Chapter 13 Machine Shop Machinery and Equipment

Machine shop practice consists of certain mechanical principles that are part of all machine shop work everywhere. Section 1.0 Purpose and Scope -To Identify: -each every equipment/machinery and tools in a machine shop -corresponding operating principles involved

Section 2.0 Standard Machine 2.1 Lathe: 2.2 Drill or Drill Press: for producing holes 2.3Shaper: for finishing flat or partly curved surfaces of metal pieces: for finishing flat or partly curved surfaces of metal pieces few in number and not over 305mm or 619mm long. 2.4Planer: for production of flat surfaces on pieces too large or too heavy 2.5Grinding Machine 2.6Vertical Boring Mill:a machine purposely designed for finishing holes. 2.7Horizontal Boring Mill: it revolves on a horizontal axis 2.8Universal Milling Machine: you can do Milling, Longitudinal feed, cross feed, vertical hand feed. 2.9Plain Milling Machin: similar with the Universal the only difference is it lacks the swivel table construction.l 2.10Vertica-spindle Milling Machine : a machine used of and end milling and face milling operation 2.11Metal-Cutting Band Saws: a machine tool designed to cut everything all the time.

Section 3.0 Special Tools and Machinery in Machine Shop of a Manufacturing Plant

3.1 Turret Lathe: consist of multiple station tool holders or turrets. Allows multiple combined cuts from both turrets to operate on the work piece. 3.2 Broaching Machine: 3.3 Mechanical Presses: classified on the basis of construction of the frame(C frame), it can also be classified single-action, double action, or triple-action 3.4Haydraulic Presses-the rated force or tonnage capacity is available over the entire length of the stroke. 3.5Shaper(a little brief discussion) -shaping on a shaper, can be done to the right or to the left. -it includes roughing cuts, finishing cuts, slotting, centering, undercutting, dovetailing, and a variety of operations. -the shape of the tool is determined: by the type of work that is to be done, kind of material being cut, and the condition of the machine, as well as feed and speed. Clearance angle : The angle between a plane containing the end surface of a cutting tool and a plane
passing through the cutting edge in the direction of cutting motion. >since the shaper feed does not operate during the cut as does the lathe feed, a side clearance of 2 or 3 deg is sufficient.

Rake Angle(Rake angle is a parameter used in various cutting and machining processes, describing the angle of the cutting face relative to the work. ): the shaper tool is usually given side rake angle of 10 deg. or more, depending on the of tool and on the hardness of the metal to be machine, but no front rake is given except on finishing tool.

Note: study fig 3-14 carefully for a simple explanation of a cutting action of a shaper tool when plane surface is being machined. Note that the tool is offset so as to get the tool point toward the center of the shank. This will prevent the tool from digging. Most shaper and planner manufacturer recommend this type of tool for general work.

Shaping with Carbide tools.: almost any type of material is machinable with high-speed-steel cutting tools can be economically machined with carbide tools. Carbide tool is more efficient and economical. Note: IN order that a shaper may be suitable for Carbide shaping, it must be capable of speeds exceeding 100 ft/min because it has been determined by experiment and actual industrial conditions that 100 ft/min is the absolute minimum speed at which carbides can be economically used.

3.6Planer(a little brief discussion):the cutting tools generally used on planers are substantially like shape tools for similar operations, the only difference being the size. A.Round-nosed Roughing Tool for cast Iron -General purpose, light roughing tool which can be used in feeding from right to left or from left to right. B.Right-Hand Round-Nosed Tool for cast Iron -used for practically all roughing in cast iron C.Right-hand Round-nosed Roughing tool - intended for roughing cuts in steel. Not suitable for cast iron and if used that purpose, will pull in and cause chatter. D.Left-hand Round-Nosed Roughing Tool -used when it is necessary to feed from left to right, toward the operator, used for planning cast iro, for cast-steel or forgings E.Right-hand Round-Nosed Roughing Tool -also intended for roughing cuts in steel. F.Left-Hand Round-Nosed Roughing tool for steel A companion to tool to D, used for roughing cuts in steel when feeding the head from left to right, that is toward the operator. G.Square-nosed Roughing Tool For cast Iron For roughing cuts on flat surfaces where sharp corner is to be secured. For straightening or heavyfinishing cuts when fine finish is not required(depth of cut 0.004 to 0.005 in). for lighter cuts and finer finishes, can also be made by brasing a piece of high-speed steel on machine steel shank. H. Square-nosed Finishing Tool for Cast Iron. A general purpose tool for straightening and finishing cuts. I.Gooseneck Finishing Tool For cast iron For finishing flat surfaces in any metal, this tool, in combination with a very shallow cut and of coarse feed, is most satisfactory. J.Right-Hand Dovetail End- Cutting Tool for cast Iron

