GURU NANAK DEV ENGINEERING

COLLEGE (GNDEC), LUDHIANA

SESSION: 2016-2020

TOPIC: REPORT ON MACHINE SHOP

Submitted To: Submitted By:

………………….. Abhinav
1607197
 Page |1

Acknowledgement

Rail Coach Factory, Kapurthala is considered one of the best manufacturing firms in
entire Asia. The technology used here is considered most advanced. So training at R.C.F
has been a great experience of our life .We are exposed to new and advanced
technology and right kind of industrial training and industrial atmosphere.
I am highly thankful to Mr. R K Sharma (Chief Instructor, Technical Training Centre) to
assist me with their knowledge and continuous help extended by them.
I am further grateful to Mr. R K KHANNA and all the shop superintendents’ workers of
various shops for their knowledge, unforgettable support and professionals’ guidance.
And last but not least I am very thankful to all friends and fellow trainees for intending
their corporation during the completion of the training.
THANKS!
With regards,
ABHINAV
 Page |2

CONTENT
S. No. Topic Page No. Remarks
1. Introduction 3-4
2. Types of coaches manufactured in RCF 5
3. Manufacturing range of RCF 6
4. Objective of six week industrial training 7
5. Objective of RCF 8
6. Technical Training Centre 9
7. Machine Shop 10
8. Layout of Machine Shop 11
9. Lathe Machine 12-22
10. Drilling Machine 22-24
11. Power Hacksaw Machine 24
12. Shaper Machine 25-30
13. Milling Machine 30-33
14. Grinding Machine 33-35
15. Shearing Machine 35-36
 Page |3

INTRODUCTION

Taking into account country’s large population, a proper system of transportation is

inevitable. No doubt that Indian is the result of the country’s Railway is taking care of
this problem.

The demand of more and more passenger trains is the result of the country’s ever
increasing prosperity and population. The decision to set up a Rail Coach Factory at
Kapurthala, Punjab In August 1985 was a timely step towards making good shortfall and
complementing the coach manufacturing capacity of Railway’s other manufacturing
units.

The foundation stone of this factory was laid by the honorable Prime Minister (Late Shri
Rajiv Gandhi) of India on 17th August 1985. It is located 9 km. From Kapurthala, near the
Jalandhar –Firozpur railway line and state highway, near the Hussainpur village.

Land acquisition proceeding was initiated by Punjab govt. and possession of land was
given to railways in March 1986. In spite of difficulties this target was achieve and first
coach was rolled out well within time on 31/03/1988. With the consummate effort of
both executive and workers the factory produced 120 coaches during 1988-89 and
henceforth the factory became self-reliant to turn out coaches with its own
components and subassemblies.

Initially R.C.F was producing the coaches based on design of I.C.F, Madras. In 1991-92
R.C.F started producing the coaches on new design develop indigenously.
 Page |4

During year 2001-02, R.C.F has manufactured, 1250 coaches having 974 non-AC and 276
AC. It also worthwhile to mention here that R.C.F has also manufactured 76 M.G
coaches for Vietnam.
During recent development R.C.F is now started manufacturing the new series of L.H.B
coaches with the help of agreement of German Technology in design and
manufacturing. These are the high speed coaches are cleared to run at 160Kmph bogies
of these coaches will also be manufactured here with the help of M/S FIAT bogie. The
transfer of technology agreement envisages transfer of technology in design,
manufacturing and assistance maintenance engineering of this state of art coaches.

RCF has manufactured Double Decker Coaches during 2001-02 for the first time. The
double Decker coaches have sitting capacity of 150 compared to 90 in conventional
coaches and much improved riding quality. RCF has manufactured 30 coaches during
the year.

Shri Nitish Kumar, Hon’ble Minister for railways inaugurated the first fire proof coach
Manufactured by RCF Kapurthala on 21st September 2003. First RCF has absorbed the
transfer of technology from LHB (Germany) and successfully manufactured three new
design LHB rakes for the prestigious Rajdhani express. Secondly, after the godhra
accident, Rail coach factory and integral coach factory were given the task of developing
fire proof coach and manufactured the first Prototype Fire Proof Coach of Indian
Railways within the targeted time.

Rail Coach Factory, Kapurthala got another feather in its cap when it was awarded with
Greentech Safety Silver award for the year 2002-2003 for industrial safety and
Environmental Protection. The award was given by Hon’ble Smt. Jayawanti Mehta,
Union Minister of Power, and Govt. of India on 26th June, 2003 at Hotel Cidade De Goa,
Madgaon.

