Machining Shop

Machining of a material involves repeated removal of material from the job to give away
the required shape and size.
Machine shop has various machines that are being used for used for the machining
process of jobs from the plant. Some of the machines in the shop are:
SLOTTER MACHINE
LATHE MACHINE
GRINDER MACHINE
BORING MACHINE
DRILLING MACHINE
MILLING MACHINE
PLANNER MACHINE
SHAPER MACHINE
SHEARING MACHINE
SHEET CUTTING MACHINE
Hard operation such as filling, cutting etc are also carried out in the machine shop.
Bench vices are provided for the same in the shop.

LATHE MACHINE

A lathe is a large machine that rotates the work, and cutting is done with a non-rotating
cutting tool. The shapes cut are generally round, or helical. The tool is typically moved
parallel to the axis of rotation during cutting. Main difference lathes where as in the other
machines cutting tools is moved an the work piece remains stationary.
HISTORY OF LATHE

Most versatile machine tool in the machine shop.

Oldest ancestor is the potters wheel (4000 B.C).
Next came pole lathe.
This was developed into current lathe which are able to make threads.
Father of modern lathe HENRY MAUD SLAYS.

Figure : Parts of Lathe Machine

PARTS OF LATHE MACHINE:

Head stock - This end of the lathe contains the driving motor and gears. Power to
rotate the part is delivered from here. This typically has levers that let the speeds
and feeds be set.
Ways - These are hardened rails that the carriage rides on.
Tail stock - This can be used to hold the other end of the part.
Bed - This is a bottom pan on the lathe that catches chips, cutting fluids, etc.
Carriage - This part of the lathe carries the cutting tool and moves based on the
rotation of the lead screw or rod.
Lead screw - A large screw with a few threads per inch used for cutting threads. It
has ACME threads with included angle of 29o for easy engagement and
disengagement of half nut.
Lead rod - a rod with a shaft down the side used for driving normal cutting feeds.
The critical parameters on the lathe are speed of rotation (speed in RPM) and how
far the tool moves across the work for each rotation (feed in IPR)

Classification of Lathe:

Engine Lathe.

Speed lathe.

Turret lathe.

Tool room lathe.

Hollow spindle lathe.

Capston Lathe.

Bench lathe.

Operations done on Lathe:

a) Facing:
This operation is carried out to produce flat surface at the end of part, which is useful for
parts that are attached to other components, or face grooving to produce grooves for Oring seals.

b) Drilling:
In this process a drilling of desire diameter is held in the tail stock and the operation of
drill is carried out.
c) Boring:
In this enlargement of hole or cylinder cavity made by previous process is done. It
improves accuracy and surface finish.

d) Threading:
In this operation internal and external threads on the surface are prepared.
e) Knurling:
In this operation a regularly shaped roughness is prepared on the cylindrical surface for
fascinating easy gripping.

Formula for Turning:

TYPES OF LATHE MACHINES FOUND IN NFL MECHANICAL

WORKSHOP:
Central lathe
Turret lathe
Capstan lathe
Centre lathe or engine lathe
It is most important and widely used machine in the lathe family its name its name is
derived from the fact that the earlier machine tools were driven by separate engines or
from the central engine with over head belt and shafts. The stepped cone pulley or gear
head are often used for varying of the lathe machine.

Capstan and Turret lathe

It is a production machine used to perform a lot of task or operation on a single job with
minimum wastage of time. Indexable square tool is provided on the cross slide. They
carry special mechanisms for indexing their tool heads. They are provided with a front
tool post which can hold 4 turning related tools and rear tool which can hold 2 to 4
turning related tools The Turret usually accommodates tools for different operations like
drilling, counter sinking etc. Capstan lateh are used for light and small jobs. It is the best
suited for the large scale production of small parts because of its light weight and short
stroke of capstan slide.
TABLE : Comparison of Capstan and Turret lathe.
S.No Turret lathe
1
Turret head is mounted on saddle.
2
3
4
5

Capstan lathe
Turret head is mounted on auxillary slide
that moves on guideways.
Above arrangement gives rigidity as Less rigidity, vibrations occur, hence
forces are transferred to bed.
suitable for lighter jobs.
Tool travel is along entire bed length. Tool travel is limited because of uxillary
slide traverse limitation.
Tool feeding is slow and causes
Tool feeding is fast and causes less
fatigue to operator hands.
fatigue.
No tail stock .
No tail stock.

