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128 views103 pagesWorkshop Lab Report
mechanical workshop lab
Uploaded by
Sakib Hasan RedwanCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 103
Machine Shop
Figure 1: Lathe Machine
Lathe Machine
Introduction: Lathe machine is a basic machine which is used In every metal
forming industries. A lathe machine is used to machine cylindrical work piece
which is 360-degree symmetrical form the axls of rotation. It used to perform
turning, chamfering, boring, facing, internal threading, shaping, slot cutting
etc. on cylindrical work piece. The lathe machine works on basic principle that
when the work piece rotate at a constant speed and a cutting tool is
introduced between its rotation, it cuts the metal, Various cutting tools are
used for this purpose.
Lathes are used in woodturning, metalworking, metal spinning, thermal
spraying, parts reclamation and glass-working. Examples of objects that can
Scanned with CamScanner 5
be produced on a lathe include- candlestick holders, gun barrels, cue sticks,
table legs, bowls, baseball bats, musical instruments (specially woodwind
instruments), crankshafts and camshafts.
Types of Metal Lathes: There are many variants of lathes within
the metalworking field. The usage of the term “metal lathe” may be
considered somewhat outdated these days, since plastics and other
composite materials are in wide use and with appropriate modifications, the
same principles and techniques may be applied to their machining as that
used for metal. The main categories for lathes are-
© Center/Engine/Bench Lathe
* Tool room Lathe
© Turret Lathe and Capstan Lathe
© Multi-spindle Lathe
© Computer numerical controlled (CNC) Lathe
Combination Lathe/ 3-in-1 Machine
Mini and Micro Lathes
Scanned with CamScanner Construction:
Compound
Spindle Chuck
. rest Cross slide
Headstock Tailstock
Hand wheel
/
Guide ways
- Bed
; \
Chipper Corriage Apron Saddle
Figure 2: Parts of a Lathe Machine
The design of lathes can vary greatly depending on the intended
application; however, basic features are common to most types. These
machines consist of (at the least) a head stock, bed, tool post, chuck, tail
stock, legs, gear chain, lead and feed screws, carriage, cross slide, split nut,
apron, chip pan, guide ways etc. These parts work together to obtain
desire motion of tool and work piece so it can be machined. Better
machines are solidly constructed with broad bearing surfaces (slide-ways)
for stability and manufactured with great precision.
i
Scanned with CamScanner Figure 3: Head Stock
Head stock: The headstock (H1) hquses the main spindle (H4), speed
change mechanism (H2, H3), and change gears (H10). The headstock is
required to be made as robust as possible due to the cutting forces
involved can induce harmonic vibrations that will transfer through to the
workpiece, reducing the quality of the finished workpiece.
The main spindle is generally hollow to allow long bars to extend through
to the work area. Chuck is used to hold the workspace. It is bolted on the
spindle which rotates the chuck and work piece. It is four-jaw and three-
jaw according to the requirement of machine. On older machines ('S0s)
the spindle was directly driven by a flat belt pulley with lower speeds
available by manipulating the bull gear. Later machines use a gear box
driven by a dedicated electric motor. A fully ‘geared head’ allows the
operator to select suitable speeds entirely through the gearbox.
Figure 4: Chuck
Scanned with CamScanner Bed: It Is the main body of the machine. All main components are bolted
onit, It’s connected to the headstock and allows the carriage and tailstock
move parallel with the axis of the spindle. It Is usually made by cast iron
due to its high compressive strength and high lubrication quality. Itis made
by casting process and bolted on floor space.
Figure S: Bed
Tool Post: The tool bit is mounted in the tool post.
It is bolted on the carriage. It is used to hold the tool
at correct position. Interchangeable tool holders
allow all tools to be preset to a center height that
does not change, even if the holder is removed from
the machine.
Feed and Lead Screw: The feed screw (H8 in the Figure 6: Too! Post
Head Stock figure) is a long driveshaft that allows a
series of gears to drive. The Lead screw (H7) is situated at the bottom side of
0
Scanned with CamScanner bed and Is driven by either the change of gears or an intermediate gearbox
These intermediate gears allow the bed to move automatically maintaining
correct ratio and direction during cutting and threading.
Carriage: The carriage serves the purpose of supporting, guiding and feeding
the tool against the workpiece during the operation. It is situated between the
head stock and tall stock. It helps to hold and move the tool post on the bed
vertically and horizontally. It slides on the guide ways. It also holds Saddle,
Cross-slide, Compound rest and Aprons. Carriage is made by cast iron.
cnusrant Larsen
wae
Figure 7: Components of Carriage
Saddle: It is the part of carriage that slides along the bed way and supports
the Cross-slide, Compound rest and Tool post.
Scanned with CamScanner Cross-slide: The cross-slide rides on the carriage and has a feed screw that
travels at right’ angles to the main spindle axis. This
permit facing operations to be performed, and the depth of cut to be
adjusted, It can either be operated by hand, by means of the cross-feed
screw, or may be given power feed through the Apron mechanism.
Compound Rest: The compound rest (or top slide) is usually where the tool
post Is mounted. It will be placed over the cross-slide and it consists of a
graduated circular base which Is having swiveling nature.
Apron: It Is situated on the carriage. It houses the feed and clutch
mechanism, nuts, gears and levers. The apron wheel can be rotated by
hand for longitudinal motion of the carriage.
Tail Stock: It is also sometimes called the “Loose Head Stock” or “Puppet
Head”. It is mounted on the bed of the lathe such that it is capable of
sliding along the latter maintaining its alignment with the head-stock. The
spindle does not rotate but does travel longitudinally under the action of
a leadscrew and hand-wheel. The main function of tail stock to support the
job when required.
=I
Rr
ae
Figure 8: Tail Stock
Scanned with CamScanner Chips Pan: Chips pan is placed lower side of bed, The main function of it to
carry all metal chips removed from the work piece.
Lathe Cutting Tools: Different types of types of cutting tools are used in a
lathe machine to perform different operations. Most commonly used tools
are-
© Cut-off blade or Knife too!
© Parting tool
© Chamfer tool
© Boring tool
© Side tool
e Thread-cutting tool
© Grooving tool
Right Hand LeftHand Chamter
Knife Too! Knife Too! Too!
Figure 9: Different types of Cutting tools
Scanned with CamScanner Lathe Operations: A lathe machine performs various operations on the
workpiece. These are-
© Facing
Turning
© Straight turning
o Step turning
© Chamfering
© Grooving
© Knurling
© Taper turning
¢ Thread cutting
© Boring
Head Stock Work-piece
~—Tool
Turning Facing Grooving
Drill bit
/ Tail Stock /
Boring Drilling
Figure 10: Different operations of Lathe machine
Scanned with CamScanner Facing: Facing is the operation of machining the ends of a workpiece to
produce flat surface normal to the axis. The operation involves feeding the
tool perpendicular to the axis of rotation of work.
Figure 11: Faced end of workpiece
Turning: Turning means removing excess materials from the workpiece to
produce a cylindrical surface of required shape and size.
© Straight Turning: The workpiece is turned straight when it Is made to
rotate about an axis and the tool is fed parallel to the lathe axis. The
straight turning produces a cylindrical surface by removing excess
materials from the workpiece.
¢ Step Turning: It is the process of turning different surfaces of different
diameters. The work is held between centers and the tool is moved
parallel to the axis of the lathe. It is also called “Shoulder Turning”.
Figure 12: Step turning
Scanned with CamScanner Chamfering: Chamfering is the operation of leveling the extreme end of
the workpiece. The form tool used for Taper turning may be used for this
purpose. Chamfering is an essential operation after thread cutting so that
nut can pass freely on the threaded workpiece.
Grooving: Grooving is the process of cutting a narrow groove on the
cylindrical surface of the workpiece. It is often done at the end of a thread
or adjacent to leave a margin. The groove may be square, radial or beveled
in shape.
Forming: The forming is an operation that produces a convex, concave or
any irregular profile on the workpiece. To form a small length surface, a
forming tool having cutting edges confronting to the shape is fed straight
into the workpiece.
Knurling: Knurling is a process of impressing a diamond shaped or straight-
line pattern into the surface of a workpiece by using specially shaped
hardened metal wheels to improve its appearance and to provide a better
gripping surface. Knurls are available in coarse, medium and fine pitches.
