Lath machine maintenance?

"Daily Maintenance Check before starting the machine: Check all the running parts no too tight, or loose."

"Lathe Preventative maintenance check list sheet for yearly and monthly pm  for machinery and CNC equipment. "

Maintenance

                     Lath machine Maintenance

°Daily Maintenance

• Check all the running parts no too tight, or loose. Bearing of headstock, longitudinal and cross feed , tool holders, etc. would be examined and adjusted by hand  or proper fitness.
• Check the sensitivity and reliability of all manual control levers: To try the speed change rate function of headstock feeds and apron in gear box and inspect their  starting, stopping, forwards and reverse action whether they are sensitive, reliable or not.
• Cleaning the machine: dust, chips and other particles should be removed from sliding surface of machine to make the rotating or sliding parts performing easy  and smoothly. All other static parts can be often also cleaned to avoid corrosion.
• Check the tightness of the bolts holding the millhead in place.
• Greasing and oiling: regular oiling should be done everyday (see lubrication plan sheet) to keep the machine properly lubricated. Check the oil site gauge under the lathe chuck and add oil if the level is below the half way point. - show the lubrication plan sheet.
• Fixture and fig of headstock, tailstock and tool holder tight clamping between tailstock and bed surface, close running fit of spindle in tailstock, clamp bolts of tool holder and figs on headstock.
• Check and adjust the lock position of the bed clamp lever on the tailstock.  Should be located before top dead center.
• Start lathe or turning machines and observe operations to ensure that specifications are met.
• Replace worn tools, and sharpen dull cutting tools and dies using bench grinders or cutter-grinding  machines.

Check after starting the machine:

• Lubricating system: Examine all lubricating system carefully and ensure all flowing line without obstacles.
• Check the electrical control system: switch the "on" and "off" button and examine the sensitiveness of starting, stopping and pilot lamp strictly.
• The sensitivity and reliability of mechanical control device: control levers for forward and reverse main spindle, automatic feed and thread change should be sensitive and reliable. Automatic control devices for longitudinal and crossfeed, gear change, threads change, carriage, and spindle direction change should be accurate also.
• Coolant system: check the quantity of coolant oil and start the oil pump for inspecting its function and leakage.

 Caution during operation:

• Noise and vibration:
If you find the noise and vibration of the machine are abnormal or irregular. Stop the machine immediately for inspection and adjustment. When starting max. speed of headstock spindle on no loading basis, check the noise and vibration whether they are over specified limit or not. Aware of vibration and unusual noises that the machine produced. Stop the machine immediately and check the following cause:
• 1) Lack of lubrication
• 2) Faulty adjustments
• 3) Dull tool bit or cutting tool
Correct any problems before resuming the work.
• Temperature of bearing and motor.
• Tap the main bearing by hand and the motor as well, feel the temperature if it is normal or not.
• Safety affairs:
• a. Must stop operation when you leave the machine.
• b. When changing main spindle speed or feeding speed stop running first.
• c. All tools and products are strictly not allowed to be left on sliding surface of bed.
• Quality of products:
• If you discover the quality of product is out of limit, stop the machine at once for finding the causes of defects.

  Check after operation:

• Cleaning the machine:
All of the oily matter, chips, etc, on the machine should be removed completely and put a thin lubricating oil on the sliding surface of machine to prevent the corrosion.
• Tailstock, carriage and tool holder should be place to proper position.
• All tools should be kept clean first then put back to original position.
• 
  

  Weekly maintenance:

• Check the lubrication of the sliding parts of the machine. Apply  light grease or oil if needed.
• Visually inspect the drive belts for excessive wear and cracking. Check the belt tension by applying finger pressure to each belt at a point midway between the two pulleys. For correct tension a deflection of about 3/8 of an inch should be evident in each belt.
• Lubricate all points as required.
• Transmission system:
Check the damage of rubber V-Belt and read just the tensile strenght of V-belts.
• Clean and coat the lead screw with oil. 
• Check all guards are secure and function correctly(includes latches, locks, fasteners,and/or interlocks if fitted).
• Removed, cleaned, and re-saturated the wipers pads with oil regularly. Wipers are designed to keep out small chips and dirt between the slides and the ways.
• Check locking levers and adjusting handlers/levers for smooth operation.
• Cooling System:
Clean-up the whole and replenish with new cooling fluid.

Monthly maintenance
• Electrical system: Carefully examine the connection of all electrical wires, terminals and switches, which occasionally have been damaged by chips or others.
• Check and adjust backlash as necessary.    
• Check the condition of all drive belts and replace if necessary
• Check all gibs adjustments.
• Cleaning and oiling of the chuck should be done on a regularly scheduled basis as well as whenever the chuck jaws become difficult to move.                         
• Adjust the accuracy of the slides on both the cross and longitudinal feeding.
• Dismantle and clean all the dust, chips and foreign matter from moving parts.


