Machine Operations I - EMM721

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EMM-Draft copy –Machine operation1 –G12 term2 A.A-version 01-2014/2015 Machine Operations I - EMM721

Transcript of Machine Operations I - EMM721

EMM-Draft copy –Machine operation1 –G12 term2 A.A-version 01-2014/2015

Machine Operations I - EMM721

EMM-Draft copy –Machine operation1 –G12 term2 A.A-version 01-2014/2015

OBJECTIVES

On successful completion of this module (and practical tasks), the student should be able to:

1. Identify general safety instructions for using machines/power tools.

2. Identify hazards and control measures associated with shaping machining.

3. Identify the main parts of shaping machine and their functions.

4. Identify kinematic systems and working principles of shaper.

5. Set and operate the shaping machines

6. correct mounting and positioning of cutting tools

7. Setting machining parameters to achieve the job requirements.

8. Identify the Classification of tools according;

9. Recognize the methods of work holding;

10. Measure to specified dimensions.

11. Using coolant/lubricant correctly.

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1-Introduction to shaping machine

1.1-General safety instructions for using machines/power tools.

Individuals working with any rotating machines or power tools must follow the below

Safety Instruction in order to avoid accidents and to prevent damage to equipment or

property:

1. Always follow the instructions given by your instructor/supervisor.

2. Appropriate PPE (such as dust coat, safety shoes, and safety goggles) MUST be

worn while operating the machine.

3. Hand gloves should NEVER be used.

4. Long hair, loose collars, neck ties, jewelry or hanging mobile earphone wires MUST

be controlled by tightening up or removal.

5. Make sure you know how to operate the machine before switching it on.

6. Machine guards MUST be put in position while operating.

7. Chuck key MUST be removed from the machine chuck when not in use.

8. Cutting tools and work piece MUST be properly clamped.

9. Make sure there are NO loose parts or pieces left on the machine table.

10. Keep hands away from any rotating objects.

11. All cutting tools should be correctly ground to correct shape and angles and in

good condition.

12. Use correct cutting speed, feed rate, and cut depth as required.

13. NEVER use hand file or emery paper for finishing work pieces while turning on a

lathe.

14. Do not leave any running machine unattended.

15. Immediately wipe off any spilt oil or cutting fluid on the floor.

16. If in doubt or in case you feel any abnormal or hazardous situation, stop the

machine and contact your instructor/supervisor for assistance.

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1.2- Shaping process.

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.

http://www.youtube.com/watch?v=I6lFRu8JG3Y

Ram

Work

Table

Tool

Fig 1 Shaping operation

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1.3- Method of machining (http://www.technologystudent.com/equip1/shape1.htm)

The work is held firmly on the table and the ram is allowed to reciprocate over

it. A single point cutting tool is attached to the ram. When the ram moves

horizontally in the forward direction, the tool removes metal from the work. On the

return stroke, metal is not removed. The ram moves at a slow speed during forward

stroke. But during return stroke, the ram moves at a faster speed. Though the

distances of ram movement during the forward and return stroke remain the same,

the time taken by the return stroke is less as it is faster. It is possible by ‘Quick return

mechanism’.

In a shaping machine, a flat horizontal surface is machined by moving the

work mounted on the table in a cross direction to the tool movement. When vertical

surfaces are machined, the feed is given to the tool.

When an inclined surface is machined, the vertical slide of the tool head is

swiveled to the required angle and the feed is given to the tool by rotating the down

feed hand wheel.

Fig2- Method of machining

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1.4-Hazards associated with shaping machines. http://www.youtube.com/watch?v=qOSdSKyxhhI

http://www.youtube.com/watch?v=yuReWb1O_w0

All machinery uses power to do work. This creates a number of possible hazards for both

operators and bystanders. Even though manufacturers take many steps to make machinery safe,

all hazards cannot be removed.

HAZARDS:

Hazards Control Measures Long hair, loose clothing etc., can become entangled in moving parts

MUST be controlled by tightening up or removal.

Work pieces, chuck keys, broken cutting tools, swarf, etc., can be violently ejected

Wear safety glasses, or plastic screen

shaper can present a hazard of electric shock

Witch of the machine from the main switch before any maintenance and use TAG

Closing movements between parts under power can be a trapping hazard.

