Machine Workshop

What I have done in my visits to workshop…

Submitted by
Moiz Husnain
2015-EE-70
Electrical Engineering
Section B
Introduction
A place where number of machines are installed to perform a specific job is called Machine Shop. As we
know that there are several ways to perform operations on a work piece but the simplest and easiest, yet
advance way to perform several tasks on a work piece is to use machine, so in Machine shop we use
machines to perform several jobs on work piece. The technique employed in Machine Shop in knows as
Machining. But before discussing it in detail, let us take a look at various ways with which a thing can be
manufactured. A thing can be manufactured with two types of process
1. Hot Working Methods
2. Cold Working Methods
Hot Working Methods
Hot working methods include following methods to perform several jobs on work piece
1. Forging
In this technique we first heat the work piece and then by applying force on in scientific terms,
forging, we turn it into several shapes and hence perform several operations on a work piece.
2. Casting
In this technique a raw material is first melted and then turned into several shapes with the help of
specially made casts and in this way we can turn a material into several useful things and this is
most commonly used technique for manufacturing of many industrial items and things.
Cold Working Methods
Cold working methods include following methods to perform several operations on work piece
1. Fabrication
In this technique first we cut a material into several pieces and then again using several adhesive
agents we re-join them and turn them into several useful items
2. Machining
In Machining we use machines to perform several tasks on work piece to turn it into useful thing.
With this technique we can obtain very sharp results and hence it’s the most useful process in the
field of manufacturing and as stated above in Machine Workshop we use this technique to perform
tasks on our work piece.
In Machine workshop we use several Machine tools and these tools are listed as follows
1. Lathe Machine
2. Shaper Machine
3. Planner Machine
4. Grinding Machine
Now before going into future details of Machine that I used in while performing several tasks in my
work piece, let us take a look at layout of our Machine shop in next section first.
Machine Workshop Layout

3
3

3
4

5 2

6 1

Escape Entrance

Way to
Fabrication
Workshop

1. Power Hacksaw
Use to split work piece into pieces.
2. Universal Hacksaw
Cutting of work piece in a specific manner by shearing.
3. Tool and Cutter Grinder
To re-sharp tools used with lathe machines.
4. Surface Grinding Tool
To produce flat surfaces, it is a special type of grinder and in this we use Magnetic Holder, to hold
the work piece.
5. Knee and Column Milling Machine
 To make gears we use this machine.
6. Shaper Machine
We can produce different shapes with this machine
7. Lathe Machines
One of the most important type of machine and used to perform several operations on a work piece
with the help of different tools provided with it as accessories.
Now I will go in detail of Lathe Machine because I have performed all operations on my work piece with
the help of Lathe Machine as with the help of Lathe Machine we can perform several operations at once
with the help of several tools provided with it.
Lathe Machine
Introduction
Lathes were developed as early as the 15th century and were known as "bow" lathes. The operator rotated
the work piece by drawing a bow back and forth, either by hand or with the use of a foot treadle. Next came
Bessons lathe in 1568, which was driven by a cord passing over a pulley above the machine. This in turn
drove two other pulleys on the same shaft which rotated the work piece and a crude, wooden lead screw,
which in turn allowed the operator to remove metal from the piece being machined. The screw cutting lathe
originates in the 17th century. Development and advancements have continued and today we have
sophisticated computerized controlled lathes.

History of Lathe Machines

Lathes have allowed man to reshape, machine and manufacture many precision cylindrical components
made of various types of metal, wood, plastics, and other materials. Without the lathe, man would still be
trying to produce cylindrical components in some crude fashion or another. However, because of advanced
technology, the lathe has allowed man to become an important asset in developing and machining many
precision components needed to operate and function in many areas of our industrial complex.
Lathe Types and Uses
The lathe is a machine tool used principally for shaping articles of metal, wood, or other material. All
Lathes, except the vertical turret type, have one thing in common for all usual machining operations; the
Work piece is held and rotated around a horizontal axis while being formed to size and shape by a cutting
Tool. The cutter bit is held either by hand or by a mechanical holder, then applied to the work piece.
Principal capabilities of the lathe are forming straight, tapered, or irregularly outlined cylinders, facing Or
radial turning cylindrical sections, cutting screw threads, and boring or enlarging internal diameters. The
typical lathe provides a variety of rotating speeds and suitable manual and automatic controls for moving
the cutting tool.
Lathes can be conveniently classified into following types
1. Engine Lathes
2. Turret Lathes
3. Special Purpose Lathes
All engine lathes and most turret and special purpose lathes have horizontal spindles and, for that reason,
are sometimes referred to as horizontal lathes. The smaller lathes in all classes may be classified as follows
1. Bench Lathes
2. Pedestal Lathes
Engine Lathes
The engine lathe is intended for general purpose lathe work and is the usual lathe found in the machine
shop. The engine lathe may be bench or floor mounted; it may be referred to as a tool room-type lathe, or
a sliding-gap or extension-type lathe. The engine lathe consists mainly of a headstock, a tailstock, a
carriage, and a bed upon which the tailstock and carriage move. Most engine lathes are back-geared and
high torque, which is required for machining large diameter work pieces and taking heavy cuts. The usual
engine lathe has longitudinal power and cross feeds for moving the carriage. It has a lead screw with gears
to provide various controlled feeds for cutting threads. Engine lathes are made in various sizes; the size is
determined by the manufacturer.

Engine Lathe Machine

Generally, the size is determined by the following measurements either the diameter of the work piece will
swing over the bed, or it will swing over the cross-slide, and the length of the bed, or the maximum distance
between centers.
Turret Lathes
The turret lathe is a lathe used extensively for the high- speed production of duplicate parts. The turret
lathe is so named because it has a hexagonal turret, or multiple tool holder, in place of the tailstock found
on the engine lathe. Most turret lathes are equipped with a pump and basin for the automatic application
of a coolant or cutting oil to the work piece.

Turret Lathe
Special Purpose Lathes
Some lathes have characteristics that enable them to do certain work well. Some of these lathes are of
the heavy-production type where large numbers of identical parts must be produced to make the operation
more economical. Other special purpose lathes are specialized for machining specific items and cannot be
adapted to the common types of lathe operations.

Special Purpose Lathe Machine

Schematic Diagram of Engine Lathe Machine:
For general purposes we use Engine Lathe Machines and here is schematic diagram of Engine Lathe
Machine
 Schematic Diagram of Lathe Machine
So as we can see that a General Lathe Machine consists of lot of parts so I’ll first move in detail about
several parts of general Lathe Machine
1. Head Stock
2. Tail Stock
3. Gear Box
4. Carriage
5. Compound Rest
6. Tool Post
7. Bed
So the details of each part is as follows
Head Stock
The headstock carries the head spindle and the mechanism for driving it. In the belt-driven type headstock,
the driving mechanism consists merely of a cone pulley that drives the spindle directly or through the back
gears. When the spindle is driven directly, it rotates the cone pulley. When the spindle is driven through
the back gears, it rotates more slowly than the cone pulley, which in this case turns freely on the spindle.
Thus two speeds are available with each position of the belt on the cone; if the cone pulley has four steps,
eight spindle speeds are available.
The headstock casing is filled with oil to lubricate the gears and the shifting mechanism contained within
it. The parts not immersed in the oil are lubricated by either the splash produced by the revolving gears or
by an oil pump. Be sure to keep the oil to the full level as indicated on the oil gage, and drain and replace
the oil when it becomes dirty or gummy.
 Head Stock
The headstock spindle is the main rotating element of the lathe and is directly connected to the work piece
which revolves with it. The spindle is supported in bearings at each end of the headstock through which it
projects. The section of the spindle between the bearings carries the pulleys or gears that turn the spindle.
The nose of the spindle holds the driving plate, the faceplate, or a chuck. The spindle is hollow throughout
its length so that bars or rods can be passed through it from the left and held in a chuck at the nose. The
chuck end of the spindle is bored to a Morse taper to receive the solid center. The hollow spindle also
permits the use of the draw-in collet chuck (to be discussed later in this lesson). At the other end of the
spindle is the gear by which the spindle drives the feed and the screw-cutting mechanism through a gear
train located on the left end of the lathe. A collar is used to adjust the end play of the spindle.
The spindle is subjected to considerable torque because it drives the work against the resistance of the
cutting tool, as well as driving the carriage that feeds the tool into the work. Because of the torque and
pressure applied to the spindle, adequate lubrication and accurately adjusted bearings are absolutely
necessary.
Tail Stock
The primary purpose of the tailstock is to hold the dead center to support one end of the work being
machined between centers. However, it can also be used to hold live centers, tapered shank drills, reamers,
and drill chucks. The tailstock moves on the ways along the length of the bed to accommodate work of
varying lengths. It can be clamped in the desired position by the tailstock clamping nut.
The dead center is held in a tapered hole (bored to a Morse taper) in the tailstock spindle. The spindle is
moved back and forth in the tailstock barrel for longitudinal adjustment. The hand wheel is turned which
turns the spindle-adjusting screw in a tapped hole in the spindle. The spindle is kept from revolving by a
key that fits a spline, or keyway, cut along the bottom of the spindle.
The tailstock body is made in two parts. The bottom, or base, is fitted to the ways; the top can move
laterally on its base. The lateral movement can be closely adjusted by setscrews. Zero marks inscribed on
the base and top indicate the center position and provide a way to measure set over for taper turning.
 Tail Stock
Before inserting a dead center, a drill, or a reamer into the spindle, carefully clean the tapered shank and
wipe out the tapered hole of the spindle. After a drill or reamer is placed into the tapered hole of the
spindle, make sure that the tool will not turn or revolve. If the tool is allowed to revolve, it will score the
tapered hole and destroy its accuracy. The spindle of the tailstock is engraved with graduations which help
in determining the depth of a cut when a piece is drilled or reamed.
Automatic Gear Mechanism
To do away with the inconvenience and loss of time involved in removing and replacing change gears,
most modern lathes have a self- contained change gear mechanism, commonly called a "quick-change gear
box." There are a number of types used on different types of lathes, but they are all similar in principle.