The patterns may be straight, inclined or diamond shape. The purpose of
knurling is-
1. To provide an effective gripping surface
2. To provide better appearance to the workpiece
3. To slightly increase the diameter of the workpiece.
Scanned with CamScanner Figure 13: Knurling
Taper Turning:
Taper: A taper may be defined as a uniform increase or decrease in
diameter of a workpiece measured along its length.
tand = a
2i
Where, D = Larger diameter
d= Smaller diameter
|= Length of the taper
@ = Half taper angle
Scanned with CamScanner Figure 14: Position for taper turning
Thread Cutting: A thread is a uniform helical groove cut inside of a
cylindrical workpiece, or on the outside of a tube or shaft. Thread cutting
is one of the most important operations performed in a lathe. Screw
threads are cut with the lathe for accuracy and for versatility. A definite
ratio between the longitudinal feed and rotation of the head stock spindle
is maintained during thread cutting. Suitable spindle speed and cutting
tool Is selected according to the shape of the workpiece.
Figure 15: Threaded workpiece
Scanned with CamScanner Boring: In machining, boring is the process of enlarging a hole that has
already been drilled by means of a single point cutting tool, such as in
boring a gun barrel or an engine cylinder. Boring is used to achieve greater
accuracy of the diameter of a hole and can be used to cut a tapered hole.
Boring can be viewed as the internal diameter counterpart to turning,
which cuts external diameters,
Figure 16: Boring
Safety Principles while using a Lathe:
« Wear appropriate safety glasses. It is necessary too for others nearby
as objects fly off the workpiece.
Ensure that entanglement hazards (e.g. loose clothing, jewelry etc.)
are removed.
Keep the floor free from obstructions and slip hazards.
+ Ensure that the lathe has a start/stop button within easy reach of the
operator.
Keep all lathe cutting tools sharp.
Scanned with CamScanner e Remove all tools, measuring instruments and other objects from saddle
or lathe bed before starting the machine.
Ensure that the chip and coolant shields are in place.
‘« Stop lathe before taking any kind of measurement.
Scanned with CamScanner BENCHWORK
Introduction:
Benchwork Is a term used to b described any type of manual work that is done
using a workbench rather than with the use of heavy machinery in a plant
setting or in a large area. The term is also sometimes used to refer to the
structures that support finished projects such as model train sets that are set
up ona more or less permanent basis. With all applications, the theme is that
the manual work is completed at a stationary setting rather than relying on
machinery to do the job.
Scanned with CamScanner 20
In terms of creation of goods, there are several different examples of
benchwork. Carpentry benchwork involves the crafting of different types of
furniture or frames for upholstered furniture pieces. The individual pieces are
hand crafted as part of the benchwork and assembled at another site. Metal
equipments can be mad or reformed by benchwork. Benchwork construction
is often thought of as being more time-consuming than using machinery to
mass produce different types of products. While the process is somewhat
construction Is of a higher quality than can be produced with the use of
machines. Others find there is no real difference in the quality of the two
approaches, or that the modern use of computer technology as part of the
manufacturing process makes it possible to mass produce furniture and
similar goods that are superior to products made in benchwork setting.
As it relates to creating permanent displays for working train model sets,
benchwork often involves the task of what is known as track planning. This
simply means that the top area of the bench of frame that will support the
train set is laid out in terms of where the tracks will be placed and what the
surrounding landscape for the presentation will be. In this scenario, the goal
is to make sure that benchwork is strong enough to support the presentation
for extended period of time, and that the underside of supporting structure is
accessible, making it possible to install and repair any type of electrical wiring
or circuitry that is necessary to the operation of the model trains.
Objectives:
To identify various types of hand tools and its usage.
Scanned with CamScanner Required Apparatus:
© Bench vise
© Marking out table
e Hand hammer
Files
© Center punch
e Ruler
Steel file brush
© Scriber
« Hacksaw
Angle plate
Dividers
Slide caliper
Required Materials:
« Cast iron
Bench Vice:
The bench vice is used to help grip the work piece for filing, hacksaw and
bending light metal. The bench vice mainly consists of fixed jaw, movable
jaw and jaw plates.
