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Machine shop Theory
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38 views13 pagesMST Module
Machine shop Theory
Uploaded by
Kim Argyle SalinasCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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MACHINE SHOP PRACTICES
MACHINE SHOP - is a place in wherein metal
arts are cut to the size required and put together
to form mechanical units or machine, the
‘machine so made to be used directly or indirectly
in the production of the necessities and luxuries
of civilization,
LATHE- is a metal tuming machine tool in
which the work, while revolving on a horizontal
axis, is acted upon by a cutting tool which is
made to move slowly in a direction more or less
parallel to the axis of the work, or in direction at
right angles to the x-axis of the work operated by
hand or by power as desired,
‘Types of engine lathes
1. Bench lathes - small engine lathes, which
can be mounted on a bench or metal cabinet,
Standard engine lathe - larger, heavier, and
‘more powerful than the bench lathe; ‘may
have bench length from 5 to 20 or more feet.
Tool room lathes - precision engine lathes
equipped with additional attachments needed
for tool and die making operations.
Manufacturing lathes - engine lathes of
various sizes equipped with special-purpose
attachments for tuming workpieces in large
quantities, which is often called production
work,
Special-purpose lathes - gap lathes, which
have a special sliding bed, making it possible
to increase the swing to accommodate large-
diameter work; wheel lathes, crankshaft
lathes, gun barrel lathes, and tracer lathes—
all are adaptations of the engine lathe.
2.
Five major parts of engine lathes:
1. Bed
.. Headstock
Tailstock
Carriage
Feed and thread cutting mechanism
veer
ithe operations and processes
Facing - is the operation of machining the
end of a worl
En rkpiece to make the end square.
with the axis, or center line.
Lat
1
LINX ENGINEERING
ST INTERNATIONAL
ER NATIONAL
2" Poor CHEF Oi Bip. 615 R. Papa St Somat, Marva
hems
2. Center drilling - is the operation of drilling
and countersinking each end of the stock to
be tumed between centers.
Straight turning - is the Process of
producing a cylindrical piece of work on
which the diameter is uniform in. size
throughout its entire length,
Undereutting - often called necking or
grooving, is the cutting of a groove next to a
shoulder on a piece of work.
Chamfering - is the operation of producing a
beveled edge at a specified angle on the end
of a turned diameter.
Knurling - is a process of rolling
depressions or indentations of various shapes
into metal by the use of revolving hardened-
steel wheels pressed against the work,
Recessing - extemal recessing is the
operation of machining e smaller diameter on
a workpiece, for a specified length. Internal
recessing is the machining of a larger
diameter, fora specified length, inside a hole.
Parting or Cutting-off - is the operation of
separating a piece of finished work from the
bar stock from which the piece was
machined.
Threading - the process of making threads
to a workpiece. Both external and internal
threads can be performed in lathe machine.
icf
Attachment and Accessories:
An attachment is a device mounted on the lathe
so that a wider range of operations may be
performed.
1. Drive plate - is used to drive a lathe dog,
which in tum, is securely clamped to the
workpiece. It is a round, slotted plate
attached to the spindle: The bent tail of the
dog fits into one of the slots in the face of the
plate.
Faceplate - is similar.to a drive plate but
larger in diameter. It contains more open
slots or T-slots so that bolts or T bolts may
be used to clamp the work piece to the face
of the plate. Many types of work that cannot
be held in chucks may be machined
conveniently when mounted on a faceplate,
5. Three-jaw universal chuck - holds cylindrical
or hexagonal work. All three jaws move
together to bring the work on center.
Four jaw independent chuck - is used to hold
most of the work for which a chuck is
required. Each jaw maybe — moved
lependently of the others so that
‘workpieces may be trued to run accurately.
Combination chuck - is usually a four jaw
chuck in which the jaws may be adjusted independently, as in a four-jaw independent
chuck, or together, as in the three jaw
universal chuck,
6. Magnetic chuck ~ holds steel workpieces by
means of permanent magnets contained
within the chuck, The face of the chuck is
magnetized by inserting a key in the chuck
and tuming it 180 degrees, The magnetic
chuck is good for holding parts that are too
thin to be held in an ordinary chuck.
