Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop
The Machine Shop is a place, where various types of machines are installed, such as Lathes, Shapers, Drills, Millings, Power Hacksaw, and Grinders etc. And there is also availability of various kinds of tools and equipments. These machines are mostly used in machining work, for cutting the metals and manufacturing different kinds of work pieces and jobs according to the dimensions as given in their drawings.

Safety Precautions in Machine Shop

For safe practice in machine shop, we must follow the following necessary instructions: 1. Do not start any machine, if you don't know about that machine. 2. Wear shoes, aprons and safety glasses when working on the machine. 3. Do not wear loose clothes, long sleeves or any thing that might get caught in the moving part of the machine. 4. Remove chuck key from the chuck of the lathe machine before starting the machine. 5. Make it sure that all the cutting tools and work pieces (jobs) are clamped properly and securely on the machine, before starting the machine. 6. Keep your fingers away from rotating work piece and moving parts of the machine. 7. Do not rest your foot on the machine, it can cause accident. 8. Always allow the moving parts and cutting tools of machine to stop by itself, do not try to stop them with your hand, because it can cause injury. 9. Chips should not be removed from the machine by hand. Use brush for that purpose. 10. Never leave the machine, while it is in operation, as a great deal of damage can be done to the machine. 11. Care must be taken, when you are working on the machine, otherwise it causes serious accident. 12. Do not joke are run in machine shop.

In Millimeters: Least Count is 0.02mm Each Vernier Scale Division is 0.02mm In Inches: y 1" is divided in 40 divisions. 05 divisions on main scale are 1/8". Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah. Least Count is 0.001" Each Vernier Scale Division is 0.001" On Main Scale: Each Division = 0.025" Four Divisions = 0.1" Eight Divisions = 0.2"

The Lathe Machine:

The lathe is the most ancient machine. It has been in use for many centuries and has been greatly improved in design. Firstly it was used to remove material from the outside of logs of wood while they were revolving, thus producing a cylindrical shape. But the modern engine lathe is credited to the English mechanic, Henry Maudsley. Maudsley made both wood working and metal working machines. At present it is mostly used for metal cutting. The lathe is one of the most important machines in any workshop. The removing of material from a piece of revolving work is the main purpose of a lathe. It is also used for different operations, such as facing, turning, cutting, threading, drilling etc.

Parts of Lathe:
It is most important to learn the parts of a lathe machine and their functions. Bed: The lathe bed is manufactured in foundry by the process of casting. It is the foundation on which the lathe is built. It has ways "V" is formed upon them. The bed is supported by cross strips. Headstock: The headstock is also manufactured by the process of casting and is fastened to the ways of on the left end of the bed. The spindle that rotates the work piece is also fitted in the headstock. The spindle is hollow in the centre. Variation in spindle speed is easily accomplished by the adjustment of speed control lever. The speed of lathe is given in rpm (Revolution per minute). The spindle speed can be changed by shifting the driving belt to a pulley of larger or smaller diameter. Chuck: The chuck is mounted on the spindle. It is used for holding and revolving the job. Types of Chucks: Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah. Chucks come in different types; the following are the most common ones. y Three-jaw Universal Chuck y Four-jaw Independent Chuck y Combination Chuck Three-jaw Universal Chuck In this type of chuck the jaws move "In and Out" together. All the three jaws move simultaneously if anyone of the jaw is operated with the chuck key. Three-jaw chucks are used to hold job's circular and hexagonal cross sections. They are manufactured in different sizes ranging from 4 to 16 inches. Four-jaw Independent Chuck It contains four jaws, each jaw is operated independently by a chuck key, and this chuck is used to hold jobs of round, square and rectangular cross-section. But setting the job with an independent jaw chuck requires higher skills. Combination Chuck A combination chuck is normally a four chuck. In this type of chuck the jaws are either moved independently or together. Tail Stock: The tail stock is a moveable casting and supports an adjustable spindle, located opposite the head stock on the ways of the bed. The tail stock can be moved longitudinally or can be clamped tightly by tightening the clamping lever. The tail stock movement makes it possible to hold work pieces of different lengths between centers. The tail stock spindle does not rotate, it may be used to hold taper shacked drills, reamers etc. The tail stock is constructed in two parts so that the upper part can be moved either toward or away from the operator to offset the work piece for taper turning. This moves the tail stock out of alignment. One end of tail stock spindle is bored to a standard taper to hold the dead centre. The spindle can be moved back and forth by turning the hand wheel. The dead centre may be removed by reversing the hand wheel. A screw running through the hollow spindle strikes the end of the dead centre and loosens it. Carriage: The carriage is attached to the bed, which slides between the head stock and tail stock. The carriage consisting of the saddle, apron that slides, compound rest and tool post. The Saddle: It is a casting that slides over the ways of the bed to carry cross slide. The Apron: It contains the clutch knob, the feed change lever, the split nut lever, and the gears that are necessary for the operation of the carriage by hand and power feeds. The split nut which engages with the lead screw in cutting threads Hand wheels on the apron allows the carriage to be moved longitudinally. Cross Slide: The cross slide is mounted on the saddle. It has a handle to move the slide transversally. Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah. The slide can also be moved automatically. Compound Rest: The compound rest is mounted on top of the cross slide. It can be swiveled in a 360 degree circle to cut my desired angle. Tool Post: It is used for holding the cutting tools. Thread Cutting Mechanism: The thread cutting mechanism includes any gear or mechanism which transmits motion from the main spindle (Head Stock) to the lead screw. The carriage movement is adjusted by the split nut on the lead screw, using the lever on the out side of the apron to move the split nut. The lead screw is used only for the thread cutting. For adjusting the gears to the required number of threads per inch (T.P.I) and the correct position of tumbler's lever is determined by charts, which are attached to the gear box. Hand Wheel: The hand wheel which is on apron is used to give feed to the cutting tool during working time.

Types of Lathes:
Lathes come in different types and sizes. The size of a lathe is designated by the swing over the bed and by the length of the bed. Different types of lathes are available in various industries, such as engine lathe, turret lathe, boring milling lathe, automatic lathe etc.

Cutting Tools of Lathe:

The tools used for cutting on the lathe are generally made of high speed steel, an alloy of carbon, tungsten, vanadium or molybdenum. Tungsten-carbide tipped tools are used for manufacturing requiring maximum cutting speeds. The most important cutting tools are common tool bits. These are ground in a variety of shapers and different names of grinding angles, according to the type of operation to be performed. Some of these are: y Left hand turning tool y Round nose turning tool y Right hand turning tool y Left hand corner tool y Threading tool y Right hand corner tool y Left hand side tool y Square nose tool y Right hand side tool y Brass tool

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah. The V-type threading tool is mostly used in cutting of threads. The 60 degree included angle to which a V-type threading tool is ground must be checked for accuracy with a centre gauge. Some other tools are: y Inside threading tool y Cut off or Parting tool y Boring tool

Vernier Caliper:
The vernier caliper is used to take accurate measurement. It comes in various types and sizes according to the work. It consists vernier scale, main scale, depth bar, slider, clamp screw, out-side jaws and inside jaws. The vernier caliper which is used in our machine shop has a 0.05mm least count. The zero mark on the vernier scale indicated the measurement to be read on the main scale.

The Shaper Machine:

The shaper is used for the production of the surfaces, which may be in a horizontal, a vertical, or an angular plane. The following are the main parts of a shaper machine: Base: The base is a hollow casting upon which the other parts of the shaper are mounted. It is also a reservoir for the supply of oil which is circulated to the moving parts of the machine. Column: The column is a hollow rectangular casting, which rests upon the base. Ram: The ram of shapers has forward and return strokes during the cutting process. Tool Head: It is used to hold the cutting tool and may be swiveled to a required angle to the left or right according to the work. Table: The table is a casting of rectangular shape, of box like construction with openings at the front and bottom. It has "T" slots on the top and sides, which are used for holding work piece or a vice to the table.

Types of Shapers:
Shapers come in different types and sizes. The size of the shaper is determined by the maximum length of its stroke. Different types of shapers are available in various industries such as crank shapers, hydraulic shaper and vertical shaper.

The Drilling Machine:

The drilling machines are mostly used for the purpose of drilling holes in all kinds of Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah. material.

Parts of Drilling Machine:

Base: The base is a heavy casting with holes for mounting the machine to the floor. Column: It is made of cylindrical type and supports the head ad the table of drilling machine. Head: The head is attached to the upper end of the column. It consist entire working mechanism. Spindle: The central part of the head is called spindle. Table: The table is supported by the column. It may be moved up and down to hold different heights of work piece. The table may also be swung horizontally. Drill Chuck: The drill chucks are made in various sizes to hold drills ranging form 1/32" to 3/4" in diameter.

Types of Drilling Machine:

So many types of drilling machine are available in various industries. The vertical spindle drilling machine is available in three types 1. Plain vertical spindle drilling machine. 2. Sensitive drilling machine. 3. Heavy duty drill press.

Machining Operations:
Turning Operation:
Turning is the operation of removing stock from the outside of a piece of material while it is being revolved in a lathe. The stock is removed by a suitable cutting tool. Turning produces a piece of work that is cylindrical in shape.

Facing Operation:
Facing is the operation of removing stock from the end of a bar of material as it is being revolved in a lathe.

Knurling Operation:
Knurling is an operation or process of roughening the surface of a piece of work by making a series of indentations on it with knurling tool held in the tool post and work piece is being revolved in a lathe. A slow speed should be used to knurl a piece of work. Force the knurling tool slowing into the work to a depth of approximately 1/64". Set the feed so that the tool will feed Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah. across the surface of the work. Reverse the feed of the carriage at the end of the cut, and repeat the operation until the knurling has been completed. The knurls should be lubricated while cutting.

Thread Gauge:
The thread gauge is a tool used for measuring the number of threads per inch (T.P.I) of external and internal threads. Thread gauge is also called screw-pitch gauge. It is a series of blades which are accurately notched and numbered. To test a thread to determine the number of threads per inch, one the blade at a time is placed on the threads until one is found that is a perfect match.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Job # 1
Object: To make a square piece by filing. Material: Mild steel strip of size 50 * 50 * 5. Tools and Equipments: Bench Vice, Try Square, Odd Leg Caliper and Flat File. Process: Lay outing, Filing. Procedure: First we take the given piece and adjust in the bench vice. Start filing one layer with flat file then check the flat surface of the given piece with try square, then start the filing the vertical side. When completed, draw a line by chalk at opposite side of flat surface. Then take odd leg caliper on one of the plane surface, open the caliper to the required size and make up side down with the help of pointing. Then start filing the piece. Check with try-square, if its 46 * 46* 5, then its completed. Note: All dimensions are in millimeters. Safety Precautions: Keep proper discipline in shop Always wear the apron and closed shoes All files should be fitted with the suitable handle at the right end of file. Drawing:

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Job # 2
Object: To make a "V" and "U" groove by filing. Material: Mild steel strip of size 50 * 50 * 5. Tools and Equipments: Bench Vice, Try Square, Odd Leg Caliper, Flat File, Square File and Triangular File. Process: Lay outing, Filing, Grooving, Cutting Procedure: First we take the given piece and adjust in the bench vice. Start filing one layer with flat file then check the flat surface of the given piece with try square, then start the filing the vertical side. When completed, draw a line by chalk at opposite side of flat surface. Then take odd leg caliper on one of the plane surface, open the caliper to the required size and make up side down with the help of pointing. Then start filing the piece. Check with try-square, if its 46 * 46* 5, then its completed. Now take a triangular file and file on it gently until and unless "V" groove appears in a M.S and filing until you get your required shape. When "U" grooving only an square file will be used instead of a triangular one. Note: All dimensions are in millimeters. Safety Precautions: Not touch any tool until the Instructor guides you about it Always wear the apron and closed shoes All files should be filled with forward stroke Drawing:

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Job # 3
Object: To make a Hexagonal Nut Material: Mild steel strip of size 50 * 50 * 5. Tools and Equipments: Bench Vice, Steel Rule, Center Punch, Divider, Scriber, Hack Saw, Flat File, Drill 5/16", Tap 3/8" with stock oil cane and Hammer. Process: Lay outing, Center making, Drilling and Tapping. Procedure: Fix the job in the bench vice and take safety precautions. With the help of try-square and scriber draw a diagonal on strip. With center punch mark the center by diagonals. Open divider with suitable angle and draw a circle. Again with center punch point the diagonal and circle. Use the divider and center punch and make a hexagonal. Use try-square, join all points and wit the help of drilling machine, drill at the center. Now cut all the suitable lines with hack saw. Then use diameter 3/8" and make threads inside the hole. Note: All dimensions are in millimeters. Safety Precautions: Not touch any tool until the Instructor guides you about it Always wear the apron and closed shoes and goggles at the time of drilling All files should be filled with forward stroke Drawing:

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.

Job # 4
Object: To make a Bolt. Material: Mild Round 3" * 3/8 diameter. Tools and Equipments: Hack Saw, Steel Rule, File diameter 3/8" with stock oil cane. Process: Lay outing, Cutting, Filing Procedure: First of all we give a M.S round 3"*3/8" rod and cut with hack saw a 3" rod. Then we make a face for holding in bench vice with filing and other side we make a taper for some filing to adjust the diameter in the rod. After this process, we are able to start diameter on rod threading. The length of face is 1/2" and length of threading approximately 1 1/2". If you find it a touch difficult to thread, oil cane may be used to make the job a bit too easy. Safety Precautions: Not touch any tool until the Instructor guides you about it Always wear the apron and closed shoes and goggles at the time of drilling All files should be filled with forward stroke Drawing:

Machine Shop (Workshop Technology) Waqas Ali Tunio (07ME34), QUEST, Nawabshah.