PRINCIPLES OF MACHINE

SHOP PRACTICES
 MACHINE SHOP PRACTICES

• A machine shop is a room, building, or company where machining is done. In

a machine shop, machinists use machine tools and cutting tools to make parts,
usually of metal or plastic (but sometimes of other materials such as glass or wood).
• the actual application or use of an idea, belief, or method as opposed to theories
about such application or use
 1.1 SAFETY PRECAUTIONS :

• Be sure that all machines have effective and properly working guards that
are always in place where machines are operating.
• Do not attempt to oil, clean, adjust or repair any machine while it is
running.
• Do not operate any machine unless authorized.
• Do not try to stop the machine with your hand or body while running.
• Always check whether the work and cutting tools properly clamped on the
machine before starting.
• Keep the floor clean of metal chips or curls and waste pieces.
• When working with another, only one should operate machine or
switches.
• Concentrate on the work, avoid unnecessary talks while operating
machine.
• Get first aid immediately for any injury.
• Wear safety shoes, if heavy work has done.
• Wear clothing suited for the job, wear shoes with thick soles.
• Do not wear rings, watches, bracelets or other jewelry that could get
caught in moving machinery.
• Do not wear neckties or loose turn clothing of any kind.
• Wear shirts or uppers with sleeves cut off or rolled above the elbows.
• Always remove gloves before turning on or operating a machine.
• Keep the floor always clean.
• Passage should be clear, at all time to avoid accident.
• Do not leave tools or work on the table of a machine even if the machine
in not turning. Tools or work may fall off and cause the fact of injury.
• Switch off the machine immediately when supply fails.
 1.2 MEASURING INSTRUMENTS
Measuring instruments have an important role in a mechanical workshop. The
quality of work is based on the accuracy and precision of the instruments used for
inspection. There are different types of measuring instruments are used in a
workshop; some of them are given below.
• Steel rule
• Calipers
• Vernier caliper
• Micrometer
• Vernier height gauge
• Dial test indicator
• Screw thread pitch gauge
• Screw cutting gauge
 1.2.1 STEEL RULE
• Steel rule is a measuring instrument having a long,
thin stainless steel strip with a marked scale of unit
division such as in centimeters or inches, used for
drawing lines, measuring distances between two
points, etc.
• available in different sizes, such as in 15cm, 30cm,
60cm, 1m, 1.5m, 2m, 3m, 4m, 5m & 6m. Generally,
least count of a steel rule is 0.5mm.
 1.2.2 CALIPERS

A caliper (British spelling also caliper) is a device used to

measure the distance between two opposite sides of an object.
An ordinary caliper may be classified as the following:
• Outside caliper: Used to measure outside diameter of a round shaped
objects or to measure distance between two points.

• Inside caliper: Used for measuring inside diameter of a pipe or to

measure inside dimensions of hollow sections.

• Jenny caliper: It is also known as odd leg caliper or hermaphrodite

caliper. It used for scribe a line at a distance from the edge of a work
piece.
 1.2.3 VERNIER CALIPER
The Vernier caliper is a precision instrument used for measuring internal and
external distances between two points extremely accurately. It has two versions, manual and
digital. The manual version has both an imperial and metric scale. The digital version
requires a small battery whereas the manual version does not need any power source.
Vernier calipers are available in the range of 0-100mm, 0-150mm, 0-200mm, 0-300mm, 0-
600mm and 0-1000mm. Accuracy of metric scale Vernier caliper is 0.02mm and imperial
scale Vernier caliper is 0.002”.
 1.2.4 MICROMETER
A micrometer (also known as screw gauge) is used for measuring dimensions smaller
than those measured by the Vernier caliper. A micrometer screw gauge is a small measuring
device, which works on the “screw” principle. The accuracy of micrometers are varies
between 0.01mm and 0.001 mm depending on the type of micrometer.
 1.2.5 VERNIER HEIGHT GAUGE
A Vernier height gauge is a measuring device used either for determining the
height of something, or for repetitive marking of items to be worked on. The pointer is
sharpened to allow it to act as a scriber and assist in marking on work pieces. Figure
below shows details and working arrangement of a Vernier height gauge.
 1.2.6 DIAL TEST INDICATOR
Dial test indicator have been used in the machine shop to
test alignment and rotation measurement of machine parts.
• Very precise instrument that measures distance between two parts
and can be used to measure distances between two or more
locations
• Typically measure ranges from 0.25mm to 300mm (0.015 inch to
12 inch), with graduations of 0.001mm to 0.01mm (metric) or
0.00005 inch to 0.001 inch (imperial)
• More expensive and are not always available, but they are
extremely useful in applications that demand them
 1.2.7 SCREW THREAD PITCH GAUGE
A screw thread pitch gauge is used to check or find the pitch of a thread. It is a
series of thin marked blades which have different pitched teeth. Thread pitch gauges also
come in the standard thread forms of metric, Whitworth, etc. which allows both the pitch of
the thread to be gauged and the form or shape of the thread, to be checked. Each set of
screw pitch gauges has the thread form stamped on it.
 1.3 CUTTING TOOLS
Cutting tool is a device with one or more cutting edges used to create
chips and remove metal from the work piece. Generally, cutting tools are classified
as single point cutting tools and multi point cutting tools. A single point cutting tool
(such as lathe, shaper and planner and boring tool) has only one cutting edge,
whereas a multi-point cutting tool (such as milling cutter, drill, reamer, broach,
hack saw blade, etc.) has more than one teeth or cutting edge on its periphery.
 1.4 CUTTING FLUIDS
During machining or metal cutting process, enough heat is developed
in the cutting zone. To remove this heat from cutting zone, soluble oils
are used as cutting fluid during machining. Emulsions (also known as
soluble oil) cool the work-piece and tool and thus relieved them from
overheat. Air circulation is required to remove the heat by evaporation.
The remaining oil forms a protecting layer over the machined work
piece and save it from rust and corrosion.
• Such coolants decrease adhesion between chip and tool, provides
lower friction and wear and a smaller built up edge
• remove chips and hence help in keeping freshly machined surface
bright
• protects the surface from corrosion
• decreases wear and tear of tool and hence increase tool life
• Improves machinability and reduce machining forces
 1.4.2 FUNCTIONS OR USES OF COOLANTS OR
CUTTING FLUIDS
• Cutting fluid washes away the chips and hence keeps the
cutting region free.
• It helps in keeping freshly machined surface bright by
giving a protective coating against atmospheric, oxygen
and thus protects the finished surface from corrosion.
• It decreases wear and tear of cutting tool and hence
increases tool life.
• It improves machinability and reduce power requirements
• It prevents expansion of work pieces.
• It cools the tool, work piece, and remove the generated heat
from the cutting zone.
• It decreases adhesion between chip and tool; provide lower
friction and wear, and a smaller built-up edge.
 1.5 LATHE MACHINE
The lathe is a machine tool, which holds the
work piece between two rigid and strong supports
called centers or in a chuck or face plate which
revolves. The cutting tool is rigidly held and
supported in a tool post, which is held against the
revolving work. The normal cutting operations are
performed with the cutting tool fed either parallel or
at right angles to the axis of the work.
PRINCIPAL PARTS OF AN ENGINE LATHE
 LATHE OPERATIONS