7. Collet attachment ~ provides a quick means
of chucking workpieces with standard
diameters or sizes. One type of collet
attachment consists of a taper sleeve, which
fits into the spindle hole of the lathe, a
drawbar, and a set of collets. Another type of
collet attachment consists of an attachment
that fastens to the spindle and a set of collets,
which may be inserted and clamped to the
workpiece by tuming a large- diameter
handwheel.
8. Steady rest - is a device that is clamped to the
ways of the lathe to support long shafts
during turing, boring, or threading
operations. By holding the work rigidly, a*
steady rest prevents the work from springing
away from the cutting tool.
9. Follower rest - is a work-supporting device,
which is bolted to the saddle.
10. Micrometer carriage stop - is a device
attached to the ways of a lathe to stop the
carriage at a definite place and limit the
travel of the cutting tool.
11. Taper attachment - is a fixed casting attached
to the back of the lathe carriage used to turn
and bore tapers.
12. Tool post is used to clamp and hold various
types of cutting-tool holders or lathe
attachments.
13. Grinding attachment - often called a tool-
post grinder, is a motor driven, self contained
unit that is held in the tool post. It is used for
outside and inside grinding.
Tool Geometry
Rake angles are important in controlling the
direction of chip flow and the strength of the tool
tip.
* Back rake angle - is the angle formed by
the top surface of the tool bit and the
ground top face of the tool.
© Side rake angle - is the angle formed by
grinding the top surface’of the tool so that
it slopes away from the side cutting edge.
Relief angles control interference and
rubbing at the tool-workpiece interface.
© Side relief angle - is that surface of the
cutting tool found below the cutting edge.
is angle permits the tool to be fed
sideways into the job so that it can cut
without rubbing.
‘+ End relief angles - is formed by the front
of the cutting tool and an imaginary line
drawn at a tangent to the job at right
angles to the center line of the lathe.
Cutting edge angles affect the chip
formation, tool strength, and. cutting forces to
various degrees.
Nose radius affects surface finish and tool
tip strength. Also, the sharper the radius, the
rougher will be the surface finish of the
workpiece and the lower will be the strength of
the tool.
Summary
Formulas :
of Turning Parameters and
The feed rate or linear speed of the tool
along a workpiece length (mm/min or
in/min)
Fai]
‘f-feed (mm/rev or in/rev)
‘N- rotational speed of the workpiece
(pm)
+ The surface speed of workpiece (mps or
fpm)
V =xD)N| for maximum speed
V = 2D jye;N] for average speed
inal diameter of workpiece
(mm or in)
Dog average diameter of workpiece
(mm or in)
Do-o1
Dy final diameter of workpiece
(mm or in)
©) The cutting time (s or min)
L- length of cut (mm or in)
© The depth of cut (mm or in)
a= Po- Dy
z
+ MRR- material removal rate
MRR = xD,,,4)N)
© The cutting torque (N-m or lb-ft)
Dang
T =F.
F,~ is the cutting force ‘The cutting power kw or bp
[P = Tw = 2x1)
@- is the angular speed in
(rad/s or rad/min)
DRILLING MACHINE - or drill press is a
‘machine tool used mainly for producing holes in
‘metal. In this machine, the work is securely held
while a revolving cutting tool falls onto it. The
cutting tool is called drill,
‘Types of standard drilling machines
1. sensitive drilling machine
2. standard upright drilling machine
3. heavy duty drilling machine
4. gang drilling machine or multiple spindle
drilling machine
5, multiple-drill-head drilling machine
6. radial drilling machine
Operations
Drilling - is the operation of producing a hole in
solid material by means of a cutting tool called a
rill
Boring - is the process of producing circular
internal profiles in hollow workpieces, or a hole
made by drilling or another process, and is done
with cutting tools that are similar to those used in
tuming.
Reaming - is an operation used to make an
existing hole dimensionally more accurate than
can be obtained by drilling alone and to improve
its surface finish. The most accurate holes are
produced by the following operations; centering,
Grilling, boring and reaming.
I~ A reamer is a multiple-cutting-cdge tool
with straight or helically fluted edges, which
removes very little material.
Work-Holding Attachments
1. Drill vise - is a work holding tool in which
the workpiece may be seated square dnd
parallel and held securely while the drilling
and other operations are performed,
2. Drill jig - is a work holding tool, which
locates the workpiece in proper position and
holds it securely,
3. Parallel bars - are hardened, accurately
ground steel bars of various thicknesses,
widths, and lengths, which are used to raise
the work piece and seat it square and parallel
with the base of a vise.
