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DEPARTMENT OF CHEMICAL ENGINEERING

MINHAJ UNIVERSITY OF INFORMATION
TECHNOLOGY, Lahore
Undergraduate Program
Assignment
Course Title: Engineering Workshop Practices

Submitted to: Muhammad Ahmad

Submitted by: Asad Ullah
Registration No: 2019F-mulchem-eng-001
Lathe Machine Definition:
A lathe machine is a machine tool that removes the undesired material
from a rotating workpiece in the form of chips with the help of a tool
that is traversed across the work and can be feed deep into the work.
A lathe is a machine tool that rotates a workpiece about an axis of
rotation to perform various operations such as cutting, sanding,
knurling, drilling, deformation, facing, and turning, with tools that are
applied to the workpiece to create an object with symmetry about that
axis.

Uses:
Lathes are used in woodturning, metalworking, metal spinning, thermal
spraying, parts reclamation, and glass-working. Lathes can be used to
shape pottery, the best-known design being the Potter's wheel. Most
suitably equipped metalworking lathes can also be used to produce
most solids of revolution, plane surfaces and screw threads or helices.
Ornamental lathes can produce three-dimensional solids of incredible
complexity. The workpiece is usually held in place by either one or two
centers, at least one of which can typically be moved horizontally to
accommodate varying workpiece lengths. Other work-holding methods
include clamping the work about the axis of rotation using a chuck or
collet, or to a faceplate, using clamps or dog clutch.

Products made by lathes:

Examples of objects that can be produced on a lathe include screws,
candlesticks, gun barrels, cue sticks, table legs, bowls, baseball bats,
musical instruments (especially woodwind instruments), crankshafts
and much more.
Lathe Machine Parts:
The Lathe Machine consists of following Main Parts:

 Bed
 Headstock
 Tail stock
 Carriage
 Saddle
 Cross Slide
 Compound rest
 Tool Post
 Apron
 Chuck
 Feed rod
 Lead Screw
 Spindle

Bed:
The bed of the lathe machine is the base on which all the other parts of
the lathe are mounted. The bed is made from Cast iron or nickel cast
iron alloy and is supported on broad box-section columns.
Its upper surface is either scraped or grounded and the guiding and the
sliding surfaces are provided.
The bed consists of heavy metal slides running lengthwise, with ways or
v’s forced upon them. It is rigidly supported by cross griths.

The three major units mounted on a bed are:

 Headstock.
 Tailstock.
 Carriage.
The scrapped or the ground guiding along with the sliding surfaces on
the lathe bed ensure the accuracy of the alignment of these three units.
Headstock:
The headstock is present on the left end of the bed. The main function
of the headstock is to transmit power to the different parts of the
lathe.
It supports the main spindle in the bearing and aligns it properly. It also
houses a necessary transmission mechanism with speed changing
levers to obtain different speeds.
Accessories mounted on the headstock spindle are:

 Three jaw chuck.

 Four jaw chuck.
 Lathe center and lathe dog.
 Collet chuck.
 Face Plate.
 Magnetic chuck.

Tailstock:
The tailstock is a movable casting located opposite to the headstock on
the way of the bed.
The basic function of the tailstock is:
1. To support the other end of the work when being machined.
2. To hold a tool for performing operations like drilling, reaming,
tapping, etc.
It consists of the dead centers, the adjusting screws, and the
handwheel. The body of the tailstock is adjustable on the base which is
mounted on the guideways of the bed and can be moved.

Carriage:
Carriage is located between headstock and tailstock. The basic function
of the carriage is to support, guide, and feed the tool against the job
during operation.
It consists of 5 main parts:
 Saddle
 Cross Slide
 Compound rest
 Tool Post
 Apron

Saddle:
It is an H-shaped casting mounted on the top of the lathe ways. It
provides support to cross-slide, compound rest, and tool post.

Cross Slide:
Cross slide is provided with a female dovetail on one side and
assembled on the top of the saddle with its male dovetail.
The top surface of the cross slide is provided with T slots to enable
fixing of rear tool post or coolant attachment. Carriage basically
provides a mounted or automatic cross-movement for the cutting tool.
Compound Rest:
Compound rest is present on the top of the cross slide. It supports the
tool post and cutting tool in its various positions. Compound rest is
necessary for turning angles and boring short tapers and forms on
forming tools.

Tool Post:
The tool post is mounted on the compound rest. It is used to hold
various cutting tool holders. The holders rest on a wedge which is
shaped on the bottom to fit into a concave-shaped ring (segmental
type), which permits the height of the cutting edge to be adjusted by
tilting the tool. It is fixed on the top slide. It gets its movement by the
movement of the saddle, cross slide, and top slide.

