Machine Shop

Definition

Machine shop is a place where we perform specific jobs with the help of
machines.

 A material removal process in which a sharp cutting tool is used to mechanically cut
away material so that the desired part geometry remains
 Most common application: to shape metal parts
 Machining is the most versatile and accurate of all manufacturing processes in its
capability to produce a diversity of part geometries and geometric features

Types of machines in machine shop

 Lathe Machine
 Milling machine
 Surface grinding machine
 Shaper machine
 Planner machine
 Power Saw
 CNC Lathe machine
 CNC milling machine

Lathe Machine:

Lathe machine is a basic machine which is used in every metal forming industries. It is
combination of many parts which works together to perform a desire function. A lathe
machine is used to machine cylindrical work piece which is 360 degree symmetrical form the
axis of rotation. It used to perform turning, chamfering, boring, facing, internal threading,
shaping, slot cutting etc. on cylindrical work piece.
There are many types of lathe machine but each machine consist some basic part which are
essential for its proper working. These parts are bed, tool post, Chuck, head stock, tail stock,
legs, Gear chain, lead screw, carriage, cross slide, split nut, apron, chip pan, guide ways etc.
These parts work together to obtain desire motion of tool and work piece so it can be
machined.

Figure 4.1

Parts of Lathe Machine:

The lathe consist following parts.

1. Bed

It is the main body of the machine. All main components are bolted on it. It is usually made
by cast iron due to its high compressive strength and high lubrication quality. It is made by
casting process and bolted on floor space.

2. Tool post

It is bolted on the carriage. It is used to hold the tool at correct position. Tool holder mounted
on it.

3. Chuck

Chuck is used to hold the workspace. It is bolted on the spindle which rotates the chuck and
work piece. It is four jaw and three jaw according to the requirement of machine.
4. Head stock

Head stock is the main body parts which are placed at left side of bed. It is serve as holding
device for the gear chain, spindle, driving pulley etc. It is also made by cast iron.

5. Tail stock

Tail stock situated on bed. It is placed at right hand side of the bed. The main function of tail
stock to support the job when required. It is also used to perform drilling operation.

6. Lead screw

Lead screw is situated at the bottom side of bed which is used to move the carriage
automatically during thread cutting.

7. Legs

Legs are used to carry all the loads of the machine. They are bolted on the floor which
prevents vibration.

8. Carriage

It is situated between the head stock and tail stock. It is used to hold and move the tool post
on the bed vertically and horizontally. It slides on the guide ways. Carriage is made by cast
iron.

9. Apron

It is situated on the carriage. It consist all controlling and moving mechanism of carriage.

10. Chips pan

Chips pan is placed lower side of bed. The main function of it to carries all chips removed by
the work piece.

11. Guide ways

Guide ways take care of movement of tail stock and carriage on bed.

12. Speed controller

Speed controller switch is situated on head stock which controls the speed of spindle.
 Figure 4.2

Operations of Lathe Machine:

Turning:

 The process in which diameter of a work piece reduces is called TURNING.

 It also used to give finishing the surface of the rod by the diameter of the rod.
 It can be done by giving feed from tail stock to head stock and by giving depth of cut.

Facing:

 The process which is used to reduce the length of a work piece is called FACING.
 It also used to give finishing along the face.
 It is done by giving feed from forward to backward (cross slide movement).
Step turning:

 The process which is used to remove excess material from the work piece is called
STEP TURNING.
 It is done by giving depth of cut continuously left and right.

Taper turning:

 The process which is used to reduce diameter along length gradually is called TAPER
TURNING.
 It is used to make metal surface inclined at an angle to a fixed length.
 It is done by fixing compound slide on a given angle.

Knurling:

 The process which is used to give straight lines angled lines and curved lines to a work
the piece is called KNURLING.
 It is used to give different patterns on the fixed length of the work piece.
 It is done by knurling tool (having two rollers of opposite pattern) touching it to work the
piece at low speed.

Threading:

 The process which is used to make threads is called THREADING.

 It is used to make threads of required length and depth on a work piece.
 It is done by fixing tool perpendicular to the axis of work piece and by giving automatic
feed at low speed.

