METALWORK MACHINES

MEANING OF METALWORK: Metalwork is the process of making things out of metal in a skillful
manner. Metalwork involves a process of working with metals to create individual parts,
assemblies or large structure. It includes a wide range of work including big structures and small
ones. Examples of metalwork structures are SHIPS, BRIDGES, ENGINE PARTS AND DELICATE
JEWELLERY. Common metalwork machines in our various metal workshops are; LATHE
MACHINES, GRIDING MACHINES, PLANING MACHINE (SHAPER NAD PLANER), MILLING
MACHINE, DRILL PRESS, FORGING MACHINE AND FOLDING MACHINE.

LATHE MACHINE

A lathe machine is a machine tool which rotates the workpiece on its axis to perform metalwork
operations. These machine remove metals by the use of rigidly controlled hard steel cutting
tool. During its operation, the workpiece is made to revolve in a chuk or between centre while
the tool cuts. There are two types of lathe machine. They are;

i. Plain lathe
ii. Screw cutting lathe

Major components of lathe machines are the headstock, the tailstock, the bed, the spindle and
the carriage.

LATHE MACHINE OPERATIONS

The common operations that are performed on lathe machines are cutting, turning, facing or
cutting of screw thread in metal, drilling, knurling etc.

FACING

Facing is when turning operation is used to produce a flat surface. Facing is done
when the cutting tool moves in a direction that is perpendicular to the axis of
rotation of the workpiece being machined.

TURNING BETWEEN CENTRES

To achieve even diameters on either end of the workpiece, turning between

centres must be ensured. Turning between centres could be reversed with
reasonable accuracy.

TAPER TURNING
It can be described as the production of a piece of round work in which one end
has a bigger diameter than the other. It is conical in shape. The turning can be
done using a form tool. Form tool tapers are also known as short tapes.

CYLINDRICAL TURNING

This is described as an operation carried out in order to reduce the diameter of a

workpiece. This is carried out by feeding the cutting tool in a direction parallel to
the axis of rotation of the workpiece

STEPPED TURNING

This is described a turning of series of diameter on different section of a

workpiece. It is power-operated to maintain concentricity between the different
diameters. The removal of the workpiece before finishing the stepped turning
operations results in loss of accuracy.

SCREW CUTTING

This is an operation of cutting threads on the workpiece. It can be used in turning

a single start or a double-start square thread on shifts

POWER SAWING MACHINES

Power sawing machines are used to cut workpieces with coarse tooth hacksaw
blades. The coarse tooth ensures that the metal chips do not clog the teeth of the
blade. When using a power saw, the workpiece should be gripped firmly to
prevent accident and to ensure an easy cut.

SHAPING MACHINE

This is a metalwork machine that is suitable for cutting keyways and slots. It is
capable of being used to achieve facing on a flat plate. To use the shaping
machine for high performance operations, the workpiece is held firmly on the
table with a machine vice while the cutting tool held on the clapper box moves to
and fro while cutting
 DRILL PRESS

This is a metalwork machine that is suite for making holes in a workpiece.

Creating holes in a workpiece is called DRILLING. Drilling with the aid of a drill
press can be achieved by holding the job in a vice fastened to the worktable by
means of a bolt while the drill bit is fed into the job either by using a hand drill or
a pillar drilling machine.

GRINDING MACHINE

This is a machine tool used for breaking up parts of a workpiece. It is mainly used
for workpiece finishing in order to show high surface quality as well as high
accuracy of shape and dimension. A typical grinding machine consists of a bed
with fixture to guide and hold the workpiece and power-driven grinding wheel
spinning at the required speed. Grinding machines remove materials from the
workpiece by means of an abrasive which can generate substantial amount of
heat. A coolant is used to cool the workpiece to prevent overheating.

