TOOL ROOM(TR):

Introduction:-
In a metal and steel factory, the Tool Room is a critical department responsible for the design, manufacturing, maintenance,
and repair of various tools, dies, molds, and fixtures used in the production processes.
FUNCTION OF THE TOOL ROOM:-
• Purpose : The Tool Room serves as the backbone of the manufacturing operation, supporting production by providing
essential tools and equipment. It ensures that all tools are well-maintained and ready for use, thereby optimizing
production efficiency and quality.
• Tool Design and Development: Engineers and tool designers in the Tool Room are responsible for designing new tools
and improving existing ones. This involves using CAD (Computer-Aided Design) software and other advanced tools to
create precise specifications that meet the production requirements.
• Tool Manufacturing: Skilled machinists and technicians in the Tool Room use various machines and equipment, such as
CNC (Computer Numerical Control) machines, milling machines, lathes, grinders, and EDM (Electrical Discharge
Machining) equipment, to manufacture tools, dies, molds, and fixtures. They work with different materials, including
steel, aluminum, and alloys, to create durable and high-precision components.
• Maintenance and Repair: Regular maintenance and timely repair of tools are crucial to minimizing downtime in
production. The Tool Room conducts preventive maintenance and immediate repairs to ensure that tools remain in
optimal condition and perform effectively.
• Quality Assurance: The Tool Room plays a significant role in maintaining product quality by ensuring that all tools and
dies meet strict dimensional and functional specifications. Quality control processes are implemented to verify the
accuracy and reliability of manufactured tools.
• Inventory Management: Efficient inventory management is essential to ensure that the Tool Room has adequate stocks
of spare parts, raw materials, and components needed for tool manufacturing and maintenance activities.
• Training and Skill Development: Continuous training programs are provided to Tool Room personnel to enhance their
skills in machining, tool design, CAD/CAM (Computer-Aided Manufacturing), and new technologies. This ensures that
they remain updated with industry trends and advancements.
• Safety and Compliance: The Tool Room adheres to strict safety protocols to prevent accidents and ensure a safe
working environment for its personnel. It also complies with environmental regulations regarding the disposal of waste
materials and chemicals used in machining processes.
KEY FEATURES OF TOOL ROOM:-
Manual lathe machine:-
cmponents :-Bed: The bed is the base of the lathe, usually made of cast iron. It provides a
stable platform for mounting all the other components.
Headstock: Located at one end of the bed, the headstock contains the main spindle and
gearbox. It provides the rotational power to the workpiece.
Tailstock: Positioned at the opposite end of the headstock on the bed, the tailstock supports
the other end of the workpiece during machining operations. It can be adjusted along the
bed to accommodate different lengths of workpieces.
Carriage: The carriage is mounted on the bed and moves along it longitudinally. It consists of
the saddle (which holds the cutting tools), cross slide (which moves perpendicular to the
axis of the lathe), and compound rest (which allows for angled cuts).
Apron: Attached to the front of the carriage, the apron houses the gears, clutches, and
levers that control the movement of the carriage and feed mechanisms.
Tool Post: Mounted on top of the compound rest, the tool post holds the cutting tools (such
as turning tools, boring bars, etc.) securely in place.
Chuck: The chuck is a device mounted on the spindle in the headstock that holds the
workpiece securely. There are different types of chucks depending on the shape and size of
the workpiece.
Leadscrew: The leadscrew is a long threaded rod that runs along the length of the bed. It
engages with the carriage to provide precise longitudinal movement.
Feed Rod: The feed rod is used to engage the feed mechanism, which controls the rate at
which the cutting tool moves across or along the workpiece.
Handwheel: Handwheels are used to manually operate the carriage and cross slide for
precise positioning of the cutting tool relative to the workpiece.
FEATURES:-
• Bed: Typically made of cast iron, the bed provides a rigid and stable
platform for mounting all the major components of the lathe.
• Headstock: Contains the main spindle, which rotates to hold and drive the
workpiece. The headstock also houses the gears and gear train that provide
different spindle speeds.
• Tailstock: Supports the opposite end of the workpiece and can be adjusted
along the bed to accommodate different lengths of workpieces. It often
includes a quill for drilling operations.
• Carriage: Moves along the length of the bed longitudinally and houses the
saddle, cross slide, and compound rest.
• Saddle: Mounted on the carriage, it holds the cross slide and compound
rest. It moves along the bed to position the cutting tool relative to the
workpiece.
• Cross Slide: Moves perpendicular to the lathe's axis and allows for precise
movement of the cutting tool across the workpiece.
• Compound Rest: Located on the cross slide, it can swivel to allow angled
cuts to be made on the workpiece.
• Tool Post: Holds the cutting tools securely and allows them to be quickly
and accurately positioned for various machining operations.
• Chuck: A device mounted on the spindle in the headstock that grips the
workpiece securely for rotational machining operations. Different types of
chucks are used depending on the workpiece's shape and size.
OPERATIONS IN CNC LATHE MACHINE:-

