No: 2

Resistance welding processes (Spot Welding)

Aim:

To prepare a Lap Joint on the given work pieces using spot welding

Material Required:

GI Sheet of 90 x 40 mm--- 2 No

Equipment:
Spot welding machine, mild steel sheets, Wire Brush, Tongs etc.

Spot Welding Principle

Resistance spot welding is a type of welding that generates heat at the interface of two metal sheets by
using electrical resistance. The heat generated by the resistance to the flow of electricity melts the
metal and forms a weld where the two sheets come into contact. This procedure is typically carried
out with the aid of a specialized welding machine that applies pressure to the sheets in order to keep
them in place and control the flow of electricity via the resistance welding process. The current is
applied under a controlled force through the electrodes. The diameter of the electrode in contact with
the workpiece determines the current density The resistance between the contact area layers is directly
affected by the force applied. In practice, the force is adjusted so that heat is generated immediately in
the contact area.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 8

 Computer Workshop Technology

In resistance welding (RW) a low voltage (typically IV) and very high current (typically 15,000
is passed through the joint for a very short time (typically 0.25 s). This high amperage heats the joint, due
to the contact resistance of the joint and melts it.

Procedure:

1. The weld sheet metal is cleaned together and that are free from dirt, oxide, grease and oxides.
2. The two pieces to be joined by spot welding are placed between the two electrodes in the required
position.
3. Set the timer for which the current flows through the electrodes with reference to the thickness of
the plates.
4. Press the foot lever, so that the movable electrode moves towards the fixed electrode.
5. This causes to develop a pressure of about 200-1000 Kg / cm2 on the sheets.
6. A low voltage and very high current are passed through the joint for a very short time. The duration
of the current flow is for about 2 sec (This high amperage heats the joint, due to contact resistance
at the joint and melts it).
7. Then the metal under electrodes pressure is squeezed and welded
8. The pressure is then released, and the process is repeated until the job is completed.

Precautions:

1. Proper pressure should be applied on the electrodes.

2. Correct electrode diameter needs to be chosen depending on the material thickness to be
joined.
3. Proper weld time should be selected for welding.
4. Use Gloves while doing operation.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 9

 Computer Workshop Technology

Job:

Result: Lap joint has been produced by using Spot welding

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 10

 Computer Workshop Technology

Experiment No: 3
SOLDERING PROCESS
AIM: To study and demonstration of Soldering processes on electronics components.

APPARATUS:
1. Solder Iron
2. Solder wire
3. Flux
4. PCB
5. Different electronic components

THEORY:

Introduction: Soldering is the act of unifying two pieces of similar or dissimilar metals by an alloy called
Solder, the melting point of which is lower than that of the metal to be united. When two surfaces of the metal
are soldered together, the solder penetrate pores of the metal and it makes firm grip with permanent electrical
continuity and strength.

Solder: The soldering material or solder usually employed for the purpose of joining together two or more
metals at temperature below their melting point and is a fusible alloy consisting essentially of lead and tin. Solder
is an alloy (mixture) of tin and lead, typically 60% tin and 40% lead. It melts at a temperature of about 200°C.
Coating a surface with solder is called 'tinning' because of the tin content of solder. Solder for electronics use
contains tiny cores of flux, like the wires inside a mains flex.
However, due to environmental concerns and regulations, lead-based solder is being phased out in many
applications.
Lead-Free Alloys: In response to environmental and health concerns associated with lead, lead-free solder
alloys have become more prevalent. Common lead-free alloys include:
Tin-Silver-Copper (Sn-Ag-Cu): This is a popular lead-free solder alloy known for its reliability and high
melting point.
Tin-Copper (Sn-Cu): Another lead-free option that is widely used, especially in electronics.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 11

 Computer Workshop Technology

Flux: When a metal is heated in free air, it is immediately affected by oxygen. A layer of oxide is formed over
the surface which is a hindrance during soldering. This layer of oxide can be removed using chemical
compounds called fluxes. They are deoxidizes agents and are used to keep the surface clean from oxide, increase
the fluidity of the solder and help the joints to adhere perfectly. The melting temperature of the flux is always
less than that of the solder used.

There are different types of flux, and they can be classified into two main categories: rosin-based flux and water-
soluble flux.

Rosin-Based Flux: This type of flux is derived from natural rosin, which is obtained from pine trees. Rosin flux
is commonly used in electronics soldering. It is available in different formulations, such as rosin (R), mildly
activated rosin (RMA), and activated rosin (RA). The level of activation affects the flux's aggressiveness in
removing oxides.