Sufficient space should exist around the machine to prevent accidental contact with passersby. The machine should be stopped before doing anything around it.

Sharp edges on tools, work pieces can cause cuts

Duel with tools and workpiece carefully, remove any sharp edges from the workpiece before duel with it.

Contact with cutting fluids, oil and grease can irritate

Wash it directly, wear special gloves.

Inadvertent starting of the machine Make sure the main switch is off until finish all settings.

Slippery floors surfaces or loose items around the machine can cause slips and trips resulting in contact with.

Stop the machine and clean any mess directly when notes it.

moving parts mechanical Guard should be used if possible and Long hair, loose clothing MUST be controlled.

Manual handling of heavy equipment (vices and indexing heads etc.) can present a hazard.

An assessment should be made and appropriate procedures developed.

Most accidents with machinery are the result of human error. The operator either forgot

something, took a shortcut or a risk, ignore a warning, wasn't paying close attention or failed to

follow safety rules.

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In many cases, accidents with machinery are very serious, even fatal. It is important to recognize

and be alert for machine hazards and to take precautions to avoid injury.

PRE- operational safety checks.

Locate and ensure you are familiar with all machine operations and controls.

Ensure all guards are fitted, secure and functional. Do not operate if guards are missing or faulty.

Check workspaces and walkways to ensure no slip/trip hazards are present.

Ensure cutter is in good condition and securely mounted.

Operational safety checks.

Keep clear of moving machine parts.

Follow correct clamping procedures. Keep overhangs as small as possible and check work piece is secure.

Ensure you have selected correct speed and rate.

Ensure you have set the correct depth of cut.

Ending operations and cleaning up.

Switch off the machine when work completed.

Before making adjustments and measurements or before cleaning swarf accumulations, switch off and bring the machine to a complete standstill.

Leave the machine and work area in a safe, clean and tidy state.

DON’T

Do not use faulty equipment. Immediately report suspect machinery. Never leave the machine running unattended. Do not leave equipment on top of the machine. No adjustment should be done on the machine parts while themachine is functioning.

Clamps holding the work should not be adjusted while the machine is in operation.

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1.5- Main parts of a shaping machine

Base

The base is hollow and is made of cast iron. It provides the necessary support for

all the other parts of the machine. It is rigidly bolted to the floor of the workshop.

Column

It is a box like casting mounted vertically on top of the base. Two

accurate guideways are machined on the top of the column. The ram

reciprocates on these guideways. The front face of the column is provided with two

vertical guideways. They act as guideways for the crossrail. Crossrail moves

vertically along these guideways. The column encloses the ram reciprocating

mechanism and the mechanism for stroke length adjustment.

Crossrail

It is mounted on the front vertical guideways of the column. The table may be

raised or lowered by adjusting the crossrail vertically. A horizontal cross feed screw is

fitted within the crossrail.

Table

It is an important part useful in holding the work firmly on it. It is mounted on the

saddle which is located above the crossrail. The top and sides of the table are

accurately machined and have T-slots. Workpieces are held on the table with the help

of shaper vise, clamps and straps. Ram

Ram supports the toolhead on its front. It reciprocates on the accurately machined

guideways on the top of the column. It is connected to the reciprocating mechanism

placed inside the column. The position of ram reciprocation may be adjusted

according to the location of the work on the table. Toolhead

The toolhead is fitted on the face of the ram and holds the tool rigidly. It

provides vertical and angular feed movement of the tool. The swivel toolhead can be

positioned at any required angle and the vertical slide can be moved vertically or at

any desired angle to machine vertical or inclined surfaces.

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Fig 3- Shaping machine parts

1.6- Types of shaping machine

The shaping machines are classified as follows:

A. According to the type of driving mechanism

1. Crank type

2. Hydraulic type

3. Geared type

B. According to the position and travel of ram

1. Horizontal shaper

2. Vertical shaper

C. According to the type of cutting stroke

1. Push cut shaper

2. Draw cut shaper

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2- Kinematic systems and working principles of shaper.

2.1- Shaping machine mechanism. http://www.youtube.com/watch?v=Ga8yoLfB-1U

http://www.technologystudent.com/cams/crank2.htm The reciprocating motion of the mechanism inside the shaping machine can be seen in the diagram. As the disc rotates the top of the machine moves forwards and backwards, pushing a cutting tool. The cutting tool removes the metal from work which is carefully bolted down.

