Maintainance Report

8/3/2019 Maintainance Report

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Project 2011- cooling tower


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Safety rules in workshop-

1. Do not work on any machine without knowledge.2. Keep away the harmful materials.3.

Do not touch the rotating parts of machine in running machine.4. Do not spread the oil, grease and viscous material on floor area.

5. Muffler, tie not to wear on work on machine.6. Tight the work-piece properly on the machine.7. Good arrangement of light in the workshop.8. Better ventilation for air.9. Put the tools of machine at right place.

Safety instructions in machine shop-

1. Do not wear breslet, ring, wrist watch etc. during work on a machine.2. Wear apron, shoes for safety during working.3. Dont push any button of machine without knowledge.4. Use wire brush for remove metal chips from machine.5. Give proper lubrication of machine before working on it.

Machines in workshop-

1. Capstan and turret lathe machine-2. Light duty lathe machine3. Milling machine4. Radial arm drilling machine5. Shaper machine6.

Grinding machine


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belt pulley with lower speeds available by manipulating the bull gear. Later machines use a

gear box driven by a dedicated electric motor. A fully geared head allows the operator toselect speeds entirely through the gearbox.

BedThe bed is a robust base that connects to the headstock and permits the carriage and tailstockto be aligned parallel with the axis of the spindle. This is facilitated by hardened and groundways which restrain the carriage and tailstock in a set track. The carriage travels by means of

a rack and pinion system, lead screw of accurate pitch, or feed screw.

Types of beds include inverted "V" beds, flat beds, and combination "V" and flat beds. "V"

and combination beds are used for precision and light duty work, while flat beds are used forheavy duty work

When a lathe is installed, the first step is to level it, which refers to making sure the bed is not

twisted or bowed. There is no need to make the machine exactly horizontal, but it must beentirely untwisted to achieve accurate cutting geometry. A precision level is a useful tool for

identifying and removing any twist. It is advisable also to use such a level along the bed to

detect bending, in the case of a lathe with more than four mounting points. In both instancesthe level is used as a comparator rather than an absolute reference.

Feed and lead screwsThe feed screw (H8) is a long driveshaft that allows a series of gears to drive the carriagemechanisms. These gears are located in the apron of the carriage. Both the feed screw and

lead screw (H7) are driven by either the change gears (on the quadrant) or an intermediategearbox known as a quick change gearbox (H6) or Norton gearbox. These intermediate gears

allow the correct ratio and direction to be set for cutting threads or worm gears. Tumbler

gears (operated by H5) are provided between the spindle and gear train along with a quadrantplate that enables a gear train of the correct ratio and direction to be introduced. This provides
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a constant relationship between the number of turns the spindle makes, to the number of turns

the lead screw makes. This ratio allows screw threads to be cut on the work piece without theaid of a die.

CarriageIn its simplest form the carriage holds the tool bit and moves it longitudinally (turning) orperpendicularly (facing) under the control of the operator. The operator moves the carriage

manually via the hand wheel (5a) or automatically by engaging the feed shaft with the

carriage feed mechanism (5c). This provides some relief for the operator as the movement of

the carriage becomes power assisted. The hand wheels (2a, 3b, 5a) on the carriage and itsrelated slides are usually calibrated, both for ease of use and to assist in making reproducible

cuts. The carriage typically comprises a top casting, known as the saddle (4), and a side

casting, known as the apron (5).

Cross-slideThe cross-slide (3) rides on the carriage and has a feed screw that travels perpendicular to themain spindle axis. This permits facing operations to be performed, and the depth of cut to be

adjusted. This feed screw can be engaged, through a gear train, to the feed shaft (mentioned

previously) to provide automated 'power feed' movement to the cross-slide. On most lathes,

only one direction can be engaged at a time as an interlock mechanism will shut out the

second gear train.

Compound restThe compound rest (or top slide) (2) is usually where the tool post is mounted. It provides a

smaller amount of movement (less than the cross-slide) along its axis via another feed screw.The compound rest axis can be adjusted independently of the carriage or cross-slide. It is used

for turning tapers, to control depth of cut when screw cutting or precision facing, or to obtain
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finer feeds (under manual control) than the feed shaft permits. Usually, the compound rest has

a protractor marked in its base (2b), enabling the operator to adjust its axis to precise angles.

Tool postThe tool bit is mounted in the tool post (1) which may be of the American lantern style,traditional four-sided square style, or a quick-change style such as the multifix arrangementpictured. The advantage of a quick change set-up is to allow an unlimited number of tools to

be used (up to the number of holders available) rather than being limited to one tool with the

lantern style, or to four tools with the four-sided type. Interchangeable tool holders allow all

tools to be preset to a center height that does not change, even if the holder is removed fromthe machine.

