::Contents::

 Introduction
 Power Supply Of Machines(Electronic Part)
 Simple Lathe
 Shaper Machine
 Milling Machine
 Conclusion
 Reference
 ::INTRODUCTION::
In this report, we will see the working of machines and
the electrical supply of those machines in mechanical
lab, as per my case study topic-
“Visit To The Mechanical Lab” .
The Lab I visited is 55-101 and 55-102 under the
guidance of Lab Assistant- Mr. Jasveer Singh.
He explained the working and electrical working of
some important machines.
There were total of 15 machines.
2 Milling Machine.
3 Simple Lathe .
2 Shaper Machine.
And 8 other machines which mainly comprises of
Capstan Machine, Turret Machine, Slotting Machine,
and Surface Grinding Machine.
And other electrical equipments like fans, lights etc.
 ::Power Supply::
In terms of power consumption, the power
consumption of every machine depends on the motor
fitted in it.
For Example: Milling Machine has 2 HP motor, Simple
Lathe Machine has 1 HP motor etc
Apart from this some part of power is also consumed
by lights and fans in the lab.
 All Machines uses 3 phase power supply.
 The lab consist of around 15 machines, each
having motor of 1HP,except milling machine
which have 2HP motor.
 1 HP motor has 1440 RPM.
 Power for milling machine will be 1492 W
and for other machines it will be 746 W
respectively. (Since 1 HP=746 W.)
 Other than machines, the power
consumption of other electrical equipments
such as Fan,Lights etc in total will be 3kW.
 So, finally the total power consumed by
machines is 12,682 W.
 Power consumption of whole lab is 15,682 W
Any piece of machinery has a normal operating full
load current (FLC) at a given voltage and/or a full load
power. So if say it is a 1-HP (0.7-kW) lathe it will draw
3.3 Amps at 220 Volts three phase when fully loaded
and in steady state operation:
746 W / 220 Vrms = I = 3.3 A single phase, so for
three phase 9.9 Amps.
9.9 A total at unity power factor and 100% efficiency.
However machines will draw 148.5 Amps or so from
the three phase when they starts up. Exactly how much
current they will draw and for how long depends on
the inertia of the load
So the lab's supply will need to be at least 148.5 Amps.
However even if the utility company has provided a
155 Amp supply this might not be enough if, at the
same time as you start your heavily loaded lathe, other
machines, lights, fans, and several electric equipments
in lab are all switched on. It is possible to get quite
technical about fuseboard ('consumer unit') design and
various sorts of load factors so as to achieve a given
probability of not tripping out, but in practice you
simply need to think about the likely domestic situation
at the times you are going to use your machinery and
make due allowance.
 SIMPLE LATHE
MACHINE
What is a lathe machine?
A lathe is a one of the oldest machine, and is known as FATHER/MOTHER of
entire tool family. A lathe machine is a machine tool which is used to remove
metals from a workpiece to give a desired shape and size. In other words it is
a machine that is used to hold the workpiece to perform various metal
removing operations such as turning, grooving, chamfering, knurling, facing,
forming etc with the help of tools.

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 revolutions , 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 dogs.
Examples of objects that can be produced on a lathe
include candlestick holders, gun barrels, cue sticks, table legs, bowls, baseballs
bats, musical instrument, and camshafts.
Parts of Simple Lathe

The main parts of the lathe are the bed, headstock, quick changing gear box,
carriage and tailstock.
1. Bed: The bed is a heavy, rugged casting in which are mounted the working
parts of the lathe. It carries the headstock and tail stock for supporting the
workpiece and provides a base for the movement of carriage assembly which
carries the tool.
2. Legs: The legs carry the entire load of machine and are firmly secured to
floor by foundation bolts.

