Department of Mechanical and Production Engineering

Ahsanullah University of Science and Technology (AUST)

SHOP 1100: Workshop Sessional

Credit Hour: 1.5

General Guidelines:
1. Students shall not be allowed to perform any experiment without apron and
shoes.
2. Students must be prepared for the experiment prior to the class.
3. Report of an experiment must be submitted in the next class.
4. Viva for each experiment will be taken on the next day with the report.
5. The report should include the following:
 Top sheet with necessary information
 Main objectives
 Work material/machine/tool/equipment used (with their
specifications)
 Experimental procedures
 Experimental results and discussions (Experimental setup,
Experimental conditions, Data, Graph, calculation etc.)
 Conclusions
 Acknowledgements
 References
6. A quiz will be taken on the experiments at the end of the semester.
7. Marks distribution:

Total Marks
Report Attendance & Job Quiz
Viva
30 20 20 30
Experiment-1:
Study of Lathe Machine and Its Various Operations

Metal lathe or metalworking lathe are generic terms for any of a large class of lathes designed for
precisely machining relatively hard materials. They were originally designed to machine metals; however,
with the advent of plastics and other materials and with their inherent versatility, they are used in a wide
range of applications, and a broad range of materials. Ln machining jargon, where the larger context is
already understood, they are usually simply called lathes, or else referred to by more-specific subtype
names (tool room lathe, turret lathe, etc.).These rigid machine tools remove material from a rotating work
piece via the (typically linear) movements of various cutting tools, such as tool bits and drill bits. A
typical lathe machine is shown in the following Fig.1.

Fig.1 Schematic view of the lathe machine

Bed: The bed is the base or foundation of the parts of the lathe. The main feature of the bed is the ways,
which are formed on the bed’s upper surface and run the full length on the bed. The ways keep the
tailstock and the carriage, which slide on them, in alignment with the headstock.
Headstock: The headstock contains the headstock spindle and the mechanism for driving it.
Tailstock: The primary purpose of the tailstock is to hold the dead center to support one end of the work
being machined. However, the tailstock can also be used to hold tapered shank drills, reamers and drill
chucks.
Carriage: The carriage is the movable support for the cross feed slide and the compound rest. The
compound rest carries the cutting tool in the tool post. The carriage has T-slot or tapped holes to use for
clamping work for boring or milling.
Feed Rod: The feed rod transmits power to the apron to drive the longitudinal feed and cross feed
mechanisms. The feed rod is driven by-the spindle through a train of gears.
Lead Screw: The lead screw is used for thread cutting. It has accurately cut ACME threads along its
length that engage the threads of half-nuts in the apron where the half-nuts are clamped over it. The lead
screw is driven by the spindle through a gear train.
Crossfeed Slide: The crossfeed slide is mounted to the top of the carriage in a dovetail and moves on the
carriage at a right angle to the axis of the lathe. A crossfeed screw allows the slide to be moved toward or
away from the in accurate increments.
Lathe Chucks: The lathe chuck is a device for holding lathe work. lt is mounted on the nose of the
spindle. The work is held by jaws which can be moved in radial slots toward the center of the chuck to
clamp down on the sides of the work.
The 4-jaw independent lathe chuck (Fig.2a) is the most practical chuck for general work. The four
jaws are adjusted one at a time, making it possible to hold work of various shapes and to adjust the
center of the work to coincide the axis of the spindle .The 3-jaw universal chuck (Fig.2b) an be used
only for holding round or hexagonal work. All three jaws move in and out together in one operation and
bring the work on center automatically.