Recently, on 01/06/2018 : Rail Coach Factory, Kapurthala has been conferred with
18thAnnual Greentech Environment Award (Platinum trophy) from Greentech
Foundation, New Delhi for maintaining healthy and safe environmental standards in
Engineering sector. RCF has received this prestigious recognition for eighth time for its
implementation of effective environmental practices. The award was presented by Sh.
Topon Kumar Gogoi, Minister of Power, Government of Assam and Sh. Kamleshwar
Sharan, Chairman & CEO, Greentech Foundation, at a function, held in Guwahati. The
Platinum Trophy – the highest award was received by Sh. S P Trivedi, General Manager,
RCF accompanied by Sh. P C Gupta, Principal Chief Mechanical Engineer, RCF.

On 18/05/2017, Rail Coach Factory delivered first Tejas rack which is fully featured with
modern on-board facilities with automatic doors. And on 30/09/2017, Rail Coach
Factory delivered first Antyodaya rack.
 Page |5

TYPES OF COACHES MANUFACTURED IN RCF

1. Broad Gauge Air Conditioned

1.1. AC Sleeper (AC First, AC-2 Tier, AC-3 Tier)
1.2. AC Chair Car (Executive Class, Second AC)

2. Broad Gauge Non Air Conditioned

2.1. General Second Class Seating
2.2. General Second Sleeper
2.3. General Second Class Day Coach
2.4. General Second Class With Luggage Rack and Guard’s Compartment
2.5. General Second Class With Disabled Compartment and Guard’s
Compartment
2.6. Power Cars

3. Stainless Steel BG Coaches

3.1. AC Sleeper (AC First, AC-2 Tier, AC-3 Tier)
3.2. AC Chair Car (Executive Class, Second AC)
3.3. AC Pantry Car
3.4. General Second Class Seating
3.5. General Second Sleeper
3.6. General Second Class With Luggage Rack and Guard’s Compartment

4. Meter Gauge Air Conditioned Coaches

4.1. AC Sleeper (AC First, AC-2 Tier, AC-3 Tier)
4.2. AC Chair Car (Executive Class, Second AC)
4.3. General Second Class Seating
4.4. General Second Class With Luggage Rack and Guard’s Compartment

5. Self-Propelled Coaches
5.1. Accident Relief Train
5.2. Mainline Electric Multiple Unit
5.3. Mainline Diesel Multiple Unit
5.4. Meter Gauge Diesel Multiple Unit

6. Special Purpose Coaches

6.1. RA Coaches
6.2. Parcel Vans
6.3. Refrigerated Parcel Vans
6.4. Postal Vans
 Page |6

MANUFACTURING RANGE OF RCF

1. First AC Sleeper coach.

2. Two Tier Ac Sleeper Coach.
3. Three Tier AC Sleeper Coach.
4. AC inspection Coach.
5. AC Chair car, Executive class and economy class.
6. Meter Gauge Diesel Electrical Multiple Units.
7. Mainline Electrical Multiple Units.
8. Non-AC Sleeper Class Coach.
9. Non-AC General Coach.
10. Refrigerated Parcel Van.
11. Accident Relief Train.
12. Coach Container Flats.
13. Double Decker Coach.
14. AC Buffet Car.
 Page |7

OBJECTIVES OF SIX WEEK INDUSTRIAL TRAINING

• The main objective of the Training was to get first hand technical and
practical knowledge about the industry.
• The main purpose was that the students would become familiar with
industrial environment so that they can take up future challenges
when they turn up in an industry with good confidence.
• The students will thus understand the flow of control and
information in an industry.
• This two-month Industrial Training has been introduced in Degree
Engineering Courses for the enhancement of student’s
administrative and professional knowledge about their respective
fields.
• After completion of their Degree Courses, this training experience
will help them to make their workplace stronger in the ever-
competitive job fields.
 Page |8

OBJECTIVES OF RCF

• DESIGN IMPROVEMENT
The emphasis is on light-weight Passenger Coaches with higher passenger
capacity, improved safety and comfort and high speed.

• TECHNOLOGY
Keeping pace with latest technological developments.

• PRODUCTIVITY
Improvement in productivity vis-à-vis the existing coach unit.

• QUALITY
Maintaining workmanship of higher International standards.

• MANPOWER DEVELOPMENTS
Development of an effective organization with pride in their work and faith in
the organization.

• NATIONAL OBJECTIVES
1. Self sufficiency
2. Energy conservation
3. Increased employment
4. Pollution free environment
 Page |9

TECHNICAL TRAINING CENTRE

Technical training centre is the centralized training centre for technical aspects of coach
building, prototype development. Railway administrative rules, budget, accounts and
computers etc.
This center arranges training for probationers, trainee from different colleges/ institutes
crash courses for staff, staff from other railways for new design of coaches built at rail
Coach Factory, Kapurthala. Center has its own small workshop to provide hands on
practical sessions other than the production shop. Faculty members with different
exposure expertise are there for providing deep and through guidance in different field.
For effective visual demonstration center has its own video film room and samples of
equipment and systems like air brake, air conditioners coach cress section modules etc
has been kept in assembled stage along with its loose components for working
demonstration.