Tailstock

The tailstockis a tool holder directly mounted on the spindle axis, opposite the headstock.The spindle (T5) does not rotate but does travel longitudinally under the action of a lead

screw and hand wheel (T1). The spindle includes a taper to hold drill bits, centers and other

tooling. The tailstock can be positioned along the bed and clamped (T6) in position asrequired. There is also provision to offset the tailstock (T4) from the spindles axis, this is

useful for turning small tapers.

The image shows a reduction gear box (T2) between the hand wheel and spindle, this is a

feature found only in the larger center lathes, where large drills may necessitate the extra

leverage.
http://en.wikipedia.org/wiki/Tailstockhttp://en.wikipedia.org/wiki/Machine_tapers#Morsehttp://en.wikipedia.org/wiki/Chuck_%28engineering%29#Drillhttp://en.wikipedia.org/wiki/File:HwacheonCentreLathe-tailstock-mask_legend.jpghttp://en.wikipedia.org/wiki/Chuck_%28engineering%29#Drillhttp://en.wikipedia.org/wiki/Machine_tapers#Morsehttp://en.wikipedia.org/wiki/Tailstock


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2.Light Duty Lathe Machine-

Light Duty

SPECIFICATIONS LD-4.6 LD-5.3 LD-6

BED

Bed Length 1375 mm / 4'-6" 1600 mm / 5'-3" 1825mm / 6'

Bed Width 241 mm / 9.5" 241 mm / 9.5" 241 mm / 9.5"

CAPACITY

Height Of Center 190 mm / 7.5" 190 mm / 7.5" 190 mm / 7.5"

Swing Over Bed 355 mm / 14" 355 mm / 14" 355 mm / 14"

Swing Over Cross

Slide180 mm / 7" 180 mm / 7" 180 mm / 7"

Admit BetweenCenter

330 mm / 13" 330 mm / 13" 330 mm / 13"

MAIN SPINDLE

Spindle Thread / Dia 8 TPI-60 MM 8 TPI-60 MM 8 TPI-60 MM

Spindle Bore 40 mm Dia / 1.625" 40 mm Dia / 1.625" 40 mm Dia / 1.625"

TAIL STOCK

Quill Dia 38 mm / 1.5" 38 mm / 1.5" 38 mm / 1.5"THREADS

Lead Screw 25.4 mm Dia X 4 TPI25.4 mm Dia X 4

TPI25.4 mm Dia X 4 TPI

Metric Thread 13 / 1 mm to 6 mm 13 / 1 mm to 6 mm 13 / 1 mm to 6 mm

Inch Thread 19 / 2 TPI to 24 TPI 19 / 2 TPI to 24 TPI 19 / 2 TPI to 24 TPI


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SPEEDS

No. Of SpindleSpeed

4 + 4 = 8 4 + 4 = 8 4 + 4 = 8

RPM ( Min / Max ) 35 / 825 35 / 825 35 / 825

3.Milling machine-

A milling machine is a machine tool used to machine solid materials. Milling machines are often

classed in two basic forms, horizontal and vertical, which refers to the orientation of the mainspindle. Both types range in size from small, bench-mounted devices to room-sized machines.

Unlike a drill press, which holds the work piece stationary as the drill moves axially to penetrate

the material, milling machines also move the work piece radially against the rotating millingcutter, which cuts on its sides as well as its tip. Work piece and cutter movement are preciselycontrolled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and lead

screws or analogous technology. Milling machines may be manually operated, mechanically

automated, or digitally automated via computer numerical control (CNC).
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Milling machines can perform a vast number of operations, from simple (e.g., slot and keyway

cutting, planning, drilling) to complex (e.g., contouring, die sinking). Cutting fluid is oftenpumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.

Vertical mill

Vertical milling machine. 1: milling cutter 2: spindle 3: top slide or over arm 4: column 5: table

6: Y-axis slide 7: knee 8: base

In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindleand rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered,

giving the same effect), allowing plunge cuts and drilling. There are two subcategories of verticalmills: the bed mill and the turret mill.

Horizontal millHorizontal milling machine. 1: base 2: column 3: knee 4 & 5: table (x-axis slide is

integral) 6: over arm 7: arbor (attached to spindle)

A horizontal mill has the same sort ofxy table, but the cutters are mounted on ahorizontal arbor across the table. Many horizontal mills also feature a built-in rotary tablethat allows milling at various angles; this feature is called a universal table. While end

mills and the other types of tools available to a vertical mill may be used in a horizontal

mill, their real advantage lies in arbor-mounted cutters, called side and face mills, whichhave a cross section rather like a circular saw, but are generally wider and smaller in

diameter. Because the cutters have good support from the arbor and have a larger cross-

sectional area than an end mill, quite heavy cuts can be taken enabling rapid material
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removal rates. These are used to mill grooves and slots. Plain mills are used to shape flat

surfaces. Several cutters may be ganged together on the arbor to mill a complex shape ofslots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any section

desired. These specialty cutters tend to be expensive. Simplex mills have one spindle,

and duplex mills have two. It is also easier to cut gears on a horizontal mill. Some

horizontal milling machines are equipped with a power-take-off provision on the table.This allows the table feed to be synchronized to a rotary fixture, enabling the milling of

spiral features such as hypoid gears.

Specification: All Geared Universal Milling MachineMODEL TABLE

M-1B M-2B M-3B M-4B M-5B M-6B

Working Surface1100 x270

1300 x290

1400 x350

1600 x360

1800 x400

2000 x450

Swivel +450 +450 +450 +450 +450 +300

T-Slot Nos/Size 3/17 3/17 3/17 3/17 5/17 5/20

T-Slot Centre 60 65 80 90 80 90

Dist. From Spindle

max/min

350-0 400-0 475-0 550-0 550-50 600-50

X-Longitudinal Travel 500 650 775 900 1100 1250

Y-Cross Travel 180 205 255 305 450 500

Z-Vertical Travel 350 400 475 550 600 650

FEEDS

No. of Feeds 9 18 18 18 18 18
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Range of LongitudinalFeed/ min

13-200 13 to 305 13 to 305 13 to 305 13 to 305 13 to 305

Range of Cross Feed /

min13-200 13 to 305 13 to 305 13 to 305 13 to 305 13 to 305

Range of Vertical Feed /min 5-100 2.5 to 62 2.5 to 62 2.5 to 62 2.5 to 62 2.5 to 62

No. of Rapid Feeds 1 2 2 2 2 2

Longitudinal Rapid Feeds

/ min700 735,1065 735,1065 735,1065 735,1065 735,1065

Cross Rapid Feeds / min 700 735,1065 735,1065 735,1065 735,1065 735,1065

Vertical Rapid Feeds /min

240 147, 210 147,210 147,210 147,210 147,210

SPINDLE

No. of Spindle Speeds 9 9 9 9 18 18Range of Spindle Speeds

(RPM)45-1100 45 to 1100 35 to 1800 35 to 1800 35 to 1800 35 to 1800

Spindle Taper ISO 40 ISO 40 ISO 40 ISO 40 ISO 40 ISO 50

Arbor Diameter 25.4 25.4 25.4 25.4 25.4 25.4

ELECTRICAL

Main Motor 3 H.P. 3 H.P. 5 H.P. 7.5 H.P. 7.5 H.P. 10 H.P.

Feed Motor 2 H.P. 2 H.P. 2 H.P. 2 H.P. 3 H.P. 3 H.P.

Coolant Motor 0.1 H.P. 0.1 H.P. 0.1 H.P. 0.1 H.P. 0.1 H.P. 0.1 H.P.

DIMENTIONS

Overall Length 1600 1850 2000 2100 2500 2700

Overall Width 1400 1600 1750 1950 2500 2600

Overall Height 1550 1680 1800 1880 2400 2700

Net Weight Kg 2000 2600 3300 3700 4200 5000

Gross Weight Kg 2200 2900 3600 4000 4600 5700

4.Radial arm drilling machine-A radial arm drill press is a large geared head drill press in which the head can be moved

along an arm that radiates from the machine's column. As it is possible to swing the arm

relative to the machine's base, a radial arm drill press is able to operate over a large area
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without having to reposition the work piece. The size of work that can be handled may be

considerable, as the arm can swing out of the way of the table, allowing an overhead

crane or derrickto place a bulky piece on the table or base. A vise may be used with a

radial arm drill press, but more often the

Radial arm drill press
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work piece is secured directly to the table or base, or is held in a fixture. Power spindle feed isnearly universal with these machines and coolant systems are common. The biggest radial armdrill presses are able to drill holes as large as four inches (101.6 millimeters) diameter in solid

steel or cast iron.

DC - 410 ( SPECIFICATIONS )DESCRIPTION DC - 410 DESCRIPTION DC - 410

Drilling M.S 42 ( 15/8 )Max / Min Dist. Spindle

nose to base1225 / 450

Drilling C.I 50 Vertical Travel of Arm 775

Rough Boring in

M.S60

Max / Min Dist. Spindle

Center to Column1025 / 275

Tapping in M.S 25Horizontal Travel of

Arm750

Spindle Taper MT-4 Max.Drilling Radius 1137

Spindle Travel 225Machine Measurement (

L X B X H )

1600 x 850 x

2270

Spindle Speeds (RPM x steps )

12 Steps Diameter of Column 225

60,90,115,165,200,290,340,480,

575,825,1005,1510Work Table

550 x 450 x

400

Diameter Of RAM (

quill )78 Coolant Tank

770 x 430 x

145 ( 50 Liters)

Spindle Auto feed

Ranges0.1, 0.15, 0.20, 0.27, 0.33, 0.52 Drill-head Motor

2 HP ( 1.5 KW

) 960 / 1440RPM

Elevating Motor ( L XB X H )

0.75 HP ( 0.56

KW ) 960

RPM

5.Shaper machine-A shaper is a type ofmachine tool that uses linear relative motion between the work pieceand a single-point cutting tool to machine a linear tool path. Its cut is analogous to that ofa lathe, except that it is (archetypal) linear instead ofhelical. (Adding axes of motion can
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yield helical tool paths, as also done in helical planning.) A shaper is analogous to a

planer, but smaller, and with the cutter riding a ram that moves above a stationary workpiece, rather than the entire work piece moving beneath the cutter. The ram is moved

back and forth typically by a crankinside the column; hydraulically actuated shapers also

exist.

Operation
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Shaper linkage. Note the drive arm revolves less for the return stroke than for the cutting stroke,

resulting in a quicker return stroke and more powerful cutting stroke.

A shaper operates by moving a hardened cutting tool backwards and forwards across the workpiece. On the return stroke of the ram the tool is lifted clear of the work piece, reducing the

cutting action to one direction only.

The work piece mounts on a rigid, box-shaped table in front of the machine. The height of the

table can be adjusted to suit this work piece, and the table can traverse sideways underneath thereciprocating tool, which is mounted on the ram. Table motion may be controlled manually, but

is usually advanced by automatic feed mechanism acting on the feed screw. The ram slides back

and forth above the work. At the front end of the ram is a vertical tool slide that may be adjusted

to either side of the vertical plane along the stroke axis. This tool-slide holds the clapper box andtool post, from which the tool can be positioned to cut a straight, flat surface on the top of the

work piece. The tool-slide permits feeding the tool downwards to deepen a cut. Thisadjustability, coupled with the use of specialized cutters and tool holders, enable the operator tocut internal and external gear tooth profiles, splines, dovetails, and keyways.

The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster on thereturn (non-cutting) stroke than on the forward, cutting stroke. This action is via a slotted link or

Whitworth link.

SPECIFICATIONS

ParticularsD.S.6

"

D.S.8

"

D.S.10

"

D.S.1

0 to

12"

D.S.12

"

D.S.14

"

D.S.16

"

D.S.18

"

Stroke 6" 8" 10"10

to12 "12" 14" 16" 18"

Rottary

Table11" 13" 15" 15" 18" 20" 20" 24"

Longitudinal Movement

8" 10" 12" 12" 14" 16" 18" 18"

Cross

Movement6" 8" 10" 10" 12" 14" 15" 16"

CuttingSpeed ofRam PerMinute

60-90 60-90 40-60 40-60 40-60 40-6020-50-

80

20-50-

80

RamAdjustment

8" 10" 12" 12" 14" 16" 18" 18"

Throat 8" 10" 11" 11" 12" 14" 15" 16"
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Depth

H.P.

Required1 HP 2 HP 2HP 2 HP 2 HP 3 HP 3HP 3 HP

Distance

from theTool to

MainColoum

10" 12" 14" 14" 16" 17" 18" 18"

WeightPacked(Complete

aprox)

950 1050 1400 1500 1800 2000 2200 2400

6.Grinding machine-

The grinding machine consists of a power driven grinding wheel spinning at the

required speed (which is determined by the wheels diameter and manufacturersrating, usually by a formula) and a bed with a fixture to guide and hold the work-

piece. The grinding head can be controlled to travel across a fixed work piece or thework piece can be moved whilst the grind head stays in a fixed position. Very fine

control of the grinding head or tables position is possible using a vernier calibrated

hand wheel, or using the features ofnumerical controls.
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Grinding machines remove material from the work piece by abrasion, which can generate

substantial amounts of heat; they therefore incorporate a coolant to cool the work piece so that itdoes not overheat and go outside its tolerance. The coolant also benefits the machinist as the heat

generated may cause burns in some cases. In very high-precision grinding machines (most

cylindrical and surface grinders) the final grinding stages are usually set up so that they remove

about 200 nm (less than 1/100000 in) per pass - this generates so little heat that even with nocoolant, the temperature rise is negligible.

-----------------------------------------------------------************------------------------------------------------------
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