The three types of tool post which are commonly used are:

 Ring and rocker tool post: It consists of a circular tool post with a
slot for accommodating the tool or tool holder.
 Quick change tool post
 Square head tool post.

Apron:
The Apron is fastened to the saddle and hangs over the front of the
bed. Apron consists of the gears and clutches for transmitting motion
from the feed rod to the carriage, and the split nut which engages with
the lead screw during cutting threads.
Two types of Apron are extensively used:

 Incorporating drop worm mechanism.

 Friction or dog clutches.

Chuck:
Chuck is basically used to hold the workpiece, particularly of short
length and large diameter or of irregular shape which can’t be
conveniently mounted between centers. It can be attached to the lathe
by screwing on the spindle nose.
Four different types of chucks are most commonly used in Lathe:

 Independent or four-jaw chuck

 Three jaw or universal chuck
 Collect chuck and
 Magnetic Chuck
Independent or four-jaw chuck:
It is used for irregular shapes, rough castings of square or octagonal in
such jobs, where a hole is to be positioned off the center. It consists of
four jaws and each jaw is independently actuated and adjusted by a key
for holding the job.
Three jaw or universal chuck:
It consists of three jaws that move simultaneously by turning a key and
the workpiece automatically remains in the center of the chuck
opening. It is used for holding a round, hexagonal bar or other
symmetric work.
Collet chuck:
It is mostly used in the places where production work is required such
as in Capstan Lathe or automats. It is used for holding the bars of small
sizes (below 63mm).

Magnetic chuck:
They are of permanent magnet type or electrically operated. In Lathe, it
does not have widespread use.

Feed Rod:
Feed rod is a power transmission mechanism used for precise linear
movement of the carriage along the longitudinal axis of the lathe. In
some lathe machines instead of feed rod lead screws are used.

Lead screw:
The lead screw is used mostly in the case when the threading operation
is to be performed on a lathe. As we know for threading operation
requires rotational movement of the job (workpiece) and the linear
movement of the tool (tool post).
So rotation of the job is obtained by the chuck and the desired linear
motion of the tool-post (as the lead screw drives the saddle when it is
engaged) is provided with the help of a lead screw.
 Lathe Machine Working Principle:
A Lathe works on the principle of rotating the workpiece and a fixed
cutting tool.
The workpiece is held between two rigid and strong supports called a
center or in a chuck or in faceplate which revolves.
Lathe removes the undesired material from a rotating workpiece in the
form of chips with the help of a tool that is transverse across the work
and can be fed deep in the work.
The main function of the lathe is to remove the metal from a job to give
it the required shape and size.
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 can be fed at an angle relative to the axis of the work
for machining tapers and angles.

Products made by Lathe Machine:

A variety of products can be made from the lathe machine and that are
Nuts, bolts, piston, ram, pump part, electric motor parts, sleeves,
Aircraft parts, gun barrels, candlesticks, train parts, cue sticks, wooden
bowls, baseball bat, crankshaft and many more things.

Lathe Machine Types:

There are 10 different types of Lathe Machine and those are:
  Engine Lathe or Center Lathe
 Speed Lathe
 Turret lathe
 Capstan Lathe
 Toolroom Lathe
 Bench Lathe
 Gap bed lathe
 Hollow spindle Lathe
 Vertical Turret Lathe and
 CNC Lathe Machine.

Shaper Machine Definition:

“A shaper is a type of machine tool that uses linear relative
motion between the workpiece and a single-point cutti ng tool to
machine a linear toolpath.”

“The shaper machine is a reciprocating type of machine basically

used for producing the horizontal, Vertical or flat surfaces. The
shaper holds the single point cutti ng tool in ram and workpiece
is fixed in the table”.
Process
A single-point cutting tool is rigidly held in the tool holder, which is
mounted on the ram. The work piece 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 the cutting tool, held in the tool holder, moves
forwards and backwards over the work piece. In a standard shaper,
cutting of material takes place during the forward stroke of the ram and
the return stroke remains idle. The return is governed by a quick return
mechanism. The depth of the cut increments by moving the workpiece,
and the workpiece is fed by a pawl and ratchet mechanism.

Types
Shapers are mainly classified as standard, draw-cut, horizontal,
universal, vertical, geared, crank, hydraulic, contour and traveling head,
with a horizontal arrangement most common. Vertical shapers are
generally fitted with a rotary table to enable curved surfaces to be
machined. The vertical shaper is essentially the same thing as a slotter
although technically a distinction can be made if one defines a true
vertical shaper as a machine whose slide can be moved from the
vertical. A slotter is fixed in the vertical plane

Parts of Shaper Machine

The following are the main parts of shaper machine:
1. Base
2. Column
3. Cross-rail
4. Table
5. Ram
Shaper Machines and Its Types:

The arrangement of shaper machine is made as shown in the figure. It

consists of the following parts.

