Book G12 T3 EMM731 Machine Operation II

Machine Operations II - EMM731
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G12-T3-EMM731-Machine operation II
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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
Tool
Table
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
Long hair, loose clothing etc., can become
entangled in moving parts
Work pieces, chuck keys, broken cutting
tools, swarf, etc., can be violently ejected
shaper can present a hazard of electric
shock
Closing movements between parts under
power can be a trapping hazard.
Sharp edges on tools, work pieces can
cause cuts
Contact with cutting fluids, oil and grease
can irritate
Inadvertent starting of the machine
Slippery floors surfaces or loose items
around the machine can cause slips and
trips resulting in contact with.
moving parts can be a trapping hazard
Control Measures
MUST be controlled by tightening up or removal.
Wear safety glasses, or plastic screen
Witch of the machine from the main switch before
any maintenance and use TAG
Sufficient space should exist around the machine
to prevent accidental contact with passersby. The
machine should be stopped before doing anything
around it.
Duel with tools and workpiece carefully, remove
any sharp edges from the workpiece before duel
with it.
Wash it directly, wear special gloves.
Make sure the main switch is off until finish all
settings.
Stop the machine and clean any mess directly
when notes it.
Mechanical Guard should be used if possible and

Long hair, loose clothing MUST be controlled.
Manual handling of heavy equipment
An assessment should be made and appropriate
(vices and indexing heads etc.) can present procedures developed.
a hazard.
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.
DONT
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 the machine 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.
Cross rail
It is mounted on the front vertical guideways of the column. The table may be
raised or lowered by adjusting the cross rail vertically. A horizontal cross feed screw is
fitted within the cross rail.
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
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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 vises 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 highspeed 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.
2.
3.
4.
machine vise
T-bolts and step blocks
Angle plate
V Block
4.1 - Work holding devices:

4.1.1-Machine Vise
Machine 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 vise
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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Fig. 11 T-bolts and step

blocks
4.1.3- Angle plate
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
Packing
Table
Fig. 12 Angle plate

81
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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.
2.
3.
4.
5.
shoulder tool
partingoff tool
grooving tool
hook tool
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 s haper is mo s tly us ed to machi ne a flat, tr ue s ur face o n 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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Assessment Tool
Grade 12 Term 3 Project
Machining operations II -EMM731
Cluster
Unit of Competency
Perform general machining
National Code
MEM07005C
Perform engineering
measurements
Mark off/out(general
engineering)
MEM12023A
Performance criteria to be assessed

1.1, 2.1, 2.2,3.1, 3.2, 4.1,4.2,4.3, 4.4,
5.1
1.2, 2.1,2.2,2.3,3.1,4.1, 4.1
MEM120026C
1.1, 1.2, 2.1, 2.2,
Student Name
No.
Date
Signature
Assessor Name
signature
Date
CO/NYC
Instruction to students
If you have any individual needs that may affect your participation in this assessment, inform your
assessor.
If you are allowed three attempts to demonstrate competence against this assessment.
You have the right to appeal an assessment result.
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A.A-version 02-2015/2016
Project brief:On successful completion of this project the student should be able to:
1.
2.
3.
4.
5.
6.
Identify general safety instructions for using machines/power tools.

Identify hazards and control measures associated with shaping machining.
Identify the main parts of shaping machine.
Set and operate the shaping machines
correct mounting and positioning of cutting tools
Measure to specified dimensions.
In this project teacher has to demonstrate to the students how to make the
project, students can be involved by preparing the shaping machine, fix the
cutting tools ,hold the work piece, select the speed, select the feed, change the
feed direction and so on ,
Part 01:- write the names of tool holder parts. In shaping machine [5marks]
N0
1
2
3
4
5
Name
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Part 02: The main parts of a shaping machine.
[8 Marks]
Label the shaping machine parts with the given word or number, write your
answer in the box provided.
4
5
8
6
Number
Answer
Number
Answer
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Part 03:-write the name of shaping tools according to application.
N0
1
2
3
4
5
[5marks]
Name
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Part04:-Practical task, [10marks] from observation sheets
[12marks]
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.
1- Get the material from the store, (possibly 100*50*20mm flat bar or any nearly DIMs)
from Brass, aluminum, or mild steel ,
2- Before setting up the work, make sure the machine is SWITCHED OFF.
3- Make sure the work is held securely and correctly in the holding device.
4- Make sure the tool is clamped correctly in the tool post.
5- Remove the any tools (spanners screw, drivers) after checking the work is secure.
6- Set the number of strokes per minute, stroke length, feed, cutting depth.
7- Touch the cutting tools with the surface of the work piece and mark the zero,
8- The depth of the cut should be 1.5mm.
9- The feed pitch should be between 4-6mm.
10- Below is the cutting tool should be used for the project,
11- The final work piece should be like this ,double cut with 90 between them
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A.A-version 02-2015/2016
Students have to take photos for their final works on shaping machine and attach them
with project.
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SKILLS-Observation Checklist
Students Name &
ID
Assessor or
Observers Name
MEM 12023A Perform engineering measurements
MEM 12006C Mark off/out general engineering
MEM 07005C Perform general machining
/2016
Date of Assessment
STS Machining Workshop
Location
Machine operation II-project
In this project you are tasked with shaping machine. Students have
PROCEDURE
to implement the skills to operate the shaping machine to produce
the project, they have to work on this machine with teacher
supervision, and During the project you will develop new
machining skills.
Power hacksaw machines, shaping machine, shaping cutting tools,
Materials and
(possibly 100*50*20mm flat bar or any nearly DIMs) from Brass,
Equipment
aluminium, or mild steel ,
During the demonstration of skills, Did the candidate perform the
following skills?
Yes
No
Unit of Competency
(code and title)
1. Drawing and job instruction are understood.

