Program: B Tech Semester: 1st

Course: Workshop Practice Course 23BTAL11C08

Code:

Machine Shop
INTRODUCTION
In a machine shop, metals are cut to shape on different machine tools. A lathe is used to cut and
shape the metal by revolving the work against a cutting tool. The work is clamped either in a
chuck, fitted on to the lathe spindle or in‐between the centers. The cutting tool is fixed in a tool
post, mounted on a movable carriage that is positioned on the lathe bed. The cutting tool can be
fed on to the work, either lengthwise or crosswise. While turning, the chuck rotates in counter‐
clockwise direction, when viewed from the tail stock end.

Principal parts of a Lathe

Figure 1 shows a center lathe, indicating the main parts. The name is due to the fact that work
pieces are held by the centers.

Bed
It is an essential part of a lathe, which must be strong and rigid. It carries all parts of the machine
and resists the cutting forces. The carriage and the tail stock move along the guide ways provided
on the bed. It is usually made of cast iron.

Head stock
It contains either a cone pulley or gearings to provide the necessary range of speeds and feeds.
It contains the main spindle, to which the work is held and rotated.
Tail stock
It is used to support the right hand end of a long work piece. It may be clamped in any position
along the lathe bed. The tail stock spindle has an internal Morse taper to receive the dead center
that supports the work. Drills, reamers, taps may also be fitted into the spindle, for performing
operations such as drilling, reaming and tapping.

Carriage or Saddle
It is used to control the movement of the cutting tool. The carriage assembly consists of the
longitudinal slide, cross slide and the compound slide and apron. The cross slide moves across
the length of the bed and perpendicular to the axis of the spindle. This movement is used for
facing and to provide the necessary depth of cut while turning. The apron, which is bolted to the
saddle, is on the front of the lathe and contains the longitudinal and cross slide controls.

Compound Rest
It supports the tool post. By swiveling the compound rest on the cross slide, short tapers may be
turned to any desired angles.

Tool Post
The tool post holds the tool holder or the tool, which may be adjusted to any working position.

Lead Screw
It is a long threaded shaft, located in front of the carriage, running from the head ‐stock to the tail
stock. It is geared to the spindle and controls the movement of the tool, either for automatic
feeding or for cutting threads.

Centers
There are two centers known as dead center and live center. The dead center is positioned in the
tail stock spindle and the live center, in the head ‐stock spindle. While turning between centers,
the dead center does not revolve with the work while the live center revolves with the work.

WORK‐HOLDING DEVICES

Three jaw chuck

It is a work holding device having three jaws (self ‐centering) which will close or open with
respect to the chuck center or the spindle center, as shown in figure. It is used for holding regular
objects like round bars, hexagonal rods, etc.

Face plate
It is a plate of large diameter, used for turning operations. Certain types of work that cannot be
held in chucks are held on the face plate with the help of various accessories.

Lathe dogs and driving plate

These are used to drive a work piece that is held between centers. These are provided with an
opening to receive and clamp the work piece and dog tail, the tail of the dog is carried by the pin
provided in the driving plate for driving the work piece.
MEASURING INSTRUMENTS

1. Outside and Inside Calipers

Firm joint or spring calipers are used for transfer of dimensions with the help of a steel rule.

2. Vernier Calipers
The Vernier caliper is a versatile instrument with which both outside and inside measurements
may be made accurately. These instruments may have provision for depth measurement also.

3. Micrometers
Outside and inside micrometers are used for measuring components where greater accuracy is
required.
LATHE OPERATIONS

1. Turning
Cylindrical shapes, both external and internal, are produced by turning operation. Turning is the
process in which the material is removed by a traversing cutting tool, from the surface of a
rotating work piece. The operation used for machining internal surfaces is often called the boring
operation in which a hole previously drilled is enlarged. For turning long work, first it should be
faced and center drilled at one end and then supported by means of the tail‐stock centre.

2. Boring
Boring is enlarging a hole and is used when correct size drill is not available. However, it should
be noted that boring cannot make a hole.
3. Facing
Facing is a machining operation, performed to make the end surface of the work piece, flat and
perpendicular to the axis of rotation. For this, the work piece may be held in a chuck and rotated
about the lathe axis. A facing tool is fed perpendicular to the axis of the lathe. The tool is slightly
inclined towards the end of the work piece.

4. Taper Turning
A taper is defined as the uniform change in the diameter of a work piece, measured along its
length. It is expressed as a ratio of the difference in diameters to the length. It is also expressed in
degrees of half the included (taper) angle. Taper turning refers to the production of a conical
surface, on the work piece on a lathe. Short steep tapers may be cut on a lathe by swiveling the
compound rest to the required angle. Here, the cutting tool is fed by means of the compound
slide feed handle. The work piece is rotated in a chuck or face plate or between centers.