Automatic Gear Mechanism

The quick-change gear box mechanism consists of a cone-shaped group of change gears. One can instantly
connect any single gear in the gear train by a sliding tumbler gear controlled by a lever. The cone of gears
is keyed to a shaft which drives the lead screw (or feed rod) directly or through an intermediate shaft. Each
gear in the cluster has a different number of teeth and hence produces a different ratio when connected in
the train. Sliding gears also produce other changes in the gear train to increase the number of different
ratios one can get with the cone of change gears. All changes are made by shifting the appropriate levers
or knobs. An index plate or chart mounted on the gear box indicates the position in which to place the
levers to obtain the necessary gear ratio to cut the threads or produce the feed desired.
Carriage
The carriage carries the cross feed slide and the compound rest which in turn carries the cutting tool in the
tool post. The carriage slides on the ways along the bed the wings of the H-shaped saddle contain the
bearing surfaces which are fitted to the V- ways of the bed. The cross piece is machined to form a dovetail
for the cross feed slide. The cross feed slide is closely fitted to the dovetail and has a tapered gib which
fits between the carriage dovetail and the matching dovetail of the cross feed slide. The gib permits small
adjustments to remove any looseness between the two parts. The slide is securely bolted to the cross feed
nut which moves back and forth when the cross feed screw is turned by the handle. The micrometer dial
on the cross feed handle is graduated to permit accurate feed. Depending on the manufacturer of the lathe,
the dial may be graduated so that each division represents a 1 to 1 ratio. The compound rest is mounted
on top of the cross feed slide.
The carriage can be locked in any position on the bed by tightening the carriage clamp screw. The clamp
screw is to be used only when doing work for which longitudinal feed is not required, such as facing or
cutting- off stock. Normally, the carriage clamp is kept in the released position. The carriage is always
moved by hand to make sure that it is free before the automatic feed is applied.

