NIT JAMSHEDPUR

 DEPARTMENT OF PRODUCTION & INDUSTRIAL ENGINEERING

Machine Shop Manual

COURSE OBJECTIVES:

1. To impart practical and working knowledge of Machine Tools like Lathe and its operations.
2. To develop machining skills with appropriate selection of tools.

COURSE CONTENT:

Preparation of model(Job) on lathe involving Plain turning, ,Step turning, Facing, Drilling
operations.

COURSE OUTCOMES:

Upon completion of this course, students should be able to:

CO1 Demonstrate practical and working knowledge of Machine Tools like Lathe and its operations.
CO2 Demonstrate machining skills with appropriate selection of tools.
 CONTENTS
Sl.No Particulars PageNo.

1 Machine shop 1-9

2 Lathe 10-19

3 Model no.1 -
 MACHINE SHOP
Introduction to Machine shop:

In our workshop, A place where hand tools and power-driven tools like machine
tools are used for making, finishing, or repairing machines or machine parts,or in other
words a facility that has machines and machine tools for working with metal, composites,
polymers, etc.

Introduction to Machinig:

The machining is the broadest technological process used in manufacturing.

Generally, in the field of manufacturing, the term of Machining means removal of material
from a raw material, by cutting small chips, in order to obtain the desired shape and
dimensions for final part. The machining is strictly necessary when finished Part has to have
very tight tolerances of Dimensions or when the roughness of surfaces Need to be very
smooth.
Machining Types

Non Traditional
Traditional Machining Machining

Cutting with Cutting with Non Machining by the

Conventional Tools Conventional Tools following Process
Lathe machining eg.
Slotting / Shaping

Electro/Chemical
turning and facing

Laser Beam

Ultrasonic
Water Jet
Grinding

Honning

Lapping
Drilling

Erosion
Milling

Fig.1 Synoptically Classification

Machine Tool:

 Machine tool is a non-portable power driven device in which the energy is utilized to
produce jobs of desired shape and size and surface finish by removing excess material from
the formed blanks in the form of chips with the help of cutting tools .

 It is machining equipment that cuts, shears, punches, presses, drills, rolls, grinds, or
forms metal, plastic, or wood stock. It may be automatic or semi-automatic.
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 Machine tools are generally power- driven. Metal cutting or forming machines used to shape
metals by:

 The removal of chips

 Pressing drawing or shearing
 Controlled electrical machining process

Any machine tool has generally has capability of:-

 Holding and supporting the work piece

 Holding and supporting a cutting tool
 Imparting a suitable movement (rotating or reciprocating) to the cutting tool or the
work
 Feeding the cutting tool so that the desired cutting action and accuracy will be
achieved

Classification
of
Machine Tools

Machine Tools Machine Tools for Prismatic

For Revolution parts Parts

 Lathes  Milling Machines

 Turning Machining Centers  Machining Centers for Drilling/Milling
 Round Grinding Machines  Planar Grinding Machines

Cutting Tool:

A tool is a device or a piece of equipment which typically provides a mechanical

advantage in accomplishing a physical task, or provides an ability that is not naturally
available to the user of a tool. These tools are hand-held, portable powers, or manual tools.

Tool Materials:

The various tool materials used in today's manufacturing operations are high-carbon steel, high-speed
steel, cemented carbides, ceramics, diamond & cubic boron nitride (CBN).

Types of Tool Materials:

 High Carbon steels  High Speed Steels  Cemented Carbides

 Medium Alloy steels  Abrasives  Diamonds

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 Types of cutting tools:

a)Single Point Cutting Tool:

The tool generally refers to a non-rotary cutting tool used in metal lathes, shapers,
and planers. Such cutters are also often referred to by the set-phrase name of single-point
cutting tool. The cutting edge is ground to suit a particular machining operation and may be
resharpened or reshaped as needed. The ground tool bit is held rigidly by a tool holder while
it is cutting. Single-point tools are used in turning, shaping and planning operations and
similar operations to remove material by means of one cutting edge.
Cutting tools must be made of a material harder than the material which is to be cut,
and the tool must be able to withstand the heat generated in the metal-cutting process. Also,
the tool must have a specific geometry, with clearance angles designed so that the cutting
edge can contact the work piece without the rest of the tool dragging on the work piece
surface. The angle of the cutting face is also important, as is the flute width, number of flutes
or teeth, and margin size. In order to have a long working life, all of the above must be
optimized, plus the speeds and feeds at which the tool is run.