• Every 6 Months meaintenance:

• Lubricate the change gears in the lathe pulley box with an aerosol chain lubricant.
• Lubricate the bearings, worm gear and worm shaft with light grease.
• Check the wear and tear of all gears in gears and packing:
Inspect the damage of all gears in various box, spindle, bearings and packing.
• Repair or replace it if necessary.
• Check the clearance fit between feed screw lever, nut and main screw spindle and nut whether they are right or not.
• The stability of machine body:
• Tighten up the foundation bolts of machine body to the ground and make the body stable.
• Lubricate the change gears in the lathe pulley box with an aerosol chain lubricant.
 Yearly maintenance
• Inspection of accuracy
1. a. Inspection work for accuracy should be rechecked, if the accuracy is over specified limit, the adjustment or alignment will be done accordingly.
2. b. Bearing inspection
3. c. Re-examine the insulating materials and clearance fit and lubrication of all bearings.
4. d. Inspection of appearance.
5. e. If the paint is peeled off, repaint it with the same color.
6. f. Check the exposed parts whether they have been damaged, corroded or deformed.
    Repair or replace them if necessary.
• Check the electrical cord, plug, circuit breakers, switches and terminals and related connections to assure that they are secure and safe.
• Positioning and leveling
According to the inspection regulation, recheck the positioning and leveling once after a year service.
• Drain the lubricant from the gear box of headstock, feed and replenish with fresh oil.
Depending on the use if necessary change or timely basis)
• Remove the X and Y axis gibs and clean with solvent. Coats gibs with way oil and reinstall.
             
CNC Machining Maintenance 


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CNC milling and machine work video.

                             CNC machining titan 27s eagle

CNC machining is a manufacturing process that uses computer numerical control (CNC) technology to automate the machining of parts from raw material. The Titan 27S Eagle is a type of CNC machine.

CNC machines, like the Titan 27S Eagle, are capable of producing highly accurate and complex parts with a high degree of consistency. They are widely used in industries such as aerospace, automotive, medical, and electronics.

The Titan 27S Eagle is a multi-axis CNC machine, which means it is capable of performing complex machining operations along multiple axes. It is designed for high precision machining and is equipped with features such as high-speed spindle, automatic tool changer, and advanced control system.

In order to produce high-quality parts using a CNC machine like the Titan 27S Eagle, it is important to properly program the machine and ensure that the correct cutting parameters (such as speed, feed, and depth of cut) are used. Additionally, it is important to use high-quality cutting tools and properly maintain the machine to ensure optimal performance.

 It’s a means to make parts by removing material via high-speed, precision robotic machines that use an array of cutting tools to create the final design. CNC machines commonly used to create the geometric shapes required by customers are vertical milling machines, horizontal milling machines, and lathes.

CNC Router cutting aluminium test high spe   

To successfully make a part on a CNC machine, programs instruct the machine how it should move. The programmed instructions are encoded using computer-aided-manufacturing manufacturing (CAM) software in conjunction with the computer-aided-design (CAD) model provided by the customer. The CAD model is loaded into the CAM software and tool paths are created based on the required geometry of the manufactured part. After determining the tool paths, the CAM software creates machine code (G-code) that instructs the machine on how fast it should move, how fast to turn the stock and/or tool, and the location to move in a 5-axis coordinate system.

                                                     Paradise box vearve on CNC

A CNC metalworking machine with a wood router attached to it, turning it into a makeshift CNC router. Cutting bit rotation speeds on metal working equipment is typically too slow to produce good results in wood.

Wood routers are frequently used to machine other soft materials such as plastics. 

Typical three-axis CNC wood routers are generally much bigger than their metal shop counterparts. 5' x 5', 4' x 8', and 5' x 10' are typical bed sizes for wood routers. They can be built to accommodate very large sizes up to, but not limited to 12' x 100'. 

Axis CNC cart 5B women 5D

Multiaxis machines offer several improvements over other CNC tools at the cost of increased complexity and price of the machine:

The amount of human labor is reduced, if the piece would otherwise have to be turned manually during the machining.      A better surface finish can be obtained by moving the tool tangentially about the surface.

