WORKSHOP TECHNOLOGY ASSIGNMENT # 01 CNC MACHINING CENTRE

INTRODUCTION: MACHINING
Machining, as a fundamental method of material removal, has evolved from individual machines which, with the aid of man, performed individual processes to machines capable of performing many processes such as turning, drilling, milling, shaping, broaching, and grinding.

CNC MACHINING
What is CNC machining? CNC machining refers to machining whereas the machine tool operates under numerical control. CNC stands for computer numerical control. CNC

machines are programmed with a cnc machining language commonly referred to as g-code. The CNC machining g-code language tells the cnc machine the cartesian coordiantes through which the cutter (end mill) should pass. The CNC machining g-code language also controls feed rates and other functions of the CNC machine such as spindle speeds, tool changers, coolant, etc. CNC machining has many advantages over manual machining. CNC machining produces parts that are very precise and repeatable. CNC machining can produce parts with complex geometries that would virtually impossible to produce with manual machining. CNC machining technology is widespread and most machine shops utilize CNC machining

TYPES OF CNC MACHINING

The most common forms of CNC machining in a typical machine shop are CNC milling, CNC turning and CNC wire EDM. A machine tool used to perform cnc milling is called a milling machine or CNC machining center. A lathe that is under CNC control to perform cnc machining (CNC turning) is often called a cnc turning center. CNC machining g-code can be programmed manually, but most machine shops use CAM software (computer aided manufacturing) to read the CAD (computer aided design) file and automate the generation of g-code to control the cnc machining.

HISTORY OF FORMATION OF MACHINING CENTRES

In the early 1950s:It became possible to control the movement of machine tools by numbers and soon numerically controlled (NC) milling machines, NC drilling machines and NC boring machines were commercially available. In 1968: Kearney & Trecker marketed a NC machine that could automatically change tools so that many different processes could be done on one machine. Such a machine became known as a Machining center __a machine that can perform and change tools automatically while under programmable control. Programmable control means that the workpiece can be moved, using software to specific locations and can even machine multiple surfaces. The study of machining centers begins with the history of NC. NC is programmable automation in which certain functions of the machine tools are

controlled by numbers or letters. The program of instruction defines how a particular part is to be made. If the design changes, it is necessary to change the program instructions. Nowadays, writing software programs for instruction/ control of machines is fairly common but in 1955, before the advent of NC machines, it was unheard of.

TYPES OF MACHINING CENTRES:

There are two main types of machining centers, - horizontal spindle type - vertical spindle types There are two main types of horizontal spindle machining centers. - traveling- column type - fixed-column type.

Horizontal spindle machining center

CONSTRUCTION AND OPERATION OF SOME COMMON TYPES OF MACHINING CENTRES:

The traveling column type: The traveling column type is equipped with one or usually two tables on which the work is mounted. With this type the column move and while it is machining the work on one table, the operator is changing the workpiece on the other table. The fixed column type: The fixed column type is equipped with a pallet shuttle.The pallet is a removable table on which the workpiece is mounted. With this type, after one

workpiece has been machined, the pallet is forced off the receiver onto the shuttle. The shuttle is then rotated bringing the new pallet into position for unloading.

(A) A new pallet ready for loading while the other pallet is ready for unloading. (B) Pallet being shuttled onto the receiver. (C) The pallet being moved into machining position.

OPERATION OF COMPUTER NUMERICAL CONTROL (CNC) SYSTEM IN MACHINING CENTRES:

The computerized numerical control (CNC) is built around a minicomputer and is either mounted on the machine or in a separate unit beside the machine. In unmanned machining centers, the computer controls the total program. It programs the parts the parts onto the machine and up to the spindle. It selects the proper program for the part and then carries out the machining program and controls the loading and unloading often performed by robots. Storage Capacity: There will also be storage for 15 to 20 programs for machining different parts as well as program editing capabilities. Indication of Malfunctioning: Most computer controls are now capable of adjusting automatic blacklash and lead screw compensation, as well as indicating any malfunction in the machine or any errors in the programs function. This diagnostic display informs the operator of any problems in the machine or control and, by referring to a maintenance manual, the user can normally correct the problem. On some controls, diagnostic units can be tied in by long distance telephone to a mainframe computer in the machine or control manufacturers plant. There the problem is assessed immediately and instructions given by phone to the user.

