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Workshop Practise for Begineers

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WORKSHOP PRACTISE-II
MED-128

Ashwani Tayal
Room No. 109
Mechanical Engineering Department
NIT Hamirpur(H.P)
INTRODUCTION

L 1 T 0 P 3 Cr 2
Machine Shop
Foundry
Smithy
Sheet Metal

Dress Code: Khaki with Close Shoes

 Groups

Groups/ shops Machine Shop Foundry Shop Smithy Shop Sheet Metal
Shop

M-I (14301- M-I M-II M-III M-IV

14312)

M-II (14313- M-II M-III M-IV M-I

14324)

M-III (14325- M-III M-IV M-I M-II

14335)

M-IV (14336- M-IV M-I M-II M-III

14346)
 Groups

Groups/ shops Machine Shop Foundry Shop Smithy Shop Sheet Metal
Shop

M-I (14347- M-I M-II M-III M-IV

14358)

M-II (14359- M-II M-III M-IV M-I

14370)

M-III (14371- M-III M-IV M-I M-II

14381)

M-IV (14382- M-IV M-I M-II M-III

14393)
 Evaluation Chart

100 (Total)

60 (Internal) 40 (External)

20 20
30 30
(Ext Viva) (Ext. Pract.)

10 7.5
10 10 7.5 7.5 7.5
Sheet Metal
(Class Test-II) (Assignment) Machine Shop Foundry Shop Smithy Shop
(Class Test-I) Shop

5 2.5
(Job) (Practical File)
 Evaluation Instruction

Three turns for each Shop.

After completing 3 turns shift to next shop
and so on.
File should be submitted for checking on
third day of the respective shop.
Files after due day will not be evaluate at
any reason.
If any have emergency, he must check his
file before due day.
Safety measures
• Do not use mobile phones & electronic gadegts in class(If
any one found , he will be punished)
• Do not enter after 8:30 AM & 01:05 PM (DO NOT
EXCUSE).
• Wear proper dress code for workshop.
• Come with Practical Note Book and Accessories.
• Follow
R A P I D
R Rule
A Attentive
P Punctual
I Interactive
D Discipline

Ashwani Tayal, MED NIT HMR

WORKSHOP

• Workshop is an educational platform

where science is translated into
technology. The process of modernizing
the workshop training in line with industry
to suit industrial requirements.The Central
workshop is functioning under the support
and services of the Institute and it is one
among those that serve, support and
enhances the academic process of B.Tech,
M.Tech Students and PhD.Reaserch
Scholars.
Ashwani Tayal, MED NIT HMR
MACHINE SHOP

• A workshop where power driven tools

are used for making, finishing, or
repairing machines or machine parts.
• Metal cutting or traditional machining
processes are also known as
conventional machining processes.
• These processes are commonly
carried out in machine shops or tool
room for machining a cylindrical or flat
jobs to a desired shape, size and finish
on a rough block of job material with
the help of a wedge shaped tool.
Ashwani Tayal, MED NIT HMR
Classification of Machine Tools

Conventional or traditional machine tools like

Lathes, Milling machines, etc. are used more
widely for faster material removal by shearing or
brittle fracturing.
• Non-conventional or non-traditional machine
tools: like EDM, ECM, USM, etc. which remove
material from exotic materials slowly by electro-
physical, electro-chemical processes.
• Modern numerical and computer controlled
machine tools: Like CNC lathe, CNC milling
Ashwani Tayal, MED NIT HMR
General Purpose Machine Tools

The basic machine tools which are commonly used for

general purposes are:
 Lathes
Drilling machines
Shaping machines
Planning machines
Slotting machines
Milling machines
Boring machines
Hobbing machines
Gear shaping machines
Broaching machines
Grinding machine
Ashwani Tayal, MED NIT HMR
 CUTTING
• In metal cutting operation, the position of cutting
edge of the cutting tool is important based on
which the cutting operation is classified as
orthogonal cutting and oblique cutting.
• Orthogonal cutting is also known as two
dimensional metal cutting in which the cutting
edge is normal to the work piece.
• Oblique cutting is the common type of three
dimensional cutting used in various metal cutting
operations in which the cutting action is inclined
with the job by a certain angle called the
inclination angle.Ashwani Tayal, MED NIT HMR
CUTTING

Ashwani Tayal, MED NIT HMR

CUTTING TOOL
• Cutting tools performs the main machining
operation. They comprise of single point
cutting tool or multipoint cutting tools. It is
a body having teeth or cutting edges on it.
A single point cutting tool (such as a lathe,
shaper and planner and boring tool) has
only one cutting edge, whereas a multi-
point cutting tool (such as milling cutter,
milling cutter, drill, reamer and broach) has
a number of teeth or cutting edges on its
periphery.
Ashwani Tayal, MED NIT HMR
Single Point Cutting Tools
• There are mainly two types of single point
tools namely the solid type as shown in
Fig. and the tipped tool . The solid type
single point tool may be made from high
speed steel, from a cast alloy.

Ashwani Tayal, MED NIT HMR

Single Point Cutting Tools
Geometry

Ashwani Tayal, MED NIT HMR

Contd........

Ashwani Tayal, MED NIT HMR

Lathe Machine

• Lathe is one of the most versatile and widely used

machine tools all over the world. It is commonly known as
the mother of all other machine tool. The main function of
a lathe is to remove metal from a job to give it the
required shape and size. The job is securely and rigidly
held in the chuck or in between centers on the lathe
machine and then turn it against a single point cutting tool
which will remove metal from the job in the form of chips

Ashwani Tayal, MED NIT HMR

Working principal

Ashwani Tayal, MED NIT HMR

Types of Lathe Machine

1. Speed lathe 5. Capstan and Turret 1athe

(a) Wood working 6. Special purpose lathe
(b) Spinning (a) Wheel lathe
(c) Centering (b) Gap bed lathe
(d) Po1ishing (c) Duplicating lathe
2. Centre or engine lathe (d) T-lathe
(a) Belt drive 7. Automatic lathe
(b) Individual motor drive
(c) Gear head lathe
3. Bench lathe
4. Tool room Lathe
Ashwani Tayal, MED NIT HMR
Costructional Detail of lathe
Machine

• A simple lathe comprises of a bed made of grey cast iron

on which headstock, tailstock, carriage and other
components of lathe are mounted. Fig. shows the
different parts of engine lathe or central lathe. The major
parts of lathe machine are given as under:
1. Bed
2. Head stock
3. Tailstock
4. Carriage
5. Feed mechanism
6. Thread cutting mechanism

Ashwani Tayal, MED NIT HMR

Contd....

Ashwani Tayal, MED NIT HMR

Bed

• The bed of a lathe machine is the base on which

all other parts of lathe are mounted. It is massive
and rigid single piece casting made to support
other active parts of lathe. On left end of the bed,
headstock of lathe machine is located while on
right side tailstock is located. The carriage of the
machine rests over the bed and slides on it. On
the top of the bed there are two sets of
guideways-innerways and outerways. The
innerways provide sliding surfaces for the tailstock
and the outerways for the carriage. The
guideways of the lathe bed may be flat and
inverted V shape. Generally cast iron alloyed with
nickel and chromium material is used for
manufacturing of theTayal,
Ashwani lathe bed.
MED NIT HMR
Ashwani Tayal, MED NIT HMR
Head Stock

• The main function of headstock is to

transmit power to the different parts of a
lathe. It comprises of the headstock
casting to accommodate all the parts
within it including gear train arrangement.
The main spindle is adjusted in it, which
possesses live centre to which the work
can be attached. It supports the work and
revolves with the work, fitted into the main
spindle of the headstock
Ashwani Tayal, MED NIT HMR
Ashwani Tayal, MED NIT HMR
Tail Stock
• Fig. shows the tail stock of central lathe, which is
commonly used for the objective of primarily
giving an outer bearing and support the circular
job being turned on centers.
• Tail stock can be easily set or adjusted for
alignment or non-alignment with respect to the
spindle centre and carries a centre called dead
centre for supporting one end of the work.
• Both live and dead centers have 60° conical
points to fit centre holes in the circular job, the
other end tapering to allow for good fitting into
the spindles.
Ashwani Tayal, MED NIT HMR
Ashwani Tayal, MED NIT HMR
Carriage

• Carriage is mounted on the outer guide ways of lathe bed

and it can move in a direction parallel to the spindle axis.
It comprises of important parts such as apron, cross-slide,
saddle, compound rest, and tool post.
• The lower part of the carriage is termed the apron in
which there are gears to constitute apron mechanism for
adjusting the direction of the feed using clutch
mechanism and the split half nut for automatic feed.
• The cross-slide is basically mounted on the carriage,
which generally travels at right angles to the spindle axis.
• On the cross-slide, a saddle is mounted in which the
compound rest is adjusted which can rotate and fix to any
desired angle. The compound rest slide is actuated by a
screw, which rotates in a nut fixed to the saddle.

Ashwani Tayal, MED NIT HMR

Ashwani Tayal, MED NIT HMR
ACCESSORIES AND
ATTACHMENTS OF LATHE
• There are many lathe accessories
provided by the lathe manufacturer along
with the lathe, which support the lathe
operations.
• The important lathe accessories include
centers, catch plates and carriers, chucks,
collets, face plates, angle plates,
mandrels, and rests.
• These are used either for holding and
supporting the work or for holding the tool.

Ashwani Tayal, MED NIT HMR

• Attachments are additional equipments
provided by the lathe manufacturer along
with the lathe, which can be used for
specific operations.
• The lathe attachment include stops, ball
turning rests, thread chasing dials, milling
attachment, grinding attachment, gear
cutting attachment, turret attachment and
crank pin turning attachments and taper
turning attachment.

Ashwani Tayal, MED NIT HMR

 Work Holding Devices

Fig : (a) and (b) Schematic illustrations of a draw-in-type collets. The workpiece is
placed in the collet hole, and the conical surfaces of the collet are forced inward
by pulling it with a draw bar into the sleeve. (c) A push-out type collet. (d)
Workholding of a part on a face plate.
Ashwani Tayal, MED NIT HMR
 Three jaw
chuck Four-Jaw Chuck

- For holding cylindrical

- This is independent chuck
stock centered.
generally has four jaws , which
- For facing/center
are adjusted individually on the
drilling the end of your
chuck face by means of
aluminum stock
adjusting screws

Ashwani Tayal, MED NIT HMR

 Collet Chuck Magnetic Chuck

Thin jobs can be held by

Collet chuck is used to
means of magnetic chucks.
hold small workpieces

Ashwani Tayal, MED NIT HMR

Lathe Centres

Ashwani Tayal, MED NIT HMR

Face Plates

Ashwani Tayal, MED NIT HMR

Lathe Rests

Ashwani Tayal, MED NIT HMR

Grinding Attachment

Ashwani Tayal, MED NIT HMR

Milling Attachment

Ashwani Tayal, MED NIT HMR

SPECIFICATION OF LATHE
• The size of a lathe is generally specified by the following
means:
(a) Swing or maximum diameter that can be rotated over the
bed ways
(b) Maximum length of the job that can be held between
head stock and tail stockcentres
(c) Bed length, which may include head stock length also
(d) Maximum diameter of the bar that can pass through
spindle or collect chuck of capstan lathe.

Ashwani Tayal, MED NIT HMR

LATHE OPERATIONS

• For performing the various machining operations

in a lathe, the job is being supported and driven
by anyone of the following methods.
1. Job is held and driven by chuck with the other
end supported on the tail stock centre.
2. Job is held between centers and driven by
carriers and catch plates.
3. Job is held on a mandrel, which is supported
between centers and driven by carriers and
catch plates.
4. Job is held and driven by a chuck or a faceplate
or an angle plate.
Ashwani Tayal, MED NIT HMR
(a) Operations, which can be performed in a lathe
either by holding the workpiece between centers or by
a chuck are:
1. Straight turning 2. Shoulder turning
3. Taper turning 4. Chamfering
5. Eccentric turning 6. Thread cutting
7. Facing 8. Forming
9. Filing 10. Polishing
11. Grooving 12. Knurling
13. Spinning 14. Spring winding

Ashwani Tayal, MED NIT HMR

(b) Operations which are performed by holding the work by
a chuck or a faceplate or an angle plate are:
1. Undercutting 2. Parting-off
3. Internal thread cutting 4. Drilling
5. Reaming 6. Boring
7. Counter boring 8. Taper boring
9. Tapping
(c) Operations which are performed by using special lathe
attachments are:
1. Milling 2. Grinding
Ashwani Tayal, MED NIT HMR
 Lathe
Operations

Ashwani Tayal, MED NIT HMR

Contd....

