1. What is Machine Tools?

Hundreds of varieties of metal machine tools, ranging in size from small machines
mounted on workbenches to huge production machines weighing several hundred tons, are used
in modern industry. They retain the basic characteristics of their 19th- and early 20th-century
ancestors and are still classed as one of the following: (1) turning machines (lathes and boring
mills), (2) shapers and planers, (3) drilling machines, (4) milling machines, (5) grinding machines,
(6) power saws, and (7) presses.

2. What are the different machine tool used in the shop?

2.1 Milling Machine

A milling machine cuts metal as the workpiece is fed

against a rotating cutting tool called a milling cutter. Cutters of
many shapes and sizes are available for a wide variety of milling
operations. Milling machines cut flat surfaces, grooves, shoulders,
inclined surfaces, dovetails, and T-slots. Various form-tooth
cutters are used for cutting concave forms and convex grooves,
for rounding corners, and for cutting gear teeth.
Milling machines are available in a variety of designs that
can be classified as the following: (1) standard knee-and-column
machines, including the horizontal and the vertical types; (2) bed-
type or manufacturing machines; and (3) machines designed for
special milling jobs.

2.2 Grinding Machine

Grinding machines remove small chips from metal

parts that are brought into contact with a
rotating abrasive wheel called a grinding wheel or an
abrasive belt. Grinding is the most accurate of all of the
basic machining processes. Modern grinding machines
grind hard or soft parts to tolerances of plus or minus
0.0001 inch (0.0025 millimeter).
The common types of grinding machines include
the following: (1) plain cylindrical, (2) internal cylindrical,
(3) centerless, (4) surface, (5) off-hand, (6) special, and (7)
abrasive-belt.
 2.3 Engine Lathe

An engine lathe is a type of machinery, shaped

horizontally, and it is often used to cut metal. The metal is
turned, and the machine uses special cutting tools to create
the desired shape. Because of the lathe, it can create various
specific forms and is commonly used to spin sheet metal. Cut
pieces are involved in automobile engines, machine engines,
or any other engine for a motorized vehicle.

2.4 Shaper

Shaper, metal-cutting machine in which the workpiece

is usually held in a vise or similar device that is clamped
to a table and can be manually operated or power driven at
right angles to the path of a chisellike cutting tool with
only one cutting edge held on the end of
a reciprocating ram. A moving table feeds the workpiece
in small, discrete increments at the end of each stroke of
the tool, and a scalloped but essentially flat surface is
generated on the workpiece. The adjustable mounting of
the tool permits the cutting of grooves and the generation
of surfaces at almost any angle to one another.
2.5 Planer

Planing machines perform the same operations as shapers

but can machine longer workpieces. Some planers can
machine parts up to 50 feet long. The workpiece is mounted
on a reciprocating table that moves the workpiece beneath a
cutting tool. This tool, which remains stationary during the
cutting stroke, automatically feeds into the workpiece after
each cutting stroke.
 2.6 Drilling Machine

Drilling machines, also called drill presses, cut holes in metal

with a twist drill. They also use a variety of other cutting tools to
perform the following basic hole-machining operations: (1)
reaming, (2) boring, (3) counterboring, (4) countersinking, and (5)
tapping internal threads with the use of a tapping attachment.

2.7 Broaching machine

Broaching is a machining process that uses a toothed

tool, called a broach, to remove material. There are two
main types of broaching: linear and rotary. In linear
broaching, which is the more common process, the broach
is run linearly against a surface of the workpiece to effect
the cut. Linear broaches are used in a broaching machine,
which is also sometimes shortened to broach. In rotary
broaching, the broach is rotated and pressed into the
workpiece to cut an axisymmetric shape. A rotary broach is
used in a lathe or screw machine. In both processes the cut
is performed in one pass of the broach, which makes it very
efficient.
3. What are the different kinds of mechanical tools?
3.1 Wrenches

Wrenches may seem like an obvious choice

but most people do not understand the need to
invest in high quality wrenches. Using good
quality branded wrenches will not only make
your task easier but also save you a lot of time.
If you have to choose between metric or standard
(US) sizes, I would suggest that you pick metric
size.
 3.2 Ratchets

There are basically three sizes of

ratchets that you must have in your tool box.
The sizes are ¼” (small), ⅜” (medium), and
½” (large). Each of these sizes is
extensively used for various projects. You
will find the set of 3 ratchets in almost all
starter tool sets.