Figure : Turret Lathe.

Figure : Capstan lathe

Turret indexing mechanism:
The hexagonal turret is rotated (for indexing) by a Geneva mechanism where a Geneva
disc having six radial slots is driven by a revolving pin. Before starting rotation, the
locking pin is withdrawn by a cam lever mechanism. The single rotation of the disc
holding the indexing pin is derived from the auxiliary shaft with the help of another
single revolution clutch as indicator.

SLOTTER MACHINE
Slotter machine is also called as vertical shaper machine the difference being that the
ram is in vertical direction instead of horizontal position. Also the table or bed is
mounted on a heavy base and provided with mechanism that make possible forward
backward and side to side movement it is also adjusted head mechanism.

Advantages of vertical shaper or slotter machine

1. Setting of job is more convenient because it is easier to see, align, measure, clamp
2. Press generated by the cutting stroke is better supported by the table bed
3. Circular and hollow jobs can be worked upon
4. Ram of vertical shaper can be adjusted up to 10 degrees

Main function of slotting machine:

Internal key ways

Tapered key ways
Slots
Centric slots
Internal gear

SHAPER MACHINE

Shaping machine is generally called as shaper. Shaper is being used for both production
and tool room work. The shaper is a reciprocating type of machine tool intented primarily
to produce flat surfaces.The shaper can machine a flat surface on a horizontal, vertical,
angular plane. Here cutting is not continuous and hence machining is known as
Intermittent cutting. On this type of machine, many types of work pieces can be
machined depending upon the tools used and the manner of work pieces can be machined
depending upon the tools used and the manner of adjusting the various parts of the
machine. Size of the shaper is determined by the largest sized cube that can be machined
on it. Working principal is quick return mechanism and forward stroke is cutting stroke
and backward is idle stroke.

Difference in shaper and lathe machine

In shaper straight cutting is done where as in lathe circular cutting is done in shaping
machine the tool moves in reciprocator fashion whereas in the lathe the tool remains
stationary and the work piece moves.

Parts of shaping machine are:

BASE: It is the reservoir for supply of oil circulated to the moving parts of machine.
APRO: It supports the table.
RAM: It is the main moving part of the shaper machine. It holds and the cutting tool back
and forth across the wok.

This is attached to rocker arm which is given an oscillating motion by turning of a large
driving gear which acts as a crank which determines the length of the ram.
TOOL HEAD: It holds the cutting tool. It is attached to the front of the ram. Tool post is
fastened to the clapper box.

Main functions of the shaping machine:

Making slots
Tapered slots
External key on shaft
Hexagonal nut heads
Square nut head

PLANNER MACHINE

Planer is one of the basic machine tools used in machine shop. Main function is to
produce flat surface on piece of work. The main difference between planner and shaper is
that in planner machine the work piece moves in reciprocating motion while tool is fixed
where as in the shaper machine it is other way round. Planar is used for very large size
jobs and invoves large setting time. Therefore it is least productive machine tool.

Figure : Planar

MILLING MACHINE

Basic functions and purposes of using milling machines

Milling machine is one of the most versatile and widely used machine tool for tool room
and production purposes.The basic function of milling machines is to produce flat
surfaces in any orientation as well as surfaces of revolution, helical surfaces and
contoured surfaces of various configurations. Such functions are accomplished by slowly
feeding the work piece into the equispaced multiedge circular cutting tool rotating at
moderately high speed as indicated in Fig. Up milling needs stronger holding of the job
and down milling needs backlash free screw-nut systems for feeding.
Cutting motion

Cutting motion

Figure - Schematic views of conventional up and down milling

Milling machines of various type are widely used for the following purposes using
proper cutting tools called milling cutters :
Flat surface in vertical, horizontal and inclined planes
Making slots or ribs of various sections
Slitting or parting
Often producing surfaces of revolution
Making helical grooves like flutes of the drills
Long thread milling on large lead screws, power screws, worms etc and short
thread milling for small size fastening screws, bolts etc.
2-D contouring like cam profiles, clutches etc and 3-D contouring like die or
mould cavities
Cutting teeth in piece or batch production of spur gears, straight toothed bevel
gears, worm wheels, sprockets, clutches etc.
Producing some salient features like grooves, flutes, gushing and profiles in
various cutting tools, e.g., drills, taps, reamers, hobs, gear shaping cutters etc.