CNC Lathe mass production turnnig by glacern machine tools

     The RenAM 500M is a laser powder-bed fusion additive manufacturing system designed specifically for the production of metal components on the factory floor. As well as incorporating a powerful 500 W laser to give faster processing than earlier models, the new equipment features an automated powder handling system that enables more consistent process quality and reduced operator time on the machine

 CNC Axle lathe for Railway axle production 7c niles-simmons 

A tried and true slant bed lathe for the finish turning of the wheel seats, bearing journal fillets, and upset axle ends for the reclaiming of railway axles. The N20 accommodates a wide range of axle lengths and diameters, and can be integrated with optional automatic loading and unloading via overhead gantry.

The N20 is controlled by an easy-to-use Siemens 840D "Solution Line" CNC system, which is accessed by a Simmons Human Machine Interface (HMI) that uses graphical user interfaces (GUIs) that are customized to wheel set maintenance facility processes and terminology.

Koffler 27_50_27 lathe at work 

National and international standards are used to standardize the definitions, environmental requirements, and test methods used for the performance evaluation of lathes. Selection of the standard to be used is an agreement between the supplier and the user and has some significance in the design of the lathe. In the United States, ASME has developed the B5.57 Standard entitled "Methods for Performance Evaluation of Computer Numerically Controlled Lathes and Turning Centers", which establishes requirements and methods for specifying and testing the performance of CNC lathes and turning centers.

Heavy machining 

   Intercon's machine shops are equipped to handle precision machining of various steels and alloys. A bank of horizontal boring mills provide travel and control features for the most demanding jobs. Single set-up work, including 60 ft. by 20 ft. travel envelopes, is routine. Late model CNC boring and milling machines are among the largest available from any job shop in the country. 
Vertical boring mills range in swing capacity from 48 in. to 20 ft. Work pieces weighing up to 100,000 lbs. can be accommodated.

A full range of lathes, machining centers, table mills and radial drills compliment Intercon's diverse machine tool invention. 

Computerized numerically controlled machines are programmed with in-house disc preparation systems. Plotters verify tool paths, and simulate set-ups, tooling, and methods. CNC formats from customer production control can be converted, or downloaded directly to Intercon's machine controllers. 

Tunning_26 the lathe 

The turning processes are typically carried out on a lathe, considered to be the oldest machine tools, and can be of four different types such as straight turning, taper turning, profiling or external grooving. Those types of turning processes can produce various shapes of materials such as straight, conical, curved, or grooved work piece. In general, turning uses simple single-point cutting tools. Each group of work piece materials has an optimum set of tools angles which have been developed through the years.

The bits of waste metal from turning operations are known as chips (North America), 

 Mechanics of machining 7c_ cutting_velocity analysis

This paper re-evaluates the known velocity relationships expressed in the form of a velocity diagram in orthogonal metal cutting, arguing that the metal cutting process be considered as cyclic and consisting of three distinctive stages. The velocity diagrams for the second and third stages of a chip-formation cycle are discussed. The fundamentals of the mechanics of orthogonal cutting, which are the upper-bound theorem applied to orthogonal cutting and the real virtual work equation, are re-evaluated using the proposed velocity diagram and corrected relationships are proposed. To prove the theoretical results, the equation for displacements in the deformation zone is derived using the proposed velocity relationships. To prove that the displacements in the deformation zone follow the derived equation and that this zone consists of two unequal parts, a metallo graphical study of chip structures has been carried out. To estimate the variation of stress and strain in the deformation zone quantitatively, a micro hardness scanning test was conducted.

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Machine Design theory.

What is machine design ? 

Mechanical Design or Machine Design is the branch of Engineering Design. Machine design can lead to the formation of the entirely new machine or it can lead to improvement of the existing machine.

●      To understand what exactly machine design or mechanical design is let us consider the example of the gear box of the car. The gear box transmits the motion and the power of the engine to the wheels of the vehicle. The gearbox comprises group of gears which are subjected to not only motion but also the load of the vehicle. For the gears to run at desired speeds and take desired loads it is important that they should be designed. During designing various calculations are performed considering desired speeds and loads and finally the gear of particular material and specific dimensions that can take all loads and that can be manufactured at least possible cost giving optimum performance is designed. In similar fashion all the components of the car, including engine, have to be designed so that they optimally meet all the functional requirements at lowest possible cost. This whole process of designing is called as machine design or mechanical design.

●      Machine Design or Mechanical Design can be defined as the process by which resources or energy is converted into useful mechanical forms, or the mechanisms so as to obtain useful output from the machines in the desired form as per the needs of the human beings. Machine design can lead to the formation of the entirely new machine or it can lead to up-gradation or improvement of the existing machine. For instance if the existing gearbox is too heavy or cannot sustain the actual loads, entirely new gearbox can be designed. But if the same gearbox has the potential to lift more loads, it can be upgraded by making certain important changes in its design.