Ashwani Tayal, MED NIT HMR

Drilling Machine

• Drilling is an operation of
making a circular hole by
removing a volume of metal
from the job by cutting tool
called drill. A drill is a rotary
end-cutting tool with one or
more cutting lips and usually
one or more flutes for the
passage of chips and the
admission of cutting fluid.
• A drilling machine is a machine
tool designed for drilling holes
in metals.
Ashwani Tayal, MED NIT HMR
Working Principle

Ashwani Tayal, MED NIT HMR

TYPES OF DRILLING MACHINE
(1) Portable drilling machine
(2) Sensitive drilling machine
(4) Radial drilling machine
(a) Bench mounting
(a) Plain
(b) Floor mounting
(b) Semi universal
(3) Upright drilling machine
(c) Universal
(a) Round column section
(5) Gang drilling machine
(b) Box column section
machine (6) Multiple spindle drilling
machine
(7) Automatic drilling
machine
(8) Deep hole drilling
machine

Ashwani Tayal, MED NIT HMR

CONSTRUCTION OF DRILLING
MACHINE

Ashwani Tayal, MED NIT HMR

TYPES OF DRILLS

• A drill is a multi point cutting tool used to

produce or enlarge a hole in the workpiece.
• It usually consists of two cutting edges set an
angle with the axis. Broadly there are three
types of drills:
1. Flat drill,
2. Straight-fluted drill, and
3. Twist drill

Ashwani Tayal, MED NIT HMR

Ashwani Tayal, MED NIT HMR
Nomenclature of Twist Drill

Ashwani Tayal, MED NIT HMR

OPERATIONS PERFORMED ON
DRILLING MACHINE
• A drill machine is versatile machine tool. A
number of operations can be performed on
it. Some of the operations that can be
performed on drilling machines are:
1. Drilling 2. Reaming
3. Boring 4. Counter boring
5. Countersinking 6. Spot facing
7. Tapping 8. Lapping
9. Grinding

Ashwani Tayal, MED NIT HMR

Drilling operations

Ashwani Tayal, MED NIT HMR

SIZE OF A DRILLING MACHINE
• Different parameters are being considered for
different types of drilling machines to determine
their size.
• The size ofa portable drilling machine is decided
by the maximum diameter of the drill that it can
hold.
• The sensitive and upright drilling machines are
specified by the diameter of the largest
workpiece which can be centered under the drill
machine spindle.
• A radial drilling machine is specified by the
length of the arm and the diameter of the
column. Ashwani Tayal, MED NIT HMR
contd....
• To specify a drilling machine completely,
following other parametersmay also be needed:
1. Table diameter
2. Number of spindle speeds and feeds available
3. Maximum spindle travel
4. Morse taper number of the drill spindle
5. Power input
6. Net weight of the machine
7. Floor space required, etc.

Ashwani Tayal, MED NIT HMR

Cutting Parameters
CUTTING SPEED
The cutting speed in a drilling operation refers to the
peripheral speed of a point on the surface of the drill in
contact with the work. It is usually expressed in meters/min.
The cutting speed (Cs) may be calculated as:
Cs= ((22/7) × D × N)/1000
Where, D is the diameter of the drill in mm and
N is the rpm of the drill spindle.
FEED
The feed of a drill is the distance the drill moves into the job at
each revolution of the spindle. It is expressed in millimeter.
The feed may also be expressed as feed per minute. The
feed per minute may be defined as the axial distance
moved by the drill into the work per minute. The feed per
minute may be calculated as:
F = Fr× N
Where, F = Feed per minute in MED
Ashwani Tayal, mm.NIT HMR
Fr = Feed per revolution in mm.,N = R.P.M. of the drill.
Shaper Machine
• Shaper is a reciprocating
type of machine tool in which
the ram moves the cutting
tool backwards and forwards
in a straight line. The basic
components of shaper are
shown in Fig. It is intended
primarily to produce flat
surfaces. These surfaces
may be horizontal, vertical, or
inclined. In general, the
shaper can produce any
surface composed of straight-
line elements.

