Project 2011- cooling tower

Project 2011- cooling tower

Safety rules in workshop1. 2. 3. 4. 5. 6. 7. 8. 9. Do not work on any machine without knowledge. Keep away the harmful materials. Do not touch the rotating parts of machine in running machine. Do not spread the oil, grease and viscous material on floor area. Muffler, tie not to wear on work on machine. Tight the work-piece properly on the machine. Good arrangement of light in the workshop. Better ventilation for air. Put the tools of machine at right place.

Safety instructions in machine shop1. 2. 3. 4. 5. Do not wear breslet, ring, wrist watch etc. during work on a machine. Wear apron, shoes for safety during working. Dont push any button of machine without knowledge. Use wire brush for remove metal chips from machine. Give proper lubrication of machine before working on it.

Machines in workshop1. 2. 3. 4. 5. 6. Capstan and turret lathe machineLight duty lathe machine Milling machine Radial arm drilling machine Shaper machine Grinding machine

Project 2011- cooling tower

1. Capstan and turret lathe machine-

The turret lathe is a form of metalworking lathe that is used for repetitive production of duplicate parts, which by the nature of their cutting process are usually interchangeable. It evolved from earlier lathes with the addition of the turret, which is an index able tool holder that allows multiple cutting operations to be performed, each with a different cutting tool, in easy, rapid succession, with no need for the operator to perform setup tasks in between, such as installing or uninstalling tools, nor to control the tool path. The latter is due to the tool paths being controlled by the machine, either in jiglike fashion, via the mechanical limits placed on it by the turret's slide and stops, or via electronically-directed servomechanisms for computer numerical control (CNC) lathes.

Parts of lathe machine Headstock The headstock (H1) houses the main spindle (H4), speed change mechanism (H2, H3), and change gears (H10). The headstock is required to be made as robust as possible due to the cutting forces involved, which can distort a lightly built housing, and induce harmonic vibrations that will transfer through to the work piece, reducing the quality of the finished work piece. The main spindle is generally hollow to allow long bars to extend through to the work area. This reduces preparation and waste of material. The spindle runs in precision bearings and is fitted with some means of attaching work holding devices such as chucks or faceplates. This end of the spindle usually also has an included taper, frequently a Morse taper, to allow the insertion of tapers and centers. On older machines the spindle was directly driven by a flat

Project 2011- cooling tower

belt pulley with lower speeds available by manipulating the bull gear. Later machines use a gear box driven by a dedicated electric motor. A fully geared head allows the operator to select speeds entirely through the gearbox.

Bed

The bed is a robust base that connects to the headstock and permits the carriage and tailstock to be aligned parallel with the axis of the spindle. This is facilitated by hardened and ground ways which restrain the carriage and tailstock in a set track. The carriage travels by means of a rack and pinion system, lead screw of accurate pitch, or feed screw. Types of beds include inverted "V" beds, flat beds, and combination "V" and flat beds. "V" and combination beds are used for precision and light duty work, while flat beds are used for heavy duty work When a lathe is installed, the first step is to level it, which refers to making sure the bed is not twisted or bowed. There is no need to make the machine exactly horizontal, but it must be entirely untwisted to achieve accurate cutting geometry. A precision level is a useful tool for identifying and removing any twist. It is advisable also to use such a level along the bed to detect bending, in the case of a lathe with more than four mounting points. In both instances the level is used as a comparator rather than an absolute reference. Feed and lead screws

The feed screw (H8) is a long driveshaft that allows a series of gears to drive the carriage mechanisms. These gears are located in the apron of the carriage. Both the feed screw and lead screw (H7) are driven by either the change gears (on the quadrant) or an intermediate gearbox known as a quick change gearbox (H6) or Norton gearbox. These intermediate gears allow the correct ratio and direction to be set for cutting threads or worm gears. Tumbler gears (operated by H5) are provided between the spindle and gear train along with a quadrant plate that enables a gear train of the correct ratio and direction to be introduced. This provides

Project 2011- cooling tower

a constant relationship between the number of turns the spindle makes, to the number of turns the lead screw makes. This ratio allows screw threads to be cut on the work piece without the aid of a die. Carriage

In its simplest form the carriage holds the tool bit and moves it longitudinally (turning) or perpendicularly (facing) under the control of the operator. The operator moves the carriage manually via the hand wheel (5a) or automatically by engaging the feed shaft with the carriage feed mechanism (5c). This provides some relief for the operator as the movement of the carriage becomes power assisted. The hand wheels (2a, 3b, 5a) on the carriage and its related slides are usually calibrated, both for ease of use and to assist in making reproducible cuts. The carriage typically comprises a top casting, known as the saddle (4), and a side casting, known as the apron (5).