CNC MACHINING CENTRES EQUIPPED WITH AUTOMATIC, NUMERICAL CONTROLLED TOOL CHANGING OPERATION:
All machining centers are equipped for automatic, numerically controlled tool changing, which is much faster and more reliable than manual tool changing. The tools are held in a storage chain (matrix) and each is identified by either the tool number or the storage pocket number. This information is stored in the computer memory. While one operation is being performed on the workpiece, the tool required for the next operation is moved to the pick-up position where the tool-change arm removes and holds it. Immediately on completion of the machining cycle, the tool change unit swings 90 degree to the tool change position. The tool-change and then rotates 90 degree and removes the cutting tool from the spindle. It then rotates 90 degree and places the new cutting tool in the spindle after which it returns the old cutting tool to its position in the tool carrier. This whole operation is completed in about 11 s.

CNC MACHINING CENTRES ACCESSORIES:

The special accessories of CNC Machining centers give exceptional characteristics to the machine making it unique and providing more facilities for use. Some of them are listed below.

TORQUE CONTROL MACHINING:

A feature that is fast becoming popular is that of torque control machining, the torque being calculated from measurements at the spindle drive motor. This device will increase productivity by preventing or sensing damage to the cutting tool. The torque is measured when the machine is turning but not cutting, and this value is stored in the computers memory.
Torque control raises or lowers the feed rate depending on the depth of cut at any time during the cutting cycle

PRECISION SURFACE-SENSING PROBE:

The precision probe is an extremely sensitive stylus for setting up and checking workpieces on the machining center. The probe is stored in the tool storage matrix and is loaded in the spindle, when required, to determine if the work is mounted and positioned properly. If there is not enough material on the workpiece or if the workpiece is not positioned properlyon the pallet, the probe will reject the part and the computer will call up the next workpiece.

THE PROCESSING CENTRE:

The Cincinnati Milacron T-10 machining center may be equipped with an eight pallet automatic work changer (AWC) that includes a manually indexible load-unload work station to permit loading and unloading while the machine is running. With this addition , eight alike or different parts may be loaded on the palestand presented to cutting tool(s) for the machining operations required. The operations for each part are programmed into the computer and if the workpiece is accepted by the probe, the computer will select the proper program and the machine will perform the necessary operations on it. This setup permits the machining of eight different parts automatically.

The processing center is a machine designed for the factory of future.

CNC MILLING MACHINE:

Most CNC milling machines or machining centres are computer controlled vertical mills with the ability to move the spindle vertically along Z-axis.This extra degree of freedom permits their use in engraving applications, and also allows to create 2.5D surfaces such asrelief sculptures. When combined with the use of conical tools or a ball nose cutter, it also significantly improves milling precision without impacting speed, providing a cost-efficient alternative to most flat surface hand-engraving work.

MACHINE FEATURES The main features of a typical CNC milling machine are shown in Figure. The machine consists of a rigid base with a moveable horizontal worktable, vertical tool spindle, automatic tool changer, and controller unit. It is designed and built to maintain a high accuracy of movement and to reduce static and dynamic deflection as well as vibration, resulting from high cutting loads and thermal distortion.

ADVANTAGES OF CNC MACHINING CENTRES:

1- Increased productivity. 2- This type of machine can machine to closer tolerances. This means, -Fewer finishing operations required, such as grinding or scraping. -Less chance of error because fewer machines are being used. -Less inspection required. -Less paper work needed. -Lower rejection or scrap rate. 3- Reduction in inventory because there is less floor time between operations.

THREADS INTRODUCTION
Threads. have been used for many hundreds of years for holding parts together, making adjustments to tools and instruments, and for transmitting power and motion. A thread is basically an inclined plane or wedge that spirals around a bolt or nut. Threads have progressed throughout the ages from the early screws, which were filed by hand, to the highly accurate ball screws used on the precision machine tools of today. Although the purpose of a thread is basically the same as when the early Romans developed it, the art of producing threads has continually improved. Today threads are massproduced by taps, dies, thread rolling, thread milling, and grinding to the very high standards so necessary for accuracy and quality control. Thread cutting is a skill that every machinist should possess since it is still necessary to cut threads on an engine lathe, especially if a special size or form of thread is required

DEFINITION OF THREADS
A thread may be defined as a helical ridge of uniform section formed on the inside or outside of a cylinder or cone. Threads are used for ,several purposes. 1. For fastening devices such as screws, bolts, studs, and nuts. 2. To provide accurate measurement as in a micrometer. 3. To transmit motion. The threaded lead screw on the lathe causes the carriage to move along when threading. 4. To increase torque. Heavy work can be raised with a. screw jack.