Carriage
Compound Rest
A compound rest is a device found on a lathe tool. Lathes feature a rotating spindle used to mount a
wooden or metal object. The spindle rotates the object, allowing users to shape or polish the item using
a series of tools or attachments. This device is found in many woodworking shops, manufacturing plants,
and industrial facilities. The tools used to shape and polish objects on a lathe are located on a movable
carriage that sits above the spindle. Many lathes feature programmable settings that automatically adjust
the carriage to make precise cuts into the wood or metal. Lathes with a compound rest give users
additional control options beyond those offered by the programming settings. The compound rest sits on
top of the carriage, where the user can manually position it to the desired location. While the carriage on
a lathe can be set to a specific range of settings, the compound rest can be used to make even finer
adjustments. For instance, most lathes can feed an object or move shaping tools only at specific intervals.
Using a compound rest, users can set the tools to spots between the intervals to make cuts as needed. It
also allows workers to adjust the cutting depth more precisely, as well as the radius or taper.

Compound Rest
Tool Post
Tool posts are used to hold cutting tools. Tool posts allow for rapid tool changeover and provide a high
degree of position repeatability and indexing. There are many types of tool posts. Examples include quick
change tool post, standard tool post, and lathe tool post. A standard tool post is used in conjunction with
high speed steel tooling. A standard tool post can only be used where cutting forces are kept low because
they have a tendency to move around under heavy cutting pressure. A quick change tool post is a tool that
is always kept in the holder of the machine so that the changes can be done easily. All quick change tool
posts offer adjustable tool heights. A lathe tool post is a machine tool which spins a block of material when
abrasive, cutting, or deformation tools are applied to the block. Other tool posts are commonly available.

Tool Post

Bed
The bed is a robust base that connects to the headstock and permits the carriage and tailstock to be moved
parallel with the axis of the spindle. This is facilitated by hardened and ground bed ways which restrain
the carriage and tailstock in a set track. The carriage travels by means of a rack and pinion system. The lead
screw of accurate pitch, drives the carriage holding the cutting tool via a gearbox driven from the
headstock.
Types of beds include inverted "V" beds, flat beds, and combination "V" and flat beds. "V" and combination
beds are used for precision and light duty work, while flat beds are used for heavy duty work
When a lathe is installed, the first step is to level it, which refers to making sure the bed is not twisted or
bowed. There is no need to make the machine exactly horizontal, but it must be entirely untwisted to
achieve accurate cutting geometry. A precision level is a useful tool for identifying and removing any twist.
It is advisable also to use such a level along the bed to detect bending, in the case of a lathe with more
than four mounting points. In both instances the level is used as a comparator rather than an absolute
reference.

Bed
Lathe Accessories
Chuck
Work pieces are held to the headstock spindle of the lathe with chucks, faceplates, or lathe centers. A
lathe chuck is a device that exerts pressure on the work piece to hold it secure to the headstock spindle
or tailstock spindle.

Chuck
Commonly used with the lathe are the independent chuck, the universal scroll chuck, the combination
chuck, the hollow headstock spindle chuck, the lathe tailstock chuck, the collet chuck, and the step chuck.
Cutting Tools
A machine tool is no more efficient than its cutting tool. There is nothing in shop work that should be
given more thoughtful consideration than cutting tools. Time is always wasted if an improperly shaped
tool is used. The cutting action of the tool depends on its shape and its adjustment in the holding device.
Lathe cutter bits may be considered as wedges which are forced into the material to cause compression,
with a resulting rupture or plastic flow of the material. The rupture or plastic flow is called cutting. To
machine metal efficiently and accurately, it is necessary that the cutter bits have keen, well-supported
cutting edges, and that they be ground for the particular metal being machined and the type of cut
desired. Cutter bits are made from several types of steel, the most common of which are described in the
following subparagraphs.