Senior staff (Chief Instructor) of TTC set schedule for the trainees having close watch and
co-ordination with different production shops for complete awareness and knowledge of
modern manufacturing process, stages, latest machinery, tools and techniques involved
coach industry with high quality standards as per ISO9001.

In net shell TTC is a unique combination of technical educational institute and production
shops.
 P a g e | 10

MACHINE SHOP
 P a g e | 11

LAYOUT OF MACHINE SHOP

CHIEF INSTRUCTOR
OFFICE
OF MACHINE SHOP

1. UNIVERSAL MILLING
MACHINE

2. MILLING
11. SCRAP MACHINE
10. SHEARING MACHINE

3. PEDESTAL BEARING

ENTRY

4. SHAPER MACHINE

9. BENCH VICE 5. RADIAL DRILLING

MACHINE

6. LATHE MACHINE

8. POWER HACK SAW MACHINE

7. SURFACE GRINDER
MACHINE
 P a g e | 12

MACHINE SHOP

1. Lathe Machine

A lathe is a machine tool which turns cylindrical material, touches a cutting tool to it,
and cuts the material. The lathe is one of the machine tools most well used by
machining.
 P a g e | 13

A material is firmly fixed to the chuck of a lathe. The lathe is switched on and the chuck
is rotated. And since the table which fixed the byte can be moved in the vertical
direction, and the right-and-left direction by operating some handles.

The purpose of a lathe is to rotate a part against a tool whose position it controls. It is
useful for fabricating parts and/or features that have a circular cross section. The
spindle is the part of the lathe that rotates. Various work holding attachments such as
three jaw chucks, collets, and centres can be held in the spindle. The spindle is driven by
an electric motor through a system of belt drives and/or gear trains. Spindle speed is
controlled by varying the geometry of the drive train.

The tailstock can be used to support the end of the work piece with a centre, or to hold
tools for drilling, reaming, threading, or cutting tapers. It can be adjusted in position
along the ways to accommodate different length work pieces. The ram can be fed along
the axis of rotation with the tailstock hand wheel.

The carriage controls and supports the cutting tool. It consists of:
• A saddle that mates with and slides along the ways.
• A cross slide that controls transverse motion of the tool (toward or away
from the operator).
• A tool compound that adjusts to permit angular tool movement.
• A tool post T-slot that holds the tool post.

(WORKING PRINCIPLE OF LATHE MACHINE)

 P a g e | 14

Three Important Elements

In order to get an efficient process and beautiful surface at the lathe machining, it is
important to adjust a rotating speed, a cutting depth and a sending speed. Please note
that the important elements cannot decide easily, because these suitable values are
quite different by materials, size and shapes of the part

1. Rotating Speed:-
It expresses with the number of rotations (rpm) of the chuck of a lathe. When
the rotating speed is high, processing speed becomes quick, and a processing
surface is finely finished. However, since a little operation mistakes may lead to
the serious accident, it is better to set low rotating speed at the first stage.

2. Cutting Depth:-
The cutting depth of the tool affects to the processing speed and the roughness
of surface. When the cutting depth is big, the processing speed becomes quick,
but the surface temperature becomes high, and it has rough surface. Moreover,
a life of byte also becomes short. If you do not know a suitable cutting depth, it
is better to set to small value.

3. Sending Speed (Feed):-

The sending speed of the tool also affects to the processing speed and the
roughness of surface. When the sending speed is high, the processing speed
becomes quick. When the sending speed is low, the surface is finished beautiful.
There are 'manual sending' which turns and operates a handle, and 'automatic
sending' which advances a byte automatically. A beginner must use the manual
sending. Because serious accidents may be caused, such as touching the rotating
chuck around the byte in automatic sending.

LATHE OPERATIONS

For performing the various machining operations in a lathe, the job is being
supported and driven by anyone of the following methods.
1. Job is held and driven by chuck with the other end supported on the tail stock
centre.
2. Job is held between centres and driven by carriers and catch plates.
 P a g e | 15

3. Job is held on a mandrel, which is supported between centres and driven by

carriers and catch plates.
4. Job is held and driven by a chuck or a faceplate or an angle plate.
The above methods for holding the job can be classified under two headings
namely job held between centres and job held by a chuck or any other fixture.
The various important lathe operations. The operations performed in a lathe can
be understood by three major categories

A) Operations, which can be performed in a lathe either by holding the work piece
between centres or by a chuck are:
1. Straight turning
2. Shoulder turning
3. Taper turning
4. Chamfering
5. Eccentric turning
6. Thread cutting
7. Facing
8. Forming
9. Filing
10. Polishing
11. Grooving
12. Knurling
13. Spinning
14. Spring winding
 P a g e | 16

B) Operations which are performed by holding the work by a chuck or a faceplate

or an angle plate are:
1. Undercutting
2. Parting-off
3. Internal thread cutting
4. Drilling
5. Reaming
6. Boring
7. Counter boring
8. Taper boring
9. Tapping

C) Operations which are performed by using special lathe attachments are:

1. Milling
2. Grinding
 P a g e | 17

Some of the important operations performed on a lathe machine are discussed as

under.