4-jaw independent lathe chuck 3-jaw universal chuck

(a) (b)
Fig.2 lathe chuck
Cutting Speed is defined as the Speed at which a point on the Surface of the work passes the cutting edge
or point of the tool and is normally given in m/min. Cutting speed can be calculated by using the
following formula:
V=πDN/1000 m/min
Where:
N = Spindle Speed (RPM)
D = Diameter of Work piece (mm)
V= Cutting Speed of metal (m/min)
Feed rate: Feed rate is used to describe the distance the tool moves per revolution of the work piece and
depends largely on the surface finish required. For roughing out a soft material a feed of up to 0.25
mm/rev may be used.
Cutting Tool for Lathe: There are various kinds of the cutting tools for a lathe which depends on the
type of work materials and shape of the parts. Fig; 4(a) shows the well-used cutting tool called a side tool.
The cutting tool shown in Fig. 4(b) is used at parting and grooving processes. The cutting tool shown in
Fig.4(c) is called a boring bar. It is used to cut at an inside surface. It can make a big hole, which cannot
be process by a drill and a high accurate hole.

Fig.4 cutting tool used in lathe machine

Various cutting operations that can be performed on a lathe

 Assignment :

(a) Measure all dimensions on the specimen turned by your group. Make a neat sketch and
indicate all measured dimensions.

(b) What is the difference between turning and threading?

(c) How does the rotational motion of the lead screw and feed rod is converted into linear motion?

(d) Write the differences between 3-Jaw Universal Chuck and 4 Jaw Independent Chuck

Exersise-1: You will need to use the Engine Lathe to perform the following operations in order to
make the following shaft.

 Facing
 Chamfering
 Straight turning
 Contour turning
 Taper turning
 Knurling
 Threading and
 Drilling

Fig
The equipments/tools you will use in this part include:

 Engine lathe
 Facing tool
 Turning tool
 Center drill
 Knurling tool
 Drill bit etc.
Experiment-2:
Study of Milling Machine and Its Various Operations
Milling machine is one of the most versatile conventional machine tools with a wide range of metal
cutting capability. Many complicated operations such as indexing, gang milling, and straddle milling etc.
can be carried out on a milling machine. Milling machines are among the most versatile and useful
machine tools due to their capabilities to perform a variety of operations. Milling machines can be
classified as horizontal and vertical.
(A)Horizontal Milling Machine

Column: The column houses the spindle, the bearings, the gearbox, the clutches, the shafts, the pumps
and the shifting mechanisms for transmitting power from the electric motor to the spindle at a selected
speed.

Knee: The knee mounted in front of the column is for up or down motion supporting the table and to
provide up and down motion along the Z axis.

Fig : Horizontal milling machine

Saddle : The saddle consists of two slide ways , one on the top and one at the bottom located at 90◦ to
each other for providing motions in the X or Y axes by means of lead screws.
Table: The table is mounted on top of the saddle and can be moved along the X axis. On top of the table
are some T-slots for the mounting of workpiece or clamping fixtures.

Arbor: The arbor is an extension of the spindle for mounting cutters. Usually, the thread end of an arbor
is of left hand helix.

(B) Vertical Milling Machine

Column : The column houses the spindle, the bearings, the gearbox, the clutches, the shafts, the pumps
and the shifting mechanisms for transmitting power from the electric motor to the spindle at a selected
speed.

Knee: the knee mounted in front of the column is for supporting the table and to provide an up or down
motion along the Z axis.

Saddle: The saddle consists of two slide ways, one on the top and one at the bottom located at 90◦to each
other, for providing motions in the X or Y axes by means of lead screws.

Table: The table is mounted on top of the saddle and can be moved along the X axis. On top of the table
are some T-slots for the mounting of workpiece or clamping fixtures.
Milling head : The milling head consisting the spindle, the motor and the feed control unit is mounted on
a swivel base such that it can be set at any angle to the table.

Ram: The ram on which the milling head is attached can be positioned forward and backward along the
slide ways on the top of the columns.

Various cutting operations that can be performed on milling machine

Peripheral Milling
a)slotting
b)slitting
c)slab milling
d)slitting
e)form milling
f)side milling
g)straddle milling
h)end milling
Face milling

Assignment :

1) What is the difference between horizontal and vertical milling machine.