:this tool has the cutting edge at the end. The corner is rounded off so as to avoid breakdown in taking roughing ccut. K.left-Hand Dovetail End-cutting Roughing Tool for Cast iron: A companion to tool I, used when feeding from, left to right and downward. L.Right-hand Dovetail End Cutting Roughing Tool for Cat iron M.Left-hand Dovetail End-cutting Roughing Tool for Cast Iron: a companion for tool K is used in feeding in the opposite direction. N. Right-Hand Dovetail End-cutting Finishing Tool for Cast Iron: Used after roughing cuts with tools I and K. O.Left-Hand Dovetail End-Cutting Finishing tool for Cast Iron: a companion to tool M. and used after tools J and L. P. Right-Hand Dovetail Side cutting Finishing Tool for Cast Iron: Used for finishing angular surface of dovetail. Q.Left-Hand Dovetail Side-Cutting Finishing Tool for Cast iron: A companion tool for tool O. feed downward with a coarse feed.

Section 4.0 Size of Motors for Machine Shop Equipment and Forging Machinery On table 13.1 the kilowatt values show are for average practice. They may be decreased for very light work and mast often be increased for heavy work. The type of motor to be used on each case is indicated by symbols A,B,C. A-adjustable speed, shunt wound, direct current motor, wherever a number of speeds are essential. B-Constant speed, shunt-wound, direct current motor, when the require speed are obtainable by a gear box or other adjustable speed transmission or when only one speed is required. C-Squirrel-cage induction motor when direct current is not available a gear box or other adjustable speed transmission must be used to obtain different speeds. D-Constant speed, compound-wound, direct-current motor, when speeds are obtainable by a gear-box or other adjustable speed transmission or when only one speed is required. E- wound secondary or squirrel-cage induction motor with approximately 10 percent slips, when direct current is not available.

f-Adjustable sped, compound-wound, direct-current motor. Section 5.0 Machine Screws

5.1 British Machine Screws In 1965 at a conference organized by the British Standards Institution, a policy statement was approved which urged British firms to regard the traditional screw thread system Withworth. B.A. and B.S.F- as obsolescent, and to make the internationally agreed ISO metric thread their first choice with ISO Unified Thread as second choice for all future designs. And right as of now it is recognized that some sections of british industry already using ISO inch screwthreads.
British Standard Whitworth (BSW) is one of a number of imperial unit based screw thread standards which use the same bolt heads and nut hexagonal sizes, the others beingBritish Standard Fine thread (BSF) and British Standard Cycle. The British Standard Fine (BSF) standard has the same thread angle as the BSW, but has a finer thread pitch and smaller thread depth. This is more like the modern "mechanical" screw and was used for fine machinery and for steel bolts. The British Association screw thread (BA) standard is sometimes classed with the Whitworth standard fasteners because it is often found in the same machinery as the Whitworth standard.

5.2 British Standard Machine Screws and Machine Screw Nuts, Metric Series Under this is the British Standard B.S. 4183:1967 gives dimensions and tolerances for countersunk head, raised countersunk head and cheese head slotted screws in a diameter range from M1(1mm) to M20(20mm); Pan head slotted head screws in a diameter range M2.5(2.5mm) to M10(10mm); countersunk head and raised countersunk head screws in a diameter range M2.5(2.5mm) to M10(10mm); and square and hexagon machine screw nuts in a diameter range from M1.6(1.6mm) ro M10(10mm)

The standards produced are titled British Standard XXXX[-P]:YYYY where XXXX is the number of the standard, P is the number of the part of the standard (where the standard is split into multiple parts) and YYYY is the year in which the standard came into effect.