Safety Precautions with Lathe Machine

In machining operations, there is one sequence of events that one must always follow: SAFETY FIRST,
ACCURACY SECOND, AND SPEED LAST. With this in mind, let's look at some of the more important safety
precautions that should be observed before and during lathe operations. Lathe accidents are usually
caused by
1. Loose clothing snagging on the revolving work piece, the chuck, or the work piece.
2. Flying chips entering the eye when turning cast iron or nonferrous metals.
3. Contact of the hands or arms with the lathe dog, chuck or work piece.
So follow the Always Be Careful Rule and follow following instructions while working with Lathe
Machine
1. Wear Lab Coat, Safety Goggles and Gloves.
2. Remove Chuck key after holding the work piece.
3. Support the long work pieces from their tail with the help of tail stock.
4. Don’t place cutting and measuring tools on the edge of machine.
5. Don’t try to measure the job when the job is rotating.
6. Don’t try to clean machine with hands and don’t try to stop machine with hands.
Preparing the Work Piece
To prepare my final work piece I performed following operations on work piece with the help of lathe
machine
Holding
The first step is to hold the work piece in chuck with the help of chuck key to perform the job on work
piece. For this we first open the chuck with the help of chuck key and then insert ¾ work piece into the
chuck and close the chuck with the help of chuck key. Hold the work piece and apply maximum pressure
to hold the work piece firmly. Then as mentioned in ABC rules, removed the chuck key and then with the
help of another key opened the tool post and inserted the basic cutting tool in it and then given an angle
so that the face of cutting tool must not touch the sides of work piece. Before doing that corrected the
center position of cutting tool with the help of tail stock point and hence completed the very first
holding operation.

Holding Chuck key

Facing
After holding the work piece I performed the facing operation and for this I again verified the angle
adjustments and remaining all adjustments and started the machine in Anti-Clockwise manner and then
given the first feed and performed a complete cut of 1 mm length for this I first adjusted the horizontal
position with the help of horizontal screw and then given the feed with left hand through vertical screw
while holding the horizontal screw with the help of right hand and performed the first cut very carefully
and hence repeating this several times performed the first operation.

Facing (First Cut) Facing (Performing Operation)

Straight Turning
After performing the first facing operation very nicely I moved on and started performing straight turning
operation to adjust the diameter of my work piece, I repeated this many times to get my required
dimensions of my work piece. So I first adjusted the diameter of one end according to my own need and
for this this time I just adjusted the vertical position of cutting tool with the help of vertical screw and
then hold it with the help of left and started giving feed with the help of horizontal screw and right hand
and hence performed the first cut and hence by repeating this step several timer I got the required
diameter and then moved on and performed the same operation on the other end and got the required
diameter and hence performed the straight turning operation. It is noted that in this operation I also used
the tail stock to support the work piece as while performing turning on other end we adjust it such that
¾ of the work piece was outside the chuck, whereas the end to be turned must be facing toward tail
stock.

Turning (Staring) Turning (Completed)

Parting off
After beautifully completing the turning operation I moved toward another operation which was actually
not the complete parting off but it was a depiction of parting tool, this time I used a special tool for this
purpose to part off my work piece.

Parting off (Tool) Parting off

This time I kept on supporting the work piece and just after taking the measurements and marking it on
work piece I performed a cut as I performed before in straight turning that kept on holding vertical screw
while giving the feed with the help of horizontal screw and hence performed the first cut, but in this one
thing must be noted that utmost care must be taken otherwise this may cause loss to previous turning
operation as this operation involves a decrease in diameter. In this way after doing this again and again
performed the parting off operation.
Tapper Turning
After performing Parting off operation, I performed the most interesting and important operation, the
tapper turning operation, in this operation I retained the adjustments with the chuck and work piece as
such and performed some changings with the Compound Rest. I opened the nut inside the compound rest
with the help of key and given an angle of 5° and again tighten the compound rest with the help of key
again and this time with moved the cutting tool after giving an angle with it to the end from where we
started the parting off operation and then after adjusting the vertical screw hold it with left hand and
moved the horizontal screw with right hand. Gradually a slop will start appearing and finally when after
doing it again and again the required length at other end reached I stopped repeating and hence
completed the operation.

Tapper Turning (Incomplete) Tapper Turning (Completed)

Threading
Then moving ahead performed the second last operation which was threading, this operation must be
performed automatically with the help of built in speed control and automatic operating functionality I
performed threading but one thing must be noted that before doing this angle of Compound rest must be
re adjusted to 0°

Threading (Incomplete) Threading (Completed)

Knurling
Finally the final step, knurling, in which I again used a special type of tool know as Knurling too, I just
mounted this tool in tool post and this time used both the vertical screw and horizontal screw. To
perform this I started the machine and then moved tool vertically by vertical screw and then moving
horizontal screw while applying pressure vertically with the help of vertical screw and this way
completed the final operation.
The Completed Work Piece