lecture on workshops in industry rev 1

8/7/2019 LECTURE ON WORKSHOPS IN INDUSTRY REV 1

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ROLE OF WORKSHOPS IN INDUSTRY

INDUSTRY

1



Weather it is a manufacturing

industry or it is a maintenance unitworkshops plays a key role in

improving the productivity of the

industrial organization by way of product manufacture or helping in

maintenance functions.

Machine shop, fabrication shop,

inspection & testing are key sections

of the workshop.2



Main equipments of the workshop section wise aregiven below:

MACHINE SHOPVarious machine tools installed in machine shop are asunder:

Lathe Machines

Shaper Slotter

Milling m/c

Boring m/c

Surface Grinder Universal drilling m/c

Tools & cutter grinder

Lapping m/c

Power Hack saw etc3



INSPECTION SECTION

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LIST OF INSTRUMENTS

VIBRATION / SOUND LEVEL MEASUREMENT

DATAPAC 1500 VIBRATION ANALYSER / BALANCER IRD 308 VIBRATION / SOUND LEVEL METER

TEMPERATURE MEASUREMENT

MIKRON M 90D

WAHL CONTACT TYPER THERMOMETER 1370MX

THERMELTIKS

THICKNESS MEASUREMENT

PANAMETRICS THICKNESS GAUGE 36DL

PULSECHO THICKNESS METER MP 200L

COATMETER

RUBBER THICKNESS METER

LIQUID PENETRANT INSPECTION

DYE PENETRANT

CLEANER

DEVELOPER

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MAGNETIC PARTICLE INSPECTION

MAGNAFLUX Y7 AC / DC (YOKE TYPE)

HARDNESS MEASUREMENT

POLDI HARDNESS TESTER

ECQ OTIP HARDNESS TESTER

SHORE A HARDNESS TESTER

SHORE D HARDNESS TESTER

BEARING INSPECTION / SPEED MEASUREMENT

SHOCK PULSE TESTER T2000

ELECTRONIC STETHOSCOPE ELS-12 WITH AMPLIFIER

ENGINEERING STETHSCOPE

REED TYPE TACHOMETER

ULTRASONIC FLAW DETECTION

ULTRASONIC FLAW DETECTOR USL-48

ULTRASONIC FLAW DETECTOR USM-35

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MISC. INSPECTION INSTRUMENTS: FERRITE CONTENT METER - For Ferrite content measurement

OLYMPUS IPLEX VIDEOSCOPE - For Fibrescopic inspection inside the

MODEL IV 7675 tube, pipelines etc.

GAUSSMETER MODEL 620 - For Residual magnetism measurement

GAUSSMETER MODEL 5080 - For Residual magnetism measurement

AUTO DEGAUSSING SYSTEM - For Demagnetization of magnetized parts

HIGH FREQ UENCY HIGH - For inspection of rubber lined piping & vessels

VOLTAGE SPARK TESTER and wrapped / coated piping

BALANCING MACHINE - Dynamic balancing of pump rotor & impeller,

HD 7000 / HDC 300 (S) Motor rotors, Turbine & compressor

rotors

8



DISCRIPTION OF LATHE

INTRODCUCTION

A lathe is a machine tool used mainly for machiningvarious parts to a required shape and size by Turning. Itis one of the most useful machines in Machine shop

and it can do a variety of operations. The job is held inthe lathe chuck and it rotates on its axis against cuttingtool. The cutting tool moves straight inclined,crosswords and in any desired direction to make the

job as per desire. The lathe is used to carry out various

operations as plain turning, step turning, drilling,boring, tapering, thread cutting , sanding, knurling, etc.to create an object , with symmetry about an axis of rotation.