Water-Soluble Flux: Water-soluble flux is used in applications where post-soldering cleaning is required. It
can be easily washed away with water, making it suitable for situations where the residue needs to be removed,
such as in electronic assemblies that undergo subsequent cleaning processes.

Soldering Techniques:
Soldering techniques can be broadly classified in two groups:
1. Iron soldering or Manual soldering
2. Mass soldering or Automatic soldering

Manual soldering requires solder iron, solder wire, flux and electronic components. Solder irons are available
in different temperature ranges, and available with ratings of 6 W, 12 W, 25 W, 35 W, 100 W, 150 W etc.
Selection of the solder iron depends on the use.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 12

 Computer Workshop Technology

Procedure:

1. Take one PCB, solder iron, solder wire and electronic components and give supply to solder iron.
2. Place the iron at the angle of 45 degree, with the tip touching as many elements of the joints as possible.
Place the solder wire near the iron and let it flow. Pass it around the joints.
3. Remove the iron and let the solder flow in the area from where the iron has been removed.
4. When the solder has successfully flowed in the lead and track, take the solder away and then remove the
iron.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 13

 Computer Workshop Technology

Result: Joint has been produced by using Soldering.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 14

 Computer Workshop Technology

Experiment No:04
SHEET METAL OPERATIONS

Aim: To understand the perform job on sheet metal working to understand Punching, blanking,
shearing, bending, and piercing operations

heet Metal Operations:

Cutting Operations

1. Blanking:

Blanking is the process of producing flat pieces from

a large sheet. Only a small amount of sheet metal
will be processed as a finished product or part over
the larger sheet area in the blanking process. In this
process, enough residue will remain. This process is
done with the help of punch and die. The blanking
process is used to manufacture various parts in
automobiles, such as doors, hoods, lids, BIW
components and etc. And in other industries like
utensils, jewellery, electrical components etc., the
blanking process is used.

2. Punching:

The punching operation is vice versa to blanking.

In this operation, extra (scrape) material removes
from the raw sheet. This operation also performed
with the help of die and punch. But here the punch
removes scrap. This process is used to create
holes and cutouts in the sheet.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 15

 Computer Workshop Technology

3. Piercing:

The word piercing means pinning any tool in the workpiece or sheet for creating circular or other
shaped holes. Almost no scrape will be created in this operation. Creating a hole in paper using a pen
or any sharp tool is also known as piercing. The piercing operation for sheet metal is also similar. For
this operation, a blanking punch is used.

4. Cut-off:

This operation separates the work material along a

curve (which may be a straight line or irregular
single curve). That’s why in the Cut-off operation no
scrape will be created. For example, cutting a paper
into two pieces using a seizer.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 16

 Computer Workshop Technology

5. Parting off:

The parting off operation is also similar to the cut-off

operation. But here scrape will separate from the
blank piece. This is the reason it is the next best
method for cutting blanks.

6. Notching:

Notching operation is to cut out a portion of the

sheet from its sides. And in semi notching
operation metal cutting out from inside of the
sheet. Sometimes, notches applied for stress
relieving during the bending. So, notches created
before the bending operations.

[Link]:

This is a process by which multiple holes

which are very small and close together are
cut in flat work material.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 17

 Computer Workshop Technology

[Link]

This operation consists of cutting unwanted excess

material from the periphery of previously formed
components.

[Link]:

It refers to the operation of making incomplete holes

in a work piece.

Cutting straight lines in the sheet. No scrap material

is produced.

[Link]

Punching a series of small overlapping slits or holes

along a path to cut-out a larger contoured shape.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 18

 Computer Workshop Technology

[Link]:

This is a cutting operation in which a hole is

partially cut and then one side is bent down to form
a sort of tab. Since no metal is actually removed,
there will be no scrap.

[Link]:

The edge of blanked parts is generally rough, uneven and

unsquare. Accurate dimensions of the part are obtained by
removing a thin strip of metal along the edges.

Forming Operations

1. Bending:

Bending operation is used to creating a bent

shape around a straight axis. A punch applies
stress more than the elastic limit but less than the
ultimate tensile strength. Hence, a permanent
contour occurs due to that stress. This angle may
as per requirement.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 19

 Computer Workshop Technology

2. Deep drawing:

Deep drawing is a metal forming process in which sheet

metal is stretched into the desired shape. A tool pushes
downward on the sheet metal, forcing it into a die cavity in
the shape of the desired part.