Cross-slide

The cross-slide (3) rides on the carriage and has a feed screw that travels perpendicular to the main spindle axis. This permits facing operations to be performed, and the depth of cut to be adjusted. This feed screw can be engaged, through a gear train, to the feed shaft (mentioned previously) to provide automated 'power feed' movement to the cross-slide. On most lathes, only one direction can be engaged at a time as an interlock mechanism will shut out the second gear train. Compound rest

The compound rest (or top slide) (2) is usually where the tool post is mounted. It provides a smaller amount of movement (less than the cross-slide) along its axis via another feed screw. The compound rest axis can be adjusted independently of the carriage or cross-slide. It is used for turning tapers, to control depth of cut when screw cutting or precision facing, or to obtain

Project 2011- cooling tower

finer feeds (under manual control) than the feed shaft permits. Usually, the compound rest has a protractor marked in its base (2b), enabling the operator to adjust its axis to precise angles. Tool post

The tool bit is mounted in the tool post (1) which may be of the American lantern style, traditional four-sided square style, or a quick-change style such as the multifix arrangement pictured. The advantage of a quick change set-up is to allow an unlimited number of tools to be used (up to the number of holders available) rather than being limited to one tool with the lantern style, or to four tools with the four-sided type. Interchangeable tool holders allow all tools to be preset to a center height that does not change, even if the holder is removed from the machine. Tailstock

The tailstock is a tool holder directly mounted on the spindle axis, opposite the headstock. The spindle (T5) does not rotate but does travel longitudinally under the action of a lead screw and hand wheel (T1). The spindle includes a taper to hold drill bits, centers and other tooling. The tailstock can be positioned along the bed and clamped (T6) in position as required. There is also provision to offset the tailstock (T4) from the spindles axis, this is useful for turning small tapers. The image shows a reduction gear box (T2) between the hand wheel and spindle, this is a feature found only in the larger center lathes, where large drills may necessitate the extra leverage.

Project 2011- cooling tower

2. Light Duty Lathe Machine-

Light Duty SPECIFICATIONS LD-4.6 BED Bed Length Bed Width CAPACITY Height Of Center Swing Over Bed Swing Over Cross Slide Admit Between Center MAIN SPINDLE Spindle Thread / Dia 8 TPI-60 MM Spindle Bore TAIL STOCK Quill Dia THREADS Lead Screw Metric Thread Inch Thread 25.4 mm Dia X 4 TPI 13 / 1 mm to 6 mm 19 / 2 TPI to 24 TPI 25.4 mm Dia X 4 TPI 13 / 1 mm to 6 mm 25.4 mm Dia X 4 TPI 13 / 1 mm to 6 mm 38 mm / 1.5" 38 mm / 1.5" 38 mm / 1.5" 40 mm Dia / 1.625" 8 TPI-60 MM 8 TPI-60 MM 40 mm Dia / 1.625" 40 mm Dia / 1.625" 190 mm / 7.5" 355 mm / 14" 180 mm / 7" 330 mm / 13" 190 mm / 7.5" 355 mm / 14" 180 mm / 7" 330 mm / 13" 190 mm / 7.5" 355 mm / 14" 180 mm / 7" 330 mm / 13" 1375 mm / 4'-6" 241 mm / 9.5" 1600 mm / 5'-3" 241 mm / 9.5" 1825mm / 6' 241 mm / 9.5" LD-5.3 LD-6

19 / 2 TPI to 24 TPI 19 / 2 TPI to 24 TPI

Project 2011- cooling tower

SPEEDS No. Of Spindle Speed RPM ( Min / Max ) 4+4=8 35 / 825 4+4=8 35 / 825 4+4=8 35 / 825

3. Milling machine-

A milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the main spindle. Both types range in size from small, bench-mounted devices to room-sized machines. Unlike a drill press, which holds the work piece stationary as the drill moves axially to penetrate the material, milling machines also move the work piece radially against the rotating milling cutter, which cuts on its sides as well as its tip. Work piece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and lead screws or analogous technology. Milling machines may be manually operated, mechanically automated, or digitally automated via computer numerical control (CNC).

Project 2011- cooling tower

Milling machines can perform a vast number of operations, from simple (e.g., slot and keyway cutting, planning, drilling) to complex (e.g., contouring, die sinking). Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.