‘Types of drills
1. twist drill
2. step drill
3. core drill
counter bore and countersink drills
center drill
spade drills
crankshaft drills
gun drill
eI
SHAPER - is a machine tool ordinarily used for
finishing flat or partly curved surfaces of metal
pieces few in number and not usually over
305mm or 610mm long. The cutting tool has a
reciprocating motion and cuts on the forward
stroke only. The work is held in a vise bolted to
the viork table and the regular feed is
accomplished by causing the work table to move
automatically at right angles to the direction of
the cutting tool.
Parts of a Shaper
1. Base - is hollow casting upon which the
other parts of the shaper are mounted, It is
also the reservoir for a supply of oil, which is
circulated to the moving parts of the
machine,
2. Apron - supports the table on the cross rail
and moves it from left to right.
3. Ram - is the main moving part of a shaper. It
holds and drives a cutting tool back and forth
across the work, It is attached to the rocker
arm which is given an oscillating motion by
the tuming of a large driving gear. An
adjustable pin attached to the driving gear as
a crank, which determines the length of the
stroke of the ram.
4. Tool head - holds the cutting tools. Attached
to the front of the arm, it may be swiveled to
the required angle to the left or to the right
and locked in place. It may also be adjusted
vertically and locked in position .The tool
post is fastened to a clapper block, which is
hinged at the top to permit the tool to ride
over the work on the retum stroke.
5. Table - is a metal box attached to the frame
of the shaper. It has T slots on the top and
sides, which are used for clamping the work
or a vise to the table. It may be adjusted
vertically and locked in position. It is
supported in front by a bracket attached to
the base. The bolts connecting the bracket to
the cross arm on which the table rests must
be loosened while the vertical adjustment is
being made,
Universal table - can be operated in the same
‘manner as a standard table or swiveled to the
left or to the right hand and if necessary,
Totated a full circle .A dial plate, graduated in
degrees, indicates the angular setting. The
top surface maybe tilted up to 15° forward or back. It too has graduations in degrees on
its curved edge. All rotating and tilting
movements are manually controlled.
The size of a shaper is determined by the
length of the stroke of the ram.
* The cutting speed equation for the crank
shaper is:
IC, = Lyd
DR 3)
NV- strokes per min
L- length of stroke (inches)
© The time to machine a work piece is:
Ip = #
IN
1 - width of work (inches)
J- feed (in/stroke)
© The return speed can be calculated from;
R, =1.5¢, -£5|
12.2
PLANER- is a machine tool used in the
production of flat surfaces on pieces too large or
too heavy or awkward to hold in a shaper.
Cutting tools used in planer work are the same as,
those used in the shaper. The table or platen, on
which the work is securely fastened, has a
reciprocating motion. The tool head maybe
automatically fed horizontally in either direction
along the heavy supported cross rail over the
‘work and automatic down feed is also provided.
* A planer is designed with a stationary
housing for holding tool heads and a table
with a reciprocating movement for holding
the work; thus the work is moved against the
cutting tool.
* The planer has a ratio of cutting to retum
speed built into its drive mechanism, the
planar ratio. The total time for the planer to
cut a length L in feet is therefore the sum of
the cutting and retum stroke.
* If the total length traveled is equal to one
complete stroke, then the equation for
cutting speed (fV/min) is:
L
Ic, = ML +)
e+e)
AN strokes per min
L- length of stroke (ft)
R-planar ratio
© The return 5
a,
is given by:
RC,
‘+ The fime to machine (s or min) is calculated
from:
W
ir = “|
a
W - width of work (inches)
(f- feed (in/stroke)
MILLING MACHINE - is a machine tool in
which metal is removed by means of a revolving
cutter with many teeth, each tooth have a cutting
edge. A milling machine designed and
constructed that the table may be swiveled to a
considerable angle in horizontal plane to permit
the milling of spiral grooves. The work table
may be longitudinally, by hand or automatically,
in either direction, called the longitudinal feed or
table feed. The saddle is arranged on the knee
that it maybe moved transversely by hand or
power in either direction, called crossfeed. The
vertical movement of the knee maybe used as a
vertical hand feed in either direction and in the
larger sizes automatic vertical feed is provided.
Operatio
1. Slab Milling - also called peripheral milling,
the axis.of cutter rotation is parallel to the
workpiece surface to be machined.