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A VIEW OF LATHE MACHINE

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MAIN PARTS OF THE LATHE

1. Head Stock 2. Tail stock

3. Carriage 4. Bed

5. Lead Screw 6. Cone pulley

7. Gear Box 8. Motor 9. Tool Post 10. Compound Slide

11. Apron 12. Spindle

13. Stud Gear 14. Count. Gear

15. Top Lever 16. Leg

17. Longitudinal slide 18. Hand Wheel 19. Cross Slide 20. Lead Screw Gear

21. Tumbler Gear 22. Coolant pump

11



TYPES OF LATHE

Central Lathe

Engine Lathe

Tool room Lathe Production Lathe

± Turret Lathe, (b) Capstan Lathe (c) Copying Lathe

Wood working Lathe Special purpose Lathe

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MAIN PARTS OF LATHE

HEAD STOCK

It is located on the left hand side of the lathe. Ithelps in rotating the spindle on which the job is

held either by the chuck or by any other method.The spindle gets drive from the electric motorthrough the step or cone pulley. The spindlerotates the lead screw of the feed shaft through

stud connecting and lead screw gears in anydesired ratio. The lead screw or feed shaft helpsthe carriage to move longitudinally or cross wise

13



TAIL STOCK

It helps in supporting jobs biggest in length

and is also used for drilling holes on lathe. The

parts of the tail stock are.

1. Base 2. Body 3. Barrel

4. Hand wheel 5.Locking nut

6.Lockjng

Lever 7.

Dead

Centre

14



CARRIAGE

Cutting tool is held in the tool post and the carriage moves the toolalong the bed and across the bed. The carriage is made to move itat desired speed with the help of the lead screw or the feed shaftthe following are the parts of the carriage.

1. Tool Post 7. Apron 2. Compound rest 8. Half Nut Lever

3. Swivel Base 9. Chasing dial

4. Saddle 10. Feed change Lever

5. Cross Slide 11. Automatic Feed Lever.

6.Longitudinal slide

15



LATHE BED

The bed of the lathe is made of cast iron on

which this carriage and the tail stock moves. It

is mainly of two types.

1. V. Shape

2. Flat shape

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WORKING OF A LATHE

The power is taken from the motor and istransmitted to step or cone pulley (of the headstock) of the spindle on which the job is held.Tothe spindle is attached stud Gear then the

connecting gears and lastly the lead screw gearor the feed shaft. The power from the spindleis transmitted to lead screw gear and the leadscrew gear rotates the lead screw and the feed

shaft, which is turn moves the carriage (i.e.Cross Slide and longitudinal slides can becontrolled by changing gears as per the desiredratio.

17



LATHE ACCESSORIES

1. Lathe Centre

2. Chucks

3. Face Plate

4. Driving Plate

5. Lathe Carriers

6. Set of change wheels 7. Lathe mandrels

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LATHE ATTACHEMENTS

1. Taper Turning attachment

2. Grinding Attachment

3. Steadies

4. Relieving attachment

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LATHE OPERATIONS

1. Facing 7. Boring

2. Plain Turning 8. Reaming

3. Taper turning 9. Thread cutting (Exand Int.)

4. Step Turning 10. Knurling

5. Eccentric Turning 11. Recessing

6. Drilling

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LATHE OPERATIONS

21



CUTTING TOOL

22



WORK HOLDING DEVICE

THREE JWA CHUCK FOR HOLDING CYLINDRICAL OBJECTS

COLLET CHUCK FOR HOLDING SMALLWORK PIECES

FOUR JAW CHUCK FOR HOLDING

UNEVEN OBJECTS

MAGNETIC CHUCK FOR HOLDING THIN

SHEETS OF FERROUS METALS

23



FORMULAS FOR DIFFERENT LATHE

OPERATIONS

24



SIZE OF THE LATHE

The following points are to be taken in to consideration for thesize and other specifications of lathe.

1. Type of lathe

2. The length of the machine bed

3. The maximum length of work that can be mounted on a lathe 4. The height of the head stock centre from the top of the

machine bed.

5. The maximum diameter of work that can be revolved over thelathe saddle.

6. The max. diameter and which of the work that can berevolved in the gap, if the lathe is provided with a gap bed.

7. H.P. of the motor.

8. Cone pulley drive or geared Head Drive.

9. No. of speeds.

10

.Max. and Min. spindle speeds. 25



SHAPING MACHINE

26



STROKES

CUTTING & RETURN STROKE

There are two strokes of the cutting tool, one is calleda cutting stroke (where in actual cutting by tool takes

place) and the other is called a return stroke or idlestroke (where in cutting took does no work). As thetime of return stroke is simple wasted, hence thearrangement have been made to reduce the time of idle stroke. The mechanism designed for this purpose is

known as Q uick Return Mechanism. In general casesthe cuttings stroke takes 1.5 to double the time of return stroke for each revolution of the crank.

28



In this machine (shaper), the tool has to start

from rest and end in rest before the nextstroke starts. Hence the velocity of the tool is

not constant dressing the stroke, but varies

from zero to maximum or maximum, to zero

every half stroke. The length of the stroke canalso be varied and stroke length depends upon

the position of the crank pin in the crank. The

stroke will be gradually reduced by moving thecrank pin towards the centre of the crank.

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TOOLS:

General patterns of the tools used for shaping are the sameas for turning except that the shank of the tolls should bemore robust to severe shock each time the cutting shuckscommences. The cutting speeds could be the same as thatfor turning/drilling etc.

This machine is generally employed far making flat surfacesbut never the less it can to easily employed for profilecutting and also automatic performing concave and conveysurfaces with some attachments. It has also been used forcutting big glass with the help of dividing attachment.Coolant is not required on shaping machine as the tool is

not performing cutting throughout the working of themachine. The table is provided with slots on the top as wellas on the sides so that the work could be fastened directlyon it. Normally very small/symmetrical jobs are held in amachine vice which is clamped on the table.

30



HYDRAULIC SHAPERS

This is a modern development and one of the

principal advantage is that the cutting speed

from the beginning to the end of cut are

constant. And also the stroke length and its

position relative to the work would be

changed quickly without stopping the

machine. Q uick return motion is alsoemployed in it and the entire operation of the

machine is quiet.

31



DRILLING MACHINES

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INTRODUCTION

Drilling is the operation of making holes in a work piece byemploying an end cutting rotating tool called Drill. The operation of drilling is performed on specifically developed machines called thedrilling machines. Drilling can be done on other machines too but adrilling machine is adopted to perform drilling operations under the

wide range and variable conditions of drilling.A Drilling Machine is a fixed style of drill that may be mounted on astand or bolted to the floor or work bench. A drill Press consists of adrill head ,usually driven by a motor. The head has a set of handles (Usually 3 Nos ) radiating from central hub, that, when turned,move the spindle & chuck vertically parrallel to the axis of column.

The table can be adjusted vertically and is generally moved by rack& pinion.

33



SIZE OF DRILLING MACHINE

The size of drilling machine is measured in

terms of the SWING. Swing is defined as twice

the throat distance, which is the distance from

the center of he spindle to the closest edge of

the pillar.

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PORTABLE DRILL

Portable drilling machines are very smalland handy to take from one place to

another. They are specified according to

their maximum drilling capacity and areused for the jobs which cannot be

transferred on the drilling machine table.

There are both electric and aircompressed driven.

36



BENCH DRILLING MACHINE

This is one of the most common machine which isused in all general mechanical workshops. This ischeap, efficient and covers a fairly good range of

work for drilling. These machines have 4 to 5 spindle speeds and drill can be fed into the workby hand employing rack and pinion arrangement.The main specifications of this machine are.

Spindle speeds.

Range of spindle speeds.

Maximum travel of the spindle.

37



RADIAL DRILLING MACHINES

The main advantage of a radial drilling machine isthat the drilling can be moved over the work toany desired position so that a large number of holes can be drilled in the work with out movingit. In this kind of machine, the heavy casting canbe kept on the base and drilled without locationthe proper position of the holes. The drilling headof this machine is mounted on the arm whichtakes round a fixed column and along which the

head traverses. In some of the sophisticatedmachines the drilling head can be rotated in andthe axis of the arm and so the drilling can bedone at any angle of the work piece.

39



MULTISPINDLE MACHINES

A multiple spindle machine can perform anumber of operations on a component withoutthe necessity of change tools or removing thecomponent from the tool. A component is passedspindle to spindle for desired operations. Each

spindle would be set to run at the correct speedfor the required operations. Multi spindleattachments are also fixed on the main spindle of the machine where a number of holes in large

batches are required. It is a mass productionprocess. This type of attachment is much used inthe air and automobile industries..Multi spindlemachines generally use a table feed.

40



AUTOMATIC DRILLING MACHINES

These machines are production

machines and multiple holes can be

drilled at one setting of the job atvarious angles as well. The main cost

on such machines is of tool setting

and is economical only for very largequantities.