Ashwani Tayal, MED NIT HMR

WORKING PRINCIPLE OF
SHAPER
• A single point cutting tool
is held in the tool holder,
which is mounted on the
ram.
• The workpiece is rigidly
held in a vice or clamped
directly on the table.
• The table may be
supported at the outer
end. The ram
reciprocates and thus
cutting tool held in tool
holder moves forward
and backward over the
workpiece.

Ashwani Tayal, MED NIT HMR

Constructional Details of Shaper

Ashwani Tayal, MED NIT HMR

Types of Shaper
• Shapers are classified under the following headings:
(1) According to the type of mechanism used for giving reciprocating
motion to the ram
(a) Crank type
(b) Geared type
(c) Hydraulic type
(2) According to the type of design of the table:
(a) Standard shaper
(b) Universal shaper
(3) According to the position and travel of ram:
(a) Horizontal type
(b) Vertical type
(c) Traveling head type
(4) According to the type of cutting stroke:
(a) Push type
(b) Draw type.

Ashwani Tayal, MED NIT HMR

Job Surface Generated by shaper

Ashwani Tayal, MED NIT HMR

Specification of Shaper
• The size of a shaper is specified by the
maximum length of stroke or cut it can make.
Usually the size of shaper ranges from 175 to
900 mm.
• Besides the length of stroke, other particulars,
such as the type of drive (belt drive or individual
motor drive), floor space required, weight of the
machine, cutting to return stroke ratio, number
and amount of feed, power input etc. are also
sometimes required for complete specification of
a shaper.

Ashwani Tayal, MED NIT HMR

SHAPER OPERATIONS
• A shaper is a machine tool primarily designed to
generate a flat surface by a single point cutting tool.
Besides this, it may also be used to perform many other
operations. The different operations, which a shaper can
perform, are as follows:

1. Machining horizontal surface

2. Machining vertical surface
3. Machining angular surface
4. Slot cutting
5. Key ways cutting
6. Machining irregular surface
7. Machining splines and cutting gears

Ashwani Tayal, MED NIT HMR

Ashwani Tayal, MED NIT HMR
Ashwani Tayal, MED NIT HMR
Ashwani Tayal, MED NIT HMR
Milling Machine

• A milling machine is a machine tool that removes metal

as the work is fed against a rotating multipoint cutter.
The milling cutter rotates at high speed and it removes
metal at a very fast rate with the help of multiple cutting
edges.
• One or more number of cutters can be mounted
simultaneously on the arbor of milling machine. This is
the reason that a milling machine finds wide application
in production work.
• Milling machine is used for machining flat surfaces,
contoured surfaces, surfaces of revolution, external and
internal threads, and helical surfaces of various cross-
sections.

Ashwani Tayal, MED NIT HMR

 PRINCIPLE OF MILLING

• In milling machine, the metal is

cut by means of a rotating cutter
having multiple cutting edges. For
cutting operation, the workpiece is
fed against the rotary cutter. As
the workpiece moves against the
cutting edges of milling cutter,
metal is removed in form chips of
trochoid shape. Machined surface
is formed in one or more passes
of the work.
Ashwani Tayal, MED NIT HMR
TYPES OF MILLING MACHINES

• Milling machine rotates the cutter mounted on the

arbor of the machine and at the same time
automatically feed the work in the required
direction. The milling machine may be classified
in several forms, but the choice of any particular
machine is determined primarily by the size of the
workpiece to be undertaken and operations to be
performed. With the above function or
requirement in mind, milling machines are made
in a variety of types and sizes.

Ashwani Tayal, MED NIT HMR

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