2. Face Milling - the cutter is mounted on a
spindle having an axis of rotation
perpendicular to the workpiece surface.
3. End Mitting - the cutter usually rotates on an
axis perpendicular to the workpiece, although
it cam be tilted to machine tapered surfaces.
Flat surfaces as well as various profiles can
be produced by end milling.
‘Summary of milling parameters and formulas
‘* Cutting speed or the pheripheral speed of the
cutter:
7 = DN
D- cutter diameter
N-- rotational speed of the cutter
* The undeformed chip thickness 1, (chip deep
of cut) can be determine by the equation:
J feed per tooth of the cutter, measured
along the wor
© Feed per tooth
equation:
5
ar
v - linear speed(feed rate) of the
workpiece nm ~ number of teeth on the cutter
Periphery.
‘The cutting time tis given by the expression;
T+l,
Ie
¥
1 -length of workpiece
J. - extent of the cutter’s first contact with
the workpiece,
© The material removal rate;
MRR = fed = way
w - width of cut, which for a workpiece
narrower than the length of the cutter.
GRINDING MACHINE- is a machine tool in
which an abrasive wheel is used as a cutting tool
to obtain a high degree of accuracy and smooth
finish on metal parts, including soft and hardened
steel.
© Abrasive - is nay material that can wear away
a substance softer than itself Sand and
sandstone are perhaps the oldest abrasives
known to mankind. Prehistoric man used
sand and sandstone to form ot shape edges of
tools. As tools became more and more
important for preservation of life, he became
more dependent on natural abrasives for the
‘maintenance of sharp tools,
« Emery and corundum are two natural
abrasives commonly used in industry to
sharpen tool edges. They occur as a mineral
deposit in the earth's crust. These abrasives,
formed into wheels, are superior to the old
sand grindstones. Although they can cut
faster and be made coarse or fine, they
cannot meet the demands of modem
manufacturing because they contain
impurities that are difficult to extract and
because the pércentage of the important
cutting clement, aluminum oxide is not
constant. 2
* Diamond is the only other element known to
be harder than emery or corundum is, but its
‘cost was prohibitive for industrial usage.
* Silicon carbide is best suited for grinding
‘materials that have low tensile strength but
are very hard, such as ceramics, pottery and
‘tungsten carbide.
+ Aluminum oxide is resistant to shock due to
its toughness therefore suitable for grinding
‘materials of high tensile strength such as tool
steel and high speed steel
* Man-made abrasive: have a distinct
advantage over natural abrasives because
purity and grain size can be readily
controlled.
© Grain size is important because undersize
grains cannot do their share of work, and
oversize grains give work a poor finish.
© Grinding wheels are formed by using a
suitable material to cement, or bond, the
abrasive grains together in the desired shape.
‘The hardness of the wheel is dependent
upon the amount and kind of bonding
material is used. The hardness of a wheel is
always understood to mean the strength of
the bond.
© There are many different kinds of bonds.
Those most commonly used are vitrified,
silicate, shellac rubber and resinoid. The
vitrified and silicate are used more frequently
than the others.
Factors affect the selection of a grinding
wheel
1, The kind of material to be ground
2. The amount of stock to be removed
3. The accuracy as to size
4, The kind of finish required
5. The area of contact between the wheel and
the work
6. The kind of grinding machine to be used.
In most modem grinding machines, the speed.
of the wheel is fixed and unchangeable. In
others, the spindle speed can be altered by
changing to different sized pulleys.
BORING MILL - consist of two types: the
vertical and horizontal boring mill.
Boring is a machining operation of
enlarging a hole, usually by means of a single
cutting tool and designed primarily for the
purpose of finishing holes that are not possible to
other machines.
METAL CUTTING BAND SAWS - a machine
tool designed t6 cut everything all the time,
because it employs an endless band with a sharp
teeth moving in one direction. There is no back
stroke.
TURRET LATHE - a production lathe
primarily consist of multiple-station tool holders
‘or turrets, in place of a lathe compound rest and
tailstock. These turrets permit the presetting of
the total number of cutters required for the job
and allow multiple and combined cuts from both
turrets to operate on the workpiece
BROACHING MACHINE . the operation of
broaching is similar to shaping, it uses multiple teeth, and can
cance machine intemal and extemal
such as holes of any cross-sectio
keyways, teeth of intemal gears, multiple ‘pling
holes and flat surfaces. There are two broad
classes of broaching machines available for
performing almost and variety of broaching
Operations, the vertical and horizontal, either of
which may have one or more arms, drives are
either hydraulic or mechanically operated. The
cutting tool for this machine is term broach, a
Jong multitooth cutting tool with successively
deeper cuts.