THREAD TERMINOLOGY
A screw thread is a helical ridge of uniform section formed on the inside or outside of a cylinder or cone. An external thread is cut on an external surface or cone such as on a cap screw or a wood screw. An internal thread is produced on the inside of a cylinder or cone, such as the thread on the inside of a nut. The major diameter is the largest diameter of an external or internal thread. ' The minor diameter is the smallest diameter of an external or internal thread. This was formerly known as the root diameter.

The pitch diameter is the diameter of an imaginary cylinder which passes through the thread at a point where the groove and thread widths are equal. The pitch' diameter is equal to the major diameter minus a single depth of thread. The tolerance and allowances on threads are given at the pitch diameter line. The pitch diameter is also used to determine the outside diameter for rolled threads. The diameter of the blank is always equal to the pitch diameter of the thread to be rolled. Thread rolling is a displacement operation and the amount of metal displaced is forced up to form the thread above the pitch line. The number of threads is the number of crests or roots per inch of threaded section. This term does not apply to metric threads. Pitch is the distance from a point on one thread to a corresponding point on the next thread, measured parallel to the axis. Pitch is expressed in millimeters for metric threads. Lead is the distance a screw thread advances axially in one revolution. On a single start thread, the lead and the pitch are equal. Root is the bottom surface joining the sides of two adjacent threads. The root of an external thread is on its minor diameter. The root of an internal thread is on its major diameter. Crest is the top surface joining two sides of a thread. The crest of an external thread is on the major diameter while the crest of an internal thread is on the minor diameter. A flank (side) is a thread surface which connects the crest with the root. Depth of thread is the distance between the crest and root measured perpendicular to the axis. Angle of thread is the included angle between the sides of a thread measured in an axial plane. The helix angle (lead angle) is the angle which the thread makes with a plane perpendicular to the thread axis. A right-hand thread is a helical ridge of uniform cross section onto which a nut is threaded in a clockwise direction. When the thread is held in a horizontal position with it&' axis pointing from right to left, a right-hand thread will slope down and to the right. When a right-hand thread is cut on a lathe, the toolbit advances from right to left. A left-hand thread. is -a helical ridge of uniform cross section onto which a nut is threaded in a counterclockwise direction. When the thread is held in a horizontal position with its axis pointing from right to left, the thread will slope down and to the left. When a left-hand thread is cut on a lathe the toolbit advances from left to right.

'THREAD FORMS
Over the past several decades, one of the world's major industrial problems has been the lack of an international thread standard whereby the thread standard used in any country could be interchanged with that of another country.

ISO METRIC THREAD STANDARD:

In April 1975, the ISO drew up an agreement covering a standard metric thread profile, the sizes and pitches for the various threads in the new ISO Metric Thread Standard. The new series has only 25 thread sizes ranging in diameter from 1.6 to 100 mm. Countries throughout the world have been encouraged to adopt the ISO series. These metric threads are identified by the letter M, the nominal diameter, and the pitch. For example, a metric thread with an outside diameter of 5 mm and a pitch of 0.8 mm would be identified as follows: M 5 X 0.8. The ISO series will not only simplify thread design but will generally produce stronger threads for a given diameter and pitch and will reduce the large inventory of fasteners now required by industry. The ISO metric thread has a 60 included angle and a crest equal to 0.125 times the pitch, similar to the National Form thread. The main difference,

however, is the depth of thread (D), which is 0.6/34 times the pitch. Because of these dimensions, the flat on the root of the thread (FR) is wider than the crest (FC). The root of the ISO metric thread is one-fourth of the pitch (0.250P).