1. TAPERS AND TAPER TURNING

A taper is defined as a uniform increase or decrease in diameter of a piece of work
measured along its length. In a lathe machine, taper turning means to produce a conical
surface by gradual reduction in diameter from a cylindrical job. Taper in the British
System is expressed in taper per foot or taper per inch.

Taper per inch = (D – d) /l

Where,
D = is the diameter of the large end of cylindrical job,
d = is the diameter of the small end of cylindrical job, and
l = is the length of the taper of cylindrical job, all expressed in inches,
When the taper is expressed in taper per foot, the length of the taper l is expressed in
foot, but the diameters are expressed in inches.

A taper is generally turned in a lathe by feeding the tool at an angle to the axis of
rotation of the work piece. The angle formed by the path of the tool with the axis of the
work piece should correspond to the half taper angle. A taper can be turned by anyone
of the methods:

1. By swivelling the compound rest,

2. By setting over the tailstock centre,
3. By a broad nose form tool,
4. By a taper turning attachment,
5. By combining longitudinal and cross feed in a special lathe and
6. By using numerical control lathe

2. THREAD CUTTING

Thread of any pitch, shape and size can be cut on a lathe using single point cutting tool.
Thread cutting is operation of producing a helical groove on spindle shape such as V,
square or power threads on a cylindrical surface. The job is held in between centres or
in a chuck and the cutting tool is held on tool post. The cutting tool must travel a
distance equal to the pitch (in mm) as the work piece completes a revolution. The
definite relative rotary and linear motion between job and cutting tool is achieved by
locking or engaging a carriage motion with lead screw and nut mechanism and fixing a
gear ratio between head stock spindle and lead screw. To make or cut threads, the
cutting tool is brought to the start of job and a small depth of cut is given to cutting tool
using cross slide.
 P a g e | 18

3. DRILLING ON A LATHE

For producing holes in jobs on lathe, the job is held in a chuck or on a face plate. The
drill is held in the position of tailstock and which is brought nearer the job by moving
the tailstock along the guide ways, the thus drill is fed against the rotating job.

Drilling on lathe

SPECIFICATION OF LATHE
The size of a lathe is generally specified by the following means:
A. Swing or maximum diameter that can be rotated over the bed ways

B. Maximum length of the job that can be held between head stock and tail stock
centres

C. Bed length, which may include head stock length also

D. Maximum diameter of the bar that can pass through spindle or collect chuck of
capstan lathe.
 P a g e | 19

1. Maximum swing over bed

2. Maximum swing over carriage
3. Height of centres over bed
4. Maximum distance between centres
5. Length of bed
6. Width of bed
7. Morse taper of centre
8. Diameter of hole through spindle
9. Face plate diameter
10. Size of tool post
11. Number of spindle speeds
12. Lead screw diameter and number of threads per cm.
13. Size of electrical motor
14. Pitch range of metric and inch threads etc.

Cutting Tools for Lathe

There are various kinds of the cutting tools for a lathe. We must choose them by the
materials and shape of a part. Three typical cutting tools are introduced in follows. Then
we consider what is an easy process or a hard process.
 P a g e | 20

A) Side Tool: - It can process to cut an outside surface and an edge surface. Since
the material is set at the right of lathe, then this tool can only cut the right of the
material.

B) Cutting-Off Tool: - The cutting tool is used at parting and grooving processes. Its
pointed end is slim, then it is too weak. Don't add a strong side-force to the tool.
This tool must send vertical direction only.

C) Boring Bar: - The boring bar is used to cut at an inside surface. It can make a big
hole, which cannot be process by a drill, and a high accurate hole.

Cutting Tool Terminology

Setting of a Cutting Tool

In case a cutting tool is fixed to a table, thin metal plates are put between the tool and
the table, and the height of the edge is adjusted to the center of material.

In the case of using the general cutting tool, when the edge is higher than the center of
material, the edge of a blade does not hit the material, and it cannot cut at all.
 P a g e | 21

Conversely, if the edge is low, it becomes impossible to cut the center of material.
Moreover, the scale of a handle does not have correct value, then accurate processing
becomes impossible.

Though the height of the cutting tool is adjusted in careful, we cannot unite with the
center of material completely. Therefore, we have to set the tool to the direction, that
the edge is easy to touch the material. The general cutting tool and the parting tool
have to be set a few low position. The boring bar has to set a few high position.

Standard Cutting Tools

Accessories
1. Chucks,
2. Collets,
3. Face plate,
4. Steady and follower rests,
5. Centres,
6. Tool holders etc.

