WORKSHOP PRACTICE

Lab Report 1

Name: Syed Muneeb Haider Gillani

Registration Number: 190301054
Submitted To: Engr. Danish Shafique
Department: Materials Science and Engineering
Section: MAT-12(B)
Table of Contents
Milling Machine..........................................................................................................................................1
 Working Principle:..........................................................................................................................1
Grinders.......................................................................................................................................................2
 Power Grinders:...............................................................................................................................2
 Hand Grinders:................................................................................................................................3
Tools Required for Workshop.....................................................................................................................3
 Non- Cutting Hand Tools:...............................................................................................................3
 Hammer:......................................................................................................................................3
 Screw Drivers:.............................................................................................................................3
 Wrenches:....................................................................................................................................4
 Hand Cutting Tools:........................................................................................................................4
 Chisels:........................................................................................................................................4
 Hacksaws:....................................................................................................................................4
 Measurement Tools:........................................................................................................................5
 Scribers:.......................................................................................................................................5
 Dividers:......................................................................................................................................5
 Trammels:....................................................................................................................................5
 Squares:.......................................................................................................................................6
 Vernier Calipers:..........................................................................................................................6
Lathe Machine.............................................................................................................................................7
Computerized Numerical Control Machines...............................................................................................7
 EDM (Electric Discharge Machine):...............................................................................................7
 CNC Milling Machine (3-Axis):......................................................................................................8
 CNC Milling Machine (5-axis):.......................................................................................................8

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Whenever we go to the workshop the most important thing is safety. We should know all the
safety measures and we should not do such activities which can cause accident. Unfortunately if
we face any accident, we should know how to deal with this accident.
In the workshop, following are the machines and materials we can see and we should know the
working principles and uses of these machines and tools. So let us see the working principles and
uses of these machines and tools:

Milling Machine:
Milling machine is basically used for machining the work piece which is metals and it cut this
metal by doing the work against the cutter which is rotatable and it has the single or multiple
cutting edges.

Working Principle:
Milling machine is a machine tool that form a work piece as it is feed against a rotating multi
point cutting tool called milling cutter. The cutter rotates at a high speed and it is provided with
many cutting edges to remove the metal at very fast rate.
There is the RPM meter which controls the speed of flute cutter. The spindle which holds the
flute cutter is stationary and the beds move in three directions that is x axis which moves in
horizontal direction, y axis which moves inward and outward and z axis which moves the bed
vertically.
The main purpose of milling machine is to make the surface flat. The milling machines
consist of one or more than one cutters at a time. These cutters cut the metals in the form
of chips.

Figure 1

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Grinders
 Power Grinders
 Hand Grinders
Power Grinders:
Power Grinders are used to cut the material or work piece through the diameter. They usual cut
the work piece from top to bottom. When we put the work piece on it, it cuts the work piece from
top to bottom. First we turn on the power grinder; we can only touch it rather than pushing it. We
need the abrasion rather than force for it.

Figure 2

Hand Grinders:
It is used to make the sharp edges on the surface of the materials or work piece. It can be used on
the occasions where materials are immoveable from a certain place. It can be used for the
building materials.

Figure 3

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Tools Required for Workshop

 Non- Cutting Hand Tools:

Hammer:
It is used as the striking tool which is used in the working of both light and heavy materials.
Depending upon the conditions you should hold it firmly or lightly.

Figure 4

Screw Drivers:
It consists of the standard or flat blades. Uses of these screw drivers include the removal and
insertion of screws. Depending on the sizes of screws we remove or insert the screws in the
particular work piece.

Figure 5

Wrenches:
Wrenches are used to turn the nut or bolt head at some angle or torque.

Figure 6

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 Hand Cutting Tools:
Chisels:
It is used for the cutting of cold metals. It has the flat, cape, round nose and diamond point head
points. Take a specific point and stick at this point and then apply the force at this point and you
will see cutting starts.

Figure 7

Hacksaws:
It is used to saw the metals by the hands. We should know how this tool is used. So if we want to
cut the metals then move this hacksaw in the forward direction.