The central large bull gear receives its rotation from the motor through the belt-pulley,

clutch, speed gear box and then the pinion. The rotation of the crank causes oscillation of

the link and thereby reciprocation of the ram and hence the tool in straight path.

Shown in Fig. 4

Fig 4 -shaping machine mechanism

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2.2- Quick return mechanism http://www.youtube.com/watch?v=Dpw_xAvo5kk

The ram moves at a comparatively slower speed during the forward cutting

stroke. During the return stroke, the mechanism is so designed to make the tool

move at a faster rate to reduce the idle return time. This mechanism is known as quick

return mechanism.

As the ram moves at a faster rate during return stroke, the time taken becomes

less. The total machining time decreases and the rate of production increases. The

following mechanisms are used for quick return of the ram.

2.3- Ratchet and Pawl mechanism (Automatic feed mechanism

for the table)

The table of a shaping machine travels in a cross direction when the cross feed

screw is rotated. The cross feed screw is attached to the ratchet wheel. A spring

loaded ‘pawl’ is positioned to be placed between the teeth of the ratchet wheel. The

pawl is housed within a frame known as rocker arm. The bull gear placed inside the

column of the shaping machine drives the gear B through the gear A.

There is a diametric slot provided on the face of the gear B. A crank pin is

attached to a slider placed in the slot. The bottom of the rocker arm and the crank pin

are connected by a connecting rod. The rotation of the gear B makes the crank

pin to rotate. This movement makes the rocker arm to rock about the centre of the

ratchet wheel. The pawl makes the ratchet to rotate by a small amount in one

direction only. As the cross feed screw is attached to the ratchet wheel, the rotation of

the ratchet wheel will make the table to move in a cross direction.

If the direction of the table feed is to be reversed, the pawl is turned about

180° from its position. The ratchet wheel and the cross feed screw will rotate in

the opposite direction resulting in the table movement in the opposite direction.

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Fig 5 - Ratchet and Pawl mechanism

2.4- Method of table movement

1. The table moves in a cross direction when the cross feed screw is rotated.

2. A crank handle is provided to rotate the cross feed screw manually.

3. When the cross feed screw is rotated in clockwise direction, the table will

move towards left.

4. When the elevating screw is rotated, the table slides up and down on the

face of the column.

5. As the handles meant for cross feed screw rotation and elevating screw

rotation are placed side by side, it is not possible to operate both of them at the same

time.

6. The work mounted on the table is provided with required feed only during the

end of the return stroke.

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2.5 Swivel tool head

The tool head of a shaper holds the cutting tool rigidly. It is fitted on the face of

the ram. The vertical slide of the tool head can be moved vertically or at a particular

angle to provide vertical and angular feed movement to the tool. It allows the tool to

have an automatic relief during the return stroke of the ram.

The tool head has a swivel base attached to the circular seat on the ram. The

swivel base has angular graduations marked on it. As the vertical slide is mounted

on the swivel base of the tool head, it may be set and moved at any desired angle to

machine angular surfaces like ‘V’ grooves and dove tail grooves.

The down feed screw handle is rotated to move the vertical slide up and down. A graduated dial is placed on the top of down feed screw to control the amount of depth of cut or feed accurately.

Apron consisting of clapper box, clapper block and tool post is clamped on

the vertical slide by a screw. By releasing the clamping screw, the apron can be

swiveled either towards left or towards right with respect to the vertical slide. The

clapper box has two vertical walls within which the clapper block is housed. It is

connected to the clapper box with the help of a hinge pin. This arrangement provides

relief to the tool while machining vertical or angular surfaces. The tool post is

mounted upon the clapper block. The tool post is provided with a slot to accommodate

the tool and a screw to hold the tool rigidly on the tool post.

The clapper block fits securely inside the clapper box to provide a rigid tool

support during forward stroke. On the return stroke, a slight frictional drag of the

tool on the work lifts the block out of the clapper box and prevents the tool cutting

edge from dragging on the work surface. Fig. 5 illustrates the swivel tool head of a

shaper.

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Fig. 6 illustrates the swivel tool head of a shaper.