Scanned with CamScanner SSS
— ae /
Figure: Parts of a bench vice
Most bench vic es have hardened insert jaws that are sharply serrated and will dig
into finished work plececs enough to mar them beyond repair. Hence soft jaws made
of copper, other soft metals or wood are often slip over the vise jaws to protect the
work piece’s finished surface.
Bench vice should be mounted correctly on the work bench where the top of the
vice jaw should be at elbow height. Inapproplately mounted bench vices causes
poor piece to be produced,
Figure 17: Bench vice
Scanned with CamScanner Filing:
Filing involves the small scale removal of ma‘
or hole, including the removal of burrs. Files are usually made of hardened
steel and are availabe in variety of cross sections such as flat, round, half
round square and triangle.They are commonly manufactured in four
different cuts:single, doube, curbed tooth and rusp. Each cut design has its
‘own purpose.For instance, rasp files are frequently used with wood while
curbed tooth files are used with soft materials such as aluminum, brass,
plastic or lead.
terial from a surface, corner
Flat-file
Semicircle-file
Triangle-file
i
Square-file
Circle-file
Figure: Files
Scanned with CamScanner
2B "
Files also vary in their coarseness: rough, coarse, bastard, second cut,
smooth and dead smooth. In order to produce a flat surface work should
be held firmly in the vise with minimum amount of projecting and with the
surface to be filed to be truly horizontal. The right hand pushes and press
while the left hand only presses with the same amount of pressure.
Pressure should be applied during forward stroke only. Success in filing flat
is dependent on hand control to keep the file horizontal throughout its
stroke and an equal distribution of pressure. In orde to test the surface of
the work during filing, a staightedge can be placed on it.If rays of light can
be seen between two surfaces of the workpiece and the straight edge
,then the surface of the work place is not flat.
Care should be taken while filing to avoid dulling and breaking of its teeth.
Teeth on files will break if the tools lie on top of each other and if too much
pressure is applied while fing. Dullig of teeth is caused by the filing of hard
Scanned with CamScanner materials or by filing too fast.A good rule of thumb is the harder the
material,the slower the strokes should be.
Sawing:
The hacksaw is one of the more frequently used hand tools. It consists of
the frame, the handle and the saw blade. The spacing of the teeth on a
hand hachsaw blade is called the pitch.Standard pitches are 14,18,24 and
32 teeth per inch,with the 18-pitch blade used as general-purpose blade.
Figure: Parts of a Hacksaw
Scanned with CamScanner 26
The hardness and thickness of the work piece determine to a great extent
which pitch blade to use.Generaly a coarse tooth blade used on soft
materials and fine tooth blade on hard materials.There are few points that
should be noted in order to obtain maximum perfomance from a blade.
© Making long steady strokes using the full length of the blade.
* maintained sufficient pressure on the forward stroke to keep the teeth
cutting.too much pressure on the saw balde will cause its teeth to dull.
Do not apply any pressure at the blade during return stroke since this
will also dull the teeth.
© the sawing speed should be at the rate of 40 to 60 strokes per
minute.Cutting stroke that is too fast causes friction that will overheat
the teeth and dull it.
Center Punch:
Figure: Center Punch
Scanned with CamScanner Scriber:
Figure: Scriber
Scanned with CamScanner | re |
28
e scriber is @ round steel piece of about 150mm to 300mm long and
3mmtosmm diameter. Its one end is sharp and pointed and the other end
jsalso sharp but bent. The bent end is used to scratch lines in places where
the straight end cannot reach,
Pocket scriber
——— EE
a]
Double ended scriber
Knife edge scriber
Ce el
Machinists scriber
pivider:
pivider is an instrument for measuring,transferring or making off
distances,consisting of two straight adjustable leg hinged togather and
ending in sharp points.
Scanned with CamScanner Figure: Divider
It is used principally in drafting for the acurate transfer of dimensions from
a measuring scale and in machine shops for scribing lines on
surfaces,usually machined, with dimensionds taken from a ruler.A
compass is essentially a divider in which one of the points has been
replaced by a pencil or rather marking devices.
Calipers:
The vernier, dial and digital calipers give a direct reading of the distance
measured with high accuracy and precision.they are functionnally identical
with different ways of reading the result.These calipers comprise a
calibrated scale with afixed jaw and another jaw with apointer that slides
along with the scale.the distance between the jaws is then read in different
ways for the three type.