Figure 8

 Measurement Tools:

Scribers:
It has sharp end point. It is generally used to scribe or mark the required material such as metals.

Figure 9

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 Dividers:
It is used to make the small circles. It has two end points. To use the dividers both end points
must be at the same point. It is also used to scribe the arcs.

Figure 10

Trammels:
It has the beam which has two heads which may be sliding or adjustable. It can be used to make
large arcs and circles.

Figure 11

Squares:
They are used to layout the lines at the perfect right angle. It consists of two scales which are
responsible for the layout of the lines at right angles.

Figure 12

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 Vernier Calipers:
It is the most used measurement tool in the workshop. It is used to measure the length, diameter
(external or internal) and the depth of the material.

Figure 13

Lathe Machine
It is used for the machining of the work piece or irregular shaped materials in the form of the
chips. It has a chuck which rotates and the speed of flute meter is controlled by RPM meter. The
work piece is tightened firmly in the chuck. Sometimes the length of work piece is large and
when we tight it, the work piece is still loose, for this purpose we use tail stock. We can perform
several operations on it such as knurling, parting, facing, boring and turning on this machine.
First of all we need a drawing of the material which we want to perform the working and then
perform the operations according the drawing.

Figure 14

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Computerized Numerical Control Machines

Types of CNC:
EDM (Electric Discharge Machine):
Two types of wires are used in this type of machining one is brass and the other is molybdenum.
The thickness of brass is round 0.25 mm and the thickness of molybdenum is close enough to
brass. This process is done in the presence of dielectric fluid which increases the water
resistivity. The spark is generated which results in the cutting of metallic material. It contains
five axis i-e x, y, z, u and v. u axis is responsible for the rotation of x axis and v axis is
responsible for the rotation of y axis and z axis is for height.

Figure 15

CNC Milling Machine (3-Axis):

It consists of three axis i-e x, y and z. It uses 12 tools for the manufacturing of the required work
piece. It is programmable and generates the g-code. First of all we have the CAD drawing for the
manufacture of required work piece then we generate the program for the CAD from the third
software, this will generate the g-code and the manufacturing of your required work piece will
start.

Figure 16

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 CNC Milling Machine (5-axis):
It consists of 5 axis i-e x, y, z, b and c. b gives -900 to +900 rotations across the y- axis and c
gives 3600 rotation across z- axis. It contains 24 tools. It is the most advanced form of CNC
milling machine. Coolant used during the cutting process comes from the bottom surface and
from vertical pipes. Working of the machine is done by the programming g-codes. X-axis has
dimension limitation of 620 mm, y-axis has 520 mm, and z-axis has 420 mm. It has precision up
to 1 micron.

Figure 17

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References:
Images of this lab report are taken from the internet and the references of these images are as
follows:
 http://hutterli-ag.ch/wp-content/uploads/2018/04/Spinner-U620.jpg
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fd2c6820d7d512d5e7e5a15d4f852118/z/n/znc250-1.jpg
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SeF_8g9IbQh0p_nLQ8NVr0Klx_-jSl-gCLcB/s1600/main%2Bparts%2Bof%2Blathe.jpg
 https://i.pinimg.com/originals/6b/db/e4/6bdbe42f01cf871f6ad0bb53b4b37445.jpg
 https://www.ottofrei.com/images/135.0704_thumb.jpg?
resizeid=6&resizeh=1800&resizew=1800
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 https://www.cusack.co.uk/imagecache/62d2462e-d83d-464d-841a-a99200a20ca1/Bahco-
317-Hacksaw---12-inch_900x900.jpg
 https://www.classichandtools.com/acatalog/Blue-Spruce-Bench-Chisels-1-800.jpg
 https://www.bigtools.com.my/image/bigtools/image/data/all_product_images/product-
1151/cstanley-87-371-adjustable-wrench-18%20a.jpg
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040ec09b1e35df139433887a97daa66f/s/e/
xsealey_ak4932.jpg.pagespeed.ic.MZ289zX0cJ.jpg
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