[Link]:

Under the operation, the metal is caused to flow to all portions of a die cavity under the action of
compressive forces.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 20

 Computer Workshop Technology

Experiment No: 5
SHEET METAL WORKING

Aim: To perform job on sheet metal working to understand Punching, blanking, shearing, bending,
and piercing operations.

Material: 150 mm × 260 mm [Link]

Tools: Try square, Scriber, Divider, Steel rule, Straight snip, Wooden mallet, Ball pin hammer, rasp file,Wire
gauge, Rivet Set.

• Bench Vice: The most commonly used in the engineer’s parallel jaw bench vice to hold the job.
• Steel Rule: This is particularly useful in measuring and laying out small work. Steel rules are made of
spring steel on stainless steel. The reading accuracy of the steel rule is 0.5mm.
• Dividers: Dividers are used for scribing circles, arcs and transferring and stepping of distance. Dividers
are available with firm joints and spring joints
• Try Square: The try square is a precision instrument which is used to check squareness (angles of 900
) of a surface. Try square are made of hardened steel. The main parts of try square are stock and blade.
• Scriber: A scriber is a pointed tool used for marking lines on metals. Scribers are made from high carbon
steel and the points are hardened and tempered.
• Straight Snip: A snip is a hand shear use to cut thin sheets of gauge size number 20 or above.
• Files: The most widely used hand tool in an engineering shop is the file. A file is a hardened piece of
high-grade steel with standing row of teeth. The cuts all metals except hardened steel.
• Rivet set: Rivet set is made up of tool steel. At the bottom of rivet set there is a deep hole and a cup
shape hole. Deep hole is to draw a rivet through sheet metal and cup shape hole is used to form the finish
head of the rivet.
• Wooden Mallet: mallet is soft hammer used to give soft blows which will not damage the sheet at the
same time will shape them

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 21

 Computer Workshop Technology

Procedure:

1. Marking: First Marking is done on [Link] with the help of steel rule and scriber,
Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 22
 Computer Workshop Technology

2. Cutting: Developed part is cut by using straight snip.

3. Folding: The tray is folded as required with the help of bench vice and wooden mallet.
4. Riveting: Riveting is done with the help of rivet set.
5. Finishing: Sharp edges are removes by using rasp file.

Development Drawing:

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 23

 Computer Workshop Technology

Product:

Results: Product (Cabinet Box) is made using sheet metal working process.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 24

 Computer Workshop Technology

Experiment No:06
PLASTIC MOLDING

Aim: To perform job on hand operated Plastic Molding Machine.

Materials Required: Plastic granules.

Machine Required: Plastic Molding Machine.

Procedure:
• Turn on switch of heater.
• Pour the raw material in hopper of machine pour and fill it.
• Adjust the temperature of heater around 320 to 350 degree.
• Heat is applied to the plastic until it becomes soft to flow
• Clamp molding tool (Die) at correct position.
• Apply pressure manually through hand lever.
• The softened plastic is forced through the nozzle into the mold cavity.
• Cavity is filled with plastic
• When cool, the halves of mold are separated
• The part is ejected from the mold.

Precautions
1. Don’t touch the barrel when it is heated.
2. Clamp the mold perfectly before applying the blow.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 25

 Computer Workshop Technology

Fig. Hand operated plastic molding machine

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 26

 Computer Workshop Technology

Fig. Parts produced in Plastic molding

Results: Required product is made using injection molding process.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 27

 Computer Workshop Technology

Experiment No - 7

3D PRINTING

Aim :- To understand the 3D Printing Technique.

Objective :-

• To identify and describe the function of different parts of the 3D printer.

• To understand the operations of the 3D printer for different parameters and can check the effect of
the different parameter on the performance of the printer.

• To Build a given 3D printer by using the different parts.

Theory :-
3D printing allows for rapid prototyping and onsite manufacturing of products. Initially done with plastic,
3D printing now uses new techniques with new materials, such as aluminum, bronze, and glass. Biomaterials
are also being incorporated, such as 3D printing ear cartilage and liver tissue. As the 3D printing industry
grows, 3D printing will become a big part of many engineering fields Introduction:- 3D printing allows for
rapid prototyping and onsite manufacturing of products. Initially done with plastic, 3D printing now uses
new techniques with new materials, such as aluminum, bronze, and glass. Biomaterials are also being
incorporated, such as 3D printing ear cartilage and liver tissue. As the 3D printing industry grows, 3D
printing will become a big part of many engineering fields