5.3 Material The materials from which the screws and nuts are manufactured have a tensile strength not less than following: Steel: 40kgf/mm 2 (392 N/mm 2 ) Brass: 32(314)

Aluminum alloy: 32(314) The unit Kgf/mm is in accordance with ISO DR 911 and the unit in parenthesis has the relationship, 1kgf=9.80665 Newtons.dxc These minimum strengths are applicable to the finished products.
This allows material with similar physical properties to be grouped together to meet the requirements of specific end uses. The stress grade indicates the basic working stresses and stiffnesses to be used for structural design purposes. For example, the basic working stress in bending for F7 grade timber is approximately 7Mpa. An example is on the book.

Computation regarding on the strength grade. Example is the strength grade designation for machine screw is 4.8
Indicated stresses in Newton/mm
2

Strength Designation Nom. Tensile Strength Min Tensile Strength Lower Yield Stress Stress at Perm. Set

3.6

4.6

4.8

5.6

5.8

6.8

8.8 =< 16mm 800

8.8 > 16

9.8

10.9

12.9

300

400

400

500

500

600

800

900

1000

1200

330 180/190 -

400 240 -

420 320/340 -

500 300 -

520 400/420 -

600 480 -

800 640

830 640/660

900 720

1000 900/940

1200 1080/100

In accordance with BS 3692:2001 and BS EN IOS 898-1 : 1999

5.4 ISO meric screw threads are designated according to the following: M5x0.8-6H for an internal thread and M8X1.25-6g for an internal thread Where M:denotes the thread system symbol for ISO Metric thread 5and 8: denote the nominal size in mm 0.8 and 1.25: denote the pitch in mm

6H and 6g: denote the thread tolerance.

5.5 Length of Thread on Screws Screws of nominal thread diameter M1, M1.2 and M1.4 and screws of larger diameters which are too short for the thread lengths are threaded as far as possible to the head. The length of the unthreaded shank is defined as the distance from the leading face of a nut which has been screwed as far as possible on to the screw by hand to 1) the junction of the basic major diameter and the countersunk and raised countersunk head.2) the underside of the head on other types of heads

5.6 Diameter of Unthreaded Shank on Screws The diameter of the unthreaded portion of the shank on screw is not greater than the basic major diameter of the screw head and not less than the minimum effective diameter of the screw thread.

generally the diameter of the unthreaded portion of shank will be nearer the major diameter of the thread for turned screws and nearer the effective diameter for those produced by cold heading associated with the method of manufacturer.

5.7 Radius Under the Head of Screws. The radius under the head of pan and cheese head screws runs smoothly into the face of head screws runs smoothly into the face of the head and shank without any step of discontinuity. A true radius is not essential providing that the curve is smooth and lies wholly within the maximum radius. Any radius under the head of countersunk head screws runs smoothly into the conical bearing surface of the head and the shank without any step or discontinuity.

5.8 Ends of Screws -when screws are made with rolled threads the lead formed by the thread rolling operation and no machining is necessary. -the ends of screws with cut threads are normally finished with a chamfer conforming to the dimension. -at the option of the manufacturer, the ends of screws smaller than M6 (6mm diameter) may be finished, with a radius approximately equal to 1 and times the nominal diameter of the shank.

Section 6.0 Gearing 6.1 Definiton of Gear Terms

Addendum, Arc of Action, Backlash and many more.

6.2 Outside and Root Diameters of Hobbed, Shaped or Pre-shaped Gears Formulas -It will be noted from the formula given that the root diameter for a gear of given pressure angle and the type of tooth depends upon whether the gear is being hobbed, shaped, or preshaved. Conditions: -when gears are finish-hobbed the standard preferred dedendum is used. -when gears are cut on the generating type of gear shaper the clearance is made larger so that a dedendum is greater than standard is required. -in preparing gears for shaveing, it is necessary to semi-finish hob or shape the gears deeper than standard depth in order to avoid interference between the tips of the shaving cutter teeth and the fillet at the base of gear tooth.