TYPES OF GRINDING MACHINE

The different types of grinding machine are;

i. Belt grinder
ii. Bench grinder
iii. Cylinder grinder
iv. Surface grinder
v. Tool and cutter grinder
vi. Gear grinder

MILLING MACHINE

A milling machine can be defined as a machine which removes metal by rotating

multi-toothed cutter that is fed into the moving workpiece. The spindle can be fed
up and down with a quill feed lever on the head. Most milling machines have
power feed for one or more axes. Power feed is smoother than manual feed and
capable of producing a better surface finish. Power feed also reduces the
operator’s fatigue level on long cuts.

The primary classification of milling machines is based on mill orientation.

However, classifications are sometimes made according to method of control,
size, purpose, and power source. The two primary classifications of milling
machines are:

i. Vertical milling machine

ii. Horizontal milling machine

VERTICAL MILLING MACHINE: This is when the cutting tool and the spindle move
in a horizontal manner. The main parts of horizontal milling machine are arm,
arbor bracket, cutting tools, machine vice, cross transverse handle, knee, vertical
transverse etc

HORIZONTAL MILLING MACHINE: This is when the cutting tool and the spindle
move up and down. The essential parts of vertical milling machine are base,
column, knee, sanddle, table, ram, tool head etc.

FOLDING MACHING

A folding machine is used primarily for the folding of metal sheets. Metal sheets
can be folded with either a buckle or a knife.

TYPES OF FOLDING MACHINE

There are three types of folding machine. These are:

i. BUCKLE FOLDER: It works by feeding the paper at high speed until no

further movement wherein the paper buckle
ii. KNIFE FOLDER: It works by striking the paper with a knife between
rollers
iii. PAPER FOLDER: It is used to create letter folds. Examples of paper
folders are parallel folder and half folder

FORGING MACHINE
Forging is a manufacturing process involving the shaping of metal using
compressive forces. Forging is classified according to the temperature at which it
is performed. Forging can be:

i. Cold forging
ii. Warm forging
iii. Hot forging

TOOL SELECTION

In machining, the type of operations involved dictates the machine to be used as

well as the type of tool;

i. The structures and properties of materials determine the choice of

cutting tool and coolant required
ii. A cutting tool chosen for a specific job must be capable of cutting the
workpiece
iii. A good cutting tool must be hard, tough and must be able to resist
abrasion and temperature

METAL WORKING FLUIDS

These can be described as oils and any other liquids that are used to cool and
lubricate metal workpieces when they are being machined, ground and drilled.
These fluids reduce heat and friction between the cutting tool and workpiece.
Cutting fluids are coolants which help to reduce distortion, power consumption,
improve surface finish and protect against corrosion of the workpiece.

TYPES OF CUTTING FLUIDS

The three types of cutting fluids are:

i. Solution oils
ii. Straight oils
iii. Water-base fluids

CARE AND MAINTENANCE OF METALWORK MACHINES

Metalwork machine require proper maintenance in order for them to have a long
lifespan. The follow are some general maintenance activities of metalwork
machines:

1. Regular lubrication of all moving parts of the machine

2. Sharpening of cutting machine components
3. Checking the alignment specifications
4. Regular cleanliness to remove dirt and debris and to prevent rust and
untimely wear

Machine accessories and component parts should be properly kept and damaged
parts should be replaced immediately

METALSWORK HAND TOOLS

These tools are either hand tools which are held by hands during machining operations. They
include marking out tools, measuring tools, cutting tools and driving tools.

Marking out Tools

Marking out tools are hand tools used for marking lines on metal surfaces, or checking alignment, or
indicating points or positions on a workpiece. There are several tools for marking out in the art of
metalworking. They are: surface plate, surface table, scriber, odd-leg callipers, dividers, punches, and
the try square.

Surface plate

The surface plate is a precision piece of equipment with a flat surface of high grade finish, on which
workpieces are placed for marking out. It is also used for testing the flatness of surfaces.

Surface plate

Surface plate in use

Surface table
It is used for supporting bigger workpieces, so that marking out can be carried out with ease and
accuracy.