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3- Setting and operation of shaping machines.

http://www.youtube.com/watch?v=Vgz3mWuoAwI http://www.youtube.com/watch?v=bcpkc3f1YQg

When operating the shaping machine there are procedures that must be followed to help

prevent accidents and injury. Below is a guide of the procedure the operator should

follow. Always follow the rules and procedure given by the instructor.

The operator should be correctly dressed for the task he is going to carry out in the

workshop. Remember your PPE.

1. Before setting up the work, make sure the machine is SWITCHED OFF.

2. Make sure the tool is clamped correctly in the tool post.

3. Make sure the work is held securely and correctly in the holding device.

4. Remove the any tools (spanners screw, drivers) after checking the work is secure.

5. When the work is set up, make sure the machine guard is in place if applicable.

3.1. Clamping the work pieces. The workpiece clamping devices have the task to bring the workpiece into a certain

position and to hold it in this position during machining.

Each workpiece clamping must be:

Firm, safe and definite in position.

Arranged in such a manner that the technically possible rated capacity of

machines can best be utilized (short preparation and finishing times).

Done in such a way that no permanent deformations result on the workpiece.

Machine vices are mainly used for small work pieces with parallel outer surfaces. Before

the workpiece is clamped the position of the machine vice must be checked.

1 − machine vice 2 − workpiece with parallel outer surfaces 3 − clamping force in the plane of the cutting force 4 − tool

Fig. 7-Workpiece clamping on machine vice

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3. 2. Clamping of tools The slotting tools are held in the tool holder which is located on the tool slide or at the base

of the ram (tool post).

When clamping the tools, make sure that:

The tools are sufficiently stable in the shank section according to the cutting

conditions (roughing or finishing).

The holding surfaces are even and free from dirt.

in the case of super high−speed steel tools point like clamping forces are distributed

to a larger area by means of supports;

The tools are clamped as short as possible and especially firmly so that lateral

twisting of the tool due to too high lateral compressive forces is prevented and does

not lead to a change of the cutting depth. Too long clamping can result in bending

and chatter marks.

1 − tool 2 − clamping bolt 3 − tool post 4 − clapper 5 − clapper holder 6 − bolt as axis of rotation

Fig. 8-Tool mounting for shaping

1 − ram head

2 − vertical slide

3 − clapper box

4 − ram clapper

5 − tool post

6 − clamping bolt

7 − bore hole for fixing the ram clapper

8 − keep the spacing as small as possible

in order to avoid chatter marks on the

workpiece surface

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3.3 Setting of cutting values Set the number of strokes per minute, stroke length, feed, cutting depth.

3.3.1 Stroke length calculation and adjustment

The length of the stroke is calculated to be nearly 30mm longer than the work.

The position of stroke is so adjusted that the tool starts to move from a distance of

25mm before the beginning of the cut and continues to move 5mm after the end of the

cut. For example as shown in Fig. 4, the length of the work is 100mm. The stroke

length of the ram is calculated to be 130mm. (25+100+5). Fig. 4 illustrates the

calculation of stroke length.

Fig. 9 stroke length calculation

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3.3.2Adjusting the stroke length

The crank pin fastened to the sliding block can be adjusted by a lever placed

outside the column. Through the bevel gears placed at the centre of the bull gear, the

radial slide lead screw can be rotated. This rotation of lead screw changes the

position of the sliding block to move towards or away from the bull gear centre. The

stroke length of the ram is adjusted by placing the sliding block at a required position

from the centre of the bull gear.

Note: The stroke length of the ram and its position should not be adjusted when the

machine is in operation. The machine should be stopped before these adjustments are

made.

3.3.3 Cutting speed, Depth of cut and Feed

1. Cutting speed

The distance an object travels in a particular period of time is known as speed. In a shaper, the cutting speed is the speed at which the metal is removed by the cutting tool in a period of one minute. In a shaper, the cutting speed is considered only during the forward cutting stroke. This is expressed in meter per minute.

The cutting speed differs to suit different machining conditions like work material, the finish required, and the type of the tool and the rigidity of the machine.

2. Depth of cut

Depth of cut (t) is the thickness of metal that is removed during machining. It is the perpendicular distance measured between the machined surface and the uncut surface of the workpiece. It is expressed in mm or in inches.

3. Feed

Feed (S) is the relative movement of the work or tool in a direction perpendicular to the axis of reciprocation of the ram per double stroke. It is expressed in mm per stroke.

If a softer metal is used a heavier feed can be used .a finer feed must be used on harder and

tougher metal. Of course the capacity of the shaper must be considered.

3.4 sequence of operations: Approach the tool to the surface to be shaped until the latter is contacted.

Set the dial (tool slide) to "O".

Swing the machine table aside so that the tool is no longer above the workpiece. Feed cutting depth according to dial.

Move machine table by hand up to the tool.

Switch on feed of machine table and machine workpiece surface.

After having machined the surface, switch off feed and disengage machine. (Switch off stroke).

Ram should be in rear position.

Switch off machine.

Check for evenness, surface finish, accuracy to size.

Unclamp and deburr the workpiece.

Note the following hints on labor safety:

− Never stand in front of the machine, but always beside the machine on the side of the

control elements (splashing chips, danger of getting injured).

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4. Work holding devices and Tools used in a shaping machine.

Work pieces can be held and supported on the shaper table directly or by

having some special devices. Depending on the size and shape of the work, it may be

supported on the table by any one of the following methods.

1. machine vise 2. T-bolts and step blocks 3. Angle plate 4. V – Block

4.1 - Work holding devices: 4.1.1-Machine Vise

Vise is the most common and simple work holding device used in a shaper.

Different types of vises are used in a shaping machine according to the need and they

are: 1. Machine vise (Plain)

2. Swivel vise

Fig. 10 machine vice

4.1. 2 -T-bolts and step blocks

The step blocks are used in combination with T-bolts and clamps to hold the

work directly on the machine table. T-bolts are fitted in the T-slots of the machine

table. One side of the clamp holds the work and the other side rests on a step of

the step block. The different steps of the block are useful in levelling the clamp when

holding works of different heights. A nut on the top of the clamp holds the work

rigidly. Fig. 6 shows ‘T’ bolt, clamp & step block.

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4.1.3- Angle plate

Fig. 11 T-bolts and step blocks

Angle plate resembles the English alphabet ‘L’. It is accurately machined to have

two sides at right angles. Slots are provided on both the sides. One of the sides is

bolted to the machine table and the work pieces are held on the other side. The use of

an angle plate is shown in Fig. 7 Work

Angle plate

Table

Fig. 12 Angle plate

81

Packing

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4.1. 4- V – block

V – Block is a metal block having a ‘V’ shaped groove on it. It is used for

holding cylindrical work pieces. Operations like keyway cutting, slot cutting and

machining flat surfaces can be performed on the cylindrical work pieces held on a ‘V’

block. The use of a

‘V’ block is illustrated in Fig. 8.

Work

Clamp

‘V’ block

‘T’ bolt

Table

Fig .13 ‘V’ block

4.2- Classification of tools according to:

4.2.1- Material of the cutting tool.

The material of the cutting tool used in a shaping machine should have more hardness

and temper when compared to the material of the workpiece. So, the shaper tools are

made of the following materials

1. High Carbon Steel

2. High Speed Steel

3. Carbide tipped tool

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4.2.2. According to Direction of cutting.

According to the type of work and the type of operation, various tools are used in a shaper. They are: 1-Right hand (R. H) tool

This is a tool used for machining by moving the job from right to the left. 2-Left hand (L. H) tool

This is a tool used for machining by moving the job from left to right.

4.2.3- According to Surface finish.

1-Roughing tool

When it is required to remove a good amount of material from the workpiece,

roughing tools are used. The cutting edge will be very thick, sharp and strong to

withstand the cutting pressure and to dissipate the heat generated at the cutting

point. The surface obtained will be very rough.

2-Finishing tool After the rough machining is performed, the finishing tool is used to obtain a very high

quality of surface finish. The cutting edge will be either flat or slightly convex. Finishing tool roughing tool Fig. 14-shaping tools according to Surface finish.

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4.2.3- According to shank form

1. straight tool

2. bent tool

3. Goose neck tool

4. offset tool Fig. 15-shaping tools according to shank form. 4.2.3- According to the application

1. shoulder tool

2. parting−off tool

3. grooving tool

4. hook tool

5. forming tool Fig. 16-shaping tools according to application.