Vertical mill

Vertical milling machine. 1: milling cutter 2: spindle 3: top slide or over arm 4: column 5: table 6: Y-axis slide 7: knee 8: base In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill and the turret mill. Horizontal mill Horizontal milling machine. 1: base 2: column 3: knee 4 & 5: table (x-axis slide is integral) 6: over arm 7: arbor (attached to spindle) A horizontal mill has the same sort of xy table, but the cutters are mounted on a horizontal arbor across the table. Many horizontal mills also feature a built-in rotary table that allows milling at various angles; this feature is called a universal table. While end mills and the other types of tools available to a vertical mill may be used in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side and face mills, which have a cross section rather like a circular saw, but are generally wider and smaller in diameter. Because the cutters have good support from the arbor and have a larger crosssectional area than an end mill, quite heavy cuts can be taken enabling rapid material

Project 2011- cooling tower

removal rates. These are used to mill grooves and slots. Plain mills are used to shape flat surfaces. Several cutters may be ganged together on the arbor to mill a complex shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any section desired. These specialty cutters tend to be expensive. Simplex mills have one spindle, and duplex mills have two. It is also easier to cut gears on a horizontal mill. Some horizontal milling machines are equipped with a power-take-off provision on the table. This allows the table feed to be synchronized to a rotary fixture, enabling the milling of spiral features such as hypoid gears.

Specification: All Geared Universal Milling Machine MODEL TABLE M-1B M-2B M-3B Working Surface Swivel T-Slot Nos/Size T-Slot Centre Dist. From Spindle max/min X-Longitudinal Travel Y-Cross Travel Z-Vertical Travel FEEDS No. of Feeds 9 18 18 1100 x 270 +450 3/17 60 350-0 500 180 350 1300 x 290 +450 3/17 65 400-0 650 205 400 1400 x 350 +450 3/17 80 475-0 775 255 475

M-4B 1600 x 360 +450 3/17 90 550-0 900 305 550 18

M-5B 1800 x 400 +450 5/17 80 550-50 1100 450 600 18

M-6B 2000 x 450 +300 5/20 90 600-50 1250 500 650 18

Project 2011- cooling tower

Range of Longitudinal Feed/ min Range of Cross Feed / min Range of Vertical Feed / min No. of Rapid Feeds

13-200 13-200 5-100 1

13 to 305 13 to 305 13 to 305 13 to 305 13 to 305 13 to 305 13 to 305 13 to 305 13 to 305 13 to 305 2.5 to 62 2 2.5 to 62 2 2.5 to 62 2 2.5 to 62 2 2.5 to 62 2 735,1065 735,1065 147,210

Longitudinal Rapid Feeds 700 / min Cross Rapid Feeds / min Vertical Rapid Feeds / min SPINDLE No. of Spindle Speeds 9 700 240

735,1065 735,1065 735,1065 735,1065 147, 210 147,210

735,1065 735,1065 735,1065 735,1065 147,210 147,210

18

18

Range of Spindle Speeds 45-1100 (RPM) Spindle Taper Arbor Diameter ELECTRICAL Main Motor Feed Motor Coolant Motor DIMENTIONS Overall Length Overall Width Overall Height Net Weight Kg Gross Weight Kg 1600 1400 1550 2000 2200 3 H.P. 2 H.P. 0.1 H.P. ISO 40 25.4

45 to 1100 35 to 1800 35 to 1800 35 to 1800 35 to 1800 ISO 40 25.4 3 H.P. 2 H.P. 0.1 H.P. 1850 1600 1680 2600 2900 ISO 40 25.4 5 H.P. 2 H.P. 0.1 H.P. 2000 1750 1800 3300 3600 ISO 40 25.4 7.5 H.P. 2 H.P. 0.1 H.P. 2100 1950 1880 3700 4000 ISO 40 25.4 7.5 H.P. 3 H.P. 0.1 H.P. 2500 2500 2400 4200 4600 ISO 50 25.4 10 H.P. 3 H.P. 0.1 H.P. 2700 2600 2700 5000 5700

4. Radial arm drilling machineA radial arm drill press is a large geared head drill press in which the head can be moved along an arm that radiates from the machine's column. As it is possible to swing the arm relative to the machine's base, a radial arm drill press is able to operate over a large area

Project 2011- cooling tower

without having to reposition the work piece. The size of work that can be handled may be considerable, as the arm can swing out of the way of the table, allowing an overhead crane or derrick to place a bulky piece on the table or base. A vise may be used with a radial arm drill press, but more often the

Radial arm drill press

Project 2011- cooling tower

work piece is secured directly to the table or base, or is held in a fixture. Power spindle feed is nearly universal with these machines and coolant systems are common. The biggest radial arm drill presses are able to drill holes as large as four inches (101.6 millimeters) diameter in solid steel or cast iron. DC - 410 ( SPECIFICATIONS ) DESCRIPTION Drilling M.S Drilling C.I Rough Boring in M.S Tapping in M.S Spindle Taper Spindle Travel Spindle Speeds ( RPM x steps ) DC - 410 42 ( 15/8 ) 50 60 25 MT-4 225 12 Steps DESCRIPTION DC - 410 Max / Min Dist. Spindle 1225 / 450 nose to base Vertical Travel of Arm 775 Max / Min Dist. Spindle 1025 / 275 Center to Column Horizontal Travel of Arm Max.Drilling Radius 750 1137

Machine Measurement ( 1600 x 850 x LXBXH) 2270 Diameter of Column 225 550 x 450 x 400 770 x 430 x 145 ( 50 Liters ) 2 HP ( 1.5 KW ) 960 / 1440 RPM 0.75 HP ( 0.56 KW ) 960 RPM

60,90,115,165,200,290,340,480, Work Table 575,825,1005,1510 Diameter Of RAM ( 78 quill ) Spindle Auto feed Ranges Coolant Tank

0.1, 0.15, 0.20, 0.27, 0.33, 0.52 Drill-head Motor Elevating Motor ( L X BXH)

5. Shaper machineA shaper is a type of machine tool that uses linear relative motion between the work piece and a single-point cutting tool to machine a linear tool path. Its cut is analogous to that of a lathe, except that it is (archetypal) linear instead of helical. (Adding axes of motion can

Project 2011- cooling tower

yield helical tool paths, as also done in helical planning.) A shaper is analogous to a planer, but smaller, and with the cutter riding a ram that moves above a stationary work piece, rather than the entire work piece moving beneath the cutter. The ram is moved back and forth typically by a crank inside the column; hydraulically actuated shapers also exist.

Operation

Project 2011- cooling tower

Shaper linkage. Note the drive arm revolves less for the return stroke than for the cutting stroke, resulting in a quicker return stroke and more powerful cutting stroke. A shaper operates by moving a hardened cutting tool backwards and forwards across the work piece. On the return stroke of the ram the tool is lifted clear of the work piece, reducing the cutting action to one direction only. The work piece mounts on a rigid, box-shaped table in front of the machine. The height of the table can be adjusted to suit this work piece, and the table can traverse sideways underneath the reciprocating tool, which is mounted on the ram. Table motion may be controlled manually, but is usually advanced by automatic feed mechanism acting on the feed screw. The ram slides back and forth above the work. At the front end of the ram is a vertical tool slide that may be adjusted to either side of the vertical plane along the stroke axis. This tool-slide holds the clapper box and tool post, from which the tool can be positioned to cut a straight, flat surface on the top of the work piece. The tool-slide permits feeding the tool downwards to deepen a cut. This adjustability, coupled with the use of specialized cutters and tool holders, enable the operator to cut internal and external gear tooth profiles, splines, dovetails, and keyways. The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster on the return (non-cutting) stroke than on the forward, cutting stroke. This action is via a slotted link or Whitworth link. SPECIFICATIONS D.S.6 D.S.8 D.S.10 Particulars " " " Stroke 6" 8" 10" D.S.1 D.S.12 D.S.14 D.S.16 D.S.18 0 to " " " " 12" 10 12" 14" 16" 18" to12 " 20" 16" 14" 20" 18" 15" 24" 18" 16"

Rottary 11" 13" 15" 15" 18" Table Longitudina 8" 10" 12" 12" 14" l Movement Cross 6" 8" 10" 10" 12" Movement Cutting Speed of 60-90 60-90 40-60 40-60 40-60 Ram Per Minute Ram 8" 10" 12" 12" 14" Adjustment Throat 8" 10" 11" 11" 12"

40-60

20-50- 20-5080 80 18" 15" 18" 16"

16" 14"

Project 2011- cooling tower

Depth H.P. Required Distance from the Tool to Main Coloum Weight Packed (Complete aprox)

1 HP

2 HP

2HP

2 HP

2 HP

3 HP

3HP

3 HP

10"

12"

14"

14"

16"

17"

18"

18"

950

1050

1400

1500

1800

2000

2200

2400

6. Grinding machine-

The grinding machine consists of a power driven grinding wheel spinning at the required speed (which is determined by the wheels diameter and manufacturers rating, usually by a formula) and a bed with a fixture to guide and hold the workpiece. The grinding head can be controlled to travel across a fixed work piece or the work piece can be moved whilst the grind head stays in a fixed position. Very fine control of the grinding head or tables position is possible using a vernier calibrated hand wheel, or using the features of numerical controls.

Project 2011- cooling tower

Grinding machines remove material from the work piece by abrasion, which can generate substantial amounts of heat; they therefore incorporate a coolant to cool the work piece so that it does not overheat and go outside its tolerance. The coolant also benefits the machinist as the heat generated may cause burns in some cases. In very high-precision grinding machines (most cylindrical and surface grinders) the final grinding stages are usually set up so that they remove about 200 nm (less than 1/100000 in) per pass - this generates so little heat that even with no coolant, the temperature rise is negligible.

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