Technical Specifications of Centre Lathe Machine

1. Make : HMT VIKRAM.
2. Plant no : 1203-001.
3. Total bed length : 1800 mm.
 P a g e | 22

4. Distance b/w center to center : 1200 mm.

5. Distance b/w center to bed : 200 mm.
6. Swing : 300 mm.
7. Spindle Bore : 50 mm.
8. Type of Head stock : Geared.
9. Type of L/S thread : ACME,Angle-290
10. Thread pitch of L/S : 6 mm.
11. Speed : 25-2000 rpm.
12. Feed : 0.04-1.00 mm.
13. Gap bed length : 200 mm.

2. DRILLING MACHINE
 P a g e | 23

It consists of vertical column with a radial arm that can be swing trough an arc of 180
degrees or more on the radial arm, which is power driven for vertical movement. It is an
independently driven head fitted with power feed? The drilling head can be moved
along the arm by hand or by gear mechanism. On a single fitting of work piece number
of holes can be drilled by rotating the arm or sliding the dr1l1 head along the arm.

The radial drilling machine consists of a heavy, round vertical column supporting a
horizontal arm that carries the drill head. Arm can be raised or lowered on the column
and can also be swung around to any position over the work and can be locked in any
position. The drill head containing mechanism for rotating and feeding the drill is
mounted on a radial arm and can be moved horizontally on the guide-ways and
clamped at any desired position. These adjustments of arm and drilling head permit the
operator to locate the drill quickly over any point on the work. The table of radial
drilling machine may also be rotated through 360 deg. The maximum size of hole that
the machine can drill is not more than 50 mm. Powerful drive motors are geared
directly into the head of the machine and a wide range of power feeds are available as
well as sensitive and geared manual feeds. The radial drilling machine is used primarily
for drilling medium to large and heavy work pieces. Depending on the different
movements of horizontal arm, table and drill head, the upright drilling machine may be
classified into following types-
1. Plain radial drilling machine
2. Semi universal drilling machine, and
3. Universal drilling machine.

Radial drilling machine

In a plain radial drilling machine, provisions are made for following three movements –
1. Vertical movement of the arm on the column,
2. Horizontal movement of the drill head along the arm, and
3. Circular movement of the arm in horizontal plane about the vertical column.
 P a g e | 24

In a semi universal drilling machine, in addition to the above three movements, the drill
head can be swung about a horizontal axis perpendicular to the arm. In universal
machine, an additional rotatory movement of the arm holding the drill head on a
horizontal axis is also provided for enabling it to drill on a job at any angle.

TECHNICAL SPECIFICATIONS OF RADIAL DRILLING MACHINE

1. Max. Drill diameter : 100m.

2. Max. Job thickness : l2.5mm.
3. Drilling capacity : For CI 60 mm
4. Cutting speed : 15¬20mm/rev
5. Feed : 6 feed ranges 0.125-1.25 mm/rev.
6. Tapping capacity : For metric system M70
For British system 2.5"(BW)
7. Min. /Max Drilling radius : 550/23P50 mm.
8. Min. / Max Distance between : 380/1645
9. Base plate and spindle nose.
10. Swing arm : 360 degrees

3. POWER HACKSAW
A power hacksaw is a type of hacksaw that is powered either by its own electric motor
(also known as electric hacksaw) or connected to a stationary engine. Most power
hacksaws are stationary machines but some portable models do exist. Stationary
models usually have a mechanism to lift up the saw blade on the return stroke and
some have a coolant pump to prevent the saw blade from overheating.

While stationary electric hacksaws are reasonably uncommon they are still produced
but saws powered by a stationary engines have gone out of fashion. The reason for
using one is that they provide a cleaner cut than an angle grinder or other types of saw.
 P a g e | 25

4. SHAPER MACHINE

A shaper is a machine tool used for shaping or surfacing metal and other material.
Shapers have been largely superseded by milling machines or grinding machines in
modern industrial practice. The basic function of a shaper machine is still sound and
tooling for them is minimal and very cheap to reproduce. They can be invaluable for
jobbing or repair shops where only one or a few pieces are required to be produced and
the alternative methods are cost or tooling intensive. The mechanically operated
machines are simple and robust in construction, making their repair and upkeep easily
achievable.

Shapers are mainly classified as standard, draw-cut, horizontal, universal, vertical,

geared, crank, hydraulic, contour and travelling head. The horizontal arrangement is the
most common. Vertical shapers are generally fitted with a rotary table to enable curved
surfaces to be machined. The vertical shaper differs from a slotted (slotting machine), as
the slide can be moved from the vertical. A slotter is fixed in the vertical plane.