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5. Operations performed in a shaping machine

Different types of operations are performed in a shaping machine. They are

broadly classified as

1. Regular operations 2. Special operations

5.1. Regular (operations )surface:

5.1.1 Machining horizontal surfaces

A shaper is mostly used to machine a flat , true surface on a

workpiece. Horizontal surfaces are machined by moving the work mounted on the

machine table at a cross direction with respect to the ram movement. The clapper box

can be set vertical or slightly inclined towards the uncut surface. This

arrangement enables the tool to lift automatically during the return stroke. The tool

will not drag on the machined surface.

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5.1.2. Machining vertical surfaces

A vertical cut is made while machining the end of a workpiece, squaring up a block or machining a shoulder. The feed is given to the tool by rotating the down feed screw of the vertical slide. The table is not moved vertically for this purpose. The apron is swiveled away from the vertical surface being machined as shown in the diagram.

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5.2. Angular surfaces (Special operations)

If the surface to be machined is neither horizontal nor perpendicular, the surface is called inclined surface. Machining ‘V’ grooves and dovetail grooves are some examples for angular machining the inclined (angular) surfaces can be done in several ways. They are:

5.2.1. Taper strip method 5.2.2. Machining dove tail groove

Dove tail joint is machined on two separate pieces of work as male and female

elements. The required shape is marked on the face of the work and the unwanted

metal is first removed by the round nose tool. A special form tool is used to finish the

machining.

5.2.3. Machining a ‘V’ block.

5.2.4. T-slot machining

Fig .17 various shaper operations

1. Inclined surface

2. Concave surface

3. ‘V’ groove

4. Deep slot

5. Horizontal surface

6. Vertical surface

7. Step cut surface

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5.3. Inspect the surface finish,

Surface finish: also known as surface texture is the nature of a surface it comprises the

small local deviations of a surface from the perfectly flat ideal (a true plane).

Surface finish is one of the important factors that control friction and transfer layer

formation during sliding.

Profilometer:-is a measuring instrument used to measure a surface's finish, in order to

quantify its roughness

http://www.youtube.com/watch?v=AaK1xtUPIpE

http://www.youtube.com/watch?v=nuBJwros2Ck

Dimensions:-use Vernier caliper to measure and check the finished work piece to

accuracy of ±1mm

http://www.youtube.com/watch?v=VOar5f3LfZs

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6. Care and maintenance of shaping machines

6.1. Recognize the benefit of using coolant

Due to the friction between the tool and the work surface during machining, heat is

generated. The tool loses its cutting capacity and the machined surface is hardened.

Coolant is used on the surfaces to avoid damage to the cutting edge of the tool as well as to

the machined surface; soluble oil is mixed with water to be used as a suitable coolant. One

part of the oil is mixed with fifteen parts of water to be used as coolant. Usage of water as

coolant may result in rust formation on the metal parts. Lubricants cannot be used as

coolants.

6.2. Maintenance of shaping machines

Shaping machines, like all machine tools, are subject to permanent wear. This can be

counteracted by careful handling and constant care and maintenance of the machines.

Note the following rules:

1. Before starting your daily work, lubricate all manual lubrication points according

to the regulations. Poor lubrication results in early wear.

2. Apply the specified lubricant in the specified quantity at the specified time to the

respective lubricating point.

3. Before starting the machine, check, whether all levers are in the correct position.

Wrong lever positions may result in breakages.

4. Protect all guideways against chips, scale, and dirt. Otherwise they will quickly

wear. Inaccurate work would be the result. Always keep perfect order at the

workplace.

Automatic lubrication: - the bull gear, ram, rocker arm shoe and other important

bearings is provided by an automatic pump which circulates oil through tubes

leading from the oil reservoir in the base of the shaper to the various bearings.

Manual Lubrication: All shafts, flat bearing surfaces, feed screws and other

bearings not lubricated automatically should be oiled manually at regular intervals

as indicated in chart below. Same oil as specified for the oil reservoir may be used.

6.3. Care and Clean the machine .

A tidy workshop is generally a safe one. Scrap material should be placed in suitable bins

and never thrown on the floor.

• Always keep gangways clear.

• Never allow the floor area around machines and benches to become cluttered.

• Always keep the floor free from fluids that may cause a person to slip.

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With best wishes and luck