Fig.2 Showing parts &important angles cut on single point cutting tool

Single point cutting tool terms and definitions:

(1) Shank: The shank is the main body of the tool.

(2) Nose: The nose is the part of the cutter bit which is shaped to produce the cutting edges.
(3) Face: The face of the cutter bit is the surface at the upper side of the cutting edge on
which the chip strikes as it is separated from the workpiece.
(4) Side: The side of the cutter bit is the near-vertical surface which, with the end of the bit,
forms the profile of the bit. The side is the leading surface of the cutter bit used when
cutting stock.
(5) Base: The base is the bottom surface of the shank of the cutter bit.
(6) End: The end of the cutter bit is the near-vertical surface which, with the side of the bit,
forms the profile of the bit. The end is the trailing surface of the cutter bit when cutting.

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(7) Heel: The heel is the portion of the cutter bit base immediatelybelow& supporting the
face.

Important angles of a Single Point Cutting Tool:

Angle Details

It is also called as Top Rake Angle. It is the slope given to the face or
Back Rake
the surface of the tool. This slope is given from the nose along the
Angle
length of the tool.

It is the slope given to the face or top of the tool. This slope is given
Side Rake
from the nose along the width of the tool. The rake angles help easy
Angle
flow of chips

These are the slopes ground downwards from the cutting edges.
Relief These are two clearance angles namely, side clearance angle and end
Angle clearance angle. This is given in a tool to avoid rubbing of the job on
the tool.

There are two cutting edge angles namely side cutting edge angle and
Cutting Edge end cutting edge angle. Side cutting edge angle is the angle, the side
Angle cutting edge makes with the axis of the tool. End cutting edge angle
is the angle, the end cutting edge makes with the width of the tool.

It is also called cutting angle. It is the angle between the face and end
Lip Angle
surface of the tool.

Nose Angle It is the angle between the side cutting edge and end cutting edge.

Tool Signature

Fig.3 Tool Signature of Single Point Cutting Tool

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Shapes of Tool Bits:

The overall shape of the lathe tool bits can be rounded, squared, or another shape as
long as the proper angles are included. Tool bits are identified by the function they perform,
such as turning or facing. They can also be identified as roughing tools or finishing tools.
Generally, a roughing tool has a radius ground onto the nose of the tool bit that is smaller
than the radius for a finishing or general purpose tool bit. Experienced machinists have
found the following shapes to be useful for different lathe operations.A right-hand turning
tool bit is shaped to be fed from right to left.
The right-hand facing tool bit is intended for facing on right hand side shoulders and
the right end of a work piece. The cutting edge is on the left-hand side of the bit and the nose
is ground very sharp for machining into a square corner. The direction of feed for this tool
bit should be away from the center axis of the work, not going into the center axis. A left-
hand facing tool bit is the opposite of the right-hand facing tool bit and is intend to machine
and face the left sides of shoulders.

Fig. 3 Left – Hand & Right-hand Cutting tools

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Multi Point Cutting Tool:

Fig.4 Multipoint cutting tools

In multi point cutting tool the multiple edges are used to remove the material. Multi
point cutting tools are used in Milling, drilling, reamers, slotting tool, wood ruff cutter, etc.
most important thing to remember is the cutting tools must be made of a material harder than
the material which is to be cut, and the tool must be able to withstand the heat generated in
the metal-cutting process. Grinding tools are also multipoint tools. Each grain of abrasive
functions as a microscopic single-point cutting edge

Fig.5 Twist drill eg. Of multipoint cutting tool

Fig. 6 Milling cutter and Grinding wheel eg. Of multipoint cutting tools
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 Type Of Cutting;
ORTHOGANAL CUTTING (Two Dimensional Cutting)