Classification of milling machines:

According to configuration and motion of the work-holding table / bed :
Knee type: Typically shown in Fig. In such small and medium duty
machines the table with the job/work travels over the bed (guides) in
horizontal (X) and transverse (Y) directions and the bed with the table and
job on it moves vertically (Z) up and down.

Machine parts :
1. Column
2. Bed
3. Cross slide
4. Work table
5. Ram
6. Ram support
7. Arbour support
Table feed motions :
a. longitudinal feed
b. cross feed
c.vertical feed

Fig.- Knee type milling machine

Planer type : These heavy duty large machines, called plano-miller, look like planing
machine where the single point tools are replaced by one or a number of milling
heads; generally used for machining a number of longitudinal flat surfaces
simultaneously, viz., lathe beds, table and bed of planning machine etc.

Rotary table type : Such open or closed ended high production milling machines
possess one large rotary work-table and one or two vertical spindles as typically
shown in Fig. the positions of the job(s) and the milling head are adjusted according
to the size and shape of the job.

Fig. Planar type milling machine

Fig. Rotary table type milling machining

Parts of Milling Machine:

Column: It includes the base which It he main casting which supports the other parts of
machine. The front of the column, the column face is machined to provide an accurate
guide for the vertical travel of the knee.
Knee: It supports the saddle. Feed change gearing is enclosed within in the knee. Knee
can be raised or lowered on the column face. It is supported and can be adjusted with a
elevating screw.
Saddle: It supports the table. It is supported by the surfaces of the knee.
Table: It holds the work piece. It has T-slots and is used to hold the jobs. Bolts fit
loosely in the T- slots and are used to clamp the vice.
Spindle: It holds and diverts various cutting tools. It has the shaft mounted on the
bearing supported by the column.
Over arm: It is mounted on the top of the column. It is guided by the machined dovetail
surfaces.

Various applications of milling machines using different types of milling cutters:

Milling machines are mostly general purpose and have wide range of applications
requiring various types and size of milling cutters.
Intermittent cutting nature and usually complex geometry necessitate making the milling
cutters mostly by HSS which is unique for high tensile and transverse rupture strength,
fracture toughness and formability almost in all respects i.e. forging, rolling, powdering,
welding, heat treatment, machining (in annealed condition) and grinding. Tougher grade
cemented carbidesare also used without or with coating, where feasible, for high
productivity and product quality.
Broad classifications of milling cutters

Slab or plain milling cutter : straight or helical fluted

Side milling cutters single side or both sided type
Slotting cutter
Slitting or parting tools
End milling cutters with straight or taper shank
Face milling cutters

Various uses of different milling cutters and milling machines

Slab or Plain milling cutters:
Plain milling cutters are hollow straight HSS cylinder of 40 to 80 mm outer diameter having 4
to 16 straight or helical equi-spaced flutes or cutting edges and are used in horizontal arbour to
machine flat surface .

Side and slot milling cutters

These arbour mounted disc type cutters have a large number of cutting teeth at equal
spacing on the periphery. Each tooth has a peripheral cutting edge andanother cutting
edge on one face in case of single side cutter and two more cutting edges on both
the faces leading to double sided cutter. One sided cutters are used to produce one flat
surface or steps comprising two flat surfaces at right angle as shown in Fig.
Both sided cutters are used for making rectangular slots bounded by three flat
surfaces. Slotting is also done by another similar cutter having only one straight
peripheral cutting on each tooth. These cutters may be made from a single piece of
HSS or its teeth may be of carbide blades brazed on the periphery or clamped type
uncoated or coated carbide inserts for high production machining.