MECHANICAL PRESSES. - these are
classified on the basis of the construction of the
frame, the mechanism for providing motion to
the ram, and whether or not it is provided with
the auxiliaries required by an automatic press.
On the basis of frame design, the presses are
classified as gap or C frame, arch type, straight
side, and pillar presses.
HYDRAULIC PRESSES- are built in sizes
varying from % ton bench-type to huge 15,000
ton four-post presses. The available operating
stroke of hydraulic presses is substantially longer
than the corresponding size of mechanical press.
FINISHING OPERATIONS
1, Honing is an operation used primarily to
give holes a fine surface finish. The
honing tool consists of a set of aluminum
oxide or silicon carbide bonded
abrasives, called stones.
2. Lapping is a finishing operation used on
flat or cylindrical surfaces, The lap is
usually made of cast iron, copper, leather,
or cloth.
3. Polishing is a process that produces a
smooth, lustrous surface finish.
2
SHOP TOOLS AND‘THEIR USES
BELT (HOLE) PUNCH - used for cutting the
bolt holes in gasket materials or in leather
belting.
BOLT CUTTERS - made in several sizes from
18-36 inches used for heavy duty cutting jobs. It
has special replaceable jaws of extra hard metal
alloys-to avoid twisting motion when material is
brittle.
CALIPERS-are used for:measuring diameters
and distance of for comparing distances and
sizes. Types are:
1, Outside Calipers- used for measuring
outside dimension.
Example: Diameter of a piece of round
stock
2. Inside Calipers- have inward curving legs
for measuring inside diameters,
‘Example: diameter of holes
3. Hermaphrodite calipers—are generally
used to scribe arc for marking gage in
layout work
(CENTER GAGE- edge of this gage has 60°,
used to check the grinding of thread cutting
tools.
CHISELS - cold chisels are used for chipping or
cutting cold metal. Classified according to their
shape:
1, Flat chisels - used and determined by the
width of the cutting edge.
2. Cape chisels - used for cutting key ways
where. square comers on the slot are
necessary.
3. Round nose chisels - usually used for
cutting oil grooves in bearing
4, Diamond pt. chisels - used for cuttnig
“V" groove and inside sharp angles.
CLAMPS - when a vise not available, a clamp
may be used to hold pieces of material tag while
they are being worked on. Types: hand screw,
toolmakers, carriage screw and beam clamps.
COMBINATION CALIPER RULE - has jaws
designed to make either inside or outside
‘measurements.
CUTTING & FLARING TUBES - consist of a
small tubing used for reftigeration lines and
similar purposes by using tubing cutter. Flaring
tubing used to expand the end of the tubing
connections.
PIPE CUTTER - usually cut with a hand
hacksaw, a power hacksaw or a pipe cutter. Pipe
cutter most popular used on most ships; these are
only adjusted and tightened by tuming the
handle.
DEPTH RULE: has a narrow blade which slide
through a slotted locking arrangement, used to
‘measure the depth holes, slots, keyways, etc.
DIES - consist die and stock, before threading @
piece of round stock its end should be tapered or
chamfered slightly with a file or by grinding, 0
that die will start cutting more easily, DRILLS - made of carbon steel high speed
alloys steel used for general purposes, making a
smaller to larger holes. Normally used to fold
the piece of metal to be drilled is a clamp block.
FILES-are used for cutting “smoothing or
removing small amounts of metal, made in
various shapes, cut of teeth and length.
HACKSAW - is used for cutting metal. Types
are solid and adjustable. Solid type can hold only
one side of blade while adjustable type can be
fitted with different length blades. Hacksaw
blade come in two forms-hard back and flexible
back.
HAMMERS - consist of ball pen or machinist
hammer used for general purposes:
© Soft bammers-used for hammering or
working on a finished surface in order not be
marked. .
© Sledge hammers - made of heavy weight
metals between 5 up to 25 pounds used for
producing heavy blows.
HANDSNIPS - these are used for cutting sheet
‘metal or other thin pieces of metal. Also used for
cutting out circular pieces.