Boring:

 The process in which material is removed from the inside of work piece is called
BORING.
 It is used to enlarge the inner diameter of the hole.
 It is done by using a tool called boring bar along the axis of the work piece.
Drilling:

 The process which is used to make a cylindrical hole in the work piece is called
DRILLING.
 It is done by a tool drill bit fixed it on the tail stock revolving against the revolution of
work piece.

Reaming:

 The process which is used to finish already drilled holes in the work piece is called
REAMING.
 It is also used to enlarge the drilled hole of the work piece.
 It is done by using a tool called reamer fixing it on the tail stock like drilling but at low
speed.

Types of Lathes

Engine lathe

 Not production lathe, found in school shops, toolrooms, and job shops
 Primarily for single piece or short runs
 Manually operated

Figure 4.3

Turret lathe

• Used when many duplicate parts required .Equipped with multisided toolpost (turret) to
which several different cutting tools mounted
 • Employed in given sequence

Figure 4.4

Speed Lathe

This types of lathe machines are simple in construction. It has a bed, headstock, tailstock and
tool post mounted on the adjustable slide. There is no feed box lead screw or carriage.

The tool is mounted on the adjustable slide and is fed into the work purely by hand control.
This characteristic of the lathe machines has the speed ranges from 1200 to 3600 rpm. The
headstock construction is very simple and has only 2 or 3 spindle speed available.

Figure 4.5

Wood Lathe:

A wood lathe is a machine used to form a piece of wood into a desired shape,
whether it be bowl, spindle, vase or a variety of other useful and/or decorative wood items. A
piece of wood is attached to a spinning arm and various tools are used to shape the piece of
wood as it spins.

Figure 4.6
Accessories of Lathe Machine

Chuck

A Chuck is a specialised type of clamp used to hold rotating tools or materials.

Collet

A collet is a sleeve with a (normally) cylindrical inside and a conical outside. The collet
has kerf cuts along its length to allow it to expand and contract. Depending on a particular collet's
design, it can be either pulled (via a threaded section at the rear of the collet) or pushed (via a
threaded cap with a second taper) into a matching conical socket to achieve the clamping action.
As the collet is forced into the tapered socket, the collet will contract, gripping the contents of the
inner cylinder. Collets are most commonly found on milling machines, lathes, wood routers, and
precision grinders. There are many different systems, common examples being the ER, 5C, and
R8 systems. Collets can also be obtained to fit Morse or Brown and Sharpe taper sockets.
Typically collets offer higher levels of precision and accuracy than self-centering chucks, and
have a shorter setting up time than independent-jaw chucks. The penalty is that most collets can
only accommodate a single size of workpiece. An exception is the ER collet which typically has a
working range of 1 mm (about 0.04 inches). Collets usually are made to hold cylindrical work,
but are available to hold square, hexagonal or octagonal work pieces. While most collets are
hardened, "emergency" collets are available that can be machined to special sizes or shapes by the
user. These collets can be obtained in steel, brass, or nylon. Step collets are available that are
machinable to allow holding of short work pieces that are larger than the capacity of normal
collets.

Drill

A drill chuck is a specialized three-jaw chuck, usually with capacity of ≤0.5" (≤13 mm) and
rarely >1" (>25 mm), used to hold drill bits or other rotary tools. The image at right shows an
assembled keyless chuck at the top. The tightening action of this chuck style is performed by
twisting the body using firm hand pressure only. The lower images show the traditional keyed
style of drill chuck with its key. The arbor is shown separately to the right. These chucks require
a key to provide the necessary torque to tighten and loosen the jaws. The rotary action of the key
turns the outer body which acts on an internal screw; this in turn moves the threaded jaws in or
out along a tapered surface. The taper allows the jaws to encompass various sizes of drill shanks.
The end view shows the three small jaws that slide within the body. Some high precision chucks
use ball thrust bearings to reduce friction in the closing mechanism and maximizing drilling
torque. These chucks are sometimes referred to as "super chucks".