Facing: Removing material from the end of a workpiece to produce a flat surface.
Turning: Removing material from the outer diameter of a rotating workpiece to
produce a cylindrical shape.
Grooving: Creating grooves on the outer surface of the workpiece.
Parting: Cutting off a portion of the workpiece.
Drilling: Creating holes in the workpiece using a drill bit.
Boring: Enlarging an existing hole in the workpiece.
Threading: Cutting threads into the outer or inner diameter of the workpiece.
Knurling: Creating a patterned texture on the surface of the workpiece.
Taper Turning: Producing a conical shape by gradually decreasing the diameter of the
workpiece.

Chamfering: Creating a beveled edge on the workpiece.

OPERATIONS IN WIRE EDM MACHINE:-
• Cutting:
• Contour Cutting: Wire EDM can cut intricate contours and shapes in the workpiece, allowing for the creation of complex profiles.
• Straight Line Cutting: Simple linear cuts can be made with high precision.
• Slotting:
• Creating slots or grooves in the workpiece. This is particularly useful in tool and die making.
• Drilling:
• Through Holes: Wire EDM can be used to create through holes in the workpiece by cutting along the perimeter of the desired hole.
• Blind Holes: Although less common, certain setups allow for the creation of blind holes.
• Taper Cutting:
• Cutting parts with tapered edges by adjusting the angles of the wire guides. This is useful for creating parts with varying cross-sectional
shapes.
• Profile Cutting:
• Complex Profiles: Cutting complex profiles and geometries with high precision, which is often required in aerospace and medical
industries.
• Multi-Axis Cutting: Advanced Wire EDM machines can perform multi-axis cutting, allowing for the creation of intricate 3D shapes.
• Punch and Die Production:
• Creating precise punches and dies used in various manufacturing processes. Wire EDM is particularly valued for its ability to produce high-
precision tooling components.
• Gear Cutting:
• Manufacturing precise gears with intricate tooth profiles, which are essential for mechanical assemblies.
• Fine Blanking:
• Producing parts with fine blanking, a process that creates smooth edges and high-precision features.
• Mold and Die Components:
• Manufacturing components of molds and dies with detailed features and high accuracy.
• Micro-Machining:
• Creating very small and detailed parts, often used in the electronics and medical device industries.
• Parting Off:
• Cutting off sections of the workpiece, similar to a parting operation in traditional lathe machining.
• Form Cutting:
• Creating specific forms and shapes by following a programmed path. This is often used in creating intricate details on parts.
• Prototyping:
• Producing prototypes of complex parts with high precision before mass production.
• Stacked Cutting:
• Cutting multiple thin sheets of material stacked together simultaneously, which increases productivity and ensures uniformity across parts.
OPERATIONS IN SHAPING MACHINES:-
• Machining Horizontal Surfaces:
The workpiece is mounted on the table and moved horizontally against the cutting tool to produce flat surfaces.
• Machining Vertical Surfaces:
The vertical surfaces are machined by clamping the workpiece vertically and moving it against the cutting tool.
• Machining Angular Surfaces:
Angular surfaces can be machined by tilting the tool head or the workpiece table to the required angle.
• Machining Irregular Surfaces:
Irregular surfaces can be machined using form tools. The tool is shaped to match the required profile of the
workpiece.
• Machining Slots and Keyways:
Slots and keyways are machined by using a tool with the required width. The table is moved horizontally to cut
the slot to the required depth and length.
• Machining Grooves:
Grooves are machined by using a grooving tool. The table is moved horizontally to cut the groove to the required
depth and length.
• Cutting Splines:
Splines can be cut by using a spline cutting tool. The table is moved horizontally to cut the splines to the required
depth and length.
• Machining Contours:
Contours and profiles can be machined by using form tools and by moving the table and tool head to follow the
required contour.
• Cutting External Gear Teeth:
External gear teeth can be cut by using a gear cutting tool. The table is moved horizontally to cut the teeth to the
required depth and profile.
• Cutting Internal Gear Teeth:
Internal gear teeth can be cut by using an internal gear cutting tool. The table is moved horizontally to cut the
teeth to the required depth and profile.
OPERATIONS IN THE CYLINDRICAL GRINDING MACHINES:-