6.3 Tooth Thickness Allowance for Shaving Noted: Proper stock allowance is important for good results in shaving operations.
Material added to a part to allow for surface preparation or precise dimensioning by machining

In a machining environment, stock allowance is a term that defines the amount of material left for finishing after rough cutting had been completed. .

Why :if much stock is left for shaving operations -the life of the shaving tool is reduces -shaving time is increased The following figure represent the amount of stock to be left on the teeth for removal by shaving under average conditions: Diametral pitch 2-4 : thickness of .0762mm -.1016mm 5-6: .0508-.0762mm 11-14: 0.0381-0.0508mm 16-18: 0.0254-.0508mm 20-48:0.1270-0.03810mm 52-72: 0.0762-0.01778mm

During shaving the thickness of the gear teeth may be measured in several ways to determine the amount of stock left on the sides of the teeth to be removed. You can use a tooth caliper or pins.

When the pre-shaved gear can be removed from the machine for checking you can use -the center distance method -the formula t2=2tanXD where t2=amount that total thickness of the tooth.

6.4 British Standard Spur and Helical Gears :British standard is a metric0unit specifications for external and internal spur and helical gears for use with parallel shafts. Table 13.3 Tabl13.4

6.5 Notation: to ptomote the international usage of common gear terminology, the terms of draft ISO recommendation No. 888, international vocabulary of gears have been adopted, and the notations is derived from ISO recommendation R701 International gear notation, symbols for geometrical data.

6.6 Basic RackTooth Profile -the basic rack generally in agreement with ISO Recommendation R53Basic rack of cylindrical gears for general and heavy engineering. In practice, the basic rack tooth is usually modified, and the extent of modification shall be in accordance with the following: A. The total depth may vary within the limits of 2.25 to 2.40 B. The root radius may vary within the limits 0.25 to 0.39 C. Tip relief may be applied within the limits shown

6.7Gear Design upon Module System Module=pitch diameter/no. of teeth The module system is in general use in countries which have adopted the metric system; hence the term module is usually understood to mean the pitch diameter in millimeter divided by the number of teeth. However it can also be based on inch measurement which is known as English module.

Table 13.6 tooth Dimensions Based Upon Module system shows the relation module, diamteral pitch and circular pitch. In table 13.4 british Standard Metric Spur and helical Gears- Basic Formulas for Limits of Tolerance on Elements. Below that table is the other formulas needd and explanation for calculation.

Section 7.0 Guarding of Point of Operating in Turning, Drilling, Shaping, Milling and Grinding Operations 7.1 Turning Machines

Machines that performing turning operations: include engine lathe Type of Accidents a.Contact with projections on face plates b.Contact with projections to the dogs and projecting set screws. c.Flying of metal chips or long burrs and turnings. Suitable Guard 1) Head-Stock Guard 2) Churck Guard 1)Counter sunk screw 1) Enclosure guard 2)Portable Perspex screen guard 3)Use chip breaker-tool to eliminate long turnings. 1) Foot-pedal brake with triple-switch 2)Pneumatic chuck and freeding tools for small jobs. 1)Automatic emerying Emery holder 1) Dial indicators 1) Safety hook/brush 1) Tube guard 2)Bar-Sock guard 1)Splash Guard 2)Full enclosure guard Spin;e jaws, mechanical feeding device like that of F.H.J. Safety fixture Splash guard/Enclosure guard mounted on rollers

d.Hand braking of machines.

e.Filling emerging without a suitable device. f.Gauging the job while machine is in motion. g.Attempting to clean chips when job is n motion. h.Projection of the work or stock beyond machine. i.Flying off the job from the two centres due to sudden movement of the tool jerking back of the tail stock. j.Inserting blanks and mobbing the processed pertwithout stopping. k.Splashing of coolant resulting in slipping hazards and dermatitis

Special Accidents in Turret and Capstan Lathes: a. Counter-wt. falling and bar flying thro turret head. 1) Tube guard 2) Blank off Hole

Special Accident in Multispindle Lathe a. Collecting Component while just parting off. b. Top parted off component comes in between tool and of first spindle. Wire-mesh, Spoon. Sharpening tools properly.