Three-jaw

A three-jaw chuck is a rotating clamp which uses three dogs or 'jaws', usually
interconnected via a scroll gear (scroll plate), to hold onto a tool or work piece. Three-jaw chucks
are usually self-centering (as a result of the jaws' meshing with the scroll plate) and are best
suited to grip circular or hexagonal cross sections when very fast, reasonably accurate (±.005"
TIR) centering is desired. Independent-jaw versions can be obtained. The image shows a three-
jaw chuck and key with one jaw removed and inverted showing the teeth that engage in the scroll
plate. The scroll plate is rotated within the chuck body by the key, the scroll engages the teeth on
the underside of the jaws which moves the three jaws in unison, to tighten or release the
workpiece. There are hybrid self-centering chucks that have adjustment screws that can be used
to further improve the concentricity after the workpiece has been gripped by the scroll jaws. This
feature is meant to combine the speed and ease of the scroll plate's self centering with the runout-
eliminating controllability of an independent-jaw chuck. Three-jaw chucks can often be found on
lathes and indexing heads.

Four-jaw

A four-jaw chuck is similar to a three-jaw chuck, but with four jaws, each of which can
be moved independently. This makes them ideal for (a) gripping non-circular cross sections and
(b) gripping circular cross sections with extreme precision (when the last few hundredths of a
millimeter [or thousandths of an inch] of run out must be manually eliminated). The non-self-
centering action of the independent jaws makes centering highly controllable (for an experienced
user), but at the expense of speed and ease. Four-jaw chucks are almost never used for tool
holding. Four-jaw chucks can be found on lathes and indexing heads. The image shows a four-
jaw chuck with the jaws independently set. The key is used to adjust each jaw separately.

Multi jaw

For special purposes, and also the holding of fragile materials, chucks are available
with six or eight jaws. These are invariably of the self-centering design, and are built to very high
standards of accuracy. Two jaw chucks are available and can be used with soft jaws (typically an
aluminum alloy) that can be machined to conform to a particular workpiece. Many chucks have
removable jaws, which allows the user to replace them with new jaws, specialized jaws, or soft
jaws.

MILLING MACHINE

Milling machine is one of the most versatile conventional machine tools with a wide range of
metal cutting capability. Many complicated operations such as indexing, gang milling, and
straddle milling etc. can be carried out on a milling machine. Milling machines are among the
most versatile and useful machine tools due to their capabilities to perform a variety of
operations.

They can be broadly classified into the following types:

Horizontal Milling Machine Vertical Milling Machine. Universal milling Machine

Bed type Milling Machines: In bed type machines, the work table is mounted directly on the bed,
which replaces the knee, and can move only longitudinally. These machines have high stiffness
and are used for high production work.

Figure 4.7
Planer Machine
A planer machine is a type of metal working machine that uses linear relative motion
(reciprocation) between the workpiece and a single-point cutting tool to cut the work piece.A
planer is very much similar to a shaper but there are some basic differences. A Planer
Machine is larger and has moving workpiece, whereas in a shaper Machine cutting tool
moves.

Figure 4.8

Working principle of Planer Machine

In a Planer Machine the job is fixed rigidly on the machine table. A single point cutting tool
held properly in the tool post is mounted on the reciprocating ram.
The reciprocating motion of the ram is obtained by a quick return motion mechanism.
Planer Machine
A planer machine is a type of metal working machine that uses linear relative motion
(reciprocation) between the workpiece and a single-point cutting tool to cut the work piece.
A planer is very much similar to a shaper but there are some basic differences. A Planer
Machine is larger and has moving workpiece, whereas in a shaper Machine cutting tool
moves.

SHAPING 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 tool path. The shaper is
a relatively simple machine. It is used fairly often in the tool room or for machining one or two
pieces for prototype work. Tooling is simple, and shapers do not always require operator attention
while cutting. A shaping machine is used to machine flat surface. It can cut grooves, angles and
many other shapes. The Main Function of shaper is to generate a flat surface by combination of
linear movement of cutting tool and work piece. Shaping is where the work piece is fed at right
angles to the cutting motion between successive strokes of the tool. Shaping and planners among
the oldest techniques used and Shapers are where the work piece is fed at right angles to the
cutting motion between successive strokes of the tool. In Planners the work piece is reciprocated
and the tool is fed at right angles to the cutting motion. These processes require skilled operators
and for the most part have been replaced by other processes The horizontal shaper is the most
common type and its principal components are shown below and described as follows:

Parts of Shaper:

Base: It is a heavy and robust cast iron body. The base supports the column or pillar which
supports all the working parts such as ram, work-table, drive mechanism etc.