The American National Standard thread :

It is divided into four main series, all having the same shape and proportions. National Coarse (NC), National Fine (NF), National Special (NS), and National Pipe (NPT). This thread has a 60 angle with a root and crest truncated to one-eighth the pitch. This thread is used in fabrication, machine construction and assembly, and for components where easy assembly is desired. The formula for calculating the depth of a 100 percent thread is 0.866/N. However, since this thread would be very difficult to cut (especially internally) the following formula, which gives 75 percent of a thread, is generally a standard in the industry. This thread application is the same as for the American National form thread. D = 0.6495 X P or 0.6495/N F = 0.125 X P or 0.125/N

The British Standard Whitworth Thread (BSW)

It has a 55 degree V-form with rounded crests and roots. This thread application is the same for the American National form thread.

D = 0.6403 x P or 0.6403/N R = 0.1373 X P or 0.1373/N

The Unified thread:

It was developed by the United States, Britain, and Canada, so that equipment produced by these countries would have a standardized thread system. Until this thread was developed, many problems were created by the non-interchangeability of threaded parts being used in these countries. D-(external thread) = 0.6134 X P or 0.6134/N (internal thread) = 0.5143 X P or 0.5143/N F-(external thread) = 0.125 X P or 0.125/N (internal thread) = 0.250 X P or 0.250/N

The American National Acme thread :

It is replacing the square thread in many cases. It has a 29angle and is u!!ed for feed screws, jacks, and vises. D = minimum 0.500P = maximum 0.500P + 0.010 F = 0.3707P C = 0.3707P - 0.0052 (for maximum depth)

The Brown and Sharp worm thread :

It has a 29 included angle as the Acme thread; however, the depth is greater and the widths of the crest and root are different. This thread is used to mesh with worm gears and transmit motion between two shafts at right angles to each other but not in the same plane. The self-locking feature makes it adaptable to winches and steering mechanisms. D = 0.6866P F = 0.335P C = 0.31OP

The square thread :

It is frequently being replaced by the Acme thread due to the difficulty of cutting it, particularly with taps and dies. Square threads were often found on vises and jack screws D = 0.500P F = 0.500P C = 0.500P + 0.002

The international metric thread It is a standardized thread used in Europe. This thread has a 60included angle with a crest and root truncated to oneeighth the depth. Although this thread is used extensively throughout Europe, its use in North America has been confined mainly to spark plugs and the manufacture of instruments. D = 0.7035P (maximum) 0.6855P (minimum) F = 0.125P .R = 0.0633P (maximum) and 0.054P (minimum

THREAD FITS AND CLASSIFICATIONS

Certain terminology is used when referring to thread classifications and fits. To understand any thread system properly, the terminology relating to thread fits should be understood. . Fit is the relationship between two mating parts which is determined by the amount of clearance or interference when they are assembled. Allowance is the ,intentional difference in size of the mating parts or the minimum clearance between mating parts (Fig. 49-11). With threads, the allowance is the permissible difference between the largest external thread and the smaliest internal thread. This produces the tightest fit acceptable for any given classification. The allowance for a 1 in.-8 UNC (Unified National Coarse) Class 2A and 2B fit is: Minimum pitch diameter of the internal thread (2B) = 0.9188 in Maximum pitch diameter of the external thread (2A) = 0.9168 Allowance or intentional difference = 0.002 in. Tolerance is the variation permitted in part size. The tolerance may be expressed as plus, minus, or both. The total tolerance is the sum of the plus and minus tolerances. For example, if a size is 1.000 :t 0.002, the total tolerance is 0.004. In the Unified and National systems, the tolerance is plus on external threads and minus on internal threads. Thus, when a thread varies from the basic or nomimiI size, it will ensure a freer rather than a tighter fit. The tolerance for a 1 in.-8 UNC Class 2A thread is: Maximum pitch diameter of the external thread (2A) = 0.9168 in Minimum pitch diameter of the external thread = 0.9100 in Tolerance or permitted variation = 0.0068 in. Limits are the maximum and minimum dimensions of a part. The limits for a 1 in.-8 UNC Class 2A thread are: Maximum pitch diameter of the external thread (2A) = 0.9168 in Minimum pitch diameter of the external thread (2A) = 0.9100 in

The pitch diameter of this thread must be 'between 0.9168 in. (upper limit) and 0.9100 in. (lower limit). Nominal size is the designation used to identify the size of the part. For example, in the designation of 1 in.-8 UNC, the figure 1 indicates a 1-in.-diameter thread. Actual size is the measured size of a thread or part. The basic size is the size from which tolerances are set. Although the basic major diameter of a 1 in.-8 UNC Class 2A thread is 1.000 in., the actual size may vary from 0.998 to 0.983 in.