41



DRILLS AND REAMERSSTUB DRILLS FOR LESS WALK / GREATER

RIGIDITY

CENTER DRILL ESTABLISHES HOLE

POSITION WITH NO WALK

REAMERS FOR FINISH OF HOLES COUNTERSINK FOR SCREW HEADS &

DEBURRING HOLE

43



MILLING MACHINE

44



INTRODUCTION

A milling machine is a power driven

machine tool which cuts metal bymulti-tooth rotating cutter. Theconstruction of a milling machine is

such that the work is fed to a rotarycutter, instead of revolving as on alathe.

45



MILLING MACHINE OPERATIONS

Milling machines may be manually operated,mechanically automated, or, digitally controlledvia COMPUTER NUMERICALLY CONTROLLED ,

which are in short are called CNC machines A great variety of operations may be performed

on a milling machine. Such as, cutting square,Hexagon, Triangular shapes cutting T- slots, Key

ways, Planning, Surfacing, Cutting different typesof gears In fact, it can cut and almost all the jobsexcept cylindrical.

47



ATTACHMENTS

1. Vertical milling attachment.

2. Slotting attachment.

3. Rock tooth spacing attachment.

4. Circular milling attachment.

5. Index centers consisting of index head and tailstock. Comprise the most important attachmentfor the milling machine.

6. Raising block.

7. Tilting table.

48



TYPES OF MILLING CUTTERS

1. Plain milling cutters

2. Helical cutters

3. Half side cutter

4. Side cutters

5. staggers tooth side cutters6. Inter-Locking side cutters

7. Insertion tooth cutters

8. Slitting and Slotting Cutters.

9. Woodruff key seat cutters

10. Angular cutters11. End Mills.

12. Form cutter

49



MILL BITS

SQUARE END-MILLS ARE WORKHORSEBITS BALL END MILLS MAKE POCKETS ORSPHERICAL POCKETS

COUNTER-ROUNDERS FORM ROUNDED

CORNERS

THIS DEVICE HOLDS A LATHELIKE TOOL BIT

TO BECOME A FLY CUTTER

50



FEED & CUTTING SPEED

FEED

The feed of a milling machine is the movement of the table in advancing the work against cutter.

CUTTING SPEED = X D X RPM12

Where D stands for Dia. of cutter.

The cutting speed of a milling cutter is the speedin ft. per minute of the cutting edge as it peels off its cheep.

51



DIVIDING HEADAn important use of the milling machine is for cutting slots grooves,teeth etc. Which are to be special round the circumference of acylinder or disc. Milling of this nature necessitates the assistance of some means of holding the work, and rotating it the correct amountfor each groove a slot' to be out. The degree of accuracy to which thespacing must be made is important, as much of the work concerned isessentially of a precision character i.e. gear teeth splined shafts, cutter

shaft and demands the highest grade of workmanship for its success.To adopt the milling machine for such purpose, a dividing load is used.This is used to divide the periphery of work accurately into any numberof equal distance, and to hold the work in the required position whilethe cuts are being made. The most essential parts of the index headare the worm and worm wheel index parts, sector arms, change gears.The worm wheel has 40 teeth and the worm has a single thread. Theworm wheel is keyed both spindle, and when the worm, which isturned by the index crank, is turned 40 times, the spindle is revolvedonce. Fractional parts of a turn are obtained by means of the indexplates which are furnished with each head.

52



TYPES OF INDEXING

1. Direct indexing.

2. Simple indexing.

3. Compound indexing.4. Differential indexing

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DIRECT INDEXING :

This is the simplest of the four methods.

The dividing head has a circulars plate

attached to the main spindle. This platehas a circle of 24 equally placed hole

struck behind it.

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SIMPLE INDEXING

Simple indexing is achieved using index

plates which the main spindle rotated by

turning the index crank.

55



COMPOUND INDEXING

When a number of division is

required which is outside the range

of the secures by simple indexing, amethod known as compound

indexing is used.

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DIFFERENTIAL INDEXING

A very useful method of indexing, and

one by which almost any number of

divisions can be obtained, is known asDIFFERENTIAL INDEXING.

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PARTS OF MILLING MACHINE

1. Base

2. Column

3. Knee

4. Over arm

5. Supporting bracket

6. Arbor

7. Arbor sleeve

8. Table

9. Indexing head

10. Cross feed handle

11. Longitudinal feed handle12. motor

13. Starter

14. Coolant Pump

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THANKS

lecture on workshops in industry rev 1

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