MACHINE SHOP

Safety Rules
1. Always wear uniform in the workshop. Never wear loose clothes.
2. Never walk bare footed inside the workshop, use of rubber sole closed
shoe is recommended.
3. Never operate any machine unless you do not know how to operate it.
. Never touch movin! parts , belts or rotatin! tools etc.
". #efective e$uipments and tools should not be used for any work.
%. Never touch any switch, knob or lever of the machine without
knowin! it.
&. Silky clothes catch fire soon, never come to the workshop wearin!
such clothes.
'. #o not touch any live wire inside the workshop.
(. )n case of any fire, the electric supply should be disconnected.
1*. Always keep in mind about the position of fire +,tin!uisher and
first aid bo,.
11. Always read the first aid charts carefully while be!innin! in the
workshop.
12. -ake sure that your work is not affectin! anybody in the
workshop.
13. Always try to learn sincerely from the instructors.
1. Always keep your mind on the .ob.
+,periment No. 1
Aim:- . To study and draw the Layout of Mahine sho!
Materia":- Measurin# ta!e
Proedure:- $.%raw the to! &iew of the mahine sho!.
'.Loate a"" the mahines on the sho! f"oor and draw the
"ayout of the mahines
+,periment no 2
A)-/ - To study onstrution and wor(in# of a "athe mahine.
APPA)AT*S:- Lathe mahine
Definition
Lathe is a machine, which removes the metal from a piece of work to the required
shape and size
Common types of lathes:
Engine Lathe: The most common form of lathe, motor driven and comes in
large variety of sizes and shapes.
Bench Lathe: A bench top model usually of low power used to make
precision machine small work pieces.
Tracer Lathe: A lathe that has the ability to follow a template to copy a
shape or contour.
Automatic Lathe: The lathe in which the work piece is automatically fed
and removed without use of an operator. utting operations are automatically
controlled by a sequencer of some form.
Turret Lathe: The lathes which have multiple tools mounted on turrent
either attached to the tailstock or the cross!slide, which allows for quick changes in
tooling and cutting operations.
Computer Controlled Lathe:
"ighly automated lathes, where cutting, loading, tool changing, and part
unloading are automatically controlled by computer coding.
Centre lathe constructional features
"ead stock
Tail stock
#ed
arriage
$eed rod
Lead screw
$eed change gear bo%
Fig (1 Engine Lathe
Lathe specifications
&istance between centers
'wing over the bed
'wing over the cross slide
"orse power of the motor
(umber of speeds
(umber of feeds
Lathes and Lathe !perations
Lathes are the oldest machine tools
Lathe omponents
#ed: supports all ma)or components
arriage: slides along the ways and consists of the cross-slide, tool post, apron
"eadstock * "olds the )aws for the work piece, supplies power to the )aws and has various drive
'peeds
Tailstock * supports the other end of the work piec$eed +od and Lead 'crew * $eed rod is powered by a set
of gears from the headstock
LAT"E BED
The bed is the base of the lathe and supports all the ma)or components of lathe.
Lathe bed material made of grey cast iron , to resist deflection and absorb vibrations during
cutting
Carriage Feed
Longitudinal $eed or ,Turning- ! The tool is fed along the work.
ross $eed or ,$acing- * The tool is fed across the work.
Tail #toc$:
.t/s like a stationary drill press
.t is centered with your work piece
$or drilling use a drill chuck that fits your bits
0am the drill chuck into the tail stock
To remove the chuck turn the tail stock back to zero and the chuck should pop out
utting Tools
There are basically two types of cutting tools:
'ingle point 1e.g. turning tools2. 1 fig .3 2
4ultiple point 1e.g. milling tools2.
P)ECA*TIONS:- $. +efore "athe mahine swithin# on , see that the tai" sto(,
too" ho"der
are !ro!er"y "am!ed.
'. *se hand !ower on"y when !uttin# on or remo&in# hu( or fae !"ate.
-. %o not try to measure wor( or feed the ed#e or ad.ust a uttin# too" when
"athe
Is runnin#.
/. Chu( (ey shou"d 0e remo&ed from the hu( after ti#htenin#. Ne&er
a""ow the
Chu( (ey to rest in the hu(.
1. %o not shift or han#e #ears whi"e "athe is runnin#.
2. Choose or ad.ust !ro!er de!th of ut.
3. *se 0rush to "ean the hi!s.
4. 5hi"e wor(in# on a "athe, use #o##"es.
Experiment No 03
AIM:

To perform lathe operations Facing Operation on a given material made of Mild steel.
MATERIAL REQUIRE:
A mild steel !ar of "" mm diameter and #$ mm length.
TOOL% A& EQUI'ME&T U%E:
(.%.%. single point c)tting tool* 'arting tool* +n)rling tool*
,h)c-e.* Tool post -e.* O)tside caliper* %teel r)le.
Facing Operation
Facing is the operation of machining the ends of a piece of /or- to prod)ce a flat
s)rface s0)are /ith the a1is. The operation involves feeding the tool perpendic)lar
to the a1is of rotation of the /or- piece.
A reg)lar t)rning tool ma. !e )sed for facing a large /or- piece. The c)tting edge
sho)ld !e set at the same height as the center of the /or- piece. The tool is !ro)ght
into /or- piece from aro)nd the center for the desired depth of c)t and then is fed
o)t/ard* generall. !. hand perpendic)lar to the a1is of rotation of the /or- piece
E1periment &o 23
AIM:
To perform lathe operations s)ch as %tep T)rning *Taper T)rning on a given material made of
Mild steel.
MATERIAL REQUIRE:
A mild steel !ar of "" mm diameter and #$ mm length.
Step Turning
Is the operation of ma-ing different diameters of desired length. The
diameters and lengths are meas)red !. means of o)tside caliper and steel r)le respectivel..
Taper Turning
A taper ma. !e defined as a )niform increase or decrease in diameter of a piece of /or-
meas)red along its length. In a lathe* taper t)rning means to prod)ce a conical s)rface !. grad)al
red)ction in diameter from a c.lindrical /or- piece.
The amo)nt of taper in a /or- piece is )s)all. specified !. the ratio of the difference in
diameters of the taper to its length. This is termed as the conicit. designated !. the letter 4+5.
+ 6 78d9 :L
;here* 6 Large diameter of taper in mm
d 6 small diameter of taper in mm
L 6 length of tapered part in mm
A taper ma. !e t)rned !. an. one of the follo/ing methods:

a9 Form tool method
!9 Tail stoc- set over method
c9 %/iveling the compo)nd rest and
d9 Taper t)rning attachment
Taper t)rning !. s/iveling the compo)nd rest:
This method emplo.s the principle of t)rning taper !. rotating the /or- piece on the lathe
a1is and feeding the tool at an angle to the a1is of rotation of the /or- piece. The tool
mo)nted on the compo)nd rest is attached to a circ)lar !ase* grad)ated in degrees* /hich
ma. !e s/iveled and clamped at an. desired angle. Once the compo)nd rest is set at the
desired half taper angle* rotation of the compo)nd slide scre/ /ill ca)se the tool to !e fed at
that angle and generate a corresponding taper. The setting of the compo)nd rest is done !.
s/iveling the rest at the half taper angle. This is calc)lated !. the e0)ation.
Tan < 6 78d9 : "L
;here < 6 (alf taper angle
Experiment No 05
AIM: To perform lathe operations s)ch as +n)rling * ,hamfering on a given material made of
Mild steel.
MATERIAL REQUIRE:
A mild steel !ar of "" mm diameter and #$ mm length.
Knurling
+n)rling is the process of em!ossing a diamond shaped pattern of the s)rface of a /or- piece.
The p)rpose of -n)rling is to provide an effective gripping s)rface on a /or- piece to proven it
from slipping /hen operated !. hand. +n)rling is performed !. a special -n)rling tool /hich
consists of a set of hardened steel rollers in a holder /ith the teeth c)t on their s)rface in a
definite pattern. The tool is held rigidl. on the tool post and the rollers are pressed against the
revolving s)rface of /or- piece to s0)ee=e the metal against the m)ltiple c)tting edges*
prod)cing depressions in a reg)lar pattern on the s)rface of the /or- piece+n)rling is done at
the slo/est speed and oil is flo/ed on the tool and /or- piece. +n)rling is done at the slo/est
speed and oil is flo/ed on the tool and /or- piece to dissipate heat generated d)ring -n)rling.
The feed varies from > to " mm per revol)tion.
Chamfering
,hamfering is the operation of !eveling the e1treme end of a /or- piece. This is done to remove
the !)rrs* to protect the end of the /or- piece from !eing damaged and to have a !etter loo-. The
operation ma. !e performed after the completion of all operations. It is an essential operation
after thread c)tting so that the n)t ma. pass freel. on the threaded /or- piece
E1periment &o 2?
AIM:
@8thread c)tting on a lathe forming right hand and left hand metric
threads as sho/n in fig.and )nder c)tting operation
MATERIAL REQUIRE
Mild steel !ar of "3 mm diameter and >22 mm length
TOOL% A& EQUI'ME&T
(.%.%. single point c)tting tool* Arooving tool* Threading tool thread ga)ge* O)tside caliper
'RI&,I'LE OF T(REA ,UTTI&A
The principle of thread c)tting is to prod)ce a helical groove on a c.lindrical or conical s)rface
!. feeding the tool longit)dinall. /hen the Bo! is revolved !et/een centers or !. a ch)c-. The
longit)dinal feed sho)ld !e e0)al to the pitch of the thread to !e c)t per revol)tion of the /or-
piece. The lead scre/ of the lathe* thro)gh /hich the saddle receives its traversing motion* has a
definite pitch. A definite ratio !et/een the longit)dinal feed and rotation of the head stoc-
spindle sho)ld therefore !e fo)nd o)t so that the relative speeds of rotation of the /or- and the
lead scre/ /ill res)lt in the c)tting of a scre/ of the desired pitch. This is affected !. change
gears arranged !et/een the spindle and the lead scre/ or !. the change gear mechanism or feed
!o1 )sed in a modern lathe.
,alc)lation of change8/heels* metric thread on English lead scre/:
To calc)late the /heels re0)ired for c)tting a scre/ of certain pitch* it is necessar. to -no/ ho/
the ratio is o!tained and e1actl. /here the driving and driven /heels areto !e placed. %)ppose
the pitch of a lead scre/ is >" mm and it is re0)ired to c)t a scre/ of C mm pitch* then the lathe
spindle m)st rotate 3 times the speed of the lead scre/ that is
%pindle t)rn 3 Lead scre/ t)rn river teeth > river teeth
(ence /e ma. sa.*

