Advance Machine Shop

1. LATHE MACHINE:
A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform various operations such
as cutting, sanding, knurling, drilling, deformation, facing, and turning, with tools that are applied to the
workpiece to create an object with symmetry about that axis.

Figure.1

Parts:

1.1 Bed:
A bed is the main body of the machine. All the main components are bolted on it. It is usually made
of cast iron due to its high compressive strength. It is made by the casting process and is bolted to the floor
space. Its top section consists of bed guideways or 'V' ways which are precision machined and used to guide
and align the other parts of the lathe.

1.2 Guideways:
Guideways take care of the movement of tailstock and carriage on the bed.

1.3 Headstock:
Headstocks are the main body parts that are placed on the left side of the bed. It serves as
a holding device for gear chains, spindles, driving pulleys, etc. The mechanism of the headstock is driven by
an electric motor that rotates the spindle. It is also made of cast iron.

1.4 Spindle:
It is the main part of the lathe which holds and rotates the chuck. It is made from good quality
alloy steel and it is heat treated. Threads, tapers, etc. are made at one end of the spindle to which holding
devices can be attached.

1.5Carriage:
It is located between headstock and tailstock. It is used to hold and move the tool post along the
bed either towards or away from the headstock. It slides on the guideways. It is also made of cast iron.
It has six main parts:
• Saddle
• Cross slide
• Compound Rest
• Compound slide
 • Tool Post
• Apron

1.5.1 Saddle:
It is an 'H' shaped casting mounted on lathe ways, supports the cross slide that provides
movement to the tool post.

1.5.2 Cross Slide:

A cross slide is a part of the carriage that allows the movement of a tool post at a right angle
to the bed guideways during machining. The cross slide is moved by the feed screw.

1.5.3 Compound Rest:

A compound rest is a part that connects the cross slide and the compound slide. The
compound rest is mounted on top of the cross slide. It has a circular base on which the graduations in degrees
are made. Its power is not feed but it is operated by hand. A certain depth of cut can be set by rotating the feed
screw of the compound rest. After setting it as required, the compound slide is solidly locked with the base.

1.5.4 Compound Slide:

A compound slide is attached to the compound rest by the dovetail joint. Compound
slides are used to cut angles or tapers that cannot be cut by rotating the headstock.

1.5.5 Tool Post:

It is bolted to the carriage on top of the compound slide. It is used to hold the tools at the
correct position with rigidity.

1.5.6 Apron:
An apron is situated on the carriage. It consists of all controlling and moving mechanisms of
carriage. The apron is fastened to the saddle with feed mechanisms that provide automatic feed to the
carriage. The apron hand wheel can be rotated to move the carriage by hand along with the bed of the lathe.

1.6 Tailstock:
Tailstock is a casting located on the right side of the bed. Its function is to support the loose end
of the workpiece or a job while machining. It can slide on the bed guideways and can be clamped in any
position.
The tailstock has the following purposes:
1. To support the loose ends of long jobs for carrying out lathe operations.
2. To hold the cutting tools such as drill chucks, drills, reamers, etc.
3. Turning of outer taper by an offsetting method.
1.7 Lead Screw:
It is used for thread cutting. Lead screw is situated at the bottom side of the bed which is
used to move the carriage automatically during thread cutting. It is made from good quality alloy and is made
of acme threads.

Figure.2

➢ Accessories

Chuck:
It is an important tool, which is used to hold and rotate the workpiece. The smallest piece of
workpiece can be hold in a chuck. It has different types of chucks.
1. 3 jaw universal chuck
2. 4 jaw independent chuck
3. Combination chuck
4. Magnetic chuck
5. Collet chuck

Figure.4

Faceplate:
The faceplate is fixed to the lathe spindle and can be job mounted to perform the turning
operation.
 Center:
Center is a part of lathe machine which is used to support long jobs in between headstock and
tailstock to carry out a lathe operation. A center that fits into the headstock spindle and rotates with the
workpiece is called a live center. The center which is used in the tailstock spindle and which does not rotate
is called the dead center.

Steady, follower rests:

Long workpieces often need to be supported in the middle, as cutting tools can push (bend) the work
piece away from where the centers can support them, because cutting metal produces tremendous forces
that tend to vibrate or even bend the workpiece. This extra support can be provided by a steady rest
(also called a steady, a fixed steady, a center rest, or sometimes, confusingly, a center). It stands
stationary from a rigid mounting on the bed, and it supports the workpiece at the rest’s center, typically
with three contact points 120° apart.

Figure.3

➢ Working Principle:
Working Principle: The lathe is a machine tool which holds the workpiece 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.
The cutting tool may also be fed at an angle relative to the axis of work for machining tapers and angles.

Figure.4
➢ Operations:

1. Facing:
It is the first operation that is done on the workpiece. It is a machining operation that is done to
produce flat surfaces at the ends of the workpiece. This operation is performed by feeding the tool
perpendicular to the axis of rotation of the chuck.

2. Turning:
In turning operation, the excess material is removed from the surface of the workpiece to produce
a cylindrical surface of desired shape and size. During the turning operation, the feed is moved along the axis
of rotation of the chuck. It reduces the diameter of the cylindrical workpiece.

3. Boring:
The process of removing material from hole of the workpiece is called boring. Holes are bored with
the help of single point cutting tool.

4. Drilling:
It is the process of making holes in the workpiece by the use of drills. The drill is held in the
tailstock and the drilling operation is done by advancing the drill in the workpiece by rotating the handle of
the tailstock.
5. Reaming:
The process of enlarging the holes to accurate sizes is called reaming. Reaming is always
performed after drilling operation. It is similar to the drilling process. The reamer is held in the tailstock to
carry out reaming operation.

6. Counter Boring:
The process of boring a hole to more than one diameter on the same axis is called
counterboring. This operation is performed by boring tool.

7. Knurling:
It is the process of making indentations (recess or sharp depression) on the border of a workpiece. The
knurling operation is done to provide a better grip to the job. It is performed by the knurling tool. The
knurling tool is pressed against the job to perform the knurling operation.

8. Chamfering:
Chamfering is the process of beveling the extreme ends of a workpiece. It is done in order to
remove the burrs, to protect the end of the workpiece from being damaged and to have a better look.
9. Parting Off:
It is the process of cutting a workpiece after it has been machined to the required shape and
size.

10. Grooving:
The process of creating a narrow slot on the workpiece is called grooving. It is also known as
recessing or necking.

11. Forming:
It is process in which a convex, concave or any irregular surface is formed on the workpiece
with the help of a forming tool. Forming tool having the required shape is used to perform forming
operation.
12. Taper Turning:
It is the process in which a conical shape is produced on the workpiece. During taper
turning the feed is set at an angle to the workpiece.

13. Threading:
The process of making threads on a cylindrical job is called threading.
2. CNC Lathe Machine:

A computer numerical control lathe is a machine that turns material around a central spindle and stationary
cutting tool. It is a stationary cutting tool used primarily for shaping wood and metal, which are referred to as
workpieces. The lathe machine removes unwanted parts of the workpiece to produce the desired product. The
movements of a traditional lathe machine are manually controlled by an operator.

Figure.5

➢ Working Principle:

• 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 sent by MCU. The drive system controls the motion
and velocity of the machine tool.
• The 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.6

➢ Parts:
The main parts of the CNC machine are:

Input Devices:

These are the devices which are used to input the part program in the CNC machine. There are
three commonly used input devices and these are punch tape reader, magnetic tape reader and computer.

Machine Control Unit (MCU):

It is the heart of the CNC machine. It performs all the controlling action of the
CNC machine, the various functions performed by the MCU are

• It reads the coded instructions fed into it.

• It decodes the coded instruction.
• It implements interpolation ( linear, circular and helical ) to generate axis motion commands.
• It feeds the axis motion commands to the amplifier circuits for driving the axis mechanisms.
• It receives the feedback signals of position and speed for each drive axis.
• It implements the auxiliary control functions such as coolant or spindle on/off and tool change.

Machine Tool:

A CNC machine tool always has a slide table and a spindle to control of the position and speed. The machine
table is controlled in X and Y axis direction and the spindle is controlled in the Z axis direction.

Driving System:

The driving system of a CNC machine consists of amplifier circuits, drive motors and ball
lead screw. The MCU feeds the signals (i.e. of position and speed) of each axis to the amplifier circuits. The
control signals are than augmented (increased) to actuate the drive motors. And the actuated drive motors
rotate the ball lead screw to position the machine table.
Feedback System:
This system consists of transducers that act as sensors. It is also called a measuring system.
It contains position and speed transducers that continuously monitor the position and speed of the cutting tool
located at any instant. The MCU receives the signals from these transducers and it uses the difference between
the reference signals and feedback signals to generate the control signals for correcting the position and speed
errors.

(i) Display Unit:

A monitor is used to display the programs, commands and other useful data of CNC
machine.
3. UNIVERSAL MILLING MACHINE:
The milling machines are also known as the multi-tasking machines (MTMs) which are multi-purpose
machines capable of milling and turning the materials as well. The milling machine has got the cutter
installed up on it which helps in removing the material from the surface of the work piece. When the
material gets cooled down then it is removed from the milling machine. It is used to make flat bevel gear
and spiral gears.

Figure.7

Parts:

1. Column & Base:

Column including base is the main casting that supports all other parts of milling
machine.

2. Knee:
It is a casting that supports the saddle and table. All gearing mechanism is enclosed within the
knee.

3. Saddle and Swivel Table:

The saddle is present on the knee and supports the table. It slides on a
horizontal dovetail on the knee and dovetail is parallel to the axis of the spindle.

4. Power Feed Mechanism:

It is the knee which contains the power feed mechanism. It is used to control
the longitudinal, transverse and vertical feeds.

5. Spindle:
It is the shaft that is used to hold and drives the cutting tools of the milling machine.

6. Ram
The overhanging arm in the vertical machine is called ram. One end of the ram is mounted on the top
of the column and on the other end milling head is attached.
 4. Bench Drilling Machine
It is the simplest and most accurate machine, which is used in the production purposes. The workpiece is held
stationary means clamped in position and drill bits rotate to make a hole. It is designed specifically to perform
the operation of drilling and similar operations. Drill bits are also called drills. Like drilling machines, milling
machines, slotting machines, planer machines are also used in production shops to perform various types of
operations.

➢ Parts:

Figure.8

1. Drill Chuck:
Drill chuck plays a very most important role in a drilling machine because it's used as a work
holding device.Basically, drill chuck, hold the straight shank cutting tools. Drill chucks may be three jaws or
four jaws .Keys are used to tighten the chuck's jaw. Alloy steel is used to make drill chuck.
2. Head:
The top part of the drilling machine is called the head, which has a spindle that moves in upward and
downward directions.
3. Table:
The table is used to hold the workpiece or a job and can be adjusted by moving it upward or downward
direction.
4. Column:
It supports the table and head as well as all other mechanisms which are attached to the head.
Because its mechanical properties are of high strength and also hardened.
5. Spindle:
It is used to hold and rotate the drill bits tool. It is fitted with the head of the drilling machine.
6. Drill Base:
It is the most important part of the drilling machine because it carries the whole weight of the
drilling machine. The drill base is very rigid due to being made of cast iron material.
7. Sleeve:
The sleeve is used in a drilling machine for the purpose of fed cutting tools into a workpiece or
a job. Drill sleeve is also used to hold the taper shank drills and that type of taper shank drill whose taper size
is equal to the taper size of the spindle. Sleeves are also called quick assembly.
8. Socket:
When the diameter of the taper shank of a drill is more than the hole of the spindle of the
machine, a special sleeve is used on the drill, which is called a socket.
9. Electric Motor:
The electric motor is used to supply power to the drilling machine.
10. Hand Wheel:
Hand wheel is a very important part of the drilling machine because with the help of this, how
much feed is to be given in a job or workpiece is controlled. The spindle moves in the up and down direction
when the hand wheel is rotated.
5. Tool & Cutting Grinder
A tool and cutter grinder is a machine used for shaping and sharpening a tool or cutter by means of wheels. It
can be operated both hydraulically and electrically.

Figure.9

➢ Parts:

Figure.10

Base:
It is strong heavy and box-type construction that supports all the other parts of the machine.
Saddle:
It is mounted directly on the top of the base which carries the table raised and traverses the table
movement crosswise.
Table:
It rests or moves on the top base mounted on the saddle which reciprocates. It can be swiveled
from a certain angle.
Column:
It is fixed on the back of the machine. It has a wheel head that moves up and down depending
on the depth of the cut.
Wheel Head:
It is mounted on a column on the back of the machine which can be swiveled at a
certain angle. It has two grinding wheels which are fitted on both ends of the spindle.
Tailstocks:
Right, and left tailstocks are placed between the centers to support the mandrel.

➢ Types of Tool and Cutter Grinder

There are the following two types of tools and cutter grinders are used.
• Universal Tool and Cutter Grinders
• Single-Purpose Tool and Cutter Grinders

1. Universal Tool and Cutter Grinders:

Universal tool and cutter grinder can be used for sharpening a
variety of tools and milling cutters. Universal tool and cutter grinders are often used for sharpening reamers,
taps, single-point tools, dies, punches and milling cutters, etc.