Very small machines have been successfully made to operate by hand power. Once size
increases, up to a potential 36 inch stroke, the power needs increase and it becomes
necessary to use an electric motor. This motor drives a mechanical arrangement (using
a pinion gear, bull gear and crank) or a hydraulic motor which supplies the necessary
movement via hydraulic cylinders

Principal parts of shaper

 P a g e | 26

WORKING PRINCIPLE OF SHAPER

A single point cutting tool is held in the tool holder, which is mounted on the ram. The
work piece is rigidly held in a vice or clamped directly on the table. The table may be
supported at the outer end. The ram reciprocates and thus cutting tool held in tool
holder moves forward and backward over the work piece. In a standard shaper, cutting
of material takes place during the forward stroke of the ram. The backward stroke
remains idle and no cutting takes place during this stroke. The feed is given to the work
piece and depth of cut is adjusted by moving the tool downward towards the work
piece. The time taken during the idle stroke is less as compared to forward cutting
stroke and this is obtained by quick return mechanism. The cutting action and
functioning of clapper box during forward and return stroke.

Working principal of shaping machine

Job surfaces generated by shaper

Cutting action and functioning of clapper box

 P a g e | 27

PRINCIPAL PARTS OF SHAPER

1. Base
2. Column
3. Cross-rail
4. Saddle
5. Table
6. Ram
7. Tool head
8. Clapper box
9. Apron clamping bolt
10. Down feed hand wheel
11. Swivel base degree graduations
12. Position of stroke adjustment hand wheel
13. Ram block locking handle
14. Driving pulley
15. Feed disc
16. Pawl mechanism
17. Elevating screw
Some of important parts are discussed as under

Parts of Standard Shaper

1. Base
It is rigid and heavy cast iron body to resist vibration and takes up high compressive
load. It supports all other parts of the machine, which are mounted over it. The base
may be rigidly bolted to the floor of the shop or on the bench according to the size of
the machine.
 P a g e | 28

2. Column
The column is a box shaped casting mounted upon the base. It houses the ram-driving
mechanism. Two accurately machined guide ways are provided on the top of the
column on which the ram reciprocates.

3. Cross rail
Cross rail of shaper has two parallel guide ways on its top in the vertical plane that is
perpendicular to the rai1 axis. It is mounted on the front vertical guide ways of the
column. It consists mechanism for raising and lowering the table to accommodate
different sizes of jobs by rotating an elevating screw which causes the cross rail to slide
up and down on the vertical face of the column. A horizontal cross feed screw is fitted
within the cross rail and parallel to the top guide ways of the cross rail. This screw
actuates the table to move in a crosswise direction.

4. Saddle
The saddle is located on the cross rail and holds the table on its top. Crosswise
movement of the saddle by rotation the cross feed screw by hand or power causes the
table to move sideways.

5. Table
The table is a box like casting having T -slots both on the top and sides for clamping the
work. It is bolted to the saddle and receives crosswise and vertical movements from the
saddle and cross rail.

6. Ram
It is the reciprocating part of the shaper, which reciprocates on the guideways provided
above the column. Ram is connected to the reciprocating mechanism contained within
the column.

7. Tool head
The tool head of a shaper performs the following functions-
1. It holds the tool rigidly,
2. It provides vertical and angular feed movement of the tool, and
3. It allows the tool to have an automatic relief during its return stroke.
The various parts of tool head of shaper are apron clamping bolt, clapper box, tool
post, down feed, screw micrometre dial, down feed screw, vertical slide, apron washer,
apron swivel pin, and swivel base. By rotating the down feed screw handle, the vertical
slide carrying the tool gives down feed or angular feed movement while machining
vertical or angular surface.

The amount of feed or depth of cut may be adjusted by a micrometre dial on the top of
the down feed screw. Apron consisting of clapper box, clapper block and tool post is
clamped upon the vertical slide by a screw. The two vertical walls on the apron called
clapper box houses the clapper block, which is connected to it by means of a hinge pin.
The tool post is mounted upon the clapper block. On the forward cutting stroke the
 P a g e | 29

clapper block fits securely to the clapper box to make a rigid tool support. On the return
stroke a slight frictional drag of the tool on the work lifts the block out of the clapper
box a sufficient amount preventing the tool cutting edge from dragging and consequent
wear. The work surface is also prevented from any damage due to dragging.