2) Explain three motions of table in milling machine.

3) What are the function of universal vice, spindle and arbor.

Exercise-2: You will need to use the milling machine and perform the following milling operations
in in order to make the following product.
 Slotting
 Form Milling
 Pocket Milling
 End Milling
Experiment-3:
Study of Shaping Machine and Its Various Operations

The shaper is a relatively simple machine. It is used fairly often in the tool room or for machining one or
two pieces for prototype work. Tooling is simple and shapers do not always require operator attention
while cutting. The horizontal shaper is the most common type and its principal components are shown
below and described as follows:
Ram: The ram slides back and forth in dovetail or square ways to transmit power to the cutter. The
starting point and the length of the stroke can be adjusted.
Toolhead: The toolhead is fastened to the ram on a circular plate so that it can be rotated for making
angular cuts. The toolhead can also be moved up or down by its hand crank for precise depth adjustments.

Shaping machine
Clapper Box: The clapper box is needed because the cutter drags over the work on the return stroke. The
clapper box is hinged so that the cutting tool will not dig in. Often this clapper box is automatically raised
by mechanical, air or hydraulic action.
Table: the table is moved left and right, usually by hand, to position the work under the cutter when
setting up. Then either by hand or more often automatically the table is moved sideways to feed the work
under the cutter at the end or beginning of each stroke.
Quick Return Mechanism
The shaping machine is used to machine is used to machine flat metal surfaces especially where a large
amount of metal has to be removed. Other machines such as milling machines are much more expensive
and are more suited to removing smaller amounts of metal very accurately.
The reciprocating motion of the mechanism inside the shaping machine can be seen in the diagram. As
the disc rotates the top of the machine moves forwards and backwards pushing a cutting tool. The cutting
tool removes the metal from work which is carefully bolted down.

Quick return mechanism

Various cutting operations that can be performed on a Shaping Machine

GROOVES T -SLOT

DOVETAILS FLATS and ANGLES

Assignment :
a) Explain quick return mechanism with neat sketch
b) Difference between shaper and planer machine
c) Discuss how rotary motion transforms into linear motion in housing (body)

Exercise-3: You will need to use the shaping machine and perform the following shaping operations
in order to make the following product.
 Side cutting
 Plain shaping
 V-grooving
 Slotting
Experiment-4:
Study of Drilling Machine and Its Various Operations

A drill press is preferable to a hand drill when the location and orientation of the hole must be controlled
accurately. A drill press is composed of a base that supports a column, the column in turn supports a table.
Work can be supported on the table with a vise or hold down clamps or the table can be swiveled out of
the way to allow tall work to be supported directly on the base. Height of the table can be adjusted with a
table lift crank than locked I place with a table lock. The column also supports a head containing a motor.
The motor turns the spindle at a speed controlled by a variable speed control dial. The spindle holds a drill
chuck to hold the cutting tools (drill bits, center drills, deburring tools etc.)

Radial drilling machines: used on large workpieces, spindle mounts on radial arm allowing drilling
operations anywhere along the arm length.
Gang–drilling machines: independent columns each with different drilling operation work piece slide
from one column to next
 Radial drill machine Gang drill machine

Various operations that can be performed on a Drilling Machine

Assignment:
1. Describe different types of drilling operations with proper figures.

2. Why did you use cast iron during the drilling operation?
Exercise-4: You will need to use the drill press and perform the following drilling operations in
order to make the following product.
 Drilling
 Step drilling
 Counterboring
 Countersinking
 Reaming