MICROMETER CALIPERS - is the most
commonly used adjustable gage. The types are:
© Outside micrometer- used to measure outside
dimension, such as diameter of a piece of
round stock.
© Inside Micrometer- used for measuring
inside dimension, example, inside diameter
of a tube or hole, bore cylinder.
NUTS, BOLTS AND SCREWS - used for
fastening or holding metal parts together in
assembly and disassembly, and that on occasion
must be removed in taken part. Cap screw and
machine screw are always used without nuts.
OFFSET SCREWDRIVER - used for screws
located in accessible places
PACKING TOOLS - are used to remove soft
packing from the packing gland of values and
‘pumps.
PHILIP SCREWDRIVER - used for Philips
type screws only
PLIERS - A 7
‘work and aoe Se purposes, electrical
‘Types are: better gripping,
Combination - has one arm of the slip
joint slotted, can be slipped from one
position to another.
* Side cutting plier- used to a electrical
work in stripping the wire insulation.
‘* Needle nose plier- used to get into tight
‘spaces or comers.
© Flat jaw- used teeth for better gripping of
nuts and measure overall length
«© Diagonals- are a special type of pliers
used exclusively for cutting and stripping
electrical wire.
PROTRACTOR - used in measuring or lying
‘cut anglers, usually made of a transparent
substance such as celluloid, semi circular shape
upto 180°
PUNCHES - consist of several types depend on
used for a variety of jobs done.
© Center punch - used to make a starting mark
fora drill when holes are to be drilled
«Prick punches - usually used for marking
centers and lines in a layout work.
© Starting punches - have long tapes from the
tip to the body and can stand heavy blows
used for knocking out rivets, bolts, etc.
© Pin punch - designed to follow through the
bole without jamming
* Aligning punch- used to line up
corresponding holes in adjacent parts of
the engine
© Drift punch- is a long tapered punch
used for loosening straight pins, taper
pins, rivets and other small parts being
disassembled
RATCHET SCREWDRIVER - a very handy
tool, that can handle infirm grasp does not turn
ccontigually called standard screwdriver
REAMERS - used in precision work to smooth
and enlarge holes to exact size. Types are
‘expansion reamer and taper reamer.
RIVETS - not thread form, are used for metal
listeners for permanent and not subject to
disassembly or taken apart
SCRAPPERS - made in many forms, used for
seraping or removing high spot from flet
surfaces, to refit a bearing,
‘SCREWDRIVERS - generally bas one purpose,
to tighten or loosen screws, Types are regular,
offset, ratchet and Phillips screw drivers. DRILLS - made of carbon steel high speed
alloys steel used for general purposes, making a
smaller to larger holes. Normally used to fold
the piece of metal to be drilled is a clamp block.
FILES-are used for cutting “smoothing or
removing small amounts of metal, made in
various shapes, cut of teeth and length.
HACKSAW - is used for cutting metal. Types
are solid and adjustable. Solid type can hold only
one side of blade while adjustable type can be
fitted with different length blades. Hacksaw
ae come in two forms-hard back and flexible
ck.
HAMMERS - consist of ball peen or machinist
hammer used for general purposes:
© Soft bammers-used for hammering or
working on a finished surface in order not be
marked.
‘© Sledge hammers - made of heavy weight
metals between 5 up to 25 pounds used for
producing heavy blows.
HANDSNIPS - these are used for cutting sheet
‘metal or other thin pieces of metal. Also used for
cutting out circular pieces.
MICROMETER CALIPERS - is the most
‘commonly used adjustable gage. The types are:
Outside micrometer- used to measure outside
dimension, such as diameter of a piece of
round stock.
+ Inside Micrometer- used for measuring
inside dimension, example, inside diameter
ofa tube or hole, bore cylinder.
NUTS, BOLTS AND SCREWS - used. for
fastening or holding metal parts together in
assembly and disassembly, and that on occasion
must be removed in taken part. Cap screw and
machine screw are always used without nuts.
OFFSEF SCREWDRIVER - used for screws
located in accessible places
PACKING TOOLS - are used to remove soft
packing from the packing gland of values and
pumps.
PHILIP SCREWDRIVER - used for Philips
type screws only
PLIERS - uséd for genera i
purposes, electrical
work and for better gripping’ "
'ypes are:
‘© Combination - has one arm of the slip
int slotted, can be slipped from one
position to another.