river teeth Lead scre/ t)rn pitch of the scre/ to !e c)t
river teeth spindle t)rn pitch of the lead scre/
T(REA ,UTTI&A O'ERATIO&:
In a thread c)tting operation* the first step is to remove the e1cess material from the /or- piece
to ma-e its diameter e0)al to the maBor diameter of the scre/ thread. ,hange gears of correct
si=e are then fitted to the end of the !ed !et/een the spindle and the lead scre/. The shape or
form of the thread depends on the shape of the c)tting tool to !e )sed. In a metric thread* the
incl)ded angle of the c)tting edge sho)ld !e gro)nd e1actl. ?22
. the top of the tool nose sho)ld !e set at the same height as the center of the /or- piece
Experiment No 07
Ai m : To perform rilling Operation on rilling Machine .
rilling machine is a machine tool designed for drilling holes in metallic and
non metallic materials. The c)tting tool is a m)lti8point c)tting tool* -no/n as
dril
;OR+I&A 'RI&,I'LE A& O'ERATIO& OF RILLI&A MA,(I&E

rilling machine is )sed to prod)ce holes in the /or- piece the end c)tting
tool )sed for drilling holes in the /or- piece is called the drill. The drill is
placed in the ch)c- and /hen the machine is 4O&5 the drill rotates. The
linear motion is given to the drill to/ards the /or- piece* /hich is called
feed. In order to remove the chips from the hole* drill is ta-en o)t from the hole so the
com!ination of rotar. and linear motion prod)ces the hole in
the /or- piece
RILLI&A O'ERATIO&%

The follo/ing are the most common operations performed on the drilling
machine:

>. rilling: it is an operation of prod)cing a circ)lar hole in a /or- piece !.
forcing a drill in the /or- piece.
". Doring: it is an operation of enlarging a hole that has alread. !een
drilled. %ingle point c)tting tool is )sed in !oring.
C. Reaming: Reaming is done /ith reamers. It is done to generate the
hole of proper si=e and finish after drilling
3. Tapping: It is an operating of prod)cing internal threads in a hole !.
means of a tap.
$. ,o)nter Doring: It is an operation of enlarging the entr. of a drilled hole
to accommodate the !olt head etc. ,o)nter !oring tool does it.
?. %pot Facing: It is an operation done on the drilled hole to provide
smooth seat for !olt head.
E. ,o)nter %in-ing: It is an operation to !evel the top of a drilled hole for
ma-ing a conical seat. A co)nter s)n- drill is )sed in this operation
RILLI&A 7,UTTI&A9 %'EE A& FEE

,)tting %peed: ,)tting speed in drilling is the peripheral speed of the drill
relative to the /or-.

