Air University, Islamabad

Department of Electrical Engineering

Workshop lab final report

GROUP NO. 1

Group Members
Laiba Ahsan (180417)
Fazeen Ahmed (180401)
Hafsa Khizer (180415)
 Main OBJECTIVES:
 MACHINING
 ELECTRICAL
 WOOD WORK
 WELDING
Title : machining
 INTRODUCTION TO MACHINING :
In this part of the workshop we have learnt the use of machines by performing
different operations on an given workpiece with different types of machines.
Before moving to the experiments let us have a brief intro of a machine.

Definition of Machine
• A device consisting of fixed and moving parts
that modifies mechanical energy and transmits it in a more useful form.
• Any device which reduces human effort and makes our works easy.
• It consists on single or a number of mechanisms
Here are a few types of machines which we have studied yet:
 Lathe machine
 Milling machine
 Shaper machine
 Drilling machine

PRECAUSIONARY MEASURES:
Some precautionary measures are required while .
1. Be sure that all machine’s have effective and properly working guards that are
always in place where machine’s are operating.
2. Don’t try to stop the machine with your hand or body.
3. Always see that work and cutting tools on any machine are clamped securely
before starting.
4. Keep the floor clean of metal chips or curls and waste pieces, put them in
container provided for such things.
5. Don’t rest against the machine.
6. Don’t forget to follow HSE Policy
PPE ( Personal Protective Equipment)
1. Coverall 2. Helmet 3. Safety glasses
4. safety shoes 5.safety west, ear plug, ,mask 6. Face shield
EXPERIMENT # 1
INTRODUCTION TO LATHE MACHINE AND USIMG IT TO PERFORM
OPERATIONS ON WORKPIECE.
OBJECTIVE: Practice of parting off material, facing operations, turning
operations, taper turning, chamfering operation, centering & drilling operation with
the help of lathe machine.
APPARATUS:
Lathe Machine. Work Piece. Cutting Tools.

INTRODUCTION TO LATHE MACHINE

Working Principle: The lathe is a machine tool which holds the work piece
between two rigid and strong supports called centers or in a chuck or face plate
which revolves. The cutting tool is rigidly held and supported in a tool post which
is fed against the revolving work. The normal cutting operations are performed
with the cutting tool fed either parallel or at right angles to the axis of the work.
CONSTRUCTION OF LATHE MACHINE
The main parts of the lathe are the bed, headstock, quick changing gear box,
carriage and tailstock.
1. Bed: The bed is a heavy, rugged casting in which are mounted the working parts
of the lathe. It carries the headstock and tail stock for supporting the workpiece and
provides a base for the movement of carriage assembly which carries the tool.
2. Legs: The legs carry the entire load of machine and are firmly secured to floor
by foundation bolts.
3. Headstock: The headstock is clamped on the left hand side of the bed and it
serves as housing for the driving pulleys, back gears, headstock spindle, live centre
and the feed reverse gear. The headstock spindle is a hollow cylindrical shaft that
provides a drive from the motor to work holding devices.
4. Gear Box: The quick-change gear-box is placed below the headstock and
contains a number of different sized gears.
5. Carriage: The carriage is located between the headstock and tailstock and
serves the purpose of supporting, guiding and feeding the tool against the job
during operation. The main parts of carriage are:
6. Tailstock: The tailstock is a movable casting located opposite the headstock on
the ways of the bed. The tailstock can slide along the bed to accommodate different
lengths of workpiece between the centers. A tailstock clamp is provided to lock the
tailstock at any desired position. The tailstock spindle has an internal taper to hold
the dead centre and the tapered shank tools such as reamers and drills.
TYPES OF LATHE MACHINE
A few types of lathe machine are given as:
 CNC (Computer Numeric Control) lathe machine
 GENERAL PURPOSE LATHE MACHINE :
 Bench lathe
 Centre lathe
 SPECIAL PURPOSE LATHE MACHINE :
 Capston and Turrent lathe
 Tool room and Tracer lathe
OPERATIONS OF LATHE MACHINE
Following are the operations of lathe machine:
Facing: Facing is used to make a flat surface at the end of the work piece. The
work part should be rotating and the implied feed should be radial. Feed for facing
operation in lathe machine : Radial feed.
Form turning: In this method a special shaped tool is used . The tool is inserted
radially. Feed for forming : Radial.
Taper turning: Like contour turning the tool is not fed parallel to the axis of
rotation of the work part. The tool is fed at an angle. This turning operation gives
a conical and taper cylindrical shape. Feed : Radial (in an angle)
Counter turning: In this operation of lathe machine the tool is not fed in a straight
path. Instead the tool follows a counter. A countered form is created in the turned
path. Feed: Countered feed
Chamfering: Only the cutting edge is used at the corner of cylindrical shapes
which is used for stress relieving of the work piece.
Cutoff or Parting: In parting operation the tool is fed radially and the end part of the
work piece is cut off. Feed : Radial.
Boring: A single point tool head is fed linearly to the end of the workpiece (on the
inside diameter) . Feed : Linear.
Threading: A pointed tool is is used at the outside surface of the workpiece with
linear feed.
Drilling: Drilling and reaming is done by feeding the lathe tool along the axis of the
rotating job part.
Knurling : It is a metal forming method which creates a regular cross hatched
pattern. It is not a machining process. It does not involve any cutting of the metal.
Grooving: A grooving tool is used to make grooves.