Factors to be considered during Machine Design. 

When the designer designs the elements of the machine or the complete machine, they have to consider several important parameters. Here are some of the important factors to be considered while doing machine design:

● 1

 Cost: Cost has always been the major factor of consideration while designing the machine elements or machine and in this age of competition it has become more important. The best machine design is the one which helps get the finished product with all the major functionalities and highest possible quality at the lowest possible cost. 

● 2

 High output and efficiency:Earlier machines used to be very heavy and consume lots of power. Now the trend is of full functional machines consuming low power and giving high output in terms of the number of the of products manufactured. Some computer controlled machines can manufacture the components very fast and are highly efficient.

●3

 Strength: The machine elements or the machine should be strong enough to sustain all the forces it is designed for so that it is not damaged or permanently deformed during its life time. Right at the time of the designing the machine the designer should consider the force machine can be applied to and consider all the relevant factors that could affects its life.

●4

 Stiffness or rigidity: The machine should be rigid enough so that under the effect of applied forces for which it is designed there is no deformation of the machine or machine elements beyond the specified limits

● 5

 Wear resistance: Wear is the removal of the material from the metallic surface when two surfaces rub with each other. If there is more removal of the material, the component will become weaker and eventually break. The wear of the contacting surfaces can be reduced by the lubrication of the surfaces, increasing the strength or the hardness of the working surfaces.

●6

 Lubrication: Lubrication between the two mating surfaces of the elements of the machine help reducing friction between them and wearing of the two surfaces, which results in the increase in life of the components of the machine.

● 7

 Operational safety: For the safety of the operator of the machine, the hazard producing things from the machine should be eliminated and the design should confirm to the safety codes.

● 8 

Ease of assembly: The elements of the machine should be such that the machine can be assembled very easily. For the mass production of the complex machines like automobiles, type writers etc, the concept of unit assemblies are common. The unit assemblies are assembled together to form the complete machine.

●9 

Ease and simplicity of disassembly: Like assembly, the disassembly of the machine also should be easy so as to easily carry out replacement of the parts, and repair and maintenance of the machine and machine elements.

● 10 

Ease and simplicity of servicing and control: The machine and its element should be simple enough so that very little maintenance and servicing is required. The repair and maintenance of the machine should be easy and cheap and simple replacements should be available.

●11

 Light weight and minimum dimensions: The machine elements and machine should be strong, rigid and wear resistant with minimum weight and least dimensions. This can be achieved by using light weight rolled sections and hardening the metals. Using high strength grades of cast iron and light alloys can further help getting light materials and minimum dimensions of the machine elements. Improving the design in this direction is very important.

● 12 

Reliability: The reliability of the machine is a very important if the machine has to find the huge market in the business.

● 13 

Durability: The longer the life of the machine more it develops the reputation of being the dependable machine and more will be its sale. Hence the right at the time of designing reliability and durability should be given priority. 

● 14 

Economy of performance: For the proper economic performance of the machine correct mechanical, hydraulic, thermodynamic and other principles should be applied while designing the elements of the machine and the whole machine.

●15 

Accessibility: The machine elements and machine the whole should be easy to handle and access.

● 16

 Processability: The shape and the materials for the elements of the machine should be such that they can the processing costs and labor costs are lowest possible.

● 17

 Compliance with state standards: Following the standards makes designing easier and availability of various parts faster and easier.

●18 

Economy of repairs and maintenance: While designing the machine elements and machine the designing should be such that least amount of repairs and maintenance will be required for the machine.

●19 

Use of standard parts: There should be maximum possible standard parts in the design of the machine. This will help reduce the cost of the machine and ensure easy availability of the parts. With standard parts the design can be modified easily.

● 20 

Use of easily available materials: Materials selected for the machine elements during the design should be available easily and lowest possible costs.

●21 

Appearance of the machine:While designing the machine the aesthetics and ergonomics of the machine should be given due consideration without affecting its functionality.

● 22 

Number of machines to be built: Designing of the machine will depend a lot on the number of machines to be manufactured. If few numbers of machines are to be manufactured then expensive materials and high production costs can be considered, but for the mass production economy of the machine should be top priority

Machine Design Procedure

There is no fixed machine design procedure for when the new machine element of the machine is being designed a number of options have to be considered. When designing machine one cannot apply rigid rules to get the best design for the machine at the lowest possible cost.

●      There is no fixed machine design procedure for when the new machine element of the machine is being designed a number of options have to be considered. When designing machine one cannot apply rigid rules to get the best design for the machine at the lowest possible cost. The designer who develops the habit of following a fixed line of steps for designing the machine or machine elements cannot come out with the best product. When the new product is to be developed the problems keep on arising at design stage, and these can be solved only by having flexible approach and considering various ways.

Important Steps of Designing Machine

  Though the machine design procedure is not standard, there are some common steps to be followed; these can be followed as per the requirements wherever and whenever necessary. Here are some guidelines as to how the machine design engineer can proceed with the design

●1

 Making the written statement:Make the written statement of what exactly is the problem for which the machine design has to be done. This statement should be very clear and as detailed as possible. If you want to develop the new produce write down the details about the project. This statement is sort of the list of the aims that are to be achieved from machine design.

●2

 Consider the possible mechanisms: When you designing the machine consider all the possible mechanisms which help desired motion or the group of motions in your proposed machine. From the various options the best can be selected whenever required.

●3

 Transmitted forces: Machine is made up of various machine elements on which various forces are applied. Calculate the forces acting on each of the element and energy transmitted by them.

● 4

 Material selection: Select the appropriate materials for each element of the machine so that they can sustain all the forces and at the same time they have least possible cost.

●

5 Find allowable stress: All the machine elements are subjected to stress whether small or large. Considering the various forces acting on the machine elements, their material and other factors that affect the strength of the machine calculate the allowable or design stress for the machine elements.

● 6

 Dimensions of the machine elements: Find out the appropriate dimensions for the machine elements considering the forces acting on it, its material, and design stress. The size of the machine elements should be such that they should not distort or break when loads are applied.

●  7

 Consider the past experience: If you have the past experience of designing the machine element or the previous records of the company, consider them and make the necessary changes in the design. Further, designer can also consider the personal judgment so as to facilitate the production of the machine and machine elements.

Skills a Good Machine Designer should possess

Machine designer is the one who designs the machine and its various elements. A good machine designer possesses some skills that help him/her design the machine elements and machine that meet all the needs of the designer and that helps develop the high quality machine at lowest possible costs.Here are some important skills that a good machine designer should possess.
● 1

 Inventiveness: This skill is the foundation stone for a good machine design engineer. Any new design starts with the need or some objective. A good designer should have inventiveness, which is the ability to think of or discover valuable and useful ideas or concepts for the things or processes to achieve the given objective. Without inventiveness the designer cannot start the process of machine design.
●2

  Engineering analysis: Engineering analysis is the ability of the designer to analyze the given component, system or the process using engineering and scientific principles. The designer who possesses this skill will be able to find answer to the engineering related problems very quickly for he or she knows what exactly the problem is and where it is.
●  3

  Engineering science: This is another skill without which the designer will just not be able to do any designing. A good designer is the one who has thorough knowledge of and in depth training in the engineering science in which they are doing designing. For instance, if the person doesn’t know what the refrigerator is and other basics of mechanical engineering how will they be able to design the refrigerator?

●  4

 Interdisciplinary ability: A good design engineer is the one who has the ability to solve the problems not only those related to his/her specialty, but also have the ability to competently and confidently deal the basic problems or ideas from other disciplines which are in some or the other manner linked to the machine they are designing.
● 5

 Mathematical skills: All types of designs involve lots of mathematical calculations and iterations. A good designer should have the knowledge of all the basics and advanced mathematical concepts so that they can be applied fruitfully and effectively wherever required.
● 6

Decision making: During designing many times a number of uncertain situations arrive, in such cases the designer should be able to take the decision with balanced mind considering all the relevant factors involved. If the person doesn’t maintain the balance of mind and doesn’t consider all the relevant factors there are greater chances of taking the wrong decision.
●7

 Manufacturing processes: The design engineer should have the knowledge of the manufacturing process like cutting, drilling, milling etc and the knowledge of all the machines. They should also the knowledge of potential and limitations of all the machines and manufacturing processes which may be old or new.
● 8

Communication skills: Communication skill is the ability of the design engineer to express oneself clearly and persuasively orally, graphically as well as in writing.
● 9

These are the important skills that the machine design engineer or rather any designer should posses. Apart from this there are many other skills desired from a good designers, these are: skill in design, good judgment, simulation skill, measurement skill, thought skill, work in team, ability to make conclusion etc.

Laminated Leaf Spring Design Procedure

You can find leaf springs in almost all four wheelers. In this article we discuss how to design a leaf spring and the typical guidelines for a leaf spring.

●      A leaf spring protects a four wheeler from the unevenness of the road. Thus a leaf spring necessarily serves the following purposes:

○      Increase service life of a four wheeler

○      Increase user comfort

             Formula to be used

●      Leaf spring design is based on thefundamental beam theory. I already have an article on how to design plates based on beam theory.

●       You have to use the following two formulas for the leaf spring design process:

○      Bending stress produced in the whole spring:

●      Tb= (3*W*L)/ (b*N*t^2)………………………………eqn1.1

○      Maximum deflection in the whole spring:

●      X= (6*W*L^3)/[{(2+(n/N)}*E*N*b*t^3]……………eqn1.2

●      Where,

●      Tb – maximum bending stress in the leaf spring

●      W – Applied load on the spring

●      t – Thickness of the individual leaves

●      X – Maximum deflection of the spring due to applied load

●      L – Span of the leaf spring

●      n – Number of full-length leaves

●      N – Number of graduated-length leaves

●      b – Width of the spring

●      E – Young’s modulus of the spring material. 

     Leaf Spring Design Procedure

●      Let’s start with a leaf spring design problem. We have the following data as input:

●      W= 24516 N

●      L= 0.445 M

●      N= 8

●      n= 2

●      E= 2.1E+11 N/m2

●      X= 0.13 M

●      Sa= 600000000 N/m2

●      Sa is the allowable bending stress for the spring material.

●      You have to find out the width (b) and the thickness (t) of the spring.

●      W= 24516 N

●      L= 0.445 M

●      N= 8

●      n= 2

●      E= 2.1E+11 N/m2

●      X= 0.13 M

●      Sa= 600000000 N/m2

●      Sa is the allowable bending stress for the spring material.

●      You have to find out the width (b) and the thickness (t) of the spring.

                            Solution 

●      Apply the eqn1.1 and you will get the value of:

●      b*t^2 = 6.81 * 10^-6…………eqn1.3

●      Now, apply the eqn1.2 and you will get the value of:

●      b*t^3 = 2.63 * 10^-8………….eqn1.4

●      By solving the eqn1.3 and eqn1.4 you will get:

●      t = 0.0038 m

●      b = 0.455 m...

How to use Machine?

The benefit of machine learning are the predictions and the models that make predictions.

 To have skill at applied machine learning means knowing how to consistently and reliably deliver high-quality predictions on problem after problem. You need to follow a systematic process.

My best advice for getting started in machine learning is broken down into a 5-step process:
Step 1: Adjust Mindset. Believe you can practice and apply machine learning.
Step 2: Pick a Process. Use a systemic process to work through problems.
Step 3: Pick a Tool. Select a tool for your level and map it onto your process.
Step 4: Practice on Datasets. Select datasets to work on and practice the process.
Step 5: Build a Portfolio. Gather results and demonstrate your skills.
Really, there is only one thing that can stop you from getting started and getting good at machine learning.

It’s you.Maybe you just can’t find the motivation. Maybe you think you have to implement everything from scratch. Maybe you keep picking advanced problems rather than beginner problems to work on. Maybe you don’t have a systematic process to follow in order to deliver a result. Maybe you’re not making use of good tools and libraries.

Machine design refers to the procedures and techniques used to address the three phases of a machine's.
invention, which involves the identification of a need, development of requirements, concept generation, prototype development, manufacturing, and verification testing;

performance engineering involves enhancing manufacturing efficiency, reducing service and maintenance demands, adding features and improving effectiveness, and validation testing;recycle is the decommissioning and disposal phase and includes recovery and reuse of materials and Aacomponents.

Machines employ power to achieve desired forces and movement (motion). A machinehas a power source and actuators that generate forces and movement, and a system of mechanisms that shape the actuator input to achieve a specific application of output forces and movement. Modern machines often include computers and sensors that monitor performance and plan movement, and are called mechanical systems.

The idea that a machine can be broken down into simple movable elements led Archimedesto define the lever, pulley and screw as simple machines. By the time of the Renaissance this list increased to include the wheel and axle, wedge and inclined plane.

A number of machine elements provide important structural functions such as the frame, bearings, splines, spring and seals.

A machine is a contrivance or mechanism by means of which a force, applied at one part of the machine, is transmitted to another part, in order to secure mechanical advantage for some particular purpose. 

There are basically six types of machine:

The inclined plane

- used for raising a load by means of a smaller applied force. Mechanical advantage is resisted by some friction.

The lever

- involves a load, a fulcrum and an applied force. Often just a uniform bar.

The pulley

- In simplest form it changes the direction of a force acting along a cord or rope.

The screw

- constructed using the principle of the inclined plane set on a cylindrical or conical surface. A screw-jack lifts heavy weights. Many screw-threads are in everyday use.

The wedge

- a double inclined plane. Mechanical advantage is considerably resisted by friction.

The wheel and axle

- Used to draw water from a well etc. by ropes attached to a large wheel and to a smaller axle. A differential wheel and axle has two-part axle sizes and gains considerable mechanical advantage.

Here are some examples of the machines:

1) Lathe: It utilizes mechanical energy to cut the metals. The other types of machine tools also perform the same task.

2) Turbines: They produce mechanical energy.

3) Compressors: They use mechanical energy to compress the air.

4) Engines: They consume the fuel and produce mechanical energy.

5) Refrigerators and air-conditioners: They use mechanical engineering to produce cooling effect.

6) Washing machines: They use mechanical energy to wash the clothes.

The machines generating mechanical energy are also called as prime movers. These machines convert some form of energy like heat, hydraulic, electrical, etc into mechanical energy or work. The most popular example of these machines is the internal combustion engine in which the chemical energy of the fuel is converted into heat energy which in turn is converted into mechanical work in the form of the rotation of the wheels of the vehicle. Some other examples of this group of machines are gas turbines, water turbines, steam engine etc.

Thank You 

What is machine shop?

Most important part of lathe machine

  5 major parts of lathe machine
      Main part of Lathe  Machine . The headstock is clamped on the left-hand side of the bed, which is consists of the spindle, transmission gear, and gear levers. Three jaw chuck and four jaw chuck are the most commonly used for holding or clamping the workpiece to cutting.     

                      Headstock 

Head stock is generally installed on the left side of the lathe machine. It is a housing for the drive pulleys and gears. The chuck is attached in this part of lathe. With the help of chuck the rotary motion is transferred to the work piece

                       

  Lath Bed 

The bed is a heavy, rugged casting made to support the working parts of the lathe. On its top section are machined ways that guide and align the major parts of the lathe.

                         

 Saddle

The saddle, an H-shaped casting mounted on the top of the lathe ways, provides a means of mounting the cross-slide and the apron

                         

 Tailstock 

The tailstock is located on the side of the bed. It can be locked in any position along the bed of the lathe by the tailstock clamp. It can be used to support the long workpiece during cutting process. Tailstock spindle are used to receive the dead center, which provides support for the end of the work.

Types of lathe machine

The four main types of lathes are

1.Speed Lathes

After completing this unit, you should be able to:

• Describe the Speed, Feed, and Depth of cut.

Speed, feed, and depth of cut are three important factors that determine the efficiency and quality of a machining operation.

1. Speed (also known as cutting speed or spindle speed) refers to the rotational speed of the cutting tool, measured in revolutions per minute (RPM).

2. Feed rate refers to the linear speed at which the cutting tool moves into the workpiece, measured in inches per minute (IPM) or millimeters per minute (mm/min).

3. Depth of cut refers to the distance that the cutting tool penetrates into the workpiece, measured in inches (in) or millimeters (mm).

Optimal values for speed, feed, and depth of cut are dependent on the specific material being machined, the type of cutting tool used, and the desired result.

• Determine the RPM for different materials and diameters.

The RPM for a given machining operation depends on various factors, including the material being machined, the diameter of the tool, and the desired surface finish and cutting speed.

As a general rule, the RPM for a given diameter of cutting tool decreases as the hardness of the material increases. The following is a rough guide for determining RPM based on material type:

.Soft materials (e.g., aluminum, brass, plastic): 800-10,000 RPM

Medium-hard materials (e.g., steel, cast iron): 400-800 RPM

Hard materials (e.g., high-speed steel, hardened steel): 100-400 RPM

The diameter of the tool also plays a role in determining the RPM. In general, as the diameter of the tool increases, the RPM should be reduced to prevent tool breakage and to ensure a proper cutting speed.

It is important to note that these are general guidelines and that the optimal RPM for a given operation may vary. It is always recommended to consult with a machining expert or to use cutting speed calculators for specific recommendations for a given material and tool diameter.

• Describe the federate for turning.

Feed rate in turning refers to the linear speed at which the cutting tool moves into the workpiece while rotating. The feed rate is usually expressed in inches per minute (IPM) or millimeters per minute (mm/min).

The feed rate in turning has a significant impact on the efficiency and quality of the machining operation. A too-slow feed rate can lead to a longer cycle time and a poor surface finish, while a too-fast feed rate can cause excessive tool wear, tool breakage, or reduced accuracy.

The optimal feed rate for a given turning operation depends on various factors, including the material being machined, the diameter of the tool, the speed of the tool, and the desired surface finish.

It is important to use the correct feed rate for a given turning operation to ensure efficient machining and high-quality results. It is always recommended to consult with a machining expert or to use cutting speed calculators for specific recommendations for a given material and tool diameter .

• Describe the setting speed.

The setting speed in machining refers to the speed at which the cutting tool is set into the workpiece. The setting speed is usually expressed in inches per minute (IPM) or millimeters per minute (mm/min).

The setting speed is important because it affects the accuracy of the machined part, the cutting speed, and the surface finish. A too-slow setting speed can cause excessive tool wear, while a too-fast setting speed can cause tool breakage or reduced accuracy.

The optimal setting speed for a given machining operation depends on various factors, including the material being machined, the diameter of the tool, the speed of the tool, and the desired surface finish.

In general, the setting speed should be adjusted based on the cutting speed and the material being machined to ensure efficient machining and high-quality results. It is always recommended to consult with a machining expert or to use cutting speed calculators for specific recommendations for a given material and tool diameter.

• Describe the setting feed.

To operate any machine efficiently, the machinist must learn the importance of cutting speeds and feeds. A lot of time can be lost if the machines are not set at the proper speed and feeds for the workpiece.

In order to eliminate this time loss, we can, and should, use recommended metal-removal rates that have been researched and tested by steel and cutting-tool manufactures. We can find these cutting speeds and metal removal rates in our appendix or in the Machinery’s.

We can control the feed on an engine lathe by using the change gears in the quick-change gearbox. Our textbook recommends whenever possible, only two cuts should be taken to bring a diameter to size: a roughing cut and a finishing cut.

It has been my experience to take at least three cuts. One to remove excess material quickly: the rough cut, one cut to establish finish and to allow for tool pressure, and one to finish the cut.

If you were cutting thread all day long: day in and day out. You might set the lathe up for only two cuts. One cut to remove all but .002 or .003 of material and the last cut to hold size and finish. This is done all the time in some shops today.

Have you noticed that when you take a very small cut on the lathe .001 to .002 that the finish is usually poor, and that on the rough cut you made prior to this very light cut, the finish was good? The reason for this is: some tool pressure is desirable when making finish cuts.

2.Engine Lathes : Romi T-

Universal lathes from Line ROMI T were carefully designed for offering total safety for the operator, according standard NR-12.

They are safe, versatile, reliable machines, ideal for tooling, maintenance and teaching work, due to the variety of optional available, for setting the machine according the need of application.

A very large variety of combinations of pitches and infeeds is possible to be obtained, due to its set design. Over and above, by changing only one gear in turn over, it is possible to obtain two settings of threads: one for metric thread and inches, other for module thread and Diametral Pitch.

3.Tool Room Lathes : 

Graded Casting with Hardened & Ground Guide waysHardened & Ground Spindle and Gears in HeadstockCam lock Spindle Nose is standardUniversal Feed Box of toughened EN-8 material with inch, mm, DP and Module threadGap Bed is standard.
  Accuracy-
As per IS Standard 1878 (Part-I)


Work piece on Chuck (Turning)-Roundness of 0.01mm taper near headstockWork piece between Centers (Facing) Flatness of 0.02mm/ 300mm length in concave direction. 
 Accessories-

Self Centering Chuck, Independent Jaws Chuck, Steady Rest, Follow Rest, Revolving Center, Digital Read Out, Taper Turning Attachment, Grinding Attachment, Electromagnetic Footbrake, Milling Attachment

4.Turret Lathes : 

Turret lathes are a type of metalworking lathe that are designed for high-volume production and efficient machining of cylindrical parts. They are named for the turret that is mounted on the top of the bed, which holds a series of cutting tools and allows for quick tool changes.

Turret lathes typically have a headstock, tailstock, and a bed, as well as a cross slide and a turret. They also typically have a leadscrew, a feed rod, and a carriage that moves along the bed to control the cutting tool's position.

Advantages of turret lathes include their ability to perform multiple operations in a single setup, the quick tool change capability, and their suitability for high-volume production. They are commonly used in industries such as automotive, aerospace, and electrical components.

It is important to properly set up and operate turret lathes to ensure efficient machining and high-quality results. This may include properly aligning the tool holders, properly tightening the tool clamps, and ensuring that the correct cutting speed and feed rate are used for the given operation

The turret lathe is a form of metalworking lathe that is used for repetitive production of duplicate parts, which by the nature of their cutting process are usually interchangeable. It evolved from earlier lathes with the addition of the turret, which is an indexable tool holder  that allows multiple cutting operations to be performed, each with a different cutting tool, in easy, rapid succession, with no need for the operator to perform setup tasks in between, such as installing or uninstalling tools, nor to control the tool path. The latter is due to the tool path's being controlled by the machine, either in jig-like like fashion, via the mechanical limits placed on it by the turret's slide and stops, or via electronically-directed directed servomechanisms for computer numerical control lathes.

                       Hartness turret Lath