SHAPER MECHANISM
In a shaper, rotary motion of the drive is converted into reciprocating motion of the ram
by the mechanism housed within the column or the machine. In a standard shaper
metal is removed in the forward cutting stroke, while the return stroke goes idle and no
metal is removed during this period. The shaper mechanism is so designed that it moves
the ram holding the tool at a comparatively slower speed during forward cutting stroke,
whereas during the return stroke it allow the ram to move at a faster speed to reduce
the idle return time. This mechanism is known as quick return mechanism. The
reciprocating movement of the ram and the quick return mechanism of the machine are
generally obtained by anyone of the following methods:

1. Crank and slotted link mechanism

In crank and slotted link mechanism, the pinion receives its motion from an individual
motor or overhead line shaft and transmits the motion or power to the bull gear. Bull
gear is a large gear mounted within the column. Speed of the bull gear may be changed
by different combination of gearing or by simply shifting the belt on the step cone
pulley. A radial slide is bolted to the centre of the bull gear. This radial slide carries a
sliding block into which the crank pin is fitted. Rotation of the bull gear will cause the
bush pin to revolve at a uniform speed. Sliding block, which is mounted upon the crank
pin is fitted within the slotted link. This slotted link is also known as the rocker arm. It is
pivoted at its bottom end attached to the frame of the column. The upper end of the
rocker arm is forked and connected to the ram block by a pin. With the rotation of bull
gear, crank pin will rotate on the crank pin circle, and simultaneously move up and
down the slot in the slotted link giving it a rocking movement, which is communicated
to the ram. Thus the rotary motion of the bull gear is converted to reciprocating motion
of the ram.
 P a g e | 30

2. Whitworth quick return mechanism, and

3. Hydraulic shaper mechanism

Technical Specification of Shaper Machine:-

1. Make : Cooper –CSH-63.

2. Plant no. : 1931-001.
3. Max length of stroke : 630 mm.
4. Max Horizontal traverse of table : 710 mm.
5. Max vertical traverse of table : 350 mm.
6. Max distance of table to ram : 450 mm.
7. Min distance of table to ram : 100 mm.
8. Range of speed to ram strokes/min : 8-125 mm.
9. Range of feed to table (in 10 steps) : 0.32-3.2 mm/min.
10. Max traverse of tool slide : 160 mm.
11. Can be swiveled through on either side of vertical : 450
12. Vice admits in length : 290 mm.
13. Width & depth of vice jaw : 330 mm.

5. MILLING MACHINE

A milling machine is a machine tool that removes metal as the work is fed against a
rotating multipoint cutter. The milling cutter rotates at high speed and it removes metal
at a very fast rate with the help of multiple cutting edges. One or more number of
cutters can be mounted simultaneously on the arbour of milling machine. This is the
reason that a milling machine finds wide application in production work. Milling
machine is used for machining flat surfaces, contoured surfaces, surfaces of revolution,
external and internal threads, and helical surfaces of various cross-sections. Typical
components produced by a milling. In many applications, due to its higher production
rate and accuracy, milling machine has even replaced shapers and slotters.
 P a g e | 31

PRINCIPLE OF MILLING

In milling machine, the metal is cut by means of a rotating cutter having multiple cutting
edges. For cutting operation, the work piece is fed against the rotary cutter. As the work
piece moves against the cutting edges of milling cutter, metal is removed in form chips
of trochoid shape. Machined surface is formed in one or more passes of the work. The
work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head,
between centres, in a special fixture or bolted to machine table. The rotatory speed of
the cutting tool and the feed rate of the work piece depend upon the type of material
being machined.

Vertical milling machine

The vertical mill has a vertically arranged spindle axis and rotate by staying at the same
axis. The spindle can also be extended and performing functions such as drilling and
cutting. Vertical mill has got two further categories as well: turret mill and bed mill.
The turret mill has got a table that moves perpendicularly and parallel to the spindle
axis in order to cut the material. The spindle is, however, stationary. Two cutting
methods can be performed with this by moving the knee and by lowering or raising the
quill.
The other is the bed mill in which the table moves perpendicular to the axis of the
spindle and the spindle moves parallel to its axis.
 P a g e | 32

Technical Specification of Vertical Milling Machine:-

1. Make/type : BATLIBOI-FA3V
2. Plant no. : 1310-001.
3. Working table length & width : 1250x300 mm.
4. Longitudinal traverse : 800 mm.
5. Vertical traverse : 390 mm.
6. Cross traverse : 265 mm.
7. Distance b/w main spindle to table surface min & max : 0 & 450 mm.
8. Distance b/w main spindle center to column slide : 300 mm.
9. Swivel of spindle head on either side : 450
10. Vertical movement of spindle : 75 mm.

UNIVERSAL HORIZONTAL MILLING MACHINE

The basic difference between a universal horizontal milling machine and a plain
horizontal milling machine is the addition of a table swivel housing between the table
and the saddle of the universal machine. This permits the table to swing up to 45° in
either direction for angular and helical milling operations. The universal machine can be
fitted with various attachments such as the indexing fixture, rotary table, slotting and
rack cutting attachments, and various special fixtures.

Technical Specification of Universal Milling Machine:-

1. Make/type : BFW-UF-I
2. Plant no. : 1307-001
3. Table overall size : 1175x230 mm.
4. Table clamping area : 1000x230 mm
5. Table longitudinal movement automatic : 560 mm.
 P a g e | 33

6. Table longitudinal movement manual : 590 mm.

7. Table traverse movement automatic : 250 mm.
8. Table traverse movement manual : 270 mm.
9. Table vertical movement manual : 340 mm.
10. Table swivel to either side : 450 mm.
11. Distance of spindle center to table surface : 0-330 mm.
12. Distance of spindle center to left hand end of table : 250 mm.