3. Headstock: The headstock is clamped on the left hand side of the bed and it
serves as housing for the driving pulleys, back gears, headstock spindle, live
centre and the feed reverse gear. The headstock spindle is a hollow cylindrical
shaft that provides a drive from the motor to work holding devices.
4. Gear Box: The quick-change gear-box is placed below the headstock and
contains a number of different sized gears.
5. Carriage: The carriage is located between the headstock and tailstock and
serves the purpose of supporting, guiding and feeding the tool against the job
during operation. The main parts of carriage are:
a). The saddle is an H-shaped casting mounted on the top of lathe ways. It
provides support to cross-slide, compound rest and tool post.
b). The cross slide is mounted on the top of saddle, and it provides a mounted
or automatic cross movement for the cutting tool.
c). The compound rest is fitted on the top of cross slide and is used to support
the tool post and the cutting tool.
d). The tool post is mounted on the compound rest, and it rigidly clamps the
cutting tool or tool holder at the proper height relative to the work centre line.
e). The apron is fastened to the saddle and it houses the gears, clutches and
levers required to move the carriage or cross slide. The engagement of split
nut lever and the automatic feed lever at the same time is prevented she
carriage along the lathe bed.
6. Tailstock: The tailstock is a movable casting located opposite the headstock
on the ways of the bed. The tailstock can slide along the bed to accommodate
different lengths of workpiece between the centers. A tailstock clamp is
provided to lock the tailstock at any desired position. The tailstock spindle has
an internal taper to hold the dead centre and the tapered shank tools such as
reamers and drills.
7. Leadscrew: A lead screw, also known as a power screw or translation screw,
is a screw used as a linkage in a machine, to translate turning motion
into linear motion.
8.Chuck: A chuck is a specialized type of clamp. It is used to hold an object
with radial symmetry, especially a cylinder. On a lathe the chuck is mounted on
the spindle which rotates within the headstock. It holds the rotating
workpiece.
9. Feed screw: Feed rod is a power transmission mechanism used for precise
linear movement of the carriage along the longitudinal axis of the lathe.
WORKING
Working Principle: The lathe is a machine tool which holds the workpiece
between two rigid and strong supports called centers 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.

Lathe removes undesired material from a rotating work piece in the form of
chips with the help of a tool which is traversed across the work and can be fed
deep in work. Lathe machine holds the work piece between two rigid and
strong supports called Centers, or in a chuck or Face plate while the latter
revolves. The chuck or the face plate is mounted on the projected end of the
machine spindle. The cutting tool is rigidly held and supported in a tool post
and is fed against the revolving work. While the work revolves about its own
axis the tool is made to move either parallel to or at an inclination with this
axis to cut the desired material. In doing so it produces a cylindrical surface, if
it is fed parallel to the axis or will produced a Tapered surface if it is fed at an
inclination.
Different Operations of Lathe
The most common operations which can be performed on the lathe
1. Plain Turning
2. Facing
3. Parting
4. Drilling
5. Reaming
6. Boring
7. Knurling
8. Grooving
9. Threading
10. Forming
11. Chamfering
12. Filling and Polishing
13. Taper Turning
Power Supply Requirement
Irrespective of how you get your power there needs to be enough of it. In this
section it is assumed that you are using a phase converter from a domestic
supply to power a small detached workshop, but the same points would apply
equally in other locations, or if you had selected a motor drive or fitted single-
phase motors etc.

Any piece of machinery has a normal operating full load current (FLC) at a
given voltage and/or a full load power. So if say it is a 3-hp (2.2-kW) lathe it will
draw 9.2 Amps at 240 Volts single phase when fully loaded and in steady state
operation:

2200 W / 240 Vrms = I = 9.17 A single phase

2200 W / 415 Vrms = I = 5.3 A total at unity power factor and 100%
efficiency
5.3 A/√3 = 3.06 Arms per phase which is what you should find on the motor
tally plate

However it will draw 50 Amps or so from the single phase when it starts up.
Exactly how much current it will draw and for how long depends on the inertia
of the load - clearly a lathe with a clutch is an easier start than a clutchless
lathe with a heavy large diameter workpiece

So the lab's supply will need to be at least 9.2 Amps. However even if the utility
company has provided a 60 Amp supply this might not be enough if, at the
same time as you start your heavily loaded lathe,other machines, lights, fans,
and several electric equipments in lab are all switched on. It is possible to get
quite technical about fuseboard ('consumer unit') design and various sorts of
load factors so as to achieve a given probability of not tripping out, but in
practice you simply need to think about the likely domestic situation at the
times you are going to use your machinery and make due allowance.
 Shaper Machine

What is a shaper machine?

A shaping machine is used to machine surfaces. It can cut curves, angles and
many other shapes. It is a popular machine in a workshop because its
movement is very simple although it can produce a variety of work.