Components of 3D Printer :-
1. axes
Fixed Rods The three axes that the 3D printer utilizes are on the Cartesian coordinate system. The linear
fixed rods are maintained at right angles to each other, and each represents a coordinate axis. Movement
The timing belts and pulleys allow the movement of the hot end (or the print bed, depending on the type of
3D printer) along each axes according to the g-code (generated by slicing software). The stepper motors
power this movement.
2. Extruder
Extrusion is the feeding of filament into the hot end of the 3D printer. This movement is also powered by a
stepper motor. Retraction This mechanism is the pulling of the melted filament from the hot end. This

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 28

 Computer Workshop Technology

movement is primarily programmed through the g-code to prevent the formation of unwanted filament
creating a bridge between two areas. The bridging of unwanted filament is referred to as stringing or the
formation of cobwebs. Dual Extrusion Some models of 3D printers are equipped with dual extrusion
capabilities. This allows for mixed material objects to be printed. Dual extrusion can used to print out
complex objects with a different color material as the support, making it easy to differentiate

between the object and the support.

3. Hot End
The hot end is heated to temperatures ranging from 160 C to 250 C, depending on the type of filament to
be used. The hot end melts the filament and pushes the melted filament through the nozzle. The hot end
needs to be thermally insulated from the other components of the 3D printer to prevent any damage.

4. Print Bed
Heated Print beds that are heated improve print quality of 3D printed objects. The heated bed is heated to
the glass transition temperature of the filament being used. This allows the model layers to slightly melt and
stick to the heated bed.
Non-Heated Print beds that are not heated require adhesion in the form of glue, tape, hairspray, etc. In the
innovation lab, painters’ tape is frequently used for adhesion.
5. Filament
Filament is a consumable used by the 3D printer to print layers. Filament comes in a variety of materials
and colors. Filament can be composed of metal, wood, clay, biomaterials, carbon fiber, etc.

• ABS: - ABS is a thermoplastic that needs to be heated to temperatures from 210C to 250C. ABS can
only be printed on a 3D printer with a heated bed, which prevents the cracking of the object. When
ABS is heated, it emits a strong unpleasant odor. ABS requires complete enclosure while printing.
• PLA: - PLA is a thermoplastic that needs to be heated to temperatures from 160C to 220C. PLA is also
biodegradable and emits slight odors. PLA is most frequently used in the Innovation Lab on all 3D printers
• PVA: PVA is a water-soluble plastic that is frequently used for support in dual extrusion 3D printers.
The printed object is left in water where the PVA support is dissolved and the finished object printed
in the other filament remains.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 29

 Computer Workshop Technology

Figure: a - Comparison between cartesian and delta 3D printers

Preparing your 3D Model in CAD Software :-

CAD software is used to create 3D models and designs. This software is available on our computers and the
level of difficulty varies. With the exception of Sketch up Pro and the industry standard software mentioned,
all of these programs are available on the innovation lab computers. Solid works main idea is user to create
drawing directly in 3D or solid form. From this solid user can assemble it directly on their workstation
checking clashes and functionality of it. Creating drawing is pretty easy just drag and drop the solid to
drawing block.

Preparing your 3D Model for print in Idea maker software:-

These are following step for 3D printing of model

1. Install the 3D print software idea maker

2. Check repair option in this software
3. Set the nozzle parameter and build tack temperature according to the printer guide.

Step:-1 Prepare the design Model using Designing Software(Solids Work, AutoCAD etc.)

Step:-2 Convert the designed Model file in Stl ,obj format.

Step:-3 Prepare the design model for printing Using Software Ultimaker Cura . Then set all parameters
(nozzle temp., build task temp and support) and also repair your design using software option. Then after
generating the file in G-code format
Step:-4 ON the 3D Printer ,

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 30

 Computer Workshop Technology

Prepare:

• Auto home position

• Auto Bed Leveling

Control:

• Temparature:210-220 0 C

• Fan Speed:80-100
Apply favicol on base and Auto Home
Print from SD Card
Select part to be print

and load the filament in nozzle and give the command print by using 3D Printing Machine.

Safety Equipment’s :-
• Safety Glasses
• Gloves (recommended for post processing.

