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DEFINITION:
A place where machining is done. In a machine shop, machinists use machine
tools and cutting tools to make parts, usually of metal.
MILLING MACHINE:
Milling machines are tools designed to machine metal, wood, and other solid
materials. The working principle of a milling machine is based on the cutting
tool being rotated while the workpiece is pushed against its edges. As the
workpiece advances, the cutter teeth remove chips from the surface of
workpiece and the desired shape is produced.
Base:
It gives support and rigidity to the machine and may act as a reservoir
for the cutting fluids.
Column:
The column is the main supporting frame mounted vertically on the
base. The column is box shaped, heavily ribbed inside and houses all the
driving mechanisms for the spindle and table feed.
Saddle:
The part that provides the feeding motion (in/out) to the table on which
the workpiece is mounted.
Table:
The part on which the workpiece is mounted and acts like a bench vice.
It moves in three directions: up/down, towards/backwards from the
column and in/out feeding motion.
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Horizontal Knee Type Milling Machine
Vertical Milling Machine:
In a vertical milling machine, the spindle is perpendicular to the table or
placed vertically.
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Knee-Type Milling Machine:
A type of milling machine, which has a knee like projection in the
middle. It is characterised by a vertically adjustable worktable resting on
a saddle supported by a knee.
Plain Milling:
Machining of a flat surface, which is parallel to the axis of the rotating
cutter.
Plain Milling
Face Milling:
Machining of a flat surface, which is at right angles to the axis of the
rotating cutter.
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Face Milling
Angular Milling:
Machining of a flat surface at an angle, other than a right angle, to the
axis of revolving cutter.
Angular Milling
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Straddle Milling:
Simultaneous machining of two parallel vertical faces of the work-pieces
by a pair of side milling cutters.
Straddle Milling
Form Milling:
Machining of surfaces, which are of irregular shape. The teeth of the
form milling cutter have a shape which corresponds to the profile of the
surface to be produced.
Form Milling
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Gang Milling:
Simultaneous machining of a number of flat horizontal and vertical
surfaces of a workpiece by using a combination of more than two cutters
mounted on a common arbor.
Gang Milling
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Tool Grinder:
A tool and cutter grinder is used to sharpen milling cutters and tool bits along
with a host of other cutting tools. It is an extremely versatile machine used to
perform a variety of grinding operations: surface, cylindrical, or complex
shapes.
The working principle of a tool grinder is based upon the rotation of grinding
wheels against a tool moving perpendicular to the rotation of the wheel.
Electric Motor:
A device that uses electricity to create a rotary motion.
Grinding Wheels:
Wheels made of an abrasive material that grinds material.
Wheel Guard:
Protects the wheels from touching any unwanted surfaces.
Safety Shield:
It prevents the machinist from flying sparks and chips.
Spark Guard:
It prevents any flying sparks going backwards.
Surface Grinding
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DRILLING MACHINE:
A drill is a tool fitted with a cutting tool attachment or driving tool attachment,
usually a drill bit or driver bit, used for boring holes in various materials or
fastening various materials together.
The working principle of a drilling machine is the rotary motion of the drill bit,
which removes small chips of a stationary material pressed against its tip.
Electric Motor:
A device that uses electricity to create a rotary motion.
Chuck:
A drill chuck is a specialised self-centring, three-jaw chuck, usually with
capacity of 0.5 in (13 mm) or less and rarely greater than 1 in (25 mm),
used to hold drill bits or other rotary tools.
Table:
The part on which the workpiece is mounted and acts like a bench vice.
It moves up/down on the column.
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Geared Head Drilling Machine
Radial Arm Drilling Machine:
A 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 without having
to reposition the workpiece.
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OPERATIONS OF DRILLING MACHINES:
The following are a few operations done on a drilling machine:
Drilling:
Drilling is a cutting process that uses a rotary cutting tool called a drill-
bit to cut a circular hole in solid materials. The bit is pressed against the
work-piece and rotated, this forces the cutting edge against the work-
piece, cutting off chips from the hole as it is drilled.
Drilling
Reaming:
It is the process of enlarging a previously formed hole either by a small
amount using precision reamers leaving smooth sides or by a large
amount using non-precision reamers.
Reaming
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Tapping:
It is the process of cutting or forming a thread on the inside surface of a
hole, creating a female surface which functions like a nut. This process is
essential for the creation of fasteners.
Tapping
Countersinking:
It is a process of cutting a conical hole in an object with the aim that the
head of a countersunk bolt or screw can sit flush or below the work-
piece’s surface. This process might also be used to remove the burr left
after a drilling or tapping operation thereby improving the finish of the
product as well as removing any dangerous sharp edges.
Countersinking
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Counterboring:
It is a process of cutting a flat-bottomed hole in an object when a
fastener such as a socket head cap screw is required to sit flush or below
the work-piece’s surface.