Column or Pillar: The column is a ribbed casting of cellular construction. The ram slide ways
are provided on the top of the column while the table slide ways are machined on the front. The
crank and slotted link mechanism that drives the ram is contained within the column. The driving
motor, variable speed gear box, levers, handles and other controls of shaper are also contained in
the column. Ram: Ram is a rigidly braced casting and is located on the top of the column. The
ram slides back and forth in dovetail or square ways to transmit power to the cutter. The starting
point and the length of the stroke can be adjusted using stroke positioning mechanism and the
down feed mechanism.

Tool head: It is the device which holds the tool. The tool head slides in a dovetail at the front
of the ram by means of T-bolt sand is fastened to the ram on a circular plate so that it can be
rotated for making angular cuts. It can swivel from 0° to 90° in a vertical plane. The tool head can
be raised or lowered by hand feed for vertical cuts on the work piece by its hand crank for precise
depth adjustments.

Clapper Box: The clapper box is needed because the cutter drags over the work on the return
stroke. The clapper box is hinged so that the cutting too] will not dig in. Often this clapper box is
automatically raised by mechanical, air, or hydraulic action.

Cross Rail: The Cross rail is a heavy casting attached to the column at its front on the vertical
guide ways. It carries the horizontal table slide ways. The cross rail can be raised or lowered by
means of an elevating screw in order to compensate for different thicknesses of work.

Table: It is made of cast iron and has box type construction. It holds and supports the work
during the operation and slides along the cross rail to provide feed to the work. T-slots are
provided on its top and sides for securing the work to it. The table is moved left and right, usually
by hand, to position the work under the cutter when setting up. Then, either by hand or more
often automatically, the table is moved sideways to feed the work under the cutter at the end or
beginning of each stroke.

Saddle: The saddle moves up and down (Y axis), usually manually, to set the rough position of
the depth of cut. Final depth can be set by the hand crank on the tool head.

Tool holders: Tool holders are the same as the ones used on at engine lathe, though often larger
in size. The cutter is sharpened with rake and clearance angles similar to lathe tools though the
angles are smaller because the work surface is usually flat. These cutters are fastened into the tool
holder.

Work holding: Work holding is frequently done in a vise. The vise is specially designed for use
in shapers and has long ways which allow the jaws to open up to 14" or more, therefore quite
large work pieces can be held. The vise may also have a swivel base so that cuts may be made at
an angle. Work that cannot be held in the vise (due to size or shape) is clamped directly to the
shaper table in much the same way as parts are secured on milling machine tables.

Figure 4.9

Surface Grinding Machine

A surface grinder is a machine tool used to provide precision ground surfaces, either to a
critical size or for the surface finish.

The typical precision of a surface grinder depends on the type and usage, however
±0.002 mm (±0.0001 in) should be achievable on most surface grinders.
The machine consists of a table that traverses both longitudinally and across the face of the
wheel. The longitudinal feed is usually powered by hydraulics, as may the cross feed,
however any mixture of hand, electrical or hydraulic may be used depending on the ultimate
usage of the machine (i.e., production, workshop, cost). The grinding wheel rotates in the
spindle head and is also adjustable for height, by any of the methods described previously.
Modern surface grinders are semi-automated, depth of cut and spark-out may be preset as to
the number of passes and, once set up, the machining process requires very little operator
intervention.

Depending on the workpiece material, the work is generally held by the use of a magnetic
chuck. This may be either an electromagnetic chuck, or a manually operated, permanent
magnet type chuck; both types are shown in the first image.

The machine has provision for the application of coolant as well as the extraction of metal
dust (metal and grinding particles).