Fig.6 Orthogonal Cutting

OBLIQUE CUTTING (Three Dimensional Cutting)

Fig.7 Oblique Cutting

Orthogonal Metal Cutting Oblique Metal Cutting

Cutting edge of the tool is perpendicular The cutting edge is inclined at an angle less
to the direction of tool travel. than 90o to the direction of tool travel.
The direction of chip flow is The chip flows on the tool face making an
perpendicular to the cutting edge. angle.
The chip coils in a tight flat spiral The chip flows sideways in a long curl.
For same feed and depth of cut the force The cutting force acts on larger area and so
which shears the metal acts on a smaller tool life is more.
area. So the life of the tool is less.
Produces sharp corners. Produces a chamfer at the end of the cut
Smaller length of cutting edge is in For the same depth of cut greater length of
contact with the work. cutting edge is in contact with the work.
Generally parting off in lathe, broaching This method of cutting is used in almost all
and slotting operations are done in this machining operations.
method.
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Cutting Fluids:-

Cutting fluids are used in metal machining for a variety of reasons such as improving tool
life, reducing work piece thermal deformation, improving surface finish and flushing away
chips from the cutting zone.

Types of cutting fluids:

Practically all cutting fluids presently in use fall into one of the four categories:

1. Cutting Oils
a. Straight oils
b. Compounded
2. Water Base Cutting Fluids
a. Soluble oils
b. Chemical (Synthetic) fluids
c. Semi- Chemical (Semi-Synthetic) fluids
3. Gases
4. Paste & Solid Lubricants

Functions of cutting fluids:

1. Reduce friction between tool & material
2. Reduce temperature of cutting zone
3. Wash away chips
4. Improve surface finish
5. Reduce power required
6. Increase tool life
7. Prevent welding of chip to tool
8. Prevent corrosion

Desired Properties of Cutting Fluids:

1. Harmless to the operator
2. Harmless to the machine
3. Good heat transfer characteristics
4. Non-Volatile
5. Non-forming
6. Good lubricating properties
7. Inexpensive

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 2. LATHE
Introduction
A lathe is a machine tool which spins a block of material to perform various
operations such as cutting, sanding, knurling, drilling, etc. or deformation with tools that
comes in contact with the work piece to create an object which has symmetry about an axis
of rotation. Lathes are used in woodturning, metalworking, metal spinning, and in glass
working. Lathes can be used to shape pottery as well. Ornamental lathes can produce three-
dimensional solids of incredible complexity. Machine shop personnel must be thoroughly
familiar with the lathe and its operations to perform various tasks.

Principal of Operations

The lathe is a machine tool used principally for shaping articles of metal (and
sometimes wood or other materials) by causing the work piece to be held and rotated by the
lathe while a tool bit is advanced into the work causing the cutting action. The basic lathe
that was designed to cut cylindrical metal stock has been developed further to produce screw
threads, tapered work, drilled holes, knurled surfaces, etc. The typical lathe provides a
variety of rotating speeds and a means to manually and automatically move the cutting tool
into the work piece.

Fig.8 Lathe
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Lathe and its Parts:
Headstock Contains the spindle in two preloaded ball bearings

The spindle is inside the headstock and is driven with a belt running from
the motor pulley to a pulley on the rear end of the spindle shaft. The nose
Spindle of the spindle is treaded on the outside to receive chucks and tapered on
the inside to receive other accessories.

A 3-jaw or 4-jaw chuck threads onto the spindle nose to hold your work,
Chucks a drill chuck are used on the tailstock to center drill your part.

Tool Post Attaches to the lathe table and holds a 1/4" square cutting tool

Cross Slide Also sometimes spelled "cross slide," it is the table with two T-slots that
Table holds the tool post.

A tapered plastic wedge that is held in place by a gib lock. It fits between
the angled surfaces of the dovetail and is used to adjust for wear. As wear
Cross Slide occurs and the table develops "slop," the lock is loosened and the gib is
Gib pushed further into the gap, taking up any play. This allows the machine
to always be kept in peak adjustment.