LATHE MACHINE
PROCEDURE:
1. Grip the work piece tightly on the lathe machine.
2. Perform the operations on the work piece mentioned above.
EXPERIMENT #2
PERFORMING OPERATIONS USING SHAPER MACHINE
OBJECTIVE:
Practice of shaping machine to perform shaping operations.
APPARATUS:
 Shaper Machine.
 Work Piece.
 Cutting Tools.

INTRODUCTION TO SHAPER MACHINE:

A shaper is a type of machine tool that uses linear relative motion between the
work piece and a single-point cutting tool to machine a linear toolpath. Its cut is
analogous to that of a lathe, except that it is linear instead of helical. A shaper is
mostly used to machine a flat on a work piece. Horizontal surfaces are machined
by moving the work mounted on the machine table at a cross direction with respect
to the ram movement.

CONSTRUCTION OF SHAPER MACHINE:

The main parts of a shaper machine is base, body (pillar, frame column), cross
rail, ram and tool head(tool post, tool slide, clamper box block).
Base: The base is a heavy cast iron casting which is fixed to the floor. It supports
the body frame and the entire load of machine. The base absorbs and withstands
vibrations and other operations which are likely to be induced during the shaping
operations.
Body (Pillar, Frame, and Column): It is mounted on the base and houses
the drive mechanism compressing the main drives, the gear box and the quick
return mechanism for the ram movement. The top of the body provides guide ways
for the ram and its front provides the guide ways for the cross rail.
Cross rail: The cross rail is mounted on the front of the body frame and can be
moved up and down. The vertical movement of the cross rail permits jobs of
 different heights to be accommodated below the tool. Sliding along the cross rail is
a saddle which carries the work table.
Ram and tool head: The ram is driven back and forth in its slides by the slotted
link mechanism. The back and forth movement of ram is called stroke and it can be
adjusted according to the length of the work piece to be-machined.

TYPES OF SHAPER MACHINE:

Following are the different types of shaper machines.