• Outside Diameter (OD) Grinding:
This is the most common type of cylindrical grinding. The workpiece is held between centers or in a chuck and rotated against the
grinding wheel, which removes material from the external surface to achieve the desired diameter.
• Inside Diameter (ID) Grinding:
This operation involves grinding the internal surface of a cylindrical workpiece. The grinding wheel is mounted on a spindle and
inserted into the bore of the workpiece to remove material and achieve the desired internal diameter.
• Plunge Grinding:
Also known as in-feed grinding, this operation involves feeding the grinding wheel into the workpiece at a specific location to
remove material in a single pass. It is used for grinding steps, shoulders, and other features.
• Creep-Feed Grinding:
This is a type of plunge grinding where the depth of cut is significantly deeper, and the workpiece feed rate is much slower. It is
used for removing large amounts of material in a single pass.
• Traverse (or Longitudinal) Grinding:
In this operation, the grinding wheel moves along the length of the workpiece while it rotates. This allows for the entire length of
the workpiece to be ground uniformly.
• Taper Grinding:
This operation involves grinding a conical surface on a cylindrical workpiece. The grinding wheel or the workpiece is tilted to
achieve the required taper angle.
• Profile Grinding:
Used for grinding complex shapes and profiles on the surface of a cylindrical workpiece. The grinding wheel is dressed to the
desired profile and moved across the workpiece to create the shape.
• Form Grinding:
Similar to profile grinding, form grinding involves shaping the grinding wheel to the desired form and then grinding the workpiece
to match that form.
• Centerless Grinding:
Unlike traditional cylindrical grinding, centerless grinding does not use centers to hold the workpiece. Instead, the workpiece is
supported by a work rest blade and driven by a regulating wheel while the grinding wheel removes material. It is used for grinding
small cylindrical parts to precise dimensions.
• Chuck and Collet Grinding:
The workpiece is held in a chuck or collet, and the grinding wheel removes material to achieve the desired dimensions. This
method is often used for small and precision parts.
• End-Face Grinding:
Involves grinding the end face of a cylindrical workpiece. This is often done to ensure that the end face is perpendicular to the axis
of the workpiece.
• Shoulder Grinding: Used for grinding the shoulder of a cylindrical workpiece to achieve a specific dimension and surface finish.
OPERATIONS OF THE SURFACE GRINDING:-
• Surface Grinding:
The primary operation where the grinding wheel is used to produce a smooth and flat surface on the workpiece.
It involves moving the workpiece back and forth under the rotating grinding wheel.
• Cylindrical Grinding:
Although typically associated with cylindrical grinders, some surface grinding machines can perform cylindrical
grinding, which involves grinding the external or internal cylindrical surfaces of a workpiece.
• Form Grinding:
Used to create complex shapes and profiles on the workpiece by using specially shaped grinding wheels. This
operation is commonly used for producing intricate parts and tools.
• Plunge Grinding:
The grinding wheel is fed into the workpiece without moving it horizontally. It is used for grinding slots, notches,
and other features on the surface of the workpiece.
• Creep-Feed Grinding:
A deep grinding process where a large amount of material is removed in a single pass of the grinding wheel. It is
used for machining tough materials and complex shapes.
• Surface Finishing:
A finishing operation to achieve the desired surface texture and smoothness. Fine grit grinding wheels are used to
improve the surface finish and achieve tight tolerances.
• Flat Grinding:
Involves grinding the flat surface of a workpiece to a precise size and surface finish. This is the most common type
of surface grinding.
• Contour Grinding:
Used to grind the contour or profile of a workpiece. Special grinding wheels and techniques are used to achieve
the desired shape.
OPERATIONS IN THE CIRCULAR GRINDING:-
• External Cylindrical Grinding:
• Plunge Grinding: The grinding wheel is fed radially into the workpiece. This is used for parts
with complex profiles.
• Traverse Grinding: The grinding wheel moves along the axis of the workpiece. This is used
for longer, uniform parts.
• Internal Cylindrical Grinding:
• Used for grinding the internal surfaces of a cylindrical workpiece. The grinding wheel is