Surface table
Surface table in use

Scriber
The scriber is the metalworker's pencil. It is used for marking out lines by hand, and together with
straight edges like steel rules, try squares or box rules.

scriber

Scriber in use

Dividers
Dividers are two-legged steel instruments, used for scribing arcs, circles, curves and for setting off
distances. Dividers are available in various sizes, and may be spring loaded with a fine adjustment screw,
or may be firmly joined at the head, like the odd leg callipers.

Spring loaded dividers Firmly joined dividers Divider in use to transfer measurement
Punches

They are two types of punches: the dot punch and the centre punch. The dot punch is 60 0 at its
conical end, while the centre punch is 90 0. Uses of the dot punch. The dot punch is use for denting
scribed lines. This is done some ace apart, to make the lines remain indelible while one is working. The
centre punch is used for providing a heavy conical dent at the end-point where a hole will be drilled.
The heavy conical dent prevents from deviating the point of the drill from diviating hole from the current
location of

Steel rule is used for testing the trueness and flatness of surfaces. It is usually graduated at the
edges by lines into millimeters and centimeters.

The steel rule The steel rule in use

Callipers

Callipers are used for measuring diameters, widths and thickness of objects. They are of three
types; external, internal and odd-leg callipers. External calipers are used for taking external
measurements while internal calipers are used for taking internal measurements. On the other
hand, odd-leg calipers are used for centering, i.e. locating centers of bars, taking distances from
the edges of holes and drawing parallel lines to given edges.
 External calliper in use internal calliper in use Odd-leg calliper in use

Micrometer

The micrometer is used for taking precision measurements. Its available in two types: the
external and internal. The external micrometer is used for taking external measurements while
the intern al micrometer is used for taking internal measurements. Measurements of objects
are read from both the barrel and the thimble.

micrometer

Vernier callipers
 Vernier callipers are used for taking very accurate external and internal measurements of
objects. For external measurements, the reading is taken directly from the graduation, while for
internal measurements, it is the addition of the scale readings and thickness of the two lips.

Vernier callipers

Depth gauge

The depth gauge is a precision measuring tool used for determining the depths of holes.

depth gauge The depth gauge in use

Height gauge

It is used to perform two functions which include to determine the height of components and
mark out dimensions. The principle of operation is similar to that of Vernier calliper.
gauge The height gauge in use

Cutting Tools

Cutting tools are used for cutting materials by sawing, filing, chiseling or scraping. Common
tools include hacksaws, files, chisels and scrapers.

Hacksaw: This tool consists of two parts; the frame and the blade. It is used mainly for cutting
metals in the metal workshop. There are three types generally in use: the adjustable, tubular
and junior hacksaws.

The tubular hacksaw

The adjustable hacksaw

The junior hacksaw

Files

Files are used for finishing jobs to the required sizes and shapes, after they have been
previously cut, using either a chisel or a hacksaw. File teeth are either single cut, double cut or
rasp cut.

A file and its main parts

Files are available in different types and shapes which include flat, hand, round, half round,
triangular, knife edge and square files.

Chisels

Chisels are tools used for shaping metals where finishing by other means such as filing cannot
be carried out. There are many types of chisels namely; flat chisel, cross-cut chisel, round-nose
chisel and diamond chisel.

The flat chisel The cross-cut chisel

 The round-nose chisel The diamond chisel

Scraper

Scrapers are used for removing imperfection from a surface that has been previously worked
on. It is aimed at getting a perfect surface worked out in a metal shop. There are usually three
types namely; flat, half round and triangular.

The flat scraper

Hammers

There are different types of hammer. They include ball pein, cross pein, straight pein and
special hammers.
 ball pein hammer cross pein hammer

straight pein hammer

Screwdrivers

Screwdrivers are used for fixing or removing screws by their heads. This is done using the blade
of the screwdriver. They are available in different sizes and types. The types include flat
screwdriver, star screwdriver and ratