Machine Shop (Job No.
-1)
OBJECTIVE
To prepare a work piece on a center lathe as per drawing.
TOOLS USED
Chuck key, tool post key, turning tool bit, parting off, knurling tool, surface gauge, steel
rule, vernier caliper.
MATERIAL
MS round bar of 25 mm dia. and length 105 mm.
OPERATION TO BE CARRIED OUT
1. Centering 2. Facing 3. Plain turning 4. Step turning
5. Taper turning 6. Knurling 7. Chamfering
THEORY
A Centre lathe is one of the oldest and perhaps most important machine tools ever
developed. The job to be machined is rotated and the cutting tool is moved relative to
the job.
MAIN PARTS OF CENTRE LATHE
Bed: - It is the base or foundation of the lathe. It is a heavy and single piece casting
made to support the working parts of the lathe.
Headstock: -It serves to support the spindle and driving arrangements. The headstock
spindle, a hollow cylindrical shaft supported by bearings, provides a drive from the
motor to the work holding device.
Tailstock: - Tailstock can be locked in any position along the bed. It is also used for
holding and feeding the tools such as drills, reamers, taps etc.
Carriage: - The carriage controls and supports the cutting tool. By the help of this, tool
moves away or towards the headstock. It has five major parts.
1. Saddle: - It is a H-shaped casting fitted over the bed. It moves along the guide
ways.
2. Cross-slide: - It is mounted on the saddle. It carries the compound slide and tool
post, can be moved by power or by hand.
3. Compound rest: - It is mounted on the top of the cross-slide. It is marked in
degrees, used during taper turning to set the tool for angular cuts.
4. Tool post: - It is mounted above the compound rest. The tool is clamped on the
tool post.
5. Apron: - It is attached to the saddle and hangs in front of the bed. It has gears,
levers and clutches for moving the carriage with the lead screw for thread
cutting.
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PROCEDURE
1. Hold the MS bar properly in chuck on lathe machine.
2. Check the position of job. It should be in centre of chuck and check with the help
of surface gauge.
3. Mount the tool bit in the tool post in proper position. It should be tight and tip of
tool bit should coincide with the centre of job.
4. Then by threading with the help of cross slide wheel tilt the tip of tool bit to
reach at the centre of job. This process of metal removing is known as facing.
5. After facing, feed will be given with the help of star wheel. This metal removing
process from surface of job is known as plain turning.
6. Make greater diameter first then turn the position of job in the chuck and do
plain turning up to desired length and diameter as per given dimensions in
drawing. This plain turning of different dia at different length is known as step
turning.
7. Replace the turning tool with knurling tool bit and do knurling same applying
feed as in plain turning applied.
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8. Calculate the angle for compound rest swivel and set the compound rest at that
angle, and feed the tool with the help of compound rest wheel till get the desired
dimensions.
9. Using a parting tool make undercuts for 12 dia or 20 dia.
10. Use a chamfering tool and turn chamfer at the end of the flat portion.
11. Check all the length and diameters turned on them.
PRECAUTIONS
1. Know the basics of operational mechanism very well before operating lathe
machine.
2. Adopt always right tool and right procedure for every operation in machine.
3. Make sure the job and tool bit are mounted well in proper position and tightened
enough before starting machining.
4. Always make large diameter first and smaller one in the last.
5. Never use outside caliper/steel rule/vernier caliper etc in running condition.
6. Threading and knurling should be done on minimum speed along with sufficient
cutting fluid etc.
7. Check tip position of threading tool bit with the help of centre gauge.
RESULTS
The work piece as per drawing is made success fully.
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Carpentry Shop (Job No.-2)
OBJECTIVE: - To make a cross half lap joint.
MATERIAL REQUIRED: - (120mm x 55mm x 22mm) two pieces.
TOOLS AND EQUIPMENT USED
1. Steel rule 2. Try square 3. Marking gauge 4. Rip saw
5. Tenon saw 6. Mortise chisel 7. Mallet 8. Jack plane
9. Wood rasp file
OPERATION TO BE CARRIED OUT
1. Planning 2. Marking 3. Sawing 4. Chiseling 5. Finishing
THEORY:
It is one of the basic shops which form an important part of all manufacturing repair
and training work all sort of carpentry and joining work, pattern making, core box
making cabinet work etc are connected with this shop. Carpentry is the art of working
with wood.
TOOLS USED IN CARPENTRY SHOP
Try Square
Marking Gauge
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Tenon Saw
Dovetail Saw
Firmer Chisel
Mortise Chisel
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PROCEDURE
1. The wooden pieces are made into two halves and are checked for dimensions.
2. One side of pieces is planned with jack planeand for straightness.
3. An adjacent side is planned and checked for square ness with a try square.
4. Marking gauge is set and lines are marked at 40-50 mm to make the thickness
and width according to given figure
5. The excess material is planned to correct size.
6. Using tenon saw, the portions to be removed are cut in both the pieces
7. The excess material in X is chiseled with mortise chisel.
8. The excess material in Y in chiseled to suit X
9. The end of both the pieces is chiseled to exact lengths.
PRECAUTIONS
1. Reaper should be free from moisture
2. Marking is done without parallax error
3. Care should be taken while chiseling
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RESULTS
The cross half lap joint is made success fully.
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Fitting Shop (Job No.-3)
OBJECTIVE
To prepare a metallic T shape in fitting shop.
TOOLS USED
Steel scale, try square, scriber, punch, hand hacksaw, bench vice, file, hammer etc
MATERIAL
Mild steel flat (50 x 50 x 5) mm – 1 piece.
OPERATION TO BE CARRIED OUT
1. Filing 2. Checking flatness and square ness
3. Marking and measuring 4. Punching
5. Sawing 6. Chipping 7. Finishing
THEORY
Bench work and assembly work its own importance in all sorts of engineering work to
complete and finish a job, even in most machined workshop. Although the jobs can be
finished to a fairly good degree of accuracy through machining operations, still they
often require the hand operations to be done on them to finish them to desired
accuracy. In addition, alignment of machine parts, bearings and similar other work call
for a fitter’s work.
TOOLS USED IN FITTING SHOP
1. Vice 7. Hammers
2. Files 8. Chisels
3. Hacksaw 9. Dividers
4. Try Square 10. Taps
5. Surface Plate 11. Scale
6. Punch
File:
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Hacksaw
Try Square
PROCEDURE
1. The burrs in the pieces are removed and the dimensions are checked with a steel
rule.
2. The pieces are clamped one after the other and the outer mating edges are filed
by using rough and smooth files.
3. The flatness, straightness and square ness i.e. right angle between adjacent sides
are checked with help of Try-square.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the T-shape are marked.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw, the unwanted portions are removed.
8. The cut edges are filed by the half round file.
9. The corners of the stepped surfaces are filed by using a square or triangular file
to get the sharp corners.
PRECAUTIONS
1. Care is taken to see that the marking dots are not crossed, which is indicated by
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the half of the punch dots left on the pieces.
2. Apply pressure in forward direction during hack sawing.
3. Don’t rub steel rule on the job.
4. Fix blade in hack saw frame with correct tension.
5. During hack sawing the coolant like water or lubricating oil is to be used.
6. Use precision instruments like vernier calipers and vernier height gauge
carefully.
7. Files are to be cleaned properly after using.
RESULTS
T-shape is made as per the required dimensions.
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Welding Shop (Job No: 4)
OBJECTIVE: - To make a butt joint using the given two M.S. pieces by are welding.
MATERIAL REQUIRED: - Two Mild steel pieces of given size.
TOOLS AND EQUIPMENT USED
1. Welding Machine 2. Connecting cables 3. Electrode holder
4. Ground clamp 5. Electrodes 6. Chipping hammer
7. Welding shield etc. 8. Goggles
THEORY:
Welding is the process of joining similar or dissimilar metals by the application of heat,
with or without application of pressure, with or without filler metal, in such a way that
the joint is equivalent in composition and characteristics of the metals joined. In the
beginning, welding was mainly used for repairing all kinds of worn or damaged parts.
Now, it is extensively used in manufacturing industry, construction industry
(construction of ships, tanks, locomotives and automobiles) and maintenance work,
replacing riveting and bolting, to a greater extent.
WELDING TOOLS AND EQUIPMENT
Arc welding power source
Both direct current (DC) and alternating current (AC) are used for electric arc welding,
each having its particular applications. DC welding supply is usually obtained from
generators driven by electric motor or if no electricity is available by internal
combustion engines. For AC welding supply, transformers are predominantly used for
almost all Arc-welding where mains electricity supply is available. They have to step
down the usual supply voltage (200-400 volts) to the normal open circuit welding
voltage (50-90 volts).
Electrode holder
Electrodes
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An electrode is a rod of a metal or alloy, with or without coatings. An arc is set up
between electrode and work piece. Welding electrodes are classified into following
types-
1. Consumable Electrodes: - Bare electrodes, coated electrodes
2. Non-consumable Electrodes: - Carbon or graphite electrodes, tungsten electrodes
Welding cables
Ground clamp
It is connected to the end of the ground cable and is clamped to the work or welding
table to complete the electric circuit. It should be strong and durable and give a low
resistance connection.
Chipping hammer
A chipping hammer is used for removing slag formation on welds.
Wire brush
A wire brush is used to clean the surface to be weld.
Welding table
It is made of steel plate and pipes. It is used for positioning the parts to be welded
properly.
Face shield
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Goggles
Hand gloves
Protective clothing
ELECTRIC ARC WELDING
Electric arc welding is a welding process where in coalescence is produced by heating
with an arc or arcs, with or without the application of pressure and with or without the
filler materials.
In electric arc welding the arc is struck between an electrode and the work. To strike an
arc, the electrode is brought in contact with the work at the point where the welding is
to be started, after connecting the work to the welding circuit. After a light contact, the
electrode is immediately with drawn to a distance of from 2 to 4 mm from the work.
Only a comparatively low potential difference is required between the electrode and the
work to strike an arc.
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From 40 to 45 V is usually sufficient for D.C. and from 50 to 60 V for A.C. The voltage
falls after the arc is established. A stable arc can be maintained between a metal
electrode and the work metal with a voltage of 15 to 30 V is needed to strike an arc
between non-consumable electrode and the work. The temperature of electric arc
depends upon the type of electrodes between which it is struck. It is about 32000C on
the cathode and about 39000C on the anode for carbon electrodes and 24000C and
26000C respectively for metal electrodes. The temperature may reach 5000 0C to 55000C
in the center of arc.
PROCEDURE
1. The given metallic pieces filled to the desired size.
2. On both pieces beveled in order to have V groove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc.
4. The metallic pieces are connected to terminals of Trans former.
5. Select electrode dia based on thickness of work piece and hold it on the electrode
holder. Select suitable range of current for selected dia.
6. Switch on the power supply and initiates the arc by either striking arc method or
touch and drag method.
7. Take welding to be done before full welding.
8. In full welding process after completion one part before going to second part.
Slag is removed from the weld bed. With the metal wire brush or chipping
hammer.
9. Then the above process will be repeated until to fill the groove with weld bed or
weld metal.
PRECAUTIONS
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
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RESULTS
The single V-butt joint is made by using arc welding process.
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Foundry Shop (Job No.-5)
OBJECT: To make a mould with core and casting.
Materials- Moulding box, pattern, core, moulding sand.
Tools -Moulding tools - shovel, riddle, rammer, strike off bar, vent wire, sprue pin, lifter, slicks, trowels,
gate cutter, bellows etc.
THEORY:
The cavity prepared in the sand for casting a job is called mould. The process of forming mould is called
moulding. A core is that portion of the mould which forms the hollow interior of the casting or hole
through the casting. A core is a mass of dry sand which is prepared separately, backed in an oven and then
placed in the mould. It gives hollow portion in the casting which cannot be readily obtained by the mould
proper. After preparing the mould, the casting is done. Casting consists of introducing the molten metal in
the mould and allowing the metal to solidify.
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PROCEDURE:
1. Place the board and drag upon it in proper position.
2. Fill in the drag with moulding sand and ram it properly.
3. Place the pattern (a gear blank) horizontally in the center of the drag on such that its half portion
is in the sand and the remaining half portion above sand.
4. Place the core in proper position.
5. Cut the gate and place the sprue pin in proper position.
6. Sprinkle the parting sand on the whole surface of the moulding sand in the drag
7. Place the cope and clamp it properly with the drag.
8. Fill in the cope with the moulding sand and ram it properly.
9. Make vent holes in the sand of the cope.
10. Remove sprue pin and then the cope.
11. Remove pattern keeping the core in position.
12. Again clamp the cope with the drag and tight them.
13. Now the mould is ready for casting.
14. Pour the molten metal in the mould through the sprue and let it solidify.
15. When it is cooled, remove the casting.
RESULT
A mould with core for gear blank is made and casted.
PRECAUTIONS:
1. Ram the sand properly.
2. Clamp the cope and drag in proper position.
3. Remove the pattern properly.
4. Finish the mould and gate properly.
5. Pouring should be done very carefully.
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CARPENTRY SHOP(Job No.-7)
OBJECTIVE:- To make a dovetail lap joint.
MATERIAL REQUIRED: - (120mm x 35mm x 22mm) two pieces.
TOOLS AND EQUIPMENT USED
1. Carpenter’s vice 2. Steel Rule 3. Try square 4. Jack plane
5. Scriber 6. Cross cut saw 7. Marking gauge 8. Firmer chisel
9. Mortise chisel 10. Mallet 11. Wood rasp file and smooth file
OPERATION TO BE CARRIED OUT
1. Measuring and Marking 2. Planning 3. Check for square ness
4. Removal of extra material 5. Sawing 6. Chiseling
7. Finishing
PROCEDURE
1. The given reaper is checked for dimensions.
2. They are planed with jack plane and checked for straightness.
3. The two surfaces are checked for square ness with a try square.
4. Marking gauge is set and lines are marked at 30 and 45 mm to mark the thickness and width of
the model respectively.
5. The excess material is first chiseled with firmer chisel and then planned to correct size.
6. The mating dimensions of the parts X and Y are then marked using steel rule and marking
gauge.
7. Using the crosscut saw, the portions to be removed are cut in both the pieces, followed by
chiseling.
8. The ends of both the parts are chiseled to the exact lengths.
9. The fine finishing is given to the parts, if required so that, proper fitting is obtained.
10. The parts are fitted to obtain a slightly tight joint.
PRECAUTIONS
1. Loose cloths are to be avoided.
2. Tools to be placed at their proper placed.
3. Hands should not be placed in front of sharp edged tools.
4. Care should be taken, when thumb is used as a guide in cross cutting and ripping.
5. Handle while chiseling, sawing and planning with care.
RESULTS
Dovetail lap joint is made as per the required dimensions.
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Job Number 8: Fitting Shop
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OBJECTIVE: To prepare a metallic U shape in fitting shop.
TOOLS USED
Steel scale, try square, scriber, punch, hand hacksaw, bench vice, file, hammer etc
MATERIAL
Mild steel flat (50 x 50 x 5) mm – 1 piece.
OPERATION TO BE CARRIED OUT
1. Filing 2. Checking flatness and square ness
3. Marking and measuring 4. Punching
5. Sawing 6. Chipping 7. Finishing
PROCEDURE
1. The burrs in the pieces are removed and the dimensions are checked with a steel rule.
2. The pieces are clamped one after the other and the outer mating edges are filed by using rough
and smooth files.
3. The flatness, straightness and square ness i.e. right angle between adjacent sides are checked
with help of Try-square.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the U-shape are marked.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw, the unwanted portions are removed.
8. The cut edges are filed by the half round file.
9. The corners of the stepped surfaces are filed by using a square or triangular file to get the sharp
corners.
PRECAUTIONS
1. Care is taken to see that the marking dots are not crossed, which is indicated by the half of the
punch dots left on the pieces.
2. Apply pressure in forward direction during hack sawing.
3. Don’t rub steel rule on the job.
4. Fix blade in hack saw frame with correct tension.
5. During hack sawing the coolant like water or lubricating oil is to be used.
6. Use precision instruments like vernier calipers and vernier height gauge carefully.
7. Files are to be cleaned properly after using.
RESULTS
U-shape is made as per the required dimensions.
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50mm
ᵩ=13mm 13mm
18.5mm
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CNC Shop (Job No.-9)
OBJECTIVE
To prepare a work piece on a CNC Machine as per drawing.
TOOLS USED
Chuck key, tool post key, turning tool bit, parting off, computer with installed CNC softare.
OPERATION TO BE CARRIED OUT
1. Centering 2. Facing 3. Plain turning 4. Step turning
5. Taper turning 6. Knurling 7. Chamfering
MATERIAL
Aluminium round bar of 25 mm dia. and length 105 mm.
PROCEDURE
Axes
We are using a 2 axes CNC Lathe Machine so literally there will be 2 axes along which the
movement of the tool will take place.
X Moves the tool vertically
Z Moves the tool horizontally
Sequence Number
N Adress
This is used to identify a certain block, it is always placed at the beginning of the block and could
be referred to as the name of that block.
Preparatory Function
G Adress
This determines how the the tool moves to the programmed target. Here are the commonly used G
adresses during my experience
WORD FUNCTION
G00 Rapid Traverse Movement
G01 Linear Interpolation
G02 Clockwise Circular Interpolation
G03 Counter Clockwise Circular Interpolation
G50 Setting Workpiece Coordinated System
G70 Finishing Cycle
G71 Axial Roughing Cycle
G72 Radial Roughing Cycle
G92 Thread Cutting Cycle
Miscellaneous Function
M Adress
This are programmed to control the machining operation and not for coordinate movement.
WORD FUNCTION
M3 Spindle Clockwise or Start of Program
M4 Spindle Counter Clockwise
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M30 End of Program
Tool Function
T Adress
This is used to select a certain tool for the programmed target.
WORD FUNCTION
T01 Represents Tool Number 1
T02 Represents Tool Number 2
T03 Represents Tool Number 3
T04 Represents Tool Number 4
These tool numbers are mainly based on the availability of the tools in your CNC Lathe Machine's Tool
Turret.
Spindle Function
S Adress
This commands the spindle speed and is measured in revolutions per minute.
WORD FUNCTION
S800 Spindle Speed at 800 RPM (Revolutions Per Minute)
S1000 Spindle Speed at 1000 RPM (Revolutions Per Minute)
S1200 Spindle Speed at 1200 RPM (Revolutions Per Minute)
Precautions
1. Ensure that your safety glasses are rigidly in place every time you are intently observing the
cutting tools.
2. Ensure that you wear applicable footwear such as safety boots at all times.
3. If you have long hair make sure that you keep it covered when you operate the CNC machine.
4. Keep your hands away from any gripping parts during machining processes.
5. Stand at distance of the machine whenever it is operational. You should also notify any other
people near the risk of being too close to it.
6. Whenever you are handling tools, avoid touching the cutting edges.
7. Make sure that you turn the machine off completely and clean it whenever you have finished using
it.
RESULTS
The work piece as per drawing is made successfully.
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We are tasked to give the correct program to display this output.
Here is the code that I made for this figure:
M3
T0303
S1000
G00 X30 Z5
G00 X0 Z5
G01 X0 Z0
G03 X10 Z-4.5 R5
G03 X6 Z-9 R5
G01 X6 Z-11
G02 X11 Z-21 R22
G03 X17 Z-24 R3
G03 X24 Z-26.5 R2.5
G01 X25 Z-26.5
G01 X25 Z-29
G00 X30 Z-29
G00 X30 Z5
M30
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3D Printing Shop
INTRODUCTION
The Printer is designed with ultimate portability and simplicity in mind. The System and software allow
you to print great models with only a few keystrokes, even if you have never used a 3D printer before. The
system uses a nozzle to deposit molten plastic, so printed parts are strong and durable. A method of
manufacturing known as ‘Additive manufacturing’, due to the fact that instead of removing material to
create a part, the process adds material in successive patterns to create the desired shape.
3D printed machine parts are-
1. Pedestale
2. Platform
3. Perfboard
4. Nozzle
5. Extruder guard
6. Filament tube
7. Roller shaft
8. Material filament
9. Pilot lamp
10. Initialize button
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Main areas of use:
Prototyping
Specialized parts – aerospace, military, biomedical engineering, dental
Future applications– medical (body parts), buildings and cars
3D Printing uses software that slices the 3D model into layers (0.01mm thick or less in most cases). Each
layer is then traced onto the build plate by the printer, once the pattern is completed, the build plate is
lowered and the next layer is added on top of the previous one.
Typical manufacturing techniques are known as ‘Subtractive Manufacturing’ because the process is one of
removing material from a preformed block. Processes such as Milling and Cutting are subtractive
manufacturing techniques. This type of process creates a lot of waste since; the material that is cut off
generally cannot be used for anything else and is simply sent out as scrap. 3D Printing eliminates such
waste since the material is placed in the location that it is needed only, the rest will be left out as empty
space.
A stationary tool is feeded closer to their revolving job and metal removes in chips for reducing the
diameter of metal etc.
Types of 3D Printing:
1. FDM – Fused Deposition Modeling
2. SLA – Stereo lithography
3. SLS - Selective laser sintering
Protection
The printer must not be exposed to water or rain, or damage may occur.
Do not shut down the System or pull out the USB cable when loading a digital model, or the model
data may be lost.
When using the ―Extrude‖ function, keep at least 50mm between the nozzle and the platform. If
too close, the nozzle may get blocked.
The printer is designed to work properly at an ambient temperature of between 15°C and 30°C
and humidity of between 20% and 50%. Operating outside these limits may result in low quality
models.
Precautions
The printer can only be used with the power adapters supplied by the product may be damaged,
with a risk of fire.
To avoid burning, or model deformation, do not touch the model, nozzle, or the platform by hand,
or any other part of the body, while the printer is working or immediately after it has finished
printing.
Protective glasses should always be worn when removing support material, especially PLA.
The brown sections of the currently supplied gloves melt at around 200 degrees, therefore please
do not hold the extruder block with the gloves.
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There is a slight smell from ABS when it is being extruded. The smell is, however, not too
unpleasant. A well-ventilated room is recommended by most people to be safe, however when
printing keep the printer away from any draughts as this can affect the the warping of ABS prints.
When ABS is burnt is releases toxic fumes.
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