Fig
The equipment you will use in this part includes:
 Scribe
 Drill press
 Center drill
 2drill bits
 Reamer
 Counter bore tool
 Countersink tool
Experiment 6:
Study on Timber and its defects, Hand tools and Machine, types of
joints
Introduction to Carpentry
The definition of carpentry is the art or craft of working with wood. Therefore, a carpentry shop is
a location where someone may learn these skills via hands-on practice. It is crucial for an engineer
to be proficient in carpentry techniques since they are relevant to practically all engineering
specialties, including mechanical, civil, and electrical, where woodworking plays a crucial role
either directly or indirectly.
A student is introduced to a variety of wood species, tools, and machinery in the carpentry shop,
but most significantly, the process of creating and manufacturing a wide range of carpentry
products.
Application of Carpentry
1. One of the products of carpentry is the variety of furniture we encounter daily.
2. Carpenters also use their expertise to make a variety of working instruments that contain
wood, such as shovels, hammers, and spades.
3. Carpenters also work on construction projects like homes and workplaces.
4. A variety of sporting things are made using carpentry products.

Timber
Timber is the material used for carpentry and joinery work. Timber is the name given to the wood
obtained from well grown trees. The trees are cut and sawn into various sizes to suit building
purposes.
According to the manner of growth of trees, timber can be classified as
1. Exogenous tree.
2. Endogenous tree.
Structure of timber is shown in the following figure:

Figure: Structure of timber tree

Types of Timber
1. Hard Wood: Hard wood has a closed structure, heavy, dark in color and is difficult to work
on it annual rings are not distinct and good tensile strength. Example: Kail wood, Pine,
Cedar, Limewood etc.

2. Soft Wood: Soft wood has less weight, less durable and is easy to work out. Soft wood
catches fire soon as compared to hardwood; annual rings are quite distinct. Example:
Maple, Oak, Cherry, Hazel, Walnut etc.

Characteristics of Good Timber

The good timber must possess the following characteristics:
1. It should have minimum moisture content, i.e., the timber should be well seasoned.
2. The grains of wood should be straight and long.
3. It must retain its straightness after seasoning.
4. It should produce a near metallic sound on hammering.
5. It should be free from knots or cracks.
6. It should be of uniform color, throughout the part of the wood.
7. It should respond well to the finishing and polishing operations.
8. During driving the nails and screw, it should not split easily.

Defects of Timber:
1. Chemical Stain: The wood is sometimes discolored by the chemical action caused with it
by some external agency. This is known as a chemical stain.
2. Coarse Grain: If the tree grows rapidly, the annual rings are widened. It is known as coarse
grain timber and such timber possesses less strength.
3. Knots: These are the bases of branches which are broken or cut off from the tree. The
portion from which the branch is removed receives nourishment from the stem for a pretty
 long time and it ultimately results in formation of dark hard rings which are known as
knots.
4. Shakes: These are longitudinal separations in wood between the annual rings. These are
cracks which partly or completely separate fibers of wood. There is different types of
shakes such as star shakes, cup shakes, ring shakes, heart shakes.
5. Upsets: These indicate wood fibers which are injured by crushing or compression. The
upsets are mainly due to improper felling of tree and exposure of tree in its young age to
fast blowing wind.
6. Blue Stain: The sap of wood is stained to bluish color by the action of certain type of fungi.
7. Brown Rot: The term rot is used to indicate decay or disease of timber; the fungus of
certain type removes cellulose compounds from wood and hence wood assumes the brown
color.
8. Chip Mark: This defect is indicated by a mark placed on finished surface of timber.
9. Wane: This defect is denoted by the presence of original rounded surface on manufactured
part of timber.
10. Diagonal Grain: The defect is formed due to improper sawing of timber. It is indicated by
diagonal marks on straight grained surface of timber.