Tail Stock Has a #0 Morse internal taper for holding chucks and other tools. A hand
spindle wheel moves it in and out for drilling

Tail Stock Locks the tailstock in place on the bed to keep it from moving.
Locking Screw When loosened, the tailstock can be slid up and down the bed.

The dovetailed steel bar that the saddle and tailstock are moved back and
Bed forth on.

The part that supports the cross slide table and is moved up and down the
Saddle bed using the lead screw hand wheel.

Functions like the cross slide gib to keep the saddle in tight adjustment
Saddle Gib against the dovetailed bed.

The threaded screw under the bed that controls movement of the saddle.
Lead Screw A "saddle nut" underneath attaches the bed to the leadscrew. Turning the
lead screw hand wheel moves the saddle down the bed.

A brass part attached to the base of the tailstock that runs on one of the
Tail Stock Gib bed dovetails. The brass part is expected to wear rather than the more
expensive bed and can be adjusted for tightness as it wears.

Lathe Base The cast metal base upon which the lathe bed and headstock sit.

Goes through the hole in the spindle to draw chucks and other accessories
Drawbolt into the headstock taper inside the spindle. A special washer locates it on
center in the spindle hole.
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 The tailstock drill chuck normally has a #0 Morse arbor threaded into the
#1 Morse back of it for use in the tailstock spindle. That arbor can be removed and
Arbor replaced with the #1 Morse arbor so the drill chuck can be used in the
headstock.

#1 and #0 Morse arbors have a 60° point and are used to locate and hold
work "between centers" on the lathe. The #1 Morse arbor rotates with the
headstock, but because the tailstock spindle does not rotate, the rear #0
Dead Centers Morse arbor is called a "dead" center. This needs to be kept lubricated
because it creates friction with the moving part it is locating. Most
machinists eventually replace this with a "live" center that turns on a ball
bearing.

Round steel bars used to tighten and loosen chucks and other spindle
Tommy Bars accessories. Sometimes called "Spindle Bars."

A cast plate that threads onto the spindle nose. A work piece can be
Faceplate bolted to it as an alternative to using a chuck. It has three slots to drive a
drive dog.

Also called a "Lathe Dog," this part is attached to a piece of bar stock by
means of a screw that goes through the side and the long point is placed
into one of the slots in the faceplate. The part is located between the lathe
Drive Dog centers (live or dead) and when the faceplate turns, the dog actually
drives the piece to rotate it for cutting. It also acts as a universal joint
when turning a part between centers when the headstock is rotated to a
slight angle, allowing a tapered part to be cut.

Holds the headstock in place. The screw is a pointed set screw. The point
Head Stock engages a tapered groove in the pin that sticks up out of the lathe bed.
Locking Screw When the screw is tightened, it pulls the headstock down onto the
alignment key and holds it tight against the lathe bed.

A precision ground key that fits in slots in the top of the bed and bottom
Alignment Key of the headstock to keep the headstock aligned straight with the tailstock.
Removing this key and rotating the headstock allows tapers to be cut.

A Kevlar-reinforced Urethane belt that drives the spindle by means of the

V-belt pulleys.

The motor turns a maximum of about 6000 RPM. Putting the drive belt in
the normal (rear) position gears the motor down about 2:1 for a maximum
2-Position speed of about 2800 RPM. The "High Torque" position (closest to the
Pulley headstock) gears it about 4:1 for lower speed but more torque when
needed for heavy cuts.

Variable Speed Controls motor speed from 0 to 2800 RPM

Control Knob
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 Lathe Dimensions Or specification.

Lathe size is determined by the swing and length of bed. Swing indicates the largest
diameter that can be turned over the ways (flat or v-shaped bearing surface that aligns and
guides moveable parts of machines). Bed length is entire length of the ways. Bed length
must not be mistaken for the maximum length of the work that can be turned between
centers.
The longest piece that can be turned is equal to the length of the bed minus the
distance taken up by the headstock and tailstock.
When comparing the size and working capacities of metal lathes there are several key
dimensions to consider:

Fig.9

Dimensions of Lathe

Swing over bed:

The diameter of the largest workpiece that can be rotatedon the spindle without
hitting the bed. This is the first ofthe two numbers used to describe the size of a
metallathe.