CLASSIFICATION OF THREAD FITS

With wide use of threads, it became necessary to establish certain limits and tolerances to properly identify classes of fit. ISO Metric Tolerances and Allowances The ISO metric screw thread tolerance system provides for allowances and tolerances defined by tolerance grades, tolerance positions, and tolerance classes. Tolerance Grades A medium tolerance, used on a general-purpose thread, is indicated by the number 6. Any number below 6 indicates a finer tolerance and any number above 6 indicates a greater tolerance. The tolerance for the thread at the pitch line and for the major diameter may be shown on the drawing. Allowance Symbols are used to indicate the allowance for external threads: e indicates a large allowance g indicates a small allowance h indicates no allowance For internal threads: G indicates a small allowance H indicates no allowance The thread fit between mating parts is indicated by the internal thread designation followed by the external thread tolerance: M 20 x 2 -6H/5g 6g Unified thread fits have been divided into three categories and the applications of each have been defined by the Screw Thread Committee. External threads are classified as lA, 2A, and 3A, and internal threads as IB, 2B, and 3B. Classes 1A and 1B include those threads for work which must be. readily assembled. They have the loosest fit, with no possibility of interference between the mating external and internal threads when the threads are dirty

or bruised. Classes 2A and 2B are used for most of commercial fasteners. These threads provide a medium or free fit and permit power wrenching with minimum galling ,and seizure. Classes 3A and 3B are used where a more accurate fit and lead are required. No allowance is provided and the tolerances are 75 percent of those used for 2A and 2B fits. By classifying the tolerances of threads, the cost of threaded parts is reduced, since manufacturers may use any combination of mating threads that suit their needs. With the former system of identifying classes of tolerances (Classes 1,2,3,4), it was felt that a Class 3 internal thread should be used with a Class 3 external thread. With reference to the Unified system it should be noted that' 'Class" refers to tolerance or tolerance and allowance, and does not refer to fit. The fit between the mating parts is determined by the selected combination used for a specific application. For example, if a closer-than-normal fit is required, a Class 3B nut may be used on a Class 2A bolt. The basic dimensions, tolerances, and allowances for these threads may be found in any machine handbook.

THREAD CALCULATIONS
To cut a correct thread on a lathe, it is necessary first to make calculations so that the thread will have proper dimensions. The following formulas will be helpful when calculating thread dimensions. The symbols used in these diagrams and formulas are: ' D = single depth of thread P = pitch

TO SET THE QUICK-CHANGE GEARBOX FOR THREADING

The quick-change gearbox provides a means of quickly setting the lathe for the desired pitch of the thread in number of threads per inch on inch-system lathes or millimeters on metric lathes. This unit contains a number of different size gears which vary the ratio between headstock spindle revolutions and the rate of carriage travel when thread cutting. 1. Check the blueprint for the pitch of the thread required. 2. From the chart on the quick-change gearbox, find the whole number which represents the pitch in threads per inch or in millimeters.

3. With the lathe stopped, engage the tumbler lever into the hole which is in line with the pitch (tpi or in millimeters) 4. Set the top lever into the proper position as indicated on the chart. 5. Engage the sliding gear in or out as required. 6. Turn the lathe spindle by hand to ensure that the screw revolves. 7. Recheck the lever settings to avoid errors.

THREAD-CHASING DIAL
To cut a thread on a lathe, the lathe spindle and the lead screw must be in the same relative position for each successive cut. Most lathes have a threadchasing dial either built into, or attached to, the carriage for this purpose. The chasing dial indicates when the split nut should be engaged with the lead screw in order for the cutting tool to follow the previously cut groove. The thread-chasing dial is connected to a worm gear which meshes with the threads of the lead screw .The dial is graduated into eight divisions, four numbered and four unnumbered, and it revolves as the lead screw turns. Fig. 49-14 indicates when the split-nut lever should. be engaged for cutting various numbers of threads per inch (tpi). - Even threads use any division. - Odd threads must stay on either numbered or unnumbered lines; cannot use both.