Slitting saw or parting tool

These milling cutters are very similar to the slotting cutters having only
one peripheral cutting edge on each tooth. However, the slitting saws
are larger in diameter and much thin possess large number of cutting teeth but of small size
used only for slitting or parting .
End milling cutters or End mills
The shape and the common applications of end milling cutters (profile sharpened
type) are shown in Fig.
The common features and characteristics of such cutters are :
Mostly made of HSS .
4 to 12 straight or helical teeth on the periphery and face .
diameter ranges from about 1 mm to 40 mm .
very versatile and widely used in vertical spindle type milling machines .
end milling cutters requiring larger diameter are made as a separate cutter
body which is fitted in the spindle through a taper shank arbour as shown in
the same figure.

GRINDING MACHINE
Grinding is the process of finishing surface by means of revolving abrasive wheel. In order to
finish the job pieces efficiently one must not only be able to operate. The grinder but also
understand abrasive and grinding wheels, their shapes and sizes for different types of work.
Grinding practice is a large and diverse area of manufacturing and toolmaking. It can produce
very fine finishes and very accurate dimensions; yet in mass production contexts it can also
rough out large volumes of metal quite rapidly. It is usually better suited to the machining of
very hard materials than is "regular" machining (that is, cutting larger chips with cutting
tools such as tool bits or milling cutters), and until recent decades it was the only practical way
to machine such materials as hardened steels. Compared to "regular" machining, it is usually
better suited to taking very shallow cuts, such as reducing a shafts diameter by half
a thousandth of an inch or 12.7 m.
ABRASIVE: An abrasive is any material that can wear material softer than itself sand and
sandstone are perhaps the oldest abrasives know to mankind.
Abrasive can be natural and manmade:
Natural Abrasive: Energy and corundum are two commonly used in the Industry to sharpen tool
edge. They occur as a miner deposit in the earth crust. Aluminum oxide is the best suited for
grinding material that has high tensile strength such as high speed steel and high carbon steel.
Man Made Abrasive. These are better than natural ones because in these purity grain size and
can be controlled.

GRINDING WHEELS:
Grinding wheel are found by using suitable material to cement, bond, abrasives, grains
together in the desired shape and size. Hardness of the wheel is dependent upon the amount and
kind of binding material being used. Hardness of wheel is always by mean of strength of bond.

TYPES OF GRINDING MACHINES

Surface Grinder
Cylindrical Grinder
Internal Grinder
Thread Grinder

Figure : Grinding machine.

SURFACE GRINDER:
Surface grinding is the process of producing a finished flat surfaces by mean of grinding
machine employing revolving abrasive wheel. Surface grinder machine consist mounting a
grinding wheel and table or magnetic chuck for holding the work piece.
Uses of abrasive grinding:
1 Sharpening cutting
2 Snagging
3 Finishing

DRILLING MACHINE

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular crosssection in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit
is pressed against the wor kpiece and rotated at rates from hundreds to thousands of revolutions
per minute. This forces the cutting edge against the work piece, cutting off chips from the hole
as it is drilled.

Basic purposes of use of drilling machines:

Drilling machines are generally or mainly used to originate through or blind straight cylindrical
holes in solid rigid bodies and/or enlarge (coaxially) existing (premachined) holes of different
diameter ranging from about 1 mm to 40 mm of varying length depending upon the
requirement and the diameter of the drill in different materials excepting very hard or very soft
materials like rubber, polythene etc.

Drill:
The twist drill does most of the cutting with the tip of the bit.
There are flutes to carry the chips up from the cutting edges to the top of the hole where they
are cast off.

Figure : Various angles in drill tool.

Cutting Speed in Drilling:

DN
V
1000
Drilling Time:

m / min

Time for drilling the hole

L
, min
fN

Types of Drilling Machines:

Column drilling machine
These box shaped column type drilling machines as shown in Fig. 4.2.3 are much more strong,
rigid and powerful than the pillar drills. In column drills the feed gear box enables automatic
and power feed of the rotating drill at different feed rates as desired. Blanks of various size and
shape are rigidly clamped on the bed or table or in the vice fitted on that. Such drilling
machines are most widely used and over wide range ( light to heavy) work.