Distance between Centers:

The longest piece of work that can be held between acenter in the headstock and a
center in the tailstock. (Seeglossary below for more information). This is the
secondof the two numbers used to describe the lathe size.

Swing over the Carriage:

The diameter of the largest workpiece that can rotate overthe carriage without hitting
it. On the 9x lathes this isabout 5"

Diameter of Spindle through hole:

The diameter of the hole that passes through the spindle.On the 9x lathes (or any
lathe having a #3 Morse Taperspindle) it is about 3/4". When facing relatively long
stock,the free end of the stock can pass through the spindle if itis no larger than the
through-hole diameter.

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 Types of Lathes:
1. Engine Lathe
The most common form of lathe, motor driven and comes in large variety of sizes
and shapes.
2. Bench Lathe
A bench top model usually of low power used to make precision machine small work
pieces.
3. Tracer Lathe
A lathe that has the ability to follow a template to copy a shape or contour.
4. Automatic Lathe
A lathe in which the work piece is automatically fed and removed without use of an
operator. Cutting operations are automatically controlled by a sequencer of some
form.
5. Turret Lathe
Lathes which have multiple tools mounted on turret either attached to the tailstock or
the cross-slide, which allows for quick changes in tooling and cutting operations.
6. Computer Controlled Lathe(CNC LATHE)
Highly automated lathes,where cutting, loading, tool changing, and part unloading
are automatically controlled by computer coding.

Machining Parameters:
Cutting Speed:
The speed in surface feet per minute or meters per minute at which the metal may be
machined efficiently

Lathe Cutting Speed:

It may be defined as the rate at which a point on the work circumferences travels past
the cutting tool. When work is machined in a lathe, it must be turned at a specific
number of revolutions per minute(r/mint), depending on its diameter, to achieve the
proper cutting speed.
Cutting speed is always expressed in feet per minute (ft/mint) or in meters per
minute (m/mint).

Lathe Feed:
The feed of a lathe may be defined as the distance the cutting tool advances along the
length of work for every revolution of spindle.
Feed of the lathe is dependent on the speed of the lead screw or feed rod. Speed is
controlled by the change gears in the quick – change gear box.

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 Various operations performed on Lathe machine

Turning : Produces straight, conical, curved, or grooved work pieces

Facing : Produces a flat surface at the end of the part
Boring : To enlarge a hole
Drilling : To produce a hole
Cutting off : To cut off a work piece
Threading : To produce threads
Knurling : Produces a regularly shaped roughness
Profiling : To turn cylindrical work pieces with rough and finished cuts
Grooving : To make furrows or channels

Operations on a Lathe:

Turning:

cutting tool is moved parallel to the axis of the

work piece to produce a cylindrical surface by
removing the unwanted material in the form of
chips. Here depth of the cut is given by moving
the tool perpendicular to the lathe axis. F
Fig.10 Plain Turning

Facing:

It is an operation to produce flat surface on the

ends of the work piece.Here the cutting tool is
fed against the rotating work piece perpendicular
to the lathe axis and the depth of the cut is given
by moving the tool parallel to the lathe axis.

Fig.11 Facing operation

Taper Turning :

It is an operation to produce conical surface on the work piece.

Methods for taper turning.

 By swivelling the compound rest

 By offsetting the tail stock
 By taper turning attachment
 By using form tool
Fig.12 Swivelling of Compound Rest

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 F
ig.1
5
Usi
Fig.13 Using Offsettingthe Tail ng
stock For
Fig.14 Using Taper m
Turning Attachment Tool
Thread Cuting:

A thread is a helical groove formed on a cylindrical surface of the work piece. The shape of
the groove will be normally v or shape which are called as vee- thread or squarThread
cutting cannot be done in single pass. It will be carried out in many passes with incremental
depth, till the required thread is formed. A typical thread cutting operation is shown in the
figure. Thread cutting can be performed both on external and internal surfaces.