3.3 Sockets

The sockets are also must-have auto

mechanic tools, and they come in 3 common
sizes –shallow, short, and long. Each size has
its own importance when it comes to making
common repairs. If you have to pick between
metric or standard (US) sizes, again choose
metric as in case of wrenches.
3.4Screwdrivers

As a beginner, you may do

away with the Flat and Phillips head
screwdrivers. However, as you gain
experience and start doing complex
repair work, you will need
screwdrivers in an assortment of
lengths and gauges. Some of the
common types of screwdrivers you
must have in your tool box are:
 3.5 Pliers

Pliers are essential tools a

mechanic needs to change hoses,
perform brake repair, and work with
tough connectors. Most of the auto
or non-auto jobs require the
following types of connectors:

3.6 Hammer

A tool box is
incomplete if it does not have a
hammer. It’s really difficult to
define the job of a hammer
because it comes handy in
almost all types of jobs.
Whether you need to knock out
any stuck component or strike
on a nail head, all you need is a
good whack using a strong
hammer and your job is done!
TYPES OF LATHE AND MILLING MACHINE
1. Bench Lathe:

It is a very small lathe and is mounted on a separately prepared bench or cabinet. It is used for
small and precision work since it is very accurate. It is usually provided with all the attachments,
which a larger lathe carries, and is capable of performing almost all the operations which a larger
lathe can do.

2. Speed Lathes:

These lathes may be of bench type or they may have the supporting legs cast and fitted to the bed.
These lathes have most of the attachments which the other types of lathe carry but have no
provision for power feed. They have no gear box, carriage and the lead screw. With the result, the
tool is fed and actuated by hand. Usually the tool is either mounted on a tool post or supported on
a T-shaped support. Such lathes are usually employed for wood turning, polishing, centring and
metal spinning, etc. Thus, they can be considered as merely of a theoretical value so far as the
modern machine shops are concerned. They are named so because of the very high speed at which
the spindle rotates.
3. Engine Lathe:

It is probably the most widely used type of lathe. The name Engine Lathe is a little confusing in
modern practice as all these lathes are now made to have an individual motor drive. However, it
carries a great historical significance that in the very early days of its development it was driven
by a steam engine. From this, it derived the name which is popular even today.

Although it practically resembles a speed lathe in most of its features, but its construction is
relatively more robust. Its headstock is bigger in size and more robust, incorporating suitable
mechanism for providing multiple speeds to the lathe spindle. The headstock spindle may receive
power, from a lathe shaft or an individual motor, through belts. In that case, it will have a cone
pulley with back gears in the headstock to provide different speeds to the spindle. It carries a
combination of gears, instead of the cone pulley and back gears combination, the lathe is known
as geared head lathe and the headstock as all geared head stock.
4. Tool Room Lathe:
It is nothing but the same engine lathe but equipped with some extra attachments to make it suitable
for a relatively more accurate angle of speeds and feeds. The usual attachments provided on a tool
room lathe are taper turning attachment, follower rest, collets, chucks, etc. This lathe is made to
have a comparatively smaller bed length than the usual engine lathe. The most commonly used
lengths are 135 to 180 cm.

5. Capstan and Turret Lathe:

These lathes form as very important and useful group and are vastly used in mass production.
These machines are actually of semi-automatic type and a very wide range of operations can be
performed on them. In operating these machines, a very wide range of operations can be performed
on them. In operating these machines, a very little skill is required of the operator. Whatever skill
is needed of the operator is only in the setting of tools in the turret or capstan head, and once this
setting has been successfully accomplished further operation of these machines is more or less
automatic. They carry special mechanisms for indexing of their tool heads.
6. Automatic Lathe:

These lathes help a long way in enhancing the quality as well as the quantity of production. They
are so designed that all the working and job handling movements of the complete manufacturing
process for a job are done automatically. No participation of the operator is required during the
operation. Another variety of this type of lathes includes the semi-automatic lathes, in which the
mounting and removal of work is done by operator whereas all the operations are performed by
the machine automatically. Automatic lathes are available having single or multi spindles. They
fall in the category of heavy duty, high speed lathes mainly employed in mass production.
MILLING MACHINE
Column
This is the most common milling machine, which has 5 basic components, They are the work table,
saddle, head, knee, and over arm. Considered as the simplest machine type, its cutting device is
vertically suspended to allow drilling of metals. This is typically used when creating car parts
because it is small and handy.