7.2 Boring Machine.

Machine performing boring functions. Causes of injury in drilling operations are: a. Contact with the spindle and drill bits. b. Braking of a tool and blunt bit. c. Being struck by a job due to insecurely clamped work. d. Catching of jair or loose sleave in the revolving spindle and bit. e. Sweeping chips by hand Telescopic chick and spindle guard. Clamps or use of L angle iron. Clamps or use of L angle iron. Cage type guard. Brush

7.3 Milling Machines Hazards involve are: -contact with removing chips and waste -flying chips -unsafe operating practice such as tightening the arber-nut by using the power of the machine or attempting to adjust the work of the tool while the machine is in motion and working with loose clothing Solution : fixed guard, automatic guard and interlocked guard of innumerable kinds are available for the described. Horizontal &Vertical Bed Movement About 2/3 of all milling machine accidents occur when operators unload and load, or make adjustment, when running. Other causes of injuries: a. Removing swarf by hand using rag to clean excess oil while it is running. b. Failure to clamp the work properly. c. Leaving the cutter exposed after the job has been withdrawn. d. Failure to draw the job back to a safe distance when loading and unloading. e. Slipping of spanner while adjusting, tighten, loosening etc. f. Attempting to remove the nut from the Brush, Magnetic sweep. Permanent magnetic plate fitted on bed, according to connection. Extending flexible guard, automatic guard, fixed bar type guard or interlocked guard. Fixed guard Fixed guard. Use of proper spanner. Education and Training

machine arber by applying power to the machine.

7.4 Planing Machines. Machine tools performing planning operation include basic planer, shaper, slotters, broachers and key seaters. A. Hazards in Planers. -Struck by the moving table/ material on the table -caught between the table and the frame or bed of the machine. -in case of huge planning machines a fall from the table or the bed, fall between the uprights may be a serious matter. -unsafe practices such as changing stop dogs when the machine is in motion, riding the table during the operation. Solution: put Guard rail or barrier to close off any space less than 457.2 mm between fixed part and planner bed. Self adjusting table guard on the sides of the planner are essential. B. Hazards in Shapers -Flying chips -flying job if the work is not securely clamped -attempting to adjust machine while it is in motion -caught between ram and fixed object and out injuries in removing chip Possible solutions Shaper can be provided with a combination container for chips and transparent shield for tool A retriever to the limit of the stroke of ram channel. The reversing dogs on the planers and shapers should be covered. If the planner bed travels within 457.2 mm of a wall or fixed objects, there should be barrier to prevent entrapping. Breaches may be covered with transparent cover and guarded be two-hand electric interlocks.

7.5 Grinding machines. It includes internal grinding, external or cylindrical grinding, polishing, buffling, honing are classified nder this cadre A. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Accidents occur due to the following: Failure to use suitable protective equipment. Holding the work improperly. No work rest or improperly adjusted work nest. Improper or no wheel guard. Excessive wheel speed. Cleaning, adjusting or gauging work while the machine is in operation. Side grinding. Using wrong type of wheel. Bursting of wheels, due to excessive tightening or damage in transit. Applying work to quickly to a cold wheel. Vibration due to improper balance. Applying too heavy cut. Using a spindle with incorrect diameter. Threads on spindle tend to loosen the nut as spindle revolves. Wrong size of flanges or glanges of unequal diameter. Flanges with un-relieved centres. Failure to use wheel washers. Wheel out of balance. Grinding too high above the center line of the wheel. Incorrect dressing of the wheel.

B. A. B. C.

Proper Inspection and Storage: Ring test by qualified person. Proper storing in dry area. Then speed test while installing.