Counterboring
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SHAPER MACHINE:
A shaper is a type of machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to machine a linear toolpath.
Base:
This is the main body of the machine.
Ram:
It holds the tool and provides the reciprocating motion to it.
Tool Head:
It is situated at the front of the ram and its function is to hold the
cutting tool.
Table:
The part on which the workpiece is mounted and acts like a bench vice.
Clapper Box:
The part, which carries the tool head and provides clearance.
Column:
It is attached to the base and provides the housing for the crank slider
mechanism.
Stroke Adjuster:
It is attached below the table and is used to control the stroke length,
which further controls the ram movement.
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Crank Shaper:
The most common type of shaping machine is the crank shaper, in
which the motion of its ram is being derived from a crank, a crank block,
and a crank pin.
Hydraulic Shaper:
In a hydraulic shaper, the reciprocating movements of the ram are
obtained by hydraulic power. Oil under high pressure is pumped into
the operating cylinder fitted with a piston. The end of the piston rod is
connected to the ram. The high pressure oil first acts on one side of the
piston causing the piston to reciprocate and the motion is transmitted to
the ram. The piston speed is changed by varying the amount of oil
delivered by the pump.
Horizontal Shaper:
In a horizontal shaper, the ram holding tool reciprocates in a horizontal
axis. Horizontal shapers are mainly used to produce flat surfaces.
Horizontal Shaper
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Vertical Shaper:
In a vertical shaper, the ram holding the tool reciprocates in vertical
axis. In some of the vertical machines, provision is made to allow
adjustment of the ram to an angle of about 100 from the vertical
position. Vertical shapers may be crank driven, rack driven, screw
driven, or hydraulic power driven.
Vertical Shaper
Travelling Head Shaper:
In a travelling head shaper, the ram carrying the tool while it
reciprocates, moves cross wise to give the required feed.
Universal Shaper:
In a Universal shaper, in addition to the two movements provided on the
table of a standard shaper, the table can be swivelled about an axis
parallel to the ram ways, and the upper portion of the table can be tilted
to second horizontal axis perpendicular to the first axis. As the work is
mounted on the table, it can be adjusted in different planes.
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Push Type Shaper:
This is the most general type of shaper used in common practice. The
metal is removed when the ram moves away from the column, i.e. it
pushes the work.
Shaping Operations
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POWER HACKSAW:
A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal.
A motor powered version of a hacksaw is called a power hacksaw. The working
principle of a power hacksaw is that the saw moves forwards and backwards
and slowly goes downwards on a stationary workpiece.
Electric Motor:
A device that uses electricity to create a rotary motion.
Bench Vice:
It is a mechanical apparatus used to secure an object to allow work to be
performed on it. Vices have two parallel jaws, one fixed and the other
movable, threaded in and out by a screw and lever.
Hacksaw Blade:
A tool with an edge that is designed to cut surfaces or materials.
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LATHE MACHINE:
A lathe is a tool that rotates the workpiece about an axis of rotation to perform
various operations such as cutting, sanding, knurling, drilling, deformation,
facing, turning, with tools that are applied to the workpiece to create an object
with symmetry about that axis.
The working principle of a lathe machine is that the workpiece is held between
two rigid and strong supports called centres or in a chuck or face plate which
revolves. The cutting tool is rigidly held and supported in a tool post, which is
fed against the revolving work. The normal cutting operations are performed
with the cutting tool fed either parallel or at right angles to the axis of the work.
The cutting tool may also be fed at an angle relative to the axis of work for
machining tapers and angles.
Bed:
Usually made of cast iron. Provides a heavy rigid frame on which all the
main components are mounted.
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Ways:
Inner and outer guide rails that are precision machined parallel to assure
accuracy of movement.
Headstock:
Mounted in a fixed position on the inner ways, usually at the left end.
Using a chuck, it rotates the work.
Spindle:
Hole through the headstock to which bar stock can be fed, which allows
shafts that are up to 2 times the length between lathe centers to be
worked on one end at a time.
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Spindle with Chuck
Chuck:
3-jaw (self centering) or 4-jaw (independent) to clamp part being
machined.
Tailstock:
Fits on the inner ways of the bed and can slide towards any position the
headstock to fit the length of the work piece. An optional taper turning
attachment would be mounted to it.
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Tailstock Quill:
Has a Morse taper to hold a lathe center, drill bit or other tool.
Carriage:
Moves on the outer ways. Used for mounting and moving most the
cutting tools.
Cross Slide:
Mounted on the traverse slide of the carriage, and uses a handwheel to
feed tools into the workpiece.
Tool Post:
To mount tool holders in which the cutting bits are clamped.
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Tool Post Quick Change Set
Compound Rest:
Mounted to the cross slide, it pivots around the tool post.
Feed Rod:
Has a keyway, with two reversing pinion gears, either of which can be
meshed with the mating bevel gear to forward or reverse the carriage
using a clutch.