2. Single-Purpose Tool and Cutter Grinders:

Single-purpose tools and cutter grinders are used for
grinding tools such as drills, tool bits, etc. in a large production plant where the volume of production is a
high and large number of similar tools need to be ground frequently.

6. Radial Arm Drilling Machine:

Radial Drilling Machine is used to drill the holes in the given radial distance when the component size is larger
in terms of height with respect to the work table. When the component is large, it cannot fit its structure in the
Machine vice. Therefore, the component has to be placed on the ground and the Radial arm of the drilling
machine has to be rotated with respect to the component to do the operation.

Figure.11

➢ Working Principle of Radial Drilling Machine:

 When the power supply is given, the spindle rotates
which was in conjunction with the motor. The Radial arm is adjusted w.r.t the type of operation and height
of the workpiece. The spindle is connected to the chuck and the drill bit is placed in between the jaws of the
chuck. The Drill head is adjusted on to the workpiece and a suitable feed is given. Then the drill bit drives
into the workpiece very easily.

➢ Parts:

1. Base
2. Column
3. Radial Arm
4. Motor for elevating the arm
5. Elevating screw
6. Guideways
7. Motor for driving drill spindle
8. Drill head
9. Drill spindle
10. Table Figure 12

Base:
It is made up of Cast Iron which possesses high compressive strength and good wear resistance. The
base is used to support the assembly of parts on it and also absorbs the vibrations induced by the machine
parts.

Column:
It is exactly placed at one end of a bed which can act as a support for rotating the radial arm in 360
degrees.

Radial Arm:
It is the arm that is connected to the Column. The Drill head is a slide from one end to another
end by the guideways.

Motor:
It is placed on the drill head for driving the work unit.

Table:
The machine vice is connected to a swivel table that can hold the workpiece for further operation.

Flywheel or Hand Wheel:

It is connected to the spindle arrangement which is used to move up and down
with respect to the workpiece.

Drive Head:
It generally consists of two levers which by varying can increase or decrease the speed of
chuck.
Chuck:
One end of the chuck is connected to the spindle arrangement and another end is connected to the
drill bit (tool).

Drill Bit:
The drill bit act as a tool for drill the holes on the specimens.

7. Surface Grinder:

Surface grinding machine is the type of grinding machine which are used to produce a flat surface. The surface
grinding machine is mainly operated by the periphery of the grinding wheel or by the flat face of the grinding
wheel.
These grinding wheels rotate and grind the workpiece or a job to achieve the flatness as per requirement.

Figure.13

➢ Uses of Surface Grinding Machine

It is used to perform the following operations:

1. Grinding flat surfaces.
2. Grinding vertical surfaces.
3. Grinding slots.
4. Grinding angular surfaces.
5. Grinding radius.
6. Cutting off.
➢ Parts:

Figure.14

Base:
It is the most important part of the surface grinding machine which is used to support the entire body of
the machine.

Vertical Column:
A vertical column is the part of the surface grinding machine where the wheel head is
mounted.
Saddle:
It is the frame that keeps the table raised. It is used to provide cross feed to the workpiece. A saddle
can be moved by a cross feed hand wheel.

Table:
It is fitted on the saddle which has 'T' slots for clamping purposes. A table can be moved by hand
traversing the wheel.
Wheel Head:
It is mounted on a column that can be raised or lowered by rotating the hand wheel to allow
workpieces of different heights and the wheel can be set for the depth of cuts.
Grinding Wheel:
It is the most important part of the surface grinding machine which performs different
operations. Most often the following grinding wheels are used:

(a) Straight

(b) Double raised

(c) Thin rubber slotting wheels, etc.

Wheel Guard:
A wheel guard is used for safety purposes which covers the entire grinding wheel.
Coolant:
A lot of heat is generated during the grinding operation, coolant is used to control this heat.
Hand traversing wheel:
This is the wheel that is used to a moving table in the longitudinal direction which
means the table can be moved longitudinal left or right.
Vertical Feed Hand Wheel:
Through this vertical feed hand wheel, the wheel head can be raised or lowered
by which the grinding wheel can be set for the depth of cuts.
Cross Side Hand Wheel:
This is the wheel is used to adjust the table with respect to the grinding wheel so
that the grinding operation can be performed with precision.