,)tting speed 6 .&:>222 m:min

;here 6 iameter of drill in mmF
& 6 ;or- speed in r.p.m
E1periment &o 2G
Shaping machine operation
>. AIM: To perform @ and ovetail machining H U8c)t on the given /or- piece.

". MATERIAL% REQUIRE: Mild steel : ,ast iron : ,ast Al)min)m.
C. MA,(I&E REQUIRE: %haping machine
3. MEA%URI&A I&%TRUME&T%:
@ernier calipers*
@ernier height ga)ge*
ial indicator*
Re0)ired steel !all.
$. ,UTTI&A TOOL%
(.%.% tool !it*
@ tool*
'lain tool*
Arooving tool.
?. %EQUE&,E OF O'ERATIO&%:
>. Meas)ring of specimen.
". Fi1ing of specimen in the machine vice of the shaping machine
C. Aiving the correct depth and a)tomatic feed for the slot is to !e made.

3. ,hec- the slot /ith the @ernier calipers H precision meas)rement !. slip
ga)ges at the end
Experiment No 09
A!: To perform plane milling operation on the given specimen 7mild steel9
H get to its correct dimensions.
MATERIAL% REQUIRE: mild steel specimen.
MA,(I&E REQUIRE: milling machine
MEA%URI&A I&%TRUME&T%:
@ernier calipers
,UTTI&A TOOL%: 'lane 7face9 milling c)tter
MAR+I&A TOOL%: steel r)le* scri!er
a. ;or- holding fi1t)res: /or- piece s)pporting fi1t)res !. Miscellaneo)s tools: (ammer* !r)sh*
Allen
-e.s
%EQUE&,E OF O'ERATIO&%:%E
i. Meas)ring of specimen ii. Fi1ing of specimen in the milling m:c.
iii. Aiving the correct depth and a)tomatic feed c)t the
specimen
iv. ,hec- the specimen /ith @ernier caliper at the end.
T"EO#$% Milling machine is a machine tool in /hich metal is removed !. means of a
revolving
c)tter /ith man. teeth 7m)ltipoint9* each tooth having a c)tting edge /hich removes
the metal from the /or- piece. The /or- ma. !e fed to the c)tter* longit)dinall.*
transversel. or verticall.* the c)tter is set to a certain depth of c)t !. raising the
ta!le. This machine is ver. m)ch s)ita!le in tool room /or- d)e to its variet. of
operations* !etter s)rface finish and acc)rac..
E1periment &o >2
&#ECSON S'#FACE (#N)N(
A!% To perform s)rface grinding operation on the given /or- piece.
MATERIAL% REQUIRE: mild steel specimen.
MA,(I&E REQUIRE: s)rface grinding machine
MEA%URI&A I&%TRUME&T%:
@ernier calipers* Micrometer.
,UTTI&A TOOL%: iamond point dressing !loc-
;OR+ (OLI&A FIITURE%: Magnetic ch)c-
SE*'ENCE OF O&E#ATONS:
J Meas)ring of specimen )sing @ernier caliper* scre/ ga)ge micro meter
J Fi1 the /or- piece on to specimen H loc- the magnetic ch)c-
J Move the specimen close to the moving grinding /heel so that it
to)ches the specimen.
J 'erform the s)rface grinding operation.
J ,hec- the final dimension )sing @ernier caliper* scre/ ga)ge micro8 meter.
T"EO#$%
Finish Arinding: Arinding is a metal c)tting operation performed !. means of a
rotating a!rasive /heel that acts as a c)tting tool. This is )sed to finish /or- pieces
/hiGch m)st sho/ a high s)rface 0)alit.* acc)rac. of shape and dimension. Mostl.
grinding is the finishing operation !eca)se it removes comparativel. little metal*
)s)all. 2."$ to$2.$ mm in most operations and the acc)rac. in dimensions is in the
order of 2.222"$ mm.