THREAD CUTTING
Thread cutting ort a lathe is a process that produces a helical ridge of uniform section on a workpiece. This is performed by taking successive cuts with a threading toolbit of the same shape as the thread form required. Work to be threaded may be held between centers or in a chuck. If work is held in a chuck , it should be turned to size and threaded before the work is removed.

THREAD-CUTTING OPERATION
Thread cutting is one of the more interesting operations which can be performed on a lathe. It involves manipulation of the lathe parts, coordination of the hands, and strict attention to the operation. Before proceeding to cut a thread for the first time on any lathe, it is wise to take several trial passes, without cutting, in order to get the feel of the machine.

TURNING MACHINES OR ENGINE LATHES

Heavy-duty Engine Lathe

INTRODUCTION
The engine lathe is so named because it was originally powered by Watt's steam engine instead of by foot treadle or hand crank. With suitable attachments the engine lathe may be used for turning, threading, boring, drilling, reaming, facing, spinning, and grinding, although many of these operations are preferably done on specialized machinery. Sizes range from the smallest jewellers or precision lathes to the massive lathes used for machining huge forgings.

USAGE OF ENGINE LATHES: General Uses:

Engine lathes are used by machinists to produce one-of-a-kind parts or a few pieces for a short-run production.They are also used for toolmaking, machine repair, and maintenance. Turret lathe are strictly production machines. They are designed to provide short machining time and quick tool charges. Two types of semi_automatic turret lathes require an operator in constant attendance, the ram type and saddle type. Small, precision, handoperated turret lathes are used to produce very small parts. Automatic bar chuckers require little operator action. Lathes are also used for metal spinning. Reflectors, covers, and pans, for example, are made by this method out of aluminum, copper, and other metals.

Manufacturing of Steels:
Manufacturing methods for spinning heavy steel plate are entirely different. Hydraulically operated tools are used to form the steel

Digital Read-out Systems:

Digital readout systems for machine tools such as the engine lathe are becoming more common. This system features a completely self-guided rack and pinion that operates on the cross slide. The direct readout resolution is . 001 in. on both the diameters and the cross slide movement These systems can also be converted to metric measure.

SOME COMMON TYPES

Some lathes have a vertical spindle instead of a horizontal one, with a large rotating table on which the work is clamped. These-huge machines, called vertical boring mills, are the largest of our machine tools. A 25 ft diameter table is not unusual Huge turbines, weighing many tons, can be placed on the table and clamped in position to be machined. The machining of such castings would be impractical on a horizontal spindle lathe. A more versatile and higher production version of the boring mill is the vertical turret lathe. It does similar work to the vertical boring mill, but on a smaller scale. It is arranged with tool holders and turret with multiple tools much like that on a turret lathe, which gives it flexibility and relatively high production.

NUMERICAL CONTROL (NC) AND COMPUTER NUMERICAL CONTROL OPERATIONS IN LATHES:

Fully automatic machines such as automatic turret lathes and automatic screw machines are programmed to do a sequence of machining operations to make a completed product. Automatic turret lathes usually are programmed by numerical control (NC) on punched tape. Automatic screw machines, used for high production of small parts, are typically programmed with cams, although some are numerically controlled, There are several types of automatic machines: the single spindle machine, the sliding head, the multiple spindle, and the revolving head wire feed type. Multiple spindle bar

and chucking machines are high production turning machines that can do a variety of operations at different stations. Tracer Lathes follow a pattern or template to reproduce an exact shape on a workpiece. Tracing attachments are often used on engine or turret lathes. Tracer lathes have been largely replaced by NC or CNC lathes. Lathes that are numerically controlled (NC) by programming and punching tape produce workpieces such as shafts with tapers and precision diameters. NC chuckers are high production automatic lathes designed for chucking operations. Similar bar-feeding NC types take a full length bar through the spindle and automatically feed it in as needed. Some automatic lathes operate as either chucking machines or bar-feed machines.

OPERATION OF ENGINE LATHES

In ordinary turning, metal is removed from a rotating workpiece with a single-point tool. The tool must be harder than the workpiece and held rigidly against it. Chips formed from the workpiece slide across the face of the tool. This essentially is the way chips are produced in all metal cutting operations. The pressures used in metal cutting can be as much as 20 tons per square inch. Tool geometry, therefore, is quite important to maintain the strength at the cutting edge of the tool bit.

SAFETY MEASURES
The lathe can be a safe machine only if the machinist is aware of the hazards involved in its operation. In the machine shock as anywhere, you must always keep your mind in order to avoid accidents. Develop safe work habits in the use of setups, chip breakers, guards, and other protective devices. Standards for safety have been established as guidelines to help you eliminate unsafe practice and procedures on lathes. 1. Pinch points due to lathe movement. A finger caught in gears between the compound rest and a chuck jaw would be an example. The rule is to keep your hands away from such dangerous position when the lathe is operating. 2- Hazards associated with broken or falling components. Heavy chucks or workpieces can be dangerous when dropped. Care must be used when handling them. If a threaded spindle is suddenly reversed, the chuck can come off and fly out of the lathe. A chuck wrench left in the chuck can become a missile when the machine turned on. Always remove the chuck wrench immediately after using.

3- Hazards resulting from contact with high-temperature component Burns usually result from handling hot chips (up to 800. F or even more) or a hot workpiece. Gloves may be worn when handling with chips or workpieces. Gloves should never be worn when you are operating the machine. 4-Hazards resulting from contact with sharp edges, corners, and projections. These are perhaps the most common cause of hand injuries in lathe work. Dangerous sharp edges may be found in many places on a long stringy chip, on a tool bit, on a burred edge of a turned threaded part. Shields should be used for protection from flying chips and coolant. These shields usually are made of clear plastic and are hinged over the chuck or clamped to the carriage of engine lathes Even when shields are in place, safety glasses must be worn. String chips must not be removed with bare hands; wear heavy gloves and use hook tools or pliers. Always turn off the machine before attempting to remove chips. Chips should be broken and 9-shaped rather than in a stringy mass or a long wire . Chip breakers on tools and correct feeds will help to produce safe, easily handled chips. Burred edges must be removed before the workpiece is removed from the lathe. Always remove the tool bit when setting up or removing workpieces from the lathe. 5-Hazards of workholding devices or driving devices. When workpieces are clamped, their components often extend beyond the outside diameter of the holding device. Guards, barriers, and warnings such as signs or verbal instructions are all used to make you aware of the hazards. On power chucking devices you should be aware of potential pinch points between workpiece and workholding device. Make certain sufficient gripping force is exerted by the jaws to hold the work safely. Never run a geared scroll chuck without having something gripped in the jaws. Centrifugal force on the jaws can cause the scroll to unwind and the jaws to come out of the chuck. Keep tools, files, and micrometers off the machine. They may vibrate off into the revolving chuck or workpiece. 6-Spindle braking. The spindle or workpiece should never be slowed or stopped by hand gripping or by using a pry bar. Always use machine controls to stop or slow it. 7-Workpieces extending out of the lathe should be supported by a stock tube. If a slender workpiece is allowed to extend beyond the headstock

spindle a foot or so without support, it can fly outward from centrifugal force. The piece will not only be bent, but it will present a very great danger to anyone standing near

OTHER SAFETY CONSIDERATIONS

Hold one end of abrasive cloth strips in each hand when polishing rotating work. Don't let either hand get closer than a few inches from the work . Keep rags, brushes, and fingers away from rotating work, especially when knurling. Roughing cuts tend to quickly drag in and wrap up rags, clothing, neckties, abrasive cloth, and hair. Move the carriage back out of the way and cover the tool with a cloth when checking boring work. When removing or installing chucks or heavy workpieces, use a board on thev; (a part of the lathe bed) so the chuck can be slid into place. To lift a chuck or workpiece (larger than an 8-in. diameter chuck), get help or crane. Remove the tool or turn it out of the way during operation. Do not shift gears or try to take measurements while machine is running and the workpiece is in motion. Never use a file with a handle as the file tang can quickly cut your hand or wrist if the file is stuck by a spinning chuck jaw or lathe dog. Left hand filing is considered in the lathe that is left hand grips the handle while the right hand holds the tip end of the file.

SAIRA KHAN 1730 FIRST YEAR OF B.E INDUSTRIAL ELECTRONICS ASSIGNMENT # 01 OF WORKSOP TECHNOLOGY 8TH OF APRIL 2006 IIEE