The simplest methode is to read the position of the pointer directly on the
scale.When the pointer Is between two markings,the user can mentally
interpolate to improve the precision of the reading. This would be a simple
calibrated caliper;but the addition of the vernier scale allows more
accurate interpolation, and is universal practice;this is the vernier caliper
Scanned with CamScanner LOCKING
SCREW
7
Hiren
"
ty
ul
N
METRICSCALE peor HEASURING
BLADE
|
EXTERNAL
JAYS
Figure: Vernier: Caliper
Vernier dial and digital Calipers can me:
‘asure internal dimensions,external
dimensions using the pictured lowered Jaws,and in many cases depth by
the use of a probe that is attached to the movable head and slides along
the center of the body. This probe is s|
lender and can go Into deep grooves
that may prove difficulty for other Measuring tools,
The vernier scale includes matric measurment on the lower part of the
scale and inch measurement on the Upper,or vice-versa,in countries that
are inches.Vernier calipers commonly used in industryprovide a precision
to .01mm or one thousand of an inch.They are available in sizes that can
measure up to 1829mm(72 inch),
Other Kinds Of Calipers:
Scanned with CamScanner PE OOOOeEEE—>~E——
I inside Calipers:
the inside callpers are used to measure internal size of an object.
The caliper shove has an adjusting screw that permits it to be carefully
adjusted without removal of the tool from the workpiece.
outside Caliper:
outside caliper are used to measure the size of an objectthe same
observation technique is applied o this type of caliper as for the above
inside caliper.With some understanding of the limitation and usage,these
instrument can provide a high degree of accuracy and repeatability.They
are specially useful while measuring over very large distances, consider if
the caliper are used to measure a large diameter pipe.A vernier caliper
does not have the depth capacity to straddle this large diameter while at
Scanned with CamScanner the same time reach the outermost point of the diameter.They are made
of high carbon steel.
Project Methodology:
use “L” square and appropiate filr to obtain flat surface
. Select another side of the work piece and file as previous step tp obtain a
flat 90 degree surface.
. Use engineering square to check the surfaces,if rays of light can not be
viewed between the work piece and the engineering square,i.e. the
Scanned with CamScanner ace is already flat.Make sure that the work piece is filed to the correct
gimension-
select the flat surface as reference surface for making process
ark the workpiece using high vernier caliper and plate angle on the
oF king t2ble.
create the rounded curve using divider based on given dimension.
; make hexagonal using divider,and cut according to the marking line.
. Begin the removing process by cutting the unused material using hacksaw
only:
smooth the edges of the workpiece through filing.
.
,, perform the drilling work for counter board according tp accurate process.
Figure:Tapping process
Scanned with CamScanner Figures: Bolt and Nut
Scanned with CamScanner fety measures:
4, Be sure that all machines have sffective and properly working guards
that are always in place where machines are operating.
2, Replace guards immediately after any repair.
3, Don’t attempt to oil,clean,adjust or repair any machine while it is
running, stop the machine and lock the power switch in the off
position.
4, Even after the power is off,don't leave the machine until it has
stopped running.
5, Don’t operate any machine unless authorized,to do so by the
instructor 00 the supervisor,
6. Don’t try to stop the machine with your hand or body
7. Always see that work and Cutting tools on any machine are clmped
securely before starting.
g. Keep the floor clean of metal chips or curls and waste pieces,put
them in container provided for such things.
g, Don’t operate machinery when the instructor is not in the workshop.
10. while working with another worker only one should operate
machine or switches
Don’t rest against the machine.
11.
42. Concentrate on the work and don’t talk while operating the
machine.
23. Get first aid immediately for any injury.
14. Be sure you have sufficient light to see clearly.
Scanned with CamScanner ntroduction:
g is a type of welding that uses a welding power supply to create
an electric arc between an electrode and the base material to melt the
etals at the welding point. They can use either direct (DC)
nating (AC) current, and consumable or non-consumable electrodes.
e welding region is usually protected by some type of shielding gas,
vapor, oF slag. Are welding processes may be manual, semi-automatic, or
full automated. First developed in the late part of the 19th century, arc
welding became commercially important in shipbuilding during the Second
rc weldin
oraltert
Scanned with CamScanner Ee —RvR—