+ Side cutting plier- used to a electrical
work in stripping the wire insulation,
© Needle nose plier- used to get into tight
spaces or comers.
‘+ Flat jaw- used teeth for better gripping of
nuts and measure overall length
‘© Diagonals- are a special type of pliers
used exclusively for cutting and stripping
electrical wire.
PROTRACTOR - used in measuring or lying
ccut anglers, usually made of a transparent
substance such as celluloid, semi circular shape
up to 180°
PUNCHES - consist of several types depend on
used for a variety of jobs done.
© Center punch - used to make a starting mark
fora drill when holes are to be drilled
© Prick punches - usually used for marking
centers and lines in a layout work.
© Starting punches - have long tapes from the
tip to the body and can stand heavy blows
used for knocking out rivets bolts, etc.
‘+ Pin punch - designed to follow through the
hole without jamming
© Aligning punch- used to line up
corresponding holes in adjacent parts of
the engine
‘© Drift punch- is a long tapered punch
used for loosening straight pins, taper
pins, rivets and other small parts being
disassembled
RATCHET SCREWDRIVER - a very handy
tool, that can handle infirm grasp does not turn
continually called standard screwdriver
REAMERS - used in precision work to smooth
‘and enlarge holes to exact size. Types are
expansion reamer and taper reamer.
RIVETS - not thread form, are used for metal
listeners for permanent and not subject (0
disassembly or taken apart.
SCRAPPERS - made in many forms, used for
seraping ot removing high spot from flat
surfaces, to refit a bearing.
SCREWDRIVERS - generally has one purpose,
to tighten or loosen screws, Types are regular,
offset, ratchet and Phillips screw drivers. SCREW GEARED CHAIN HOIST - a handy
Portable hoist which is light and powerful, that
hold securely and will not lower unless the chain
is pulled.
SCREW PITCH GAGE - used to check the
‘umber of threads on bolt, screw nut, etc. Each
blade or finger is stamped with the number of
threads cut on it,
‘SCRIBER - used to make clean narrow lines on
metal, made up of tool steel having single and
double end,
SHEET METAL SCREW - used to hold
together section of sheet metal, fiber, plastic, etc.
especially on board for insulation purposes.
SPEED INDICATOR - indicate the number of
revolutions per minute made by an electric
motor, turbine rotor, and other revolving
equipment.
SQUARE & COMBINATION SET - used to
setibe, measure and check angles, to construct
line at right angles to the edge of a piece of
material, to establish points for lines parallel to
the edge, and guide for other instrument,
TACHOMETER - differs from speed indicator;
it directly registered revolutions of the rotating
shaft, no timing or computation being necessary
TAPS - usually in sets of three for each diameter
and thread series, set contain a taps,. plug and
bottom tap. Usually used for making and exact
hole thread each job.
‘THICKNESS GAGE - or feeler gage is used for
‘measuring distances of,¢learances between two
surfaces. The number ‘stamped on each blade is
thickness of that particular blade in thousandths
of an inch.
WIRE AND SHEET GAGE - used to measure
cross sections of wire and sheet gage and to
determine the thickness of metal sheets,
WRENCHES ~ are tools for tightening or
removing bolts, nuts, studs, etc, or for gripping
round material such as pipe, stud, round rod,
classified in three heading adjustable, solid and
open end. Also for their shape like S-wrench,
angle, pipe, monkey, tap wrenches.
‘+ Single-ended wrench- is one that is made to
fit one size of nut or bolt.
Double-ended wrench- has two openings,
fone at each end of the handle, to fit two
different sizes of nuts or bolts heads.
Closed-end wrench- is similar to a single-
ended wrench, but, because it entirely
encloses a nut, there is little danger of the
wrench slipping off the nut or of the jaws
spreading apart.
Adjustable wrench- has a movable. jaw,
which makes it adjustable to various sizes of
nuts.
Lever-jaw wrench- is a combination
gripping tool with adjustable jaws, which
maybe locked in place.
Combination wrench- has two types of
openings of the same size.
Tool post wrench- is a combination box and
opemend wrench.
‘Square box wrench- is a single head closed-
‘end wrench having a rather short handle.
‘T-handle tap wrench- is used to hold and
tum small taps up to about 0.5 in Jt usually
has two inserted jaws, which can be adjusted
to fit the square end of the tap.