Shaper is commonly used to produce flat surfaces can be horizontal, vertical or

inclined by machining with the help of a reciprocating tool. Due to its limited
length of its ram stroke, shaper is conveniently adapted to smaller jobs.
However it’s a slow machine and is only considered suitable only for unit or
batch production rather than mass production. It is even preferred to other
quick metal cutting machines with even multiple teeth cutters because it can
give all kinds of surface finish on this single machine along with ease of
machining varieties of surfaces with minimum change over time since the set
up time for a shaper is much less for most of the jobs.
Parts of shaper machine
The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column),
Cross rail, Ram and tool head (Tool Post, Tool Slide, Clamper Box Block).

Base: The base is a heavy cast iron casting which is fixed to the shop floor. It
supports the body frame and the entire load of the machine. The base absorbs
and withstands vibrations and other forces which are likely to be induced
during the shaping operations.
Body (Pillar, Frame, Column): It is mounted on the base and houses the drive
mechanism compressing the main drives, the gear box and the quick return
mechanism for the ram movement. The top of the body provides guide ways
for the ram and its front provides the guide ways for the cross rail.
Cross rail: The cross rail is mounted on the front of the body frame and can be
moved up and down. The vertical movement of the cross rail permits jobs of
different heights to be accommodated below the tool. Sliding along the cross
rail is a saddle which carries the work table.
Ram and tool head: The ram is driven back and forth in its slides by the slotted
link mechanism. The back and forth movement of ram is called stroke and it
can be adjusted according to the length of the workpiece to be-machined.
Table: It is the metal body attached over the frame. Its main function is to hold
the work piece and vice over it. It has two T slots which used to clamp vice and
work piece over it.
Working of shaper machine

The job is rigidly fixed on the machine table. The single point cutting tool held
properly in the tool post is mounted on a reciprocating ram. The reciprocating
motion of the ram is obtained by a quick return motion mechanism. As the ram
reciprocates, the tool cuts the material during its forward stroke. During
return, there is no cutting action and this stroke is called the idle stroke. The
forward and return strokes constitute one operating cycle of the shaper.
Uses of shaper machine
 Keyways in the boss of a pulley or gear can be machined without resorting
to a dedicated broaching setup.
 Dovetail slides
 Internal splines and gear teeth.
 Keyway, spline, and gear tooth cutting in blind holes
 Cam drums with toolpaths of the type that in CNC milling terms would
require 4- or 5-axis contouring or turn-mill cylindrical interpolation
 It is even possible to obviate wire EDM work in some cases. Starting from a
drilled or cored hole, a shaper with a boring-bar type tool can cut internal
features that don't lend themselves to milling or boring (such as irregularly
shaped holes with tight corners).
 Smoothness of a rough surface.
 Power supply requirement

As the size of machine increases, its power requirement also increases. These
machines can generally be installed anywhere, 220V 16A single-phase current.
 Milling Machine
What is a milling machine?
Milling is a process performed with a machine in which the cutters rotate to
remove the material from the work piece present in the direction of the angle
with the tool axis. With the help of the milling machines one can perform many
operations and functions starting from small objects to large ones.
Milling machining is one of the very common manufacturing processes used in
machinery shops and industries to manufacture high precision products and
parts in different shapes and sizes.

The milling machines are also known as the multi-tasking machines

(MTMs) which are multi-purpose machines capable of milling and turning
the materials as well. The milling machine has got the cutter installed up on
it which helps in removing the material from the surface of the work piece.
Parts of Milling Machine
The main part of machine is base, Column, Knee, Saddle, Table, Overarm,
Arbor Support and Elevating Screw.
1. Base: It gives support and rigidity to the machine and also acts as a reservoir
for the cutting fluids.
2. 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.
3. Knee: The knee is a rigid casting mounted on the front face of the column.
The knee moves vertically along the guide ways and this movement enables to
adjust the distance between the cutter and the job mounted on the table. The
adjustment is obtained manually or automatically by operating the elevating
screw provided below the knee.

4. Saddle: The saddle rests on the knee and constitutes the intermediate part
between the knee and the table. The saddle moves transversely, i.e., crosswise
(in or out) on guide ways provided on the knee.
5. Table: The table rests on guide ways in the saddle and provides support to
the work. The table is made of cast iron, its top surface is accurately machined
and carriers T-slots which accommodate the clamping bolt for fixing the work.
The worktable and hence the job fitted on it is given motions in three
directions:
a). Vertical (up and down) movement provided by raising or lowering the knee.
b). Cross (in or out) or transverse motion provided by moving the saddle in
relation to knee.
c). Longitudinal (back and forth) motion provided by hand wheel fitted on the
side of feed screw.
In addition to the above motions, the table of a universal milling machine can
be swiveled 45° to either side of the centre line and thus fed at an angle to the
spindle.
6. Overarm: The Overarm is mounted at the top of the column and is guided in
perfect alignment by the machined surfaces. The Overarm is the support for
the arbor.
7. Arbor support: The arbor support is fitted to the Overarm and can be
clamped at any location on the Overarm. Its function is to align and support
various arbors. The arbor is a machined shaft that holds and drives the cutters.
8. Elevating screw: The upward and downward movement to the knee and the
table is given by the elevating screw that is operated by hand or an automatic
feed.
Working
The workpiece is holding on the worktable of the machine. The table
movement controls the feed of workpiece against the rotating cutter. The
cutter is mounted on a spindle or arbor and revolves at high speed. Except for
rotation the cutter has no other motion. As the workpiece advances, the cutter
teeth remove the metal from the surface of workpiece and the desired shape
is produced. Adjustable working table of milling machine will hold the
workpiece and movement of adjustable working table will govern the feeding
of workpiece against rotating milling cutter. As we have discussed above,
rotating cutter will be mounted with spindle which will be driven by electric
motor and hence rotating cutter will rotates with high rpm. Rotating cutter will
have only one motion i.e. rotating motion and apart from rotating motion,
there will not be any movement in rotating cutter. When workpiece will be
inserted against rotating cutter, rotating cutter teeth will remove the
unwanted material from the workpiece to secure the desired shape.
S Milling Operation : Up milling Milling Operation : Down milling
1 Direction of feeding of workpiece Direction of feeding of workpiece and
and direction of rotating cutter direction of rotating cutter will be same
will be opposite

2 Up milling process used for Down milling process used for

machining hard materials machining soft materials

3 Unwanted material will be Unwanted material will be removed in

removed in form of thicker chips form of thinner chips

4 Larger clamping force will be Larger clamping force will not be

required because cutting force required because cutting force will be in
will be in direction of upwards direction of downwards and will tend to
and will tend to lift the workpiece press the workpiece against the working
table.

5 Chips will be accumulated at Chips will be thrown away during cutting

cutting area process

6 Surface finishing will be poor Surface finishing will be good

MILLING OPERATIONS
1. Plain or slab milling
2. Face Milling
3. Angular Milling
4. Straddle Milling
5. Form Milling
6. Gang Milling
7. Side Milling
8. End Milling
9. Profile Milling
10. Saw Milling
11. Keyway Milling
12. Gear Cutting Milling
Power Supply Requirement
Depends on the machine. Most are 3 phase which here in the India can be
220 VAC 60 Hz. Power consumption of machine during some cases:

1. Rough Surface:: During rough facing with paraxial feed rate the feed
motors have a mean power consumption of 200W.
2. Circular Pocket:: The circular pocket is machined with a roughing and
a finishing cycle. The mean power of feed drives here is 100W.

During Milling process the power remains almost constant.

 ::Conclusion::
The current supply of lab is not direct to machine.the supply is goes to machine
via Fuse board and MCB. So as to prevent the overload or any tripping it is
necessary in a lab full of heavyload machines,to have such arrangements of
MCB and Fuse board.
As we have discussed earlier that some machines have powerfull motor which
may create a over load on the supply which can create any malfunction or
problem to other circuit.
A quick glance on the supply can be as follow :
Firstly the main supply is switched on from fuse box.

Then the current flows from MCB and goes to socket where machine is
connected.
As seen in lab of 55 block, a meter box is also connected for every machine to
check the consumption.

And hence the supply is given to the machines.

 ::Reference::
 Machine Lab - 55-101,55-102.Lab
Assistant Mr. Jasveer Singh.
 https://en.wikipedia.org/wiki/Lathe
 https://en.wikipedia.org/wiki/Shaper
 https://en.wikipedia.org/wiki/Milling_(machining)
 engineering.myindialist.com/2009/principle-
and-working-of-milling-machine/
 engineering.myindialist.com/2009/working-
principle-of-lathe-machine/
 engineering.myindialist.com/2009/principle-
and-working-of-milling-machine/