Types of surface grinders

Horizontal-spindle (peripheral) surface grinders

The periphery (flat edge) of the wheel is in contact with the workpiece, producing the flat
surface. Peripheral grinding is used in high-precision work on simple flat surfaces; tapers or
angled surfaces; slots; flat surfaces next to shoulders; recessed surfaces; and profiles.[1]

Vertical-spindle (wheel-face) grinders

The face of a wheel (cup, cylinder, disc, or segmental wheel) is used on the flat surface.
Wheel-face grinding is often used for fast material removal, but some machines can
accomplish high-precision work. The workpiece is held on a reciprocating table, which can
be varied according to the task, or a rotary-table machine, with continuous or indexed
rotation. Indexing allows loading or unloading one station while grinding operations are
being performed on another.

Disc grinders and double-disc grinders.

Disc grinding is similar to surface grinding, but with a larger contact area between disc and
workpiece. Disc grinders are available in both vertical and horizontal spindle types. Double
disc grinders work both sides of a workpiece simultaneously. Disc grinders are capable of
achieving especially fine tolerances.
 Figure 4.10

PLANER MACHINE

The planer machine is similar to a shaper is a machine. It expected to

produce flat and plane surfaces by a single point cutting tool. The planer machine is very
large compared to a shaper machine. the planer machine is capable of a machining heavy
work-piece, which cannot be fit on a Shaper table

WORKING PRINCIPE OF PLANER MACHINE:

1.In this type of machine cutting tool is held stationary on tool post which is mounted on
cross rail.

2. For the work piece from the metal the table used to reciprocator in horizontal direction

3.The cutting action take place in forward stroke of table and return stroke is idel.

4.The feed is given by the linear moment of tool.

APPLICATION:

1. For large type of flat surfaces this machining is used.

Parts of Planer machine:

1. Bed: This is heavy structure which is made up of cast iron, this is the base of machine. in
this the length of bed is double than table. there are guide ways are provided to support the
table and used as guide also.

2. Table: This is a rectangular shape that used to move over bed by the help of guide ways,
the top of the table has 'T' slot to hold the workpiece.
3. Housing: This is the long in length which is used to support the cross rail, over arm, this is
mounted on the top od bed. it carries the total work by this.

4. Cross-rail: This is to transverse of saddle, this is used to hold tool head, the tool head can
moved by the help of cross-rail.

Figure 4.11

Power Saw

A circular saw is a power-saw using a toothed or abrasive disc or blade to cut different
materials using a rotary motion spinning around an arbor. A hole saw and ring saw also use a
rotary motion but are different from a circular saw. Circular saws may also be loosely used
for the blade itself. .A circular saw is a tool for cutting many materials such as wood,
masonry, plastic, or metal and may be hand-held or mounted to a machine. In woodworking
the term "circular saw" refers specifically to the hand-held type and the table saw and chop
saw are other common forms of circular saws. "Skil saw" has become a generic trademark for
conventional hand-held circular saws. Circular saw blades are specially designed for each
particular material they are intended to cut and in cutting wood are specifically designed for
making rip-cuts, cross-cuts, or a combination of both. Circular saws are commonly powered
by electricity, but may be powered by a gasoline engine or a hydraulic motor which allows it
to be fastened to heavy equipment, eliminating the need for a separate energy source.

Figure 4.12
 CNC Lathe Machine
CNC stands for Computer Numerical Control. When computers are used to control a Numerical
Control (NC) machine tool than the machine is called CNC machine. In other words the use of
computers to control machine tools like lathe, mills, shaper etc is called CNC machine.

Figure 4.13

The cutting operations performed by the CNC is called CNC machining, in CNC machining,
programs are designed or prepared first and then it is fed to the CNC machine. According to the
program, the CNC controls the motion and speed of the machine tools.