Fig. Left Hand Tread curring Fig. Right Hand Treaad cutting

Fig.16 Threading Operations

Drilling:

Drilling operation is performed by fixing twist drill bit on the tail stock and advancing the
tool towards the workpiece and making hole to the desired length. Other operations like
Boring, Centre Drilling, Counter Boring, Counter Sinking, Reaming, Tapping, etc can also
be performed using suitable tools

Drilling Borling Reaming

Fig.17 Types of Drilling operations performed on Lathe Machine

Profile Turing:

Profile turning is performed when curve surfaces are

required on the given job. The skills of the operator
plays a very important role as this operation is very
difficult to be performed. Here carriage assembly and
compound rest are simultaneously moved to get the
givenprofile. 16
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.

Parting/Cutting Off/slotting/grooving operation:

This operation is used to cutoff the finished part from

the lengther workpiece or to make groove on the
workpiece. Flat cutting tool is used for this opeartion.

Fig.19 Profile Turning

Forming Operation:

A tool which is in the shape of the impression to be

made on the work piece is fixed to the tool post and is
advanced towards the work piece. This operation saves
time and is costly.
Fig.20 Forming Operation

Knurling Operation:

Knurling is an operation performed on the lathe to

generate serrated surface on the work piece. This is
used to produce a rough surface for griping like the
barrel of the micrometer.
This is done by a special tool called knurling tool.
Which has a set of hardened roller with the desired
serrations.There are 3 different knurling operations such
as diamond, angled and straight. Fig.21 Knurling Operation

Work Holding Devices:

The self-centering chuck (3 – Jaw Chuck)

This is the most convenient and most used method of work
holding. This can take wide range of diameters. When adjusting
jaws move equal amount light cuts should carry out, because the
work may slip in the jaws. In addition, the work should be firmly
round to fix in this chuck. Fig.22Three Jaw Chuck
The independent centering chuck (4 – Jaw Chuck)
Each jaw is individually adjust and moves along its own slot. One
advantage of this four-jaw chuck is that work can be located in the
centre to run true or off centre. One of the most useful applications
of this type is to hold square or rectangular material positioned
either centrally or off centre. Setting time is greatly increased when
compared to three-jaw chuck. However, for highly accurate work,
this is the most suitable method. Fig.23Four Jaw Chuck

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 Fig.24Magnetic Chuck Fig.25Collet Chuck

Fig.26Face Plate &Lathe Dog Fig. 27Mandrels

Fig.28Follower rest Fig.29Steady rest

Other Cutting Tool Holders are:

 Tool holders for the Lathe Carriage:
 Turning tool holder
 Threading tool holder
 Drill tool holder
 Boring tool holder
 Tailstock turret
 A four-tool turret tool holder (it can hold facing, turning, threading or boring tools)

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 INSTRUCTION SHEET

DO’s & DON’TSFOR THE LATHE

DO’s

 Do Become Acquainted with the function of the important parts of lathe

 Do keep your machine properly lubricated
 Do keep machines clean and orderly. A dirty machine is not conducive to good
workmanship.
 Do thoroughly understand & plan the job before starting to work on machine.
 Do keep the cutting tool sharp, dull cutting tools require a longer time to do the same
job and give a poor finish and put the machine under an unwarranted strain.
 Do take as heavy a cut as a machine, work and cutting tool will permit. A series of
light cuts wastes time and make necessary work for the operator.
 Do take interest in your work with responsibility.

DON’TS

 Don’t wear loose fitting shop coats or aprons when operating any machine.
 Don’t ever leave the chuck wrench in the chuck.
 Don’t push any lever or turn any handle on a lathe unless you know what will happen
as a result.
 Don’t wear long ties, finger rings while operating machine.
 Don’t try to run a machine & engage in conversation at the same time. If you must
talk then shut down the machine.
 Don’t be afraid to wear goggles when turning work which produces flying chips.
 Don’t attempt to check the hole when boring, without first covering the boring tool to
guard against arm and hand injuries.
 Don’t put your hand or fingers on any revolving work or toll at any time.
 Don’t go away and leave your machine running. If you must leave then shut down.
 Don’t drop chucks, face or drive plates or lay work or tools on the ways of the lathe
 Don’t offer excuses when you scrap a job. Accept your responsibility and try to do
better the next time.
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THANK YOU