5. Drilling
Holes that are axially located in cylindrical parts are produced by drilling operation, using a twist
drill. For this, the work piece is rotated in a chuck or face plate. The tail stock spindle has a
standard taper. The drill bit is fitted into the tail stock spindle directly or through drill chuck. The
tail stock is then moved over the bed and clamped on it near the work. When the job rotates, the
drill bit is fed into the work by turning the tail stock hand wheel.

6. Knurling
It is the process of embossing a diamond shaped regular pattern on the surface of a work piece
using a special knurling tool. This tool consists of a set of hardened steel rollers in a holder with
the teeth cut on their surface in a definite pattern. The tool is held rigidly on the tool post and the
rollers are pressed against the revolving work piece to squeeze the metal against the multiple
cutting edges. The purpose of knurling is to provide an effective gripping surface on a work
piece to prevent it from slipping when operated by hand.

7. Chamfering
It is the operation of beveling the extreme end of a work piece. Chamfer is provided for better
look, to enable nut to pass freely on threaded work piece, to remove burrs and protect the end of
the work piece from being damaged.

8. Threading
Threading is nothing but cutting helical groove on a work piece. Threads may be cut either on
the internal or external cylindrical surfaces. A specially shaped cutting tool, known as thread
cutting tool is used for this purpose. Thread cutting in a lathe is performed by traversing the
cutting tool at a definite rate, in proportion to the rate at which the work revolves.
Types of Lathe Cutting Tools
1. Thread Cutting Tools These are of two types –
External threading tool – External threading tools are also called as screw thread tools. They
are defined as the tools which are used for external threading of the work piece.
Internal treading tool – Internal threading tools are defined as those tools which are used for
internal threading in a work piece.
2. Chamfering Tool
Chamfering tool may be defined as the tool which is used to design bevel or furrow on the bolt.
These tools are used for bevelling the corner of the work piece. When a large number of chamfer
works are to be performed, then a specific chamfering tool is used with side cutting angle edge.
3. Turning Tool
Turning tool may be defined as a tool which is used in lathe machine for finishing or cutting the
external diameter of an object. This is basically used to generate cylindrical parts.
4. Grooving Tool
Grooving tool is basically defined as the tool used for making a narrow cavity of a certain depth,
on a cone, cylinder, or a face of the part. In this the groove to be cut according to the edges is
square, rounded etc.
5. Facing Tool
Facing tools may be defined as the tools which are used to cut the plane surface which is
perpendicular to rotational axis of the work piece. This facing tool is carried by a tool holder that
is fixed on the carriage of the machine. It is used for reducing the length of the work piece by
providing perpendicular to the axis of lathe. The cutting edge of the tool should set to the same
height to the centre of the work piece.
6. Forming Tool
In this a special type of cover or holder is used for holding the forming tool. From this we do
many types of operations like making internal radius, outer radius etc.
7. Boring Tool
Enlarging the diameter of the hole is known as boring. Boring tool is just like a bit which is
inserted in a boring cover. The bar is made up of mild steel with holes in it to carry the tool bit
which is fixed with the help of Allen screw.
8. Reaming Tool
Reaming tool is defined as the tool which is used for finishing and sizing of the hole which is
already drilled or bored.
9. Drilling Tool
Drilling tool is also very important tool in the lathe machine. Drilling tool is basically used for
making cylindrical holes in the given work piece. In this the work piece is fixed in faceplate and
drill is held in tailstock drill holder and hole should be done by movement of tailstock spindle.
This is used for regular shaped work piece.
10. Knurling Tool
Knurling tools are used to impart a regular surface pattern on the outside of a part for gripping or
aesthetic purposes. Often, the imparted pattern is diamond shaped or parallel. A knurling tool is a
manufacturing and repairing tool used on lathe machines.
 Experiment
Aim: - To prepare a job on a lathe involving facing, outside turning, taper turning, step turning,
grooving, knurling and boring operation.

All dimensions in mm

Material required: - Mild steel rod.

Equipment & Tool Required: - Lathe Machine, Work piece, Turning Tool, Grooving Tool
Drill bit, Knurling Tool, Tool kit (Chuck key, Tool post key, inside & outside Caliper, Steel
Scale, Packing pieces & Brush)

Procedure: -

1. Job is fixed in three jaw chuck for proper alignment.

2. Single point cutting tool is fixed in the tool post and facing operation is completed.
3. A rough cut is used to mark the outer periphery.
4. Final turning and step turning operations are completed in sequence.
5. Grooving tool is used to make the required grooves on the job.
6. Drilling tool is used for making required hole in the job.
7. The compound slide is set at the taper angle as per calculation with the center line and tapering
operation is completed through different cuts.
8. Knurling tool is fixed in tool post for completing knurling operation.
9. Final Job is checked for all the required dimensions.

Precautions: -
1. Work piece should be firmly gripped in the three jaw chuck.
2. Hand gloves and apron must be used while working.
3. Proper rpm should be selected before the operation.