1. Base:
 The base is the necessary bed or support required for all machines
tools.
 The base is hollow casting made of cast iron to resist vibration and
on which all parts of the shaper are mounted.
 It is so designed that is can take up the entire load of the machine
and the forces set up by cutting tool over the work.

2. Column:
 This is made of cast iron, which is a box-like and is mounted on
the base.
  two accurately machined guideways are provided on the top of
the column on which the ram reciprocates.
 The column acts as a cover to the drive mechanism and also
supports the reciprocating ram and the worktable.

3. Cross-rail:
 Cross rail is mounted on the front vertical surface of the column
on which saddle is mounted.
 The vertical movement is given to the table by raising or lowering
the cross rail using the elevating screw.
 The horizontal movement is given to the table by moving the
saddle using the crossfeed screw.
4. Table:
 The table is bolted to the saddle and receives crosswise and
vertical movements from saddle cross rail.
 T-bolts are used for clamping on top and sides.
 The table can be swiveled at any required angle.
 In a universal shaper, the table may be swiveled on a horizontal
axis and the upper part of the table may be fitted up or down.
 In heavier type shaper the table clamped with table support to
make it more rigid.

5. Ram:
 The ram reciprocates on the column guideways and carries the
tool head with a single-point cutting tool.
 The tool head is in the clapper box, which causes cutting action
only in a forward stroke of the ram and sliding movement of the
tool in the reverse stroke of the ram.
 The depth of cut or feed of the tool is given by down feed screw.
  The tool head has swivel base degree graduations, which helps to
move the tool head to any desired inclination for machining
inclined surfaces on the workpieces.

Types of Shaper Machines:

Following are the different types of shaper machines.
1. Based on the type of driving mechanism.
 Crank type shaper.
 Geared type shaper.
 Hydraulic type shaper.
2. Based on ram travel.
 Horizontal shaper
 Vertical shaper.
3. Based on the table design.
 Standard shaper.
 Universal shaper.
4. Based on cutting stroke.
 Push cut type
 Draw cut type

Advantages of Shaper Machine:

 The tool (Single Point cutting tool) cost is low.
 The workpiece can be held easily in this machine.
 It produces flat or angular surfaces.
 Setup of Shaper is very easy and tool changing is also easy.
Disadvantages of Shaper Machine:
 The cutting speed is not much high.
 Only one cutting tool can be fixed. There is no option for more
than one cutting tool.

Application of Shaper Machine:

 A shaper Machine is used to make internal splines.
 It generates straight and flat surfaces either horizontal, vertical or
angular planes.
 It also makes gear teeth.
 Make keyways in pulleys or gears.
 It also producing contour of concave/convex or a combination of
these.

Power Hacksaw:
Power hacksaws are used to cut large sizes (sections) of metals such as
steel. Cutting diameters of more than 10/15mm is very hard work with
a normal hand held hacksaw. Therefore power hacksaws have been
developed to carry out the difficult and time consuming work.

When a hacksaw is operated using a machine, it is known as a power

hacksaw. It is a type of reciprocating sawing machine. Power hacksaw is
used when a material cannot be cut using a hand hacksaw. When the
cutting diameter of the material to be cut is large, then it is very hard to
cut with a handheld hacksaw, in this situation power hacksaw is used.
Power hacksaw can cut workpieces of large diameter or workpieces
which requires a large amount of time and hard work to cut.
This machine can be used to cut any type of material in the workshops
as the hacksaw blade used is made up of HSS (High-Speed Steel). For
cutting hard materials some cutting fluids are provided in this machine.

Working Of Power Hacksaw:

The machine vice has two jaws. One jaw is fixed and the second one is
movable. There is a threaded row that is connected with the movable
jaw on one side and a handle on the other side. When we rotate this
handle, the movable jaw of the machine vice moves in forward and
backward direction over this threaded rod of the machine vice.
We can clamp any workpiece in this machine vice easily to use the
movable jaw.
After that cooling pipe supplies the coolant during the cutting process
between the hacksaw and the workpiece.
This coolant increases the life of the tool, helps in removing chips and
removes the heat produced during cutting and keeps the tool and
workpiece cool. This coolant works as a lubricant to make the cutting
process smooth.
The hacksaw blade along with the frame moves forward and backward
using the driving mechanism of the power hacksaw present inside the
column.
When the hacksaw blade is brought near the workpiece and the switch
is switched on. The driving mechanism starts and the cutting process or
the material removal process from the workpiece starts.
The forward stroke of the power hacksaw is a cutting stroke in which
the material removal process occurs and the backward stroke is the idle
stroke.
Only cutting during forward stroke prevents unnecessary wear on the
saw blade.
A backward stroke is used to remove chips from the workpiece
produced during the forward stroke.
Welding plant:
Welding is a fabrication process whereby two or more parts are fused
together by means of heat, pressure or both forming a join as the parts
cool. Welding is usually used on metals and thermoplastics but can also
be used on wood. The completed welded joint may be referred to as a
weldment.
The parts that are joined are known as a parent material. The material
added to help form the join is called filler or consumable. The form of
these materials may see them referred to as parent plate or pipe, filler
wire, consumable electrode (for arc welding), etc.
Consumables are usually chosen to be similar in composition to the
parent material, thus forming a homogenous weld, but there are
occasions, such as when welding brittle cast irons, when a filler with a
very different composition and, therefore, properties is used. These
welds are called heterogeneous.
How Does Welding Work?
Joining Metals
As opposed to brazing and soldering, which do not melt the base metal,
welding is a high heat process which melts the base material. Typically
with the addition of a filler material.
Heat at a high temperature causes a weld pool of molten material
which cools to form the join, which can be stronger than the parent
metal. Pressure can also be used to produce a weld, either alongside
the heat or by itself.
It can also use a shielding gas to protect the melted and filler metals
from becoming contaminated or oxidised.
Joining Plastics:
Plastics welding also uses heat to join the materials (although not in the
case of solvent welding) and is achieved in three stages.
Firstly, the surfaces are prepared before heat and pressure is applied
and, finally, the materials are allowed to cool to create fusion. Joining
methods for plastics can be separated into external or internal heating
methods, depending on the exact process used.
Joining Wood
Wood welding uses heat generated from friction to join the materials.
The materials to be joined are subjected to a great deal of pressure
before a linear friction movement creates heat to bond the workpieces
together.
This is a fast process which allows wood to be joined without adhesives
or nails in a matter of seconds.

What are the Different Welding Types:

Arc:
This category includes a number of common manual, semi-automatic
and automatic processes. These include metal inert gas (MIG) welding,
stick welding, tungsten inert gas (TIG) welding also know as gas
tungsten arc welding (GTAW), gas welding, metal active gas (MAG)
welding, flux cored arc welding (FCAW), gas metal arc welding (GMAW),
submerged arc welding (SAW), shielded metal arc welding (SMAW) and
plasma arc welding.

These techniques usually use a filler material and are primarily used for
joining metals including stainless steel, aluminium, nickel and copper
alloys, cobalt and titanium. Arc welding processes are widely used
across industries such as oil and gas, power, aerospace, automotive,
and more.

Friction
Friction welding techniques join materials using mechanical friction.
This can be performed in a variety of ways on different welding
materials including steel, aluminium or even wood.

The mechanical friction generates heat which softens the materials

which mix to create a bond as they cool. The manner in which the
joining occurs is dependant on the exact process used, for example,
friction stir welding (FSW), friction stir spot welding (FSSW), linear
friction welding (LFW) and rotary friction welding (RFW).
Friction welding doesn't require the use of filler metals, flux or shielding
gas.
Friction is frequently used in aerospace applications as it is ideal for
joining otherwise 'non-weldable' light-weight aluminium alloys.
Friction processes are used across industry and are also being explored
as a method to bond wood without the use of adhesives or nails.

Electron Beam:
This fusion joining process uses a beam of high velocity electrons to join
materials. The kinetic energy of the electrons transforms into heat
upon impact with the workpieces causing the materials to melt
together.
Electron beam welding (EBW) is performed in a vacuum (with the use
of a vacuum chamber) to prevent the beam from dissipating.

There are many common applications for EBW, as can be used to join
thick sections. This means it can be applied across a number of
industries from aerospace to nuclear power and automotive to rail.

Laser:
Used to join thermoplastics or pieces of metal, this process uses a laser
to provide a concentrated heat ideal for barrow, deep welds and high
joining rates. Being easily automated, the high welding speed at which
this process can be performed makes it perfect for high volume
applications, such as within the automotive industry.
Laser beam welding can be performed in air rather than in a vacuum
such as with electron beam joining.

Drilling Machine:
Drilling is a material-removing or cutting process in which the tool uses
a drill bit to cut a hole of circular cross-section in solid materials .

Drilling Machine Main Parts:

A drilling machine consists of the following parts:
  Base
 Column or Pillar
 Arm
 Worktable
 Drill head
 Feed Mechanism
 Spindle
 Drill jigs
 Chuck
 Electric Motor
 Pully or gears

Filling:
Filing is a material removal process in manufacturing. Similar,
depending on use, to both sawing and grinding in effect, it is
functionally versatile, but used mostly for finishing operations, namely
in deburring operations. Filing operations can be used on a wide range
of materials as a finishing operation. Filing helps achieve workpiece
function by removing some excess material and deburring the surface.
Sandpaper may be used as a filing tool for other materials, such as
wood.