2.Appropriate material is selected (brass ,aluminium or mild steel)
3. Choosing the suitable hacksaw blade to cut the material.
Using the engineer square every while to check the datum.
4. select the correct cutting tools for the task,
5. Set up the machine correctly to meet job specification. This include mounted the
tools and the work piece is held on the machine correctly.
6. All marking off/out
is carried out using appropriate tools and equipment
7. Measurements are correctly obtained and recorded. Using Vernier calliper ,

8. Sequence of operation is determined for maximum efficiency.
9. Appropriate calculations are used where required. Stroke length adjusted ,
10. Machining is performed in a safe manner. utilizing all safety procedures and PPE
11. Cleaning the workshop and storage the tools and measuring instrument.in their
place.
The students performance was
`
Satisfactory
Unsatisfactor
y
Feedback to student:
Students signature:
Assessor/Observer signature:
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A.A-version 02-2015/2016
Part 05:- Stroke length calculation and adjustment
[5marks]
Use Vernier calliper to measure the final work piece and write the DIMs on the table
below.
The DIMs you have to measure:DIMs
Length
Width
Thickness
The pitch
stroke length
Measurements ,mm
Calculate the L=
Part6:- Maintenance of shaping machines.
[5marks]
Answer the following questions:1-what type of lubrication system on the shaping machine you are using
Automatic, manual or both,
2- These lubrication systems are used to lubricate what in the shaper?
3-what type of lubricants is used for lead screw on shaper?
4-what type of hazards associated with lubricants?
5-what Control Measures should be taken to reduce the hazards from lubricants?
Students Final Project Marks

Rubric - 30
Part
1
2
3
4
5
6
Total
Marks Distribution
5
8
5
12
5
5
30
Student Mark
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A.A-version 02-2015/2016
With best wishes and luck
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Book G12 T3 EMM731 Machine Operation II

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Machine Operations II - EMM731

Identify general safety instructions for using machines/power tools.

Identify hazards and control measures associated with shaping machining.

Identify the main parts of shaping machine and their functions.

Identify kinematic systems and working principles of shaper.

Set and operate the shaping machines

correct mounting and positioning of cutting tools

Setting machining parameters to achieve the job requirements.

Identify the Classification of tools according;

Recognize the methods of work holding;

10. Measure to specified dimensions.

1-Introduction to shaping machine

Always follow the instructions given by your instructor/supervisor.

Hand gloves should NEVER be used.

Machine guards MUST be put in position while operating.

Cutting tools and work piece MUST be properly clamped.

Keep hands away from any rotating objects.

Do not leave any running machine unattended.

1.2- Shaping process.

Fig 1 Shaping operation

1.3- Method of machining

Fig2- Method of machining

1.4-Hazards associated with shaping machines.

Mechanical Guard should be used if possible and

Do not use faulty equipment. Immediately report suspect machinery.

1.5- Main parts of a shaping machine

Fig 3- Shaping machine parts

1.6- Types of shaping machine

2- Kinematic systems and working principles of shaper.

Fig 4 -shaping machine mechanism

2.2- Quick return mechanism

2.3- Ratchet and Pawl mechanism (Automatic feed mechanism

Fig 5 - Ratchet and Pawl mechanism

2.4- Method of table movement

2.5 Swivel tool head

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

3- Setting and operation of shaping machines.

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

3.1. Clamping the work pieces.

Fig. 7-Workpiece clamping on machine vice

Fig. 8-Tool mounting for shaping

3.3 Setting of cutting values

3.3.1 Stroke length calculation and adjustment

Fig. 9 stroke length calculation

3.3.2Adjusting the stroke length

3.3.3 Cutting speed, Depth of cut and Feed

3.4 sequence of operations:

Feed cutting depth according to dial.

4. Work holding devices and Tools used in a shaping

4.1 - Work holding devices:

Fig. 10 machine vise

4.1. 2 -T-bolts and step blocks

Fig. 11 T-bolts and step

Fig. 12 Angle plate

Fig .13 V block

4.2- Classification of tools according to:

4.2.2. According to Direction of cutting.

4.2.3- According to Surface finish.

Fig. 14-shaping tools according to Surface finish.

4.2.3- According to shank form

Fig. 15-shaping tools according to shank form.

4.2.3- According to the application

Fig. 16-shaping tools according to application.

5. Operations performed in a shaping machine