Turret

The turret is also known as the Bridgeport-type and can be repositioned anytime you want making
this machine very functional. Its versatility makes it more practical since a variety of products can
be made in addition to car parts.

C-frame
Because it is sturdier than a turret, this type is popular in industrial settings. It comes with a
hydraulic motor, which makes it very powerful.

Horizontal

This machine runs parallel to the ground. The table from which the object to be worked on is
placed moves sideways while the cutting device goes up and down.

Bed type
The worktable is located on the bed itself, instead of being paced on top, its usual position. The
knee part of the machine is omitted to allow movement in a longitudinal direction.

Planer-style
This machine type is basically the same as the bed mill. However, the planner-style includes cutters
and heads that allow for a wider range of milling actions.

Tracer controlled

This type of machine has the ability to reproduce parts based on a master model. Most of the
industrial sectors, especially the automotive industry, choose this type of machine because it make
production and specialization of machine parts easier. With the vast classifications of milling
machines, you need to choose the one you need according to how you intend to use it. However if
you find it difficult to decide, do not hesitate to seek the help of a specialist who can help you
select the one that will give you maximum benefits.

OPERATIONS DONE IN LATHE AND MILLING MACHINE

Facing:
Facing is used to make a flat surface at the end of the work piece. The work part should be rotating
and the implied feed should be radial. S0 –

Feed for facing operation in lathe machine : Radial feed.

Contour turning:
In this operation of lathe machine the tool is not fed in a straight path . Instead the tool follows a
contour. A contoured form is created in the turned part.
Feed : Contoured feed . Not parallel to the axis of of w/p roatation.

Form turning:
In this method a special shaped tool is used . The tool is inserted radially.

Feed for forming : Radial.

Diagram for lathe machine operation which involves facing, forming and contour turning

turing, forming and contour turning operations on lathe machine

Taper turning:
Like contour turning the tool is not fed parallel to the axis of rotation of the work part. The tool is
fed at an angle. This turning operation gives a conical and taper cylindrical shape.

Feed : radial (in an angle)

Chamfering:
Only the cutting edge is used at the corner of cylindrical shapes which is used for stress relieving
of the workpiece.

Cutoff or Parting:
In parting operation the tool is fed radially and the end part of the workpiece is cut off.

Feed : Radial.

lathe machine operation

Boring:
A single point tool head is fed linearly to the end of the workpiece (on the inside diameter) .

Feed : Linear.

Threading:
A pointed tool is is used at the outside surface of the workpiece with linear feed. Watch this lathe
machine operation youtube video for clear idea.

Drilling:
Drilling and reaming is done by feeding the lathe tool along the axis of the rotating job part.

Knurling:
It is a metal forming method which creates a regular cross hatched pattern. It is not a machining
process. It does not involve any cutting of the metal

MILLING MACHINE
Plain milling:
As the name implies, this operation used to get place surface. In this milling, the cutting tool axis
is parallel to the machining surface or the face of the machining surface. This operation is very
common and done on almost all jobs. This can be carried out on every milling machine.
Milling Machine Operation
End milling:
This operation is also used to get plain surface. In this operation, the cutting tool axis is
perpendicular to the machining surface or the face of the machining surface. It is also used to slot
cutting on the milling axis.
Milling Machine Operation
Gang milling:
As the name is gang, in this milling operation more than one milling cutters are used to machining.
It is a horizontal milling operation, more than one cutter with different shape and sizes are fixed at
the arbor, which cut the desire shape in one pass. This milling operation can save most of time of
milling.
Milling Machine Operation
Straddle milling:
In this operation, two or more parallel vertical surface machined in a single pass. In this milling
the work piece is situated between the two cutters which can machined the surface vertically. The
cutter are fixed on the same arbor and cut the metal in one pass.
Milling Machine Operation
Slotting:

In this operation slots are cut by a cutter on the work piece. The slots are in various shapes like
circular, rectangular etc. and sizes according to the requirement.
Milling Machine Operation
Angular milling:
In this operation, surfaces which are at an angle to the axis of the cutter, is machined by the rotary
cutter.