1. Facing
2. Centering
3. Turning
4. Parting
5. Drilling
6. Boring
7. Reaming
8. Knurling
9. Forming
10. Chamfering
11. Thread cutting
 1.5.4.1 FACING

Facing is the process of removing

metal from the end of a work piece by
using a single point cutting tool, to
produce a flat surface. Figure shows the
details of facing operation.
 1.5.4.2 CENTERING

Centering is the process of

providing a small tapered hole at end of a
work piece by using centering tool, which
can helpful to accommodate and support
a running centre in the tailstock. Figure
shows the details of centering operation.
 1.5.4.3 TURNING

Turning is the process of removal

of metal from the outer diameter of a
rotating cylindrical work piece. Turning is
used to reduce the diameter of the work
piece, usually to a specified dimension,
and to produce a smooth finish on the
metal.
 1.5.4.4 PARTING

Parting is the process of cut off the

work piece at a specific length by using a
blade-like cutting tool. It is normally used
to remove the finished end of a work
piece from the bar stock that is clamped
in the chuck.
 1.5.4.5 DRILLING

Drilling is the process of making

holes at the end face of the work piece by
using a drill bit, fixed with drill chuck,
clamped at tailstock.
 1.5.4.6 BORING

Boring is the process of enlarging

a hole that has already been drilled or
cast, by using a single point cutting tool or
boring head containing several such
tools.
 1.5.4.7 REAMING

Reaming is the process of

finishing a drilled or bored hole with
great degree of accuracy. The drilled or
bored hole not always is straight or
accurate.
 1.5.4.8 KNURLING

Knurling is a process of making

easy-to-grip geometric pattern on a
finished outer surface of work pieces like
handles, knobs, rollers, etc. to hold them
firmly. Figure shows the details and
geometric pattern of knurled grips.
 1.5.4.9 FORMING

Forming is a process of
produces a convex, concave or any
irregular profile on the work piece
by using a form tool. Figure shows
the details of forming operation.
 1.5.4.10 CHAMFERING

Chamfering is a process of
beveling the extreme end of a
work piece. This is done to
remove the burrs and sharp
edges from the extreme end of
the work piece.
 1.5.4.11 THREAD CUTTING
Thread cutting is a process of
cutting very accurate screw threads by
using a single point cutting tool, which is
the process of guiding the linear motion
of the tool bit in a precisely known ratio to
the rotating motion of the work piece.
 1.6 SHAPING MACHINE

Shaping is a process of machining a

flat surface which may be horizontal,
vertical, inclined, concave or convex using a
reciprocating single point tool. A shaping
machine is a reciprocating type of machine
tool.
 1.7 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 arbor
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.
 1.8 SLOTTING MACHINE

• The slotter or slotting machine is also a

reciprocating type of machine tool
similar to a shaper. It may be
considered as a vertical shaper. The
machine operates in a manner similar to
the shaper, however, the tool moves
vertically rather than in a horizontal
direction. The job is held stationary. The
slotter has a vertical ram and a hand or
power operated rotary table.
PRINCIPAL PARTS OF A SLOTTING MACHINE
FIGURE
 USES OF SLOTTING MACHINES
1. It is used for machining vertical surfaces
2. It is used angular or inclined surfaces
3. It is used It is used to cut slots, splines, keyways for both
internal and external jobs such as machining internal and
external gears
4. It is used for works as machining concave, circular, semi-
circular and convex surfaces
5. It is used for shaping internal and external forms or profiles
6. It is used for machining of shapes which are difficult to produce
on shaper
7. It is used for internal machining of blind holes
8. It is used for machining dies and punches