Feed Rod
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Lead Screw:
For cutting threads.
Split Nut:
When closed around the lead screw, the carriage is driven along by
direct drive without using a clutch.
Steady Rest:
Clamped to the lathe ways, it uses adjustable fingers to contact the
workpiece and align it. Can be used in place of tailstock or in the middle
to support long or unstable parts being machined.
Steady Rest
Follow Rest:
Bolted to the lathe carriage, it uses adjustable fingers to bear against the
workpiece opposite the cutting tool to prevent deflection.
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Follow Rest
TYPES OF LATHES:
There are various types of lathe machines, some of which are:
Speed Lathes:
Very simple in design as it has only a headstock, tailstock and a very
simple tool post. It can operate in 3-4 speeds. The spindle speed is very
high. It is used for light machine works like wood turning, metal
spinning and metal polishing.
Speed Lathe
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Engine Lathes:
Engine lathes are the most common types of lathe machine. It is
designed for low power operations as well as high power operations. It
can machine various metals. The machine can operate at a wide range of
speed ratios.
Engine Lathe
Tool Room Lathes:
A very versatile lathe machine and gives better accuracy and finishing. It
has wider range of speeds and can be operated with different types of
feeds. It is a great device to manufacture dies.
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Turret Lathes:
It is a great machine for quick operations as it has various types of tool
posts mounted on a single structure. A sequential machining process can
be done by using the turret lathe without moving the workpiece and
helps eliminate the error that occurs due to misalignment.
Turret Lathes
Centres:
There are two types of centres i.e., live centre and dead centre. A centre
which fits into the headstock spindle and revolves with the work is
called live centre whereas the centre which is used in a tailstock spindle
and does not revolve is called dead centre.
Centre
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Lathe Dog:
The work placed on a mandrel or held between centers is rotated
positively by clamping the dog or carrier to the end of the work. This is
engaged with a pin attached to the drive plate or faceplate. The lathe
dog or carrier may be of straight type or bent type.
Lathe Dog
Driveplate:
The drive plate is a circular plate, which is bored out and threaded so
that it can be attached to the spindle nose. It also carries a hole for the
pin, which is used only when the work is held in a lathe dog having
straight tail. When bent-tail dog is used, this pin is taken out and the
bent portion of the tail is inserted into the hole.
Driveplate
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Faceplate:
The faceplate is similar to driveplate except that it is larger in diameter.
It contains more open slots or T-slots so that bolts may be used to clamp
the workpiece to the face of the plate. The faceplate is used for holding
work pieces which can not be conveniently held in a chuck.
Faceplate
Angleplate:
An angleplate is simply a cast iron plate with to faces planed at right
angles to each other and having slots in various positions for the
clamping bolts. It is always used with the faceplate for holding such
parts, which cannot be clamped against the vertical surface of the
faceplate.
Mandrels:
The lathe mandrel is a cylindrical bar with centre hole at each end. It is
used to hold hollow work pieces to machine their external surface. The
work revolves with the mandrel, which is mounted between the centres
of the lathe.
Mandrel
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OPERATIONS OF LATHE MACHINE:
The following are a few operations done on a lathe machine:
Plain Turning:
Plain turning is the operation of removing excess amount of material
from the surface of a cylindrical job.
Step Turning:
Step turning produces various steps of different diameters.
Facing:
The facing is a machining operation by which the end surface of the
work piece is made flat by removing metal from it.
Drilling:
Drilling is the operation of producing a cylindrical hole in the
workpiece.
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Reaming:
The holes that are produced by drilling are rarely straight and cylindrical
in form. The reaming operation finishes and sizes the hole already
drilled into the workpiece.
Boring:
The boring operation is the process of enlarging a hole already produced
by drilling.
Boring
Knurling:
The knurling is a process of embossing (impressing) a diamond-shaped
or straight-line pattern into the surface of workpiece. Knurling is
essentially a roughening of the surface and is done to provide a better
gripping surface.
Knurling
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Grooving:
Grooving is the act of making grooves of reduced diameter in the
workpiece.
Grooving
Threading:
Threading is the act of cutting of the required form of threads on the
internal or external cylindrical surfaces.
Threading
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Forming:
The forming is an operation that produces a convex, concave or any
irregular profile on the workpiece.
Forming
Chamfering:
Chamfering removes the burrs and sharp edges, and thus makes the
handling safe. Chamfering can be done by a form tool having an angle
equal to chamfer which is generally kept at 45°.
Chamfering
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Filing & Polishing:
The filing is the finishing operation that removes burrs, sharp corners
and feed marks from the workpiece. After filing, the surface quality of
the workpiece is improved by polishing.
Filing
Taper Turning:
The taper turning is an operation of producing a conical surface by
gradual reduction in the diameter of a cylindrical workpiece.
Taper Turning
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