‘T-socket wrench- is made in the form of a
'
Strap wrench- is used for turning cylindrical
parts or pipes, or revolving any job on which
the surface finish must be preserved.
ipe wrench - is designed with adjustable
jaws that are serrated, making it possible to
‘gzip round pipe and other cylindrical pars,
Torque wrench- are used when it is
necessary to know the amount of turning or
‘twisting force being applied to a nut. MACHINE
QUESTIONs, SHOP PRACTICE REVIEW
2) What is di
What is diference betwesn a shaper and a
4@. the tool of the sh
fat oft the Planer is stationary,
. the : i
wie the planer eaunat tans eration
cc. the shaper handles la1 Tr
planer handles only. Tena poses eh
@. the tool of the shaper moves in
reciprocating motion while the tool in ‘the
planer move in rotary motion
2) Caleulate the revolutions per minute required to
finish-tum a 25 in, diameter piece of machine
steel (Cutting speed for machine sted is 100
ft/min)
A.40 8.79.57
C.250 D153,
3) Device used to measure speed accurately ;,
a. speedometer ‘b. dial indicator
©. tachometer 4. dial gauge
4) The purpose of these parts in application is to
have better bearings to seal the guard against
marring ete.
‘a. a. bearing journal
b. bd. metallic seal
© ¢. washer
d. di shaft seal
) The best instrument for measuring a thousandth
ofan inch:
‘a. micrometer _ b. tachometer
, c.caliper _ d. pyrometer
©) Calculate the revolutions per minute required to
finish-turn a 45-mm diameter piece of machine
steel (Cutting speed for machine steel is 30
m/min)
a. A209 B.1g50
| b. C213 1.667
| 7) Which of the following is not used to resemble
the shape of tool bit?
‘a. round nose b. center cut
e square nose __d-thread cutting
8) A shaft is to be checked for eccentricity. A
Suitable method of performing the checks:
‘a. bench centers and dial indicator
b.bench side and caliper
¢ bench top and tachometer
4. bench target and seriber
| 9) What is the cutting speed in m/min of a tool
passing thru a 75 mm diameter material at 4 Hz?
A57 B. 942
C388 D. 2261
| 10) Alathe with multiple cutting stations:
j a.turret lathe b. lathe
| shaper ‘@ mone of
the above
43) The most known lubricants being utilized in
whatever category of load and speed are oil, air,
\| ‘grease and dry lubricants like:
il abronze blend
} graphite
/ 12) "is work supporting device which is
t DoReT tthe saddle of the lathe machine. 1
travels with the cutting tool. It is a prevention of
the springing away of the work piece from cutting
tools
a. rubber-flex collets
b. tool post
g follower rest
carriage stop
13) The following are parts of
se goontng re pars of a micrometer caliper
athimble b. head serew
say Thence sBinge dean
ive principal parts of as
Toolalie base atin and nn we He be
acolumn _b,vise
ss) Compare memMIO apo
ompute for cutting speed in fpm of a
with’ inches dlameter and runaing at oo ran
a7 b102 662 dga
16) A research agency handling assistance to all
foundry, machine shop and metallurgical plant
operation
@. MIRDC b. all ofthese °
¢.DOST 4.BOL
end can also be generally
17) Ina cutting tool, cutis
called.
a, end cutting edge
a
b. binose
c — c-backrake
d. disiderake
18) What factors can’ modify the recommended
cutting speed of known work piece?
‘a. rough cutting of work piece
’, modify the shape ofthe cutting tools
«use correctly shaped cutting tools
d. depth of cut
39) A machine shop equipment that can fatten
horizontally, vertically or angular plane.
a. shaper machine
D. b. welding machine
© drill machine
4. power saw
+20) Which of the following services is not considered
to be work of machinist?
‘a.reboring b. grinding
c.overhauling d. honing
a1) Type of chuck wherein the workpiece with
standard diameter or size could be attached fast
‘and quick especially small size work of mass
production.
a. lathedrive plate
b. collet attachment
fe. steady center rest
4._ clamp toe do
‘ot ‘high’ carbon and alloy used in the
22)
production of precision work tools.
‘a. chrome manganese
b. titanium
high speed
Ne olybdemin
sade of tool blank consist of faces
es
c. round nose ae
24) The cutting tool ‘used in the shaper. simi
ie
Ce tba
come usttioane
ee. 15-38 ‘tooth/is,
ere 26) Alathe carri
iage part tha
cary the erat side and
. automatic feed
apron
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