smaller and fitted inside the workpiece.
• Centerless Grinding:
• The workpiece is held between two rotating wheels: a grinding wheel and a regulating
wheel, which controls the rotation of the workpiece. This operation is used for mass
production and achieving high precision.
• Creep Feed Grinding:
• A deep cut is taken at a slow feed rate. This is used for removing large amounts of material
quickly.
• Form Grinding:
• The grinding wheel is shaped to produce a specific form on the workpiece. This is used for
creating intricate shapes and profiles.
• Surface Grinding:
• The workpiece is held on a rotating chuck, and the grinding wheel is fed horizontally. This is
used for achieving a high degree of flatness and smooth surface finish.
• Thread Grinding:
• Used to produce precision threads on cylindrical parts. The grinding wheel is shaped like a
thread, and the workpiece rotates in synchronization with the wheel.
OPERATIONS IN MILLING MACHINES:-
• 1 Face Milling
• Description: Cutting with the face of the cutting tool to produce a flat surface.
• Application: Used to create flat surfaces or to finish large surfaces.
• 2. End Milling
• Description: Cutting with the end of the cutting tool.
• Application: Used to produce slots, pockets, and complex contours.
• 3. Peripheral Milling (Slab Milling)
• Description: Cutting with the periphery (side) of the cutting tool.
• Application: Used for cutting deep slots, threads, and gear teeth.
• 4. Slotting
• Description: Creating a slot in the workpiece.
• Application: Used to create keyways, grooves, and slots.
• 5. Side Milling
• Description: Cutting with the side of the milling cutter to create a flat vertical surface.
• Application: Used for machining the sides of workpieces and cutting deep slots.
• 6. Straddle Milling
• Description: Using two side milling cutters to machine opposite sides of a workpiece simultaneously.
• Application: Ideal for machining parallel surfaces on workpieces.
• 7. Form Milling
• Description: Using a cutter with a specific shape to produce a corresponding contour on the workpiece.
• Application: Used to create complex shapes such as contours, curves, and intricate details.
• 8. Gang Milling
• Description: Using multiple cutters mounted on the same arbor to machine different surfaces simultaneously.
• Application: Increases productivity by performing multiple operations in one pass.
• 9. Thread Milling
• Description: Using a single or multi-point tool to cut threads in a workpiece.
• Application: Used to produce threads, both internal and external.
• 10. Gear Cutting
• Description: Using specialized cutters to machine gear teeth.
• Application: Essential for manufacturing gears of various sizes and types.
• 11 Profile Milling
• Description: Following a contour or outline on the workpiece.
• Application: Used for creating complex shapes and profiles.
• 12. Chamfer Milling
• Description: Creating a bevel or chamfer on the edge of the workpiece.
• Application: Used to remove sharp edges and prepare workpieces for assembly.
• 13. Drilling
• Description: Creating holes in the workpiece using a rotating drill bit.
• Application: Often performed on milling machines for precision hole placement.
• 14. Boring
• Description: Enlarging an existing hole with a single-point cutting tool.
• Application: Used for creating precise hole diameters and improving hole concentricity.
• 15. Reaming
• Description: Finishing a drilled hole to a precise diameter with a multi-point cutting tool.
• Application: Used to achieve tight tolerances and improve surface finish.
• 16. Tapping
• Description: Cutting internal threads in a pre-drilled hole.
• Application: Commonly used to create threaded holes for fasteners.
• 17. Counterboring
• Description: Enlarging the upper part of a hole to a specific diameter.
• Application: Used to allow the head of a fastener to sit flush with or below the surface.
• 18. Countersinking
• Description: Creating a conical hole to accommodate the head of a countersunk screw.
• Application: Used for fastener installation and improving aesthetics.
• 19. Pocket Milling
• Description: Removing material from a specified pocket or cavity in the workpiece.
• Application: Used for creating pockets, recesses, and complex cavities.
PRODUCTION OVERVIEW:-
BLANKS:- refer to the raw pieces of material that are prepared and ready to be
machined into finished parts. The term "blank" is used to denote that the material has
not yet undergone any significant machining processes but has been cut or shaped to
a preliminary size and shape that makes it ready for further processing