Hand Tools
Steel Rule and Steel Tape: Steel rule is a simple measuring instrument consisting of a long, thin
metal strip with a marked scale of unit divisions. It is an important tool for linear measurement.
Steel tape is used for large measurements, such as marking on boards and checking the overall
dimensions of the work.
Try-Square: It is used for marking and testing the squareness and straightness of plane surfaces.
It consists of a steel blade, fitted in a cast iron stock. It is also used for checking the planed surfaces
for flatness. Its size varies from 150 to 300 mm, according to the length of the blade. It is less
accurate when compared to the try-square used in the fitting shop.
Hand Saw: It is also known as ‘panel saw’. A hand saw is a manual tool featuring a sturdy blade
with a toothed edge used to cut wood. It requires physical effort to push and pull through the
material, offering precision for straight cuts. Hand saws come in various tooth configurations for
different types of cuts, such as cross-cutting or rip-cutting.
Chisel: Chisels are used for cutting and shaping wood accurately. Wood chisels are made in
various blade widths, ranging from 3 to 50 mm. They are also made in different blade lengths.
Most of the wood chisels are made into tang type, having a steel shank which fits inside the
handle. These are made of forged steel or tool steel blades.
Claw Hammer: A claw hammer, a type of hammer, features a dual-purpose head with one flat-
faced side for driving nails and a 'claw' on the other side for removing nails. It's a staple tool in
carpentry and general household maintenance.
Screwdriver: A screwdriver is a hand tool used for driving screws into various materials. It
consists of a handle, shaft, and a tip that corresponds to the screw head type, such as flat-head or
Phillips. Screwdrivers vary in size and shape to accommodate different screw types and
applications.
Auger: An auger is a hand tool used in woodworking to bore holes into wood. It consists of a
helical bit for making deep, precise holes and is turned with a handle that facilitates the drilling
process. Augers are particularly useful for rough drilling work where precision is less critical, such
as when starting holes for larger drills or for running wiring and piping.
Wood Planer: Also known as a thickness planer, this tool trims boards to a consistent thickness
throughout their length and flat on both surfaces. It's essential for preparing rough lumber for fine
woodworking.

Steel Tape
Steel Rule Chisel

Try-Square Planer
Claw Hammer

Hand Saw Screwdriver

Auger
Wood Working Machines
Band Saw: A band saw is a versatile tool that uses a long, sharp blade consisting of a continuous
band of toothed metal stretched between two or more wheels. It's excellent for making precise
cuts, resawing, and cutting irregular shapes.
Scroll Saw: The scroll saw is ideal for intricate and delicate cuts, using a fine blade to make precise
curves and corners with detail. It's commonly used for decorative woodworking, such as intricate
inlays and patterns.
Circular Saw: A circular saw is a robust tool that uses a round blade to make straight cuts. It's
portable, can be hand-held or table-mounted, and is perfect for quickly cutting through lumber or
sheet materials.
Jointer: A jointer is a woodworking machine used to flatten and straighten the edges of boards. It
has infeed and outfeed tables and a rotating cutting head to create a flat surface along the length of
a board.
Disc Sander: A disc sander is a stationary machine that uses a rotating abrasive disc to smooth
surfaces. It's excellent for removing material quickly and is commonly used for shaping and
finishing wood and other materials.
Hand Drill: Carpenter's brace is used to make relatively large size holes, whereas hand drill is
used for drilling small holes. A straight shank drill is used with this tool. It is small, light in weight
and may be conveniently used than the brace. The drill bit is clamped in the chuck at its end and
is rotated by a handle attached to gear and pinion arrangement.
Wood Lathe Machine: A wood lathe is a machine tool that rotates a piece of wood on its axis to
perform various operations such as cutting, sanding, knurling, drilling, or deformation, with tools
that are applied to the workpiece to create an object with symmetry about an axis of rotation. It's
widely used in woodworking for making intricate designs, cylindrical shapes, and detailed work
on wood pieces. Lathes can range from small benchtop units to large industrial machines, and
typically feature adjustable speeds to suit different materials and tasks. Accessories like chisels,
gouges, and faceplates are used in conjunction with the lathe to shape the wood.

Wood Working Joints:

Basic Butt Mitered Butt Half Lap Dovetail

 Rabbet Joint Biscuit Joint Tongue & Groove Joint Dado Joint

Assignment
a. Difference between soft wood and hard wood.
b. Write down the selection criteria of timber.
Exercise: make a picture frame.