1. Based on the type of driving mechanism

1. Crank type shaper
2. Geared type shaper
3. Hydraulic type shaper
2. Based on ram travel
1. Horizontal shaper
2. Vertical shaper
3. Based on the table design
1. Standard shaper
2. Universal shaper
4. Based on cutting stroke
1. Push cut type
2. Draw cut type

OPERATIONS OF SHAPER MACHINE:

It includes following operations:
1. Machining Horizontal Surface:
A shaper is mostly used to machine a flat surface on a work piece held in a vise.
After a work is properly held on the table the tool is set in the tool post. The table
is raised till there is clearance of 25 to 30 mm between tool and work piece. Then
the length of stroke is adjusted. Proper cutting speed and feed is adjusted. Then
both roughing and finishing cut are perform on shaper machine.
A vertical cut is made while the end of work piece, squaring up a block or cutting
shoulder. The work is mounted on table and the surface to be machined is carefully
aligned with axis of ram. A side cutting tool is set on the tool post and the position
and length of stroke is adjusted. The vertical slide is set exactly zero position and
the apron is swiveled in a direction away from the surface being cut.
3. Machining Angular Surface:
An angular cut is made at any angle other than a right angle to the horizontal or to
the vertical plane. Work is set on table vertical slide of the tool head is swiveled to
the required angle either towards left or right. Then down feed is given by rotating
the down feed screw. Thus the angular surface being machined

PROCEDURE:
The job is right fully fixed on the machine table.
1. The single point cutting tool held properly in the tool post mounted on Ram.
2. The Ram is obtained by a quick return motion mechanism.
3. The tool cuts the material during forward stroke.
4. The forward and return stroke constitute one operating cycle of the shaper.

CONCLUSION:
In the shaper machine, the cutting tool has a reciprocating motion, and it cuts only
during the forward stroke. Cutting tool repeatedly travels along a line. Work is fed
a small distance each time. Feed of work and line of tool motion are in same plane
but parallel. The shaper machine is easy to use. It is precise and accurate. It also
saves a lot of time, work & energy.
EXPERIMENT # 3
PERFORMING OPERATIONS USING MILLING MACHINE
OBJECTIVE:
Practice of indexing and spur gear cutting using milling machine.
APPARATUS:
Milling Machine. Work Piece. Cutting Tools.

INTRODUCTION TO MILLING MACHINE:

Milling is a cutting operation that removes metal by feeding the work against a
rotating cutter having single or multiple cutting edges. Flat or curved surfaces of
many shapes can be machined by milling with good finish and accuracy. A milling
machine may also be used for drilling, slotting, making a circular profile and gear
cutting by having suitable attachments.
WORKING PRINCIPLE:The work piece is holding on the worktable of the
machine. The table movements control the feed of work piece against the rotating
cutter. The cutter is mounted on a spindle or arbor and revolves at high speed. As
the work piece advances, the cutter teeth remove the metal from the surface of
work piece and the desired shape is produced.
MILLING MACHINE CONSTRUCTION:
The main part of the machine is base, column, knee, saddle, table, overarm, arbor
support and elevating screw.
1) Base;
It gives support and rigidity to the machine and also act as a
reservoir for the cutting fluids.
2) Column:
The column is the main supporting frame mounted vertically on
the base. The column is box shaped, heavily ribbed inside and houses all the
driving mechanism for the spindle and table feed.
 3) Knee:
The knee is the rigid casting mounted on the front face of the
column. The knee moves vertically along the guide ways and this movement
enables to adjust the distances between the cutter and the job mounted on the table.
The adjustment is obtained manually or automatically by operating the elevation
screw provided below the knee.
4) Saddle:
The saddle rests on the knee and constitutes the intermediate
parts between the knee and table. The saddle moves transversely that is cross wise
on guide ways provided on the knee.
5) Table:
The table rests on the guide ways in the saddle and provides
support to the work. The table is made of cast iron. Its top surface is accurately
machined and carries t slots which accommodate the clamping bolt for fixing the
work. The worktable and hence the job fitted on it is given motions in three
directions.
a) Vertical(up and down)
b) Cross(In and out)
c) Longitudinal(back and fourth)

6) Overarm:
The overarm is mounted at the top of the column and is
guided in perfect alignment by the machined surface. The overarm is the support
for the arbor.
7) Arbor support:
The arbor support is fitted to the overarm and can be
clamped at any location on the overarm. Its function is to align and support various
arbors. The arbor is the machine shaft that holds and drives the cutters.
8) Elevating screw:
The upward and downward movement to the knee and
the table is given by the elevating screw that is operated by hand or an automatic
feed.
MILLING OPERATIONS:

1) Plain or slab milling:

The machining of a flat surface which is parallel to
the axis of rotating cutter is called plain milling.

2) Face Miling:
The machining of a flat surface which is at right angle to the axis of rotating cutter
is called face milling.
 3) Angular milling:
The machining of a flat surface at an angle other
than a right angle tp the axis of revolving cutter is called angular milling.

4) Straddle milling:
Simultaneous machining of two parallel vertical
faces of the work pieces by the pair of side milling cutters is called straddle
milling.
 5) Form milling:
Machining of surfaces which are of irregular shape,
the teeth of the form of milling cutter have a shape which corresponds to the
profile of the surface to be produced.

6) Gang milling:
Simultaneous machining of the number of flat horizontal and
vertical surfaces of a work piece using a combination of more than two cutters on a
common arbor is called gang milling.
 MILLING MACHINE

PROCEDURE:
1. Grab the work piece in machine & grip it tight. Perform all the given operations
on the work piece one by one.
2. Observe the operations of indexing and spur cutting.
3. Note the readings
EXPERIMENT # 4
INTRODUCTION TO RADIAL DRILLING MACHINE AND USING IT
TO DRILL HOLES IN THE WORK PIECE
OBJECTIVE:
The objective of this lab was to make us known with the radial drilling machine
and to enable us to use it with confidence for further usage.
APPARATUS: The apparatus used in this experiment is given below:
I. Radial Drilling Machine
II. Workpiece
III. Tools for opening drill chuck and the drill bench.
INTRODUCTION TO DRILLING MACHINE
The drilling machine or drill press is one of the most common and useful machine
employed in industry for producing forming and finishing holes in a workpiece.
The unit essentially consists of:
1. A spindle which turns the tool (called drill) which can be advanced in the
workpiece either automatically or by hand.
2. A work table which holds the workpiece rigidly in position.
Working principle: The rotating edge of the drill exerts a large force on the
workpiece and the hole is generated. The removal of metal in a drilling operation is
by shearing and extrusion.
Working Principle of Drill machine Sensitive Drill Machine/Drill Press

CONSTRUCTION OF DRILLING MACHINE

The machine has only a hand feed mechanism for feeding the tool into the
workpiece. This enables the operator to feel how the drill is cutting and
accordingly he can control the down feed pressure. Sensitive drill presses are
manufactured in bench or floor models, i.e., the base of machine may be mounted
on a bench or floor.
The main operating parts of a sensitive machine/drill press are Base, Column,
Table, and Drill Head.
1. Base: The base is a heavy casting that supports the machine structure; it
provides rigid mounting for the column and stability for the machine. The base is
usually provided with holes and slots which help to Bolt the base to a table or
bench and allow the work-holding device or the workpiece to be fastened to the
base.
2. Column: The column is a vertical post that Column holds the worktable and the
head containing the driving mechanism. The column may be of round or box
section.
3. Table: The table, either rectangular or round. Drill machine/press in shape
supports the workpiece and is carried by the vertical column. The surface of the
table is 90-degree to the column and it can be raised, lowered and swiveled around
it. The table can be clamp/hold the required the workpiece. Slots are provided in
most tables to allow the jigs, fixtures or large workpieces to be securely fixed
directly to the table.
4. Drilling Head: The drilling head, mounted close to the top of the column,
houses the driving arrangement and variable speed pulleys. These units transmit
rotary motion at different speeds to the drill spindle. The hand feed lever is used to
control the vertical movement of the spindle sleeve and the cutting tool.
The system is called the sensitive drilling machine/press as the operator is able to
sense the progress of drill with hand-face.
TYPES OF DRILL MACHINE
A wide variety of drilling machines are available ranging from the simple portable
to highly complex automatic and numerically controlled machines are as follows:
 Portable drilling machine (or) Hand drilling machine.
 Sensitive drilling machine (or) Bench drilling machine.
 Upright drilling machine.
 Radial drilling machine.
 Gang drilling machine.
 Multiple spindle drilling machine.
 Deep hole drilling machine.
OPERATIONS OF DRILLING MACHINE
Following are the operations of lathe machine:
Drilling:
Drilling is the operation of producing a cylindrical hole of required
diameter and depth by removing metal by the rotating edge of a cutting tool
called drill. Drilling is one of the simplest methods of producing a hole.
Reaming:
The size of hole made by drilling may not be accurate and the internal
surface will not be smooth. Reaming is an accurate way of sizing and finishing a
hole which has been previously drilled by a multi point cutting tool known as
reamer.The surface obtained by reaming will be smoother and the size accurate.
Boring:
Boring tool is a tool with only one cutting edge. The tool is held in a
boring bar which has a taper shank to fit into the spindle or a socket. For
perfectly finishing a hole, the job is drilled undersize slightly
Counterboring:
Counterboring is the operation of enlarging the end of the hole
cylindrically. The enlarged hole forms a square shoulder with the original hole.
This is necessary in some cases to accommodate the heads of bolts, studs and
pins
Countersinking:
Countersinking is the operation of making a cone shaped
enlargement at the end of the hole. The included angle of the conical surface may
be in the range of 60° to 90°. It is used to provide recess for a flat headed screw
or a counter sunk rivet fitted into the hole
Spot facing:
Spot facing is the operation of smoothing and squaring the surface
around a hole. It is done to provide proper seating for a nut or the head of a
screw
Tapping:
Tapping is the operation of cutting internal threads by means of a
cutting tool called ‘tap’. Tapping in a drilling machine may be performed by
hand or by power.
Trepanning:
Trepanning is the operation of producing a hole in sheet metal by
removing metal along the circumference of a hollow cutting tool. Trepanning
operation is performed for producing large holes
 Drilling machine
PROCEDURE:
I. First, we fitted the drill bit of our choice in the drill chuck.
II. Then, we fixed our workpiece in the drill bench and leveled the surfaces to get the
most accurate hole possible.
III. Then, we lowered the drill bit and drilled the holes carefully.
CONCLUSION:
We learned how to use a radial drill machine correctly and we drilled holes in the workpiece
according to our needs.
EXPERIMENT#5
INTRODUCTION TO THREADING AND USING TOOLS TO THREAD
THE WORK PIECE
OBJECTIVE:
The objective of this lab is to learn how to thread and learn the different methods
of threading: I. Internal Threading II. External Threading

APPARATUS: The apparatus used in this experiment is given below:

I. Workpiece
II. Threading Tools
III. Bench Vice to hold the tool steady.
IV. Horizontal Level
INTRODUCTION TO THREADING :
Threading is the process of making markings on the workpiece which resemble to
those of a screw and a nut. This process can be done manually or automatically if
the correct instructions are given to the machine. Threading make it easy to
interlock two piece together like screwing a screw in a metal piece will interlock
the threads together, hence giving it larger surface area of contact and increasing
the bond strength between the two pieces.
PROCEDURE:
1. External Threading:
I. First, we measured the major diameter.
II. Then, we set the workpiece in the lathe machine.
III. Then, we added a chamfer to the workpiece to make it easy for us to put the
threading tool on the workpiece.
IV. Then, we turned off the lathe machine and started to turn the threading tool
until it reached the end. And hence we have completed EXTERNAL
THREADING.
2. Internal Threading:
I. First, we set the piece in the machine vice.
II. Then, we drilled holes in the workpiece.
III. Then, we used the internal threading tool and put it in the holes and started to
twist.
IV. Hence, we got INTERNAL THREADING as a result.

CONCLUSION:
We learnt how to thread in two different ways which will aid us in our practical
lives ahead of us.