8

MACHINE SHOp
8.1 INTRODUCTION
The shop where most of the work is performed on different
chines is called machine shop. In machine shop, the raw material
cut, machined, formed or shaped with the help of mahines.
machines used in machine shop are: Dif erent
1. Lathe machine. 2. Shaper.
3. Milling machine. 4. Planning machine.
5. Drilling machine. 6. Grinding machine.
7. Thrèading machine.
Some of the above machines are explained below:
8.2 LATHE
Alathe is a powered mechanical device in which the work is held
and rotated against asuitable cutting tool for producing cylindrical forms
in the metal, wood or any other machinable material.
Principle of working
The principle of lathe machine is that it holds the work between two
strong supports called as centres, or in a check
or face plate which revolves. The chuck or
the centre is mounted on the main spindle of Job
the machine. The cutting tool is rigidly supported
in a tool port and it is fed against the rotating Tool
job. The job rotates in its axis and the tool is
moved either parallel or to an inclination with Fig. Fig. 8.1
its axis as such a cylindrical or tapered surface
is produced.
Types of Lathe: There are various types of lathe. They are as folloWS
(a) Precision lathe. (b) Tool room lathe
(C) Capstan and turret lathe (a) Automatic lathe
(e) Speed lathe () Engine lathe
(g) Bench lathe (h) Special purpose lathe

188
 189
MACHINE SHOP
The principle parts of lathe are discussed
d The bed is the below briefly:
function of the lathe. is supported on
It broad
box columns and is made of cast iron. It
metal slides running lengthwise with ways, consists of two heavy
)
Head stock

Tail stock

Bed

Carriage
Legs

Fig. 8.2. Parts of Lathe

Units which are mounted on the
tailstock and the carriage. Lathe bed is bed are the headstock, the
made of high grade special
cast iron having high
vibration damping qualities. It is secured rig
idly over cabinet leg and leg. In its use care should be
avoid formation of scratches, nicks taken to
should be and dents by falling tools. It
lubricated regularly.
Gap beds: Some beds
the head stock. It is gap have a gap just adjacent to the front of
beds. This type of beds can
jobs which are bigger in diameter, but it is true for jobsaccomodate
of shorter
length only.
2. Head Stock: It supports the
main spindle in the bearings and
It properly. It also
houses necessary aligns
speed changing levers to obtain transmission mechanism with
gears could be used to change speed ofdifferent speeds. Cone pulleys or
which are mounted on spindle. Holding devices
0) Three jaw headstock spindle:
(ii) Face plate chuck (i) Four jaw chuck
V) Magnetic chuck (iv) Collet chuck
3. Main (vi) Lathe dog.
job can Spindle: It is a hollow cylinderical shaft and long cylinderical
pass through the main spindle. The spindle end facing the
tailstock is
taper called the spindle nose. The spindle nose has a morse
hole (self locking taper) and threads on outside. The morse
190
MANUFACTURING PRACTICE
taper is used to accommodate centre or collet chuck or
portion of chuck. threaded
4. Tailstock: It is a movable part located opposite to headstock on tha
ways of the bed. It is capable of sliding along the bed maintainina
its alignment with the head stock. On medium size and smaller
lathe it is moved along the bed manually, whereas in heavier Lathes
it is moved by hand wheel through a pinion that meshes with rack
provided in front of Lathe bed. It is used for four purposes:
() to support free end during machi ing.
() to hold tool for peforming operations like drilling, reaming, tap
ping etc.
(ii) to centre the job and the tool before any lathe operations.
(iv) to help in the operation of taper turning by tail stock set over
method.
5. Carriage: It is located between headstock and tailstock. It can slide
along bed guide-ways and be locked at any position by tightening
the carriage lock screws. It consists of following five main parts :
() Apron: It is fastened to saddle. It contains gears and clutches
for transmitting motion from feed rod and hand wheel to the
carriage. Also split nut which engages with the lead screw during
threading. The clutch mechanism is used for transmitting motion
from feed rod whereas the split nut along with the lead screw
moves the carriage during thread cutting.
(ii) Saddle: It is made up of H shaped casting. It aids saddle to
slide on bed guideways by operating hand wheel.
(ii) Compound Rest: It supports the tool post and cutting tool in
its various positions. It may be swivelled on the cross-side to
any angle in the horizontal plane.
(iv) Cross-slide: It is provided with a female dovetail on one side
and assembled on top of saddle having a male dovetail.
(v) Tool Post: It is used to hold various tool holders and tools.
Three types of tool post commonly used are:
(a) Ring and rocker tool post.
(b) Square head tool post.
(c) Quick change tool post.
6. Legs: They are supports which carry entire load of the machine.
Legs are casted and it is placed on the floor of the shop on foundation
by grouting. The left leg acts as a housing for the motor, the pulleys
and the counter shaft at the same time the right leg acts as a
housing or the coolent tank, pump and the connecting pipes.
 MACHINE SHOP
SPECIFICATION OF LATHE
ofthe lathe is specified by one of the
Thesize
following
A. Length of the Bed (Bed length will include headstock). ways:

Fig. 8.3 Specification of Lathe

B. Distance between centres (Max. job length that can be held
between centres).
C. Diameter of the work which can be turned between the ways.
(max. dia. that can be rotated).
D. Height of centres
E. Swing over carriage.
8.4 OPERATIONS PERFORMED ON LATHE MACHINE
Ine tollowing operations can be performed on a lathe machine.
1. Facing
2. Rough Turning
3. Shouldering
4. Radius Turning
5. Necking
6. Taper Turning
7. Thread Cutting
8. Forming
9. Chamfering
10. Knurling
11. Driling
12. Boring
13. Counter Sinking
14. Counter Boring
192 MANUFACTURING PRACTICE
Important operations are shown in the Fig. 8,4.
Facing Rough

Radius turning (Form tool)

Shouldering

Necking (Form tool) Taper turning

External thread cutting

Forming

Facing workpiece in chuck Parting or cutting off

Diamond knurt
193
MACHIHE SHOP

Bore Internal fhresding

Orling Reaming

Fig. 8.4.

8.5 DIFFERENT METHODS OF TAPER TURNING

1. Compound Rest Method: Compound rest method is used for
turning steep and short tapers. It is having a circular base gradu
ated in degree.
When taper of required degrees is turned, the base of Compound
rest is swivelled through an angle equal to half of the taper angle.
2. Tail Stock Set-over Method: This method is used for turning taper
on the long jobs. The tail stock is set over by loosening the nut from
its centre line equal to value obtained by calculations.
Set-over = taper length x sin of half of taper angle
= Isin
Where D = diameter at large end.
d= diameter at small end.
When a part of length of job is to be given
total length of the job
length of taper

Fig. 8.5
194 MANUFACTURING PRACTICE

3. Taper Turning Attachment: It is bolted on the back of the lathe and

has a guide bar which may be set at the desired angle of taper. As
the carriage moves along the bed length, a slide over the bar causes
the tool to move in and out according to the setting of the bar. Lathe
centre remains aligned and same taper can be given on various jobs.
4. Form tool method: When the length of the taper is very short it
can be turned by a broad nosed tool consisting of cutting edge half
the taper angle a. While using this type of tool lot-of chattering is
there, as such this type of tool is used specially when the machine
have a very rigid basé] endSebta ty
AIM- TOMAKE THE MULTI OPERATION JOB AS PER GIVEN BELOW
MATERIAL+ MILD STEEL ROUND BAR 32 X105 MM
MEASURING INSTRUMENT OPERATION ON CENTERLATHE MACHINE
VERNIER CALLIPER (2) SCALE 1 FACING
30 28 25:5
Q 20.5 19 2 CENTER DRILLING
2X30 CHAMFER 3CYLINDERICAL TURNING
4.STEPTURNING
5. KNURLING
6 TAPER.TURNING
7. CHAMEFRJNG

ALL DIMENSIONS
25 25 25 25 ARE IN MM
SAFETY PRECAUTIONS FORTHE BEGINNERS
The following precautions must be observed while working in
shops to achieve efficient and accidental free work.
1. Always wear uniform in the workshop. Never wear lo0se
clothes.
2. Never walk bare footed inside the workshop, use of rubber
sole closed shoe is recommended. is
1d
3. Never operate any machine unless you do not know how S.

to operate it. 1d
re
4. Never touch moving parts, belts or rotating tools etc,
5. Defective equipments and tools should not be used for art
any work. st

6. Never touch any switch, knob or lever of the

machine is
without knowing it.
er
7. Silky clothes catch fire soon, never come to the
wearing such clothes.
workshop is
ar.
8. Do not touch any live wire inside the workshop.
9. In case of any fire, the electric supply should be discon ng
nected.
)ut
10. Always keep in mind about the position of fire
extinguishers and first aid box. ily
11. Always read the first aid charts carefully while beginning
in the workshop.
12. Make sure that your work is not effecting any se

workshop.
body in the ed

13. Always try to learn sincerely from the

instructors.
14. Always keep your mind on the job.
0on