MACHINE SHOP
(NOTES)
VIVA QUESTIONS
PREPARED BY
MR. RAHUL KESHARI
DEPARTMENT OF MECHANICAL ENGINEERING DEPARTMENT
MACHINE SHOP(Notes)
There is no need to write this, Read only for Viva
Manufacturing: It is the term used to convert materials into things that have value in the market
place. It involves a series of related activities such as product design and development, material
selection, quality assurance, marketing, etc.
Manufacturing Processes: These are the processes which convert engineering materials into
usable goods. It is a value adding process where the conversion of material into things adds value to
the material.
Man, Machine (Equipment) and Material (3Ms): These are related factors in
manufacturing that must be combined properly in order to achieve low cost, superior quality and on
time delivery of engineering goods.
Machine (M/C): A machine is a device which can transform available energy into useful work.
Or a machine is a device which reduces human effort.
Machine Tools: These are the machines which can reproduce themselves. They hold the work
piece, hold the tool and move the tool relative to the work piece. Examples: Lathe machine, shaper,
planer, milling machine, etc.
Importance of Manufacturing
1. Manufacturing adds value to the material and converts it into usable goods.
2. Manufacturing is the backbone of any industrialised nation. It comprises 20% to 30% of the
economy of any such nation.
Basic manufacturing processes
1. Casting
2. Forming/forging/Black smithy
3. Machining
4. Welding
1. Casting: In casting the work material is made to flow initial to final shape in molten state. The
molten metal is introduced into a previously prepared cavity mould and is allowed to solidify
there.
2. Forming/forging/Black smithy: Also called as mechanical working. Here work material
is made to flow to the required shape in the solid state with the application of external force.
3. Machining: Machining is that manufacturing process in which raw material is given the
required shape by removing extra material out of it.
4. Welding: Welding is a method of joining materials with the application of heat with or without
use of filler material, with or without use of pressure.
Engineering Materials:
Material
Metals Non- Composite
Metals Materilals
Non- Particle
Ferrous Ferrous Inorganic Organic Fibre Structurals
Reinforced Reinforced
Pig Cast Wrought Carbon Alloy
Iron Iron Iron Steel Steel
Dead Mild Medium High Carbon High Speed
Steel Steel Steel Steel Steel Stainless Spring
Steel Steel
Grey White Alloy
C. I. C.I. C. I.
Fig: Engineering Materials
Science: Science deals with innovation, new idea or concept.
Engineering: Engineering is the application of scientific concepts with stress on related theoretical
aspects.
Technology: Technology is the specific field of engineering dealing with practical aspects.
Mechanical Engineering: Mechanical Engineering is the branch of engineering concerned with
design, fabrication, and maintenance of all types of machinery.
Workshop: Workshop is a place where engineering goods are manufactured or repaired.
Shops: The different section of workshop are called shops.
Purpose of Workshop: The purpose of the practical in the workshop is to familiarize the students
with the practices, tools and equipment used in each shop rather than making them expert
operators/workers.
Vernier Calliper
A scale cannot measure objects which are smaller than 1mm but a Vernier calliper can measure
objects up to 1mm. As already know that Vernier Calliper has two scales the main scale and the
Vernier scale together this arrangement is used to measure very small lengths like 0.02mm (For 50
division of Vernier Scale).
Fig: Vernier Calliper
Least Count of Vernier Calliper
Value of one main scale division
Least Count =
Total no. of division in Vernier scale
1mm
Least Count = = 0.02mm for 50 divisions
50
Vernier Calliper Zero Error (For 10 divisions in Vernier scale)
Zero error in the Vernier calliper is a mathematical error due to which, the zero of the Vernier scale
does not coincide with the zero of the main scale.
In other words, if the zero mark on the Vernier scale doesn’t coincide with the zero mark on the main
scale, then the error that occurs is called zero error.
1. No zero error
2. Positive zero error
3. Negative zero error
1. No Zero Error
In no zero error, when we bring two jaws together. You will see zero of the Main scale is
coinciding with the zero of the Vernier scale. they are exactly in a straight line so this Vernier
calliper is free from zero error or you can say there is no zero error in this Vernier calliper.
2. Positive Zero Error
In positive zero error, Let’s bring these jaws together. you see, the zero of Vernier scale is ahead of
main scale zero. Or you can say zero of Vernier scale is at the right side of main scale zero.
In both cases either it is ahead of main scale zero or it is the right side of main scale zero. this is called
as zero error and it is positive.
3. Negative Zero Error
So if Vernier scale zero is either backside or to the left of main scale zero, in both cases, zero error is
the negative error.
Summary
Machine Shop
Machining is a process in which extra material is removed in the form of chips. Place where
machining is done is called as machine shop.
Machining Processes
1. Conventional(old) machining processes
2. Non-Conventional(Modern) machining processes
1. Conventional(old) machining processes
In conventional machining process, tool materials must be harder than the work materials. Here
metal removal mechanism is shear.
2. Non-Conventional(Modern) machining processes
In modern machining process, tool material may not be harder than work material. Even there is
no physical contact between them. Mechanism of metal removal may be vaporization, abrasion,
ion displacement, etc.
EDM – Electro Discharge Machining
CHM – Chemical Machining
ECM – Electro Chemical Machining
EBM – Electron Beam Machining
LBM – Laser Beam Machining
USM – Ultrasonic Machining
NC Machine: NC stands for “Numerical Control”. It is defined as the form of programmable
automation, in which the process is controlled by the number, letters, and symbols.
CNC Machine: CNC stands for “Computer Numerical Control”. In CNC machines, a dedicated
computer replaces much of the conventional
Types of Chuck
1. Three jaw chuck/Universal Chuck/Self Centring chuck – Used in Centre Lathe Machine
2. Four jaw chuck – Used in Centre Lathe Machine
3. Drill chuck – Used in Drill Machine
4. Collet chuck – Used in Capstan/Turret Lathe Machine
5. Magnetic chuck – Used in Surface Grinding Machine
Types of Lathe Machine
1. Engine or Centre Lathe Machine
2. Capstan & Turret Lathe Machine
3. Bench Lathe Machine
4. Speed and Production Lathe
5. CNC Lathe
Lathe Machine Cutting Tools
Viva Voice Questions
1. What do you mean by workshop in engineering terms?
2. What is a shop as related to a workshop?
3. What is the importance of practical work in a workshop?
4. List at least four general safety precautions to be observed in the workshop to avoid
accidents.
5. What is manufacturing and its importance?
6. How is a machine tool different from a machine?
7. List the basic manufacturing processes.
8. Machine beds are generally made of C. I., why?
9. What is the mechanism of metal cutting?
10. Specify the size of the lathe that you are using for making your jobs.
11. What is an CNC Lathe? How is it different from a conventional lathe machine?
12. Write the functions of the following lathe parts:
a) Carriage
b) lead screw
c) feed shaft
d) Tail stock
e) half nut
13. Define the following for a turning operations:
a) Cutting Speed
b) Feed
c) Depth of cut
14. Find the least count and dimension of Vernier calliper.
Fig: A Fig: B