PUNCH:-The tool that strikes the material to create a hole or shape.

EJECTION PINS:- Ejection pins are critical components in various types of machinery,
particularly in the injection molding and die casting industries. They play a vital role in
removing molded parts from the mold after the cooling and solidification process
ADAPTERS:- devices used to connect tools or workpieces to the machine, ensuring
proper alignment, stability, and functionality during the machining process. They help
in optimizing the efficiency and precision of machining operations.

QUALITY CONTROL ROOM:-

1 HEIGHT MICROMETER:-A height micrometer, also known as a height gauge
micrometer or height measuring micrometer, is a precision instrument used to
measure the height of an object or the distance between two points with high
accuracy.
DEPTH GAUGE:- A depth gauge is a precision measuring instrument used to determine
the depth of holes, slots, recesses, and other features in machining and other
technical fields. It ensures accurate and consistent measurements, which are crucial
for maintaining the quality and functionality of machined parts.

VERNIER CALIPER:- A vernier caliper is a precision instrument used for measuring

internal and external dimensions, as well as depths, with high accuracy. It consists of
two scales: a main scale and a sliding vernier scale.

SCREW GAUGE:- A screw gauge, also known as a micrometer screw gauge or simply a
micrometer, is a precision instrument used for measuring small dimensions with high
accuracy. It is widely used in mechanical engineering and machining to measure the
thickness of materials, diameters of small parts, and other fine measurements.
QUALITY CONTROL PROCESS:-
• 1. Design and Specification Review:
• Drawings and Specifications: Review engineering drawings and specifications to understand the
required tolerances, dimensions, and surface finishes.
• Material Requirements: Verify the material specifications to ensure that the correct type and
grade of material are used.
• 2. Inspection Plan Development:
• Inspection Criteria: Define the inspection criteria based on the drawings and specifications.
• Measurement Tools: Choose appropriate measurement tools and gauges, such as micrometers,
calipers, depth gauges, and CMM (Coordinate Measuring Machine) systems.
• Inspection Points: Determine critical inspection points and features that need to be checked
throughout the machining process.
• 3. Incoming Material Inspection:
• Material Verification: Check the material against specifications and certificates of conformity.
• Visual Inspection: Look for visible defects or inconsistencies in the material.
• Dimensional Checks: Measure the material to ensure it meets size and shape requirements.
• 4. Process Monitoring:
• Machine Calibration: Regularly calibrate machines and tools to ensure accuracy.
• Tool Condition: Monitor tool wear and performance. Replace or sharpen tools as needed to
maintain precision.
• Process Parameters: Ensure that machining parameters (speed, feed, depth of cut) are set
correctly and remain consistent.
• 5. In-Process Inspection:
• First Article Inspection (FAI): Perform a detailed inspection of the first part
produced to verify that it meets all specifications.
• Intermittent Checks: Periodically check parts during production to detect and
address deviations early.
• Workpiece Fixtures: Ensure that workpieces are properly fixtured and secured
during machining.
• 6. Final Inspection:
• Dimensional Measurement: Measure finished parts using appropriate gauges and
instruments to ensure they meet specifications.
• Surface Finish Check: Inspect surface finishes for smoothness, texture, and any
defects.
• Functional Testing: Perform any necessary functional tests to ensure that parts
operate correctly in their intended application.
• 7. Documentation and Reporting:
• Inspection Records: Maintain detailed records of inspection results, including
measurements, tool conditions, and any deviations observed.
• Non-Conformance Reports: Document any defects or non-conformances and the
actions taken to correct them.
• Quality Certificates: Provide certificates of compliance or quality assurance as
required by customers or standards.
• 8. Corrective and Preventive Actions:
• Root Cause Analysis: Investigate the root cause of any defects or issues that arise.
• Corrective Actions: Implement corrective actions to address and fix identified
problems.
• Preventive Actions: Develop and apply preventive measures to avoid recurrence of
similar issues in the future.
• 9. Continuous Improvement:
• Feedback Loop: Use feedback from inspections and quality control processes to
make improvements in machining processes and practices.
• Training: Provide ongoing training for operators and inspectors to enhance their
skills and awareness of quality standards.
• Process Optimization: Continuously review and optimize machining processes for
better efficiency and quality.
CONCLUSION:-
The tool room is essential for maintaining the efficiency and precision
of manufacturing operations. It acts as a central location for the
management, upkeep, and customization of tools and equipment used
across various production processes. By ensuring that tools are properly
maintained, calibrated, and repaired, a tool room contributes
significantly to minimizing downtime, improving product quality, and
enhancing overall productivity.A well-organized tool room is
characterized by its systematic approach to tool inventory management,
preventive maintenance schedules, and the use of precision
measurement instruments. Effective tool room operations support not
only the longevity and performance of tools but also the safety and
efficiency of the manufacturing process.Investing in a well-equipped and
efficiently managed tool room is crucial for any manufacturing or
engineering enterprise. It enables seamless production flow, supports
high-quality standards, and ultimately contributes to the success and
competitiveness of the business.