Applications of 3D Printer:

Automotive, Medical, Engineering, Customize parts, Less transport, Freedom for design,etc.
Manufacturing Replacement parts - cheaper to build than to buy
Aerospace - Develop new/lightweight materials
Biomedical - Soft tissue reconstruction Functional prosthetic limbs
Dental - Dental fillings, implants, appliances
3D Printed Food - Extruder output: chocolate, dough, sauce!
3D printed HOUSES - Extruder output: concrete 3D printing for Mars astronauts Allow mission
participants to colonize
Metal Printing - Laser sintering to produce strong/dense/complex parts.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 31

 Computer Workshop Technology

Experiment No - 8

Practical demonstration on Fastner Manufacturing on Lathe Machine

Introduction

Lathe is considered as one of the oldest machine tools and is widely used in industries. It is
called as mother of machine tools. It is said that the first screw cutting lathe was developed by an
Englishman named Henry Maudslay in the year 1797. Modern high speed, heavy duty lathes are
developed based on this machine.

The primary task of a lathe is to generate cylindrical workpieces. The process of machining
a workpiece to the required shape and size by moving the cutting tool either parallel or perpendicular
to the axis of rotation of the workpiece is known as turning. In this process, excess unwanted metal
is removed. The machine tool useful in performing plain turning, taper turning, thread cutting,
chamfering and knurling by adopting the above method is known as lathe.

Main parts of a lathe

Every individual part performs an important task in a lathe. Some important parts of a lathe
are listed below:
1. Bed
2. Headstock
3. Spindle
4. Tailstock
5. Carriage
a. Saddle
b. Apron
c. Cross-slide
d. Compound rest
e. Compound slide
f. Tool post

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 32

 Computer Workshop Technology

6. Feed mechanism
7. Lead screw
8. Feed rod
Operations performed in a lathe:
Various operations are performed in a lathe other than plain turning. They are:
1. Facing 7. Undercutting
2. Turning 8. Eccentric turning
a. Straight turning 9. Taper turning
b. Step turning 10. Thread cutting
3. Chamfering 11. Drilling
4. Grooving 12. Reaming
5. Forming 13. Boring
6. Knurling 14. Tapping

Facing
Facing is the operation of machining the ends of a piece of work to produce flat surface which is
square with the axis. The operation involves feeding the tool perpendicular to the axis of rotation of
the work.

Turning
Turning in a lathe is to remove excess material from the workpiece to produce a cylindrical surface
of required shape and size.
Straight turning
The work is turned straight when it is made
to rotate about the lathe axis and the tool is
fed parallel to the lathe axis. The straight
turning produces a cylindrical surface by
removing excess metal from the
workpieces.
Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 33
 `

Chamfering
Chamfering is the operation of bevelling the extreme end of the workpiece. The form tool used for
taper turning may be used for this purpose. Chamfering is an essential operation after thread cutting
so that the nut may pass freely on the threaded workpiece.

Grooving
Grooving is the process of cutting a narrow groove on the cylindrical surface of the workpiece. It is
often done at end of a thread or adjacent to a shoulder to leave a small margin. The groove may be
square, radial or bevelled in shape.

Forming
Forming is a process of turning a convex, concave or any irregular shape. For turning a small length
formed surface, a forming tool having cutting edges conforming to the shape required is fed straight
into the work.
Knurling
Knurling is the process of embossing a diamond shaped pattern on the surface of the workpiece. The
knurling tool holder has one or two hardened steel rollers with edges of required pattern. The tool
holder is pressed against the rotating work. The rollers emboss the required pattern. The tool holder
is fed automatically to the required length. Knurls are available in coarse, medium and fine pitches.
The patterns may be straight, inclined or diamond shaped.

The purpose of knurling is

1. To provide an effective gripping surface
2. To provide better appearance to the work
3. To slightly increase the diameter of the work

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 34

 `

Undercutting
Undercutting is done (i) at the end of a hole (ii) near the shoulder of stepped cylindrical surfaces
(i) at the end of the threaded portion in bolts. It is a process of enlarging the diameter if done
internally and reducing the diameter if done externally over a short length. It is useful mainly to make
fits perfect. Boring tools and parting tools are used for this operation.

Taper Turning
A taper may be defined as a uniform increase or decrease in diameter of a piece of work measured
along its length.
Taper turning methods
1. Form tool method
2. Compound rest method
3. Tailstock set over method
4. Taper turning attachment method
5. Combined feed method

Thread cutting
Thread cutting is one of the most important operations performed in a lathe. The process of thread
cutting is to produce a helical groove on a cylindrical surface by feeding the tool longitudinally. The
job is revolved between centres or by a chuck. The longitudinal feed should be equal to the pitch of
the thread to be cut per revolution of the work piece.

Department of Computer Engineering, B V (DU) College of Engineering, Pune Page 35

 Computer Workshop Technology

Fastner Manufacturing on lathe machine