6. GRINDING MACHINE

Rotating abrasive wheel

A grinding machine is a machine tool used for grinding, which is a type of machining
using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's
surface cuts a small chip from the work piece via shear deformation.

The grinding machine consists of a power driven grinding wheel spinning at the required
speed and a bed with a fixture to guide and hold the work-piece

Grinding machines remove material from the work piece by abrasion, which can
generate substantial amounts of heat; they therefore incorporate a coolant to cool the
work piece so that it does not overheat and go outside its tolerance. The coolant also
benefits the machinist as the heat generated may cause burns in some cases. In very
high-precision grinding machines (most cylindrical and surface grinders) the final
grinding stages are usually set up so that they remove about 2/10000mm (less than
1/100000 in) per pass - this generates so little heat that even with no coolant, the
temperature rise is negligible.
 P a g e | 34

Surface grinding machine

Surface grinding is a widely used process of machining in which a spinning wheel

covered in rough particles cuts chips of metallic or non-metallic substance making them
flat or smooth.
Spark out is a term used when precision values are sought and literally means "until the
sparks are out (no more)". It involves passing the work piece under the wheel, without
resetting the depth of cut, more than once and generally multiple times. This ensures
that any inconsistencies in the machine or work piece are eliminated.

As with any grinding operation, the condition of the wheel is extremely important.
Diamond dressers are used to maintain the condition of the wheel, these may be table
mounted or as the first image shows, mounted in the wheel head where they can be
readily applied.

Surface grinder, which has a head that is lowered to a work piece, which is moved back
and forth under the grinding wheel on a table that typically has a controllable
permanent magnet (magnetic chuck) for use with magnetic stock
(especially ferrous stock) but can have a vacuum chuck or other fixture means. The
most common surface grinders have a grinding wheel rotating on a horizontal axis
cutting around the circumference of the grinding wheel. Rotary surface grinders,
commonly known as "Blanchard" style grinders, have a grinding head which rotates the
grinding wheel on a vertical axis cutting on the end face of the grinding wheel, while a
table rotates the work piece in the opposite direction underneath. This type of machine
removes large amounts of material and grinds flat surfaces with noted spiral grind
marks. It can also be used to make and sharpen metal stamping die sets, flat shear
blades, fixture bases or any flat and parallel surfaces. Surface grinders can be manually
operated or have CNC controls.

Effects on work material properties

The high temperatures encountered at the ground surface create residual stresses and
a thin martensitic layer may form on the part surface; this decreases the fatigue
 P a g e | 35

strength. In ferromagnetic materials, if the temperature of the surface is raised beyond

the Curie temperature then it may lose some magnetic properties. Finally, the surface
may be more susceptible to corrosion.

7. SHEARING MACHINE
A shear force is applied that will cut off part of a sheet. The cut off ‘blank’ becomes the
work piece.

Shearing, also known as die cutting, is a process which cuts stock without the formation
of chips or the use of burning or melting. In strict technical terms, the process of
“shearing” involves the use of straight cutting bladesorm of sheet metal or plates,
however rods can also be sheared. Shearing-type operations include: blanking, piercing,
roll slitting, and trimming.

When you apply a high pressure tool through a metal plate and remove part of the
metal, the process is called shearing. Shear machining devices include punching
machines, which make small discs, and blanking machines, which produce washers and
similar objects.

Direct tool ordinary machining is NOT the same as shear machining. With standard tool
machining, a single or multiple point tool can be employed to take out a piece of metal
from the metal sheet and/or block. This process required repeated pounding of the
metal until the required dimensions are achieved. With shear machining, the tool’s
cutting edge removes the metal from the plate. While this happens, maximum pressure
is applied. The tool, however, only touches the metal one time.

Both mechanical and hydraulic machines can perform shear machining. Hydraulic
shears cut and score sheet metal quickly and accurately. They work well for factories
that do a lot of metal fabrication. In addition, hydraulic shears are best if the operation
requires intense pressure. They don’t require a lot of maintenance, will operate
continuously, and are fast and quiet. Hydraulic shear machines also take up less space
than mechanical shear machines while applying the same amount of pressure.
 P a g e | 36

Working Of Hydraulic Shearing Machine:

When the metal is inserted into hydraulic machines, it is secured by clamps so it does
not shift under high pressure. To ensure that the cut is smooth and even for a 90 degree
cut, a squaring arm or back gauge must be used. Minute burrs may be formed by the
edge of the cut metal; these must be removed by grinding. If you use hydraulic shears,
be careful of the little marks left by the cutting blades and holding clamps while
working. You will need to remove them or otherwise account for them.