How CNC Machine Works

 First the part program is inserted into the MCU of the CNC.
 In MCU all the data process takes place and according to the program prepared, it prepares
all the motion commands and sends it to the driving system.
 The drive system works as the motion commands are send by MCU. Drive system controls
the motion and velocity of the machine tool.
 Feedback system, records the position and velocity measurement of the machine tool and
sends a feedback signal to the MCU.
 In MCU, the feedback signals are compared with the reference signals and if there are errors,
it corrects it and sends new signals to the machine tool for the right operation to happen.
 A display unit is used to see all the commands, programs and other important data. It acts as
the eye of the machine.
 Figure 4.14

CNC Milling Machine

The CNC controller in a CNC milling machine gives signals to the motor of the machine to
move in CNC axes. It is the electronic control that works as the brain of the machine. This
electrical and electronics equipment executes the code given as the input

CNC Milling Machine parts

Frame

Frame lies above the ground or foundation of CNC milling machine. It works as a support
and also damper for the machine vibration. The material of the frame may be Cast Iron or
granite filled welded structure. Barely steel is not used generally as a milling machine frame
because it has some spring properties and very less dampening ability. Though steel is very
stiff, Cast Iron is a better choice. Another innovative idea is using epoxy resins with different
sizes of stones in a welded steel container. Epoxy granite mixture is a good damper and when
it is confined in a steel container the strength is also improved.
Axes

CNC milling machine axes are connected to the frame for providing motion to each direction.
As the machine is computer controlled it is done by the program. It can also be done
manually. A common CNC is called 3 axis CNC. and can move in 3 directions. The
components attached to a CNC axis include motor, different types of ways, table, limit
switches and lead screw. Generally, the axes move in X, Y and Z directions but sometimes
optional 4th Axis is necessary and it is kept in the list of accessory. 5 axes millings are also
seen but not very common. The motor provides the motion to the table and the ways provide
smooth sliding motion. Dovetail ways and linear ways are frequently used in the axes
assembly. Leadscrew provides the linear motion while it is extracting the rotary motion of the
motor.

Table

The table is placed on the top of the saddle. It holds the jobs and also the job holding devices.
A number of T slots are there for holding the workpiece and jigs and fixtures. In CNC milling
operation the table is moved by the motor which gets signals from the program codes.

Spindle

The spindle is the rotating tool holder. The tools are installed in the tapered part of the
spindle. The spindle has different RPMs. From the main transmission speed, the spindle
speed may vary. The spindle speed is set up according to the properties of the material
needed to be machined. Mainly three different types of spindles are seen. These are cartridge
spindles, self-contained spindles, and fabricated spindle.

CNC Controller

The CNC controller in a CNC milling machine gives signals to the motor of the machine to
move in CNC axes. It is the electronic control that works as the brain of the machine. This
electrical and electronics equipment executes the code given as the input.
CNC Milling Machine Accessories

Coolant

The role of coolant in CNC milling machine is vital. It improves tool life and ensures smooth
machining of the work. The different coolant used in CNC milling includes Mist Coolant,
Flood Coolant, Cool Air Gun or Air Blast coolant and Dust Collector. Actually, the dust
collector is not a coolant but it creates the initial condition for the coolant to work. It collects
the chips and clears the surface. Mist coolant is used where the machine is not in a closure
and requires pressure. For the closed condition of the machine flooding coolant is better.

Way Oiler

Like any moving engine or machine CNC milling also needs lubrication. The guideways need
lubrication to allow the smooth motion over the table. The leadscrew is needed to be
lubricated as it is getting engaged with gears and motors and also handing heavy loads. In a
CNC machine, oilers are generally automated. But it can be done manually too. Automated
oilers are good as they ensure timely lubrication.

Powered Drawbar

Drawbars are good if you need to change your tool frequently. If automatic tool changer is
used then drawbars are required. Capture and release of the tool holders from the spindle can
be done by the means of powered drawbars. Drawbars include Impact wrenches, Pull Stud
and Tormach TTS Style. With powered drawbars, you don’t need an operator each time when
you want to loosen the drawbar. It reduces the time required by half.

Enclosure

Enclosures create a cover for the machine. A milling machine is always cutting and throwing
cheaps. It can be very messy. So an enclosure comes in very handy and the chips or the chips
mixed with coolant keeps inside and the production floor remains clean.
4th Axis

As the name implies it gives another movement in a direction different from the direction of
X, Y and Z. It is required in many cases. With this, the operator can hold extra parts on the
table and can do some extra work on the workpiece.

Figure 4.15