Figure : Column type Drilling machine.

Radial drilling machine

This usually large drilling machine possesses a radial arm which along with the drilling head
can swing and move vertically up and down as can be seen in Fig. 4.2.4. The radial, vertical
and swing movement of the drilling head enables locating the drill spindle at any point within a
very large space required by large and odd shaped jobs. There are some more versatile radial
drilling machines where the drill spindle can be additionally swivelled and / or tilted.

Fig : Radial Drilling Machine

Cutting motion:
The cutting motion in drilling machines is attained by rotating the drill at different speeds
(r.p.m.). Like centre lathes, milling machines etc, drilling machines also need to have a
reasonably large number of spindle speeds to cover the useful ranges of work material, tool
material, drill diameter, machining and machine tool conditions. The drill gets its rotary
motion from the motor through the speed gear box (SGB) and a pair of bevel gears.
For the same motor speed, the drill speed can be changed to any of the 12 speeds by shifting the
cluster gears in the SGB. The direction of rotation of the drill can be changed, if needed, by
operating the clutch in the speed reversal mechanism.
Feed motion:
In drilling machines, generally both the cutting motion and feed motion are imparted to the
drill. Like cutting velocity or speed, the feed (rate) also needs varying (within a range)
depending upon the tool-work materials and other conditions and requirements.

The wide range of applications of drilling machines include :

Origination and / or enlargement of existing straight through or stepped holes of
different diameter and depth in wide range of work materials this is the general or
common use of drilling machines.
Making rectangular section slots by using slot drills having 3 or four flutes and 180 0
cone angle
Boring, after drilling, for accuracy and finish or prior to reaming
Counterboring, countersinking, chamfering or combination using suitable tools .

FABRICATION
This process of joining metals or non metal to from an object which has specific shape.This
process is know as fabrication. Different types of machines and welding are used in the
fabrication process or to fabricate an object.

THE WORKDONE AT THE SHOP ARE CLASSIFIED AS:

1Metal cutting method:
Oxy fuel gas cutting
Plasma cutting
2 Metal joining method:
Oxy- acetylene welding
Are welding
Tungsten inert gas welding
OXY- acetylene Gas welding

This process is particularly suitable for joining metal sheet and plates and having
thickness 2 to 50mm.
The filler metal is the addition, which is added to weld in the form of welding rod.
The composition of the filler rod is usually the same or nearly the same as that of the
part being welded
To remove the impurities oxides present on the metal to be joined and to obtain
stationary bond flux is always implied during the welding expect sheet.
Various gas combustion can be used for producing a hot flame for welding metals.
Common mixture of gases oxygen and other fuel gases
The oxy-acetyl welding mixture is used to a much greater extent than other in the
welding industry
The temperature of this welding flame in its hottest region is about 3200C
CaC2 + 2H2O

C2H2 + Ca(OH)2

ARC WELDING METHODS

Metal arc welding: In the arc welding metal rod is used as an electrode while the work
being welded is used as another electrode. The temperature produced is about 2400C
and 2600C on the ve and +ve electrode respectively. During the welding operation,
this metal electrode is melted by the heat of the arc and is fused with the base metal,
thus forming a solid union after the metal has been cooled. Both AV and DC can be
used. Adjusting the machine to correct amperage, which is determined by then size of
the rode to be used start the welding operation. The correct welding speed is important.

SPECIFICATION OF ELECTRODES:
Where:
1 E is used for covered electrode that is for coated electrode
2 Next two XX multiple with 1000spin shows the tensile strength
3 Next X shows the position of joint to be welded in current condition. i.e it may
horizontal, vertical or incline
4 Last X shows the types of coating.

AWS Classification

Type of covering

Type of current

E6010
E6011
E6012
E6013
E6020
E6022
E6027

High cellulose sodium

High cellulose potassium
High titanium sodium
High titanium potassium
High iron oxide
High iron oxide
High iron oxide powder

DC (+)
AC/DC(+)
AC/DC(-)
AC/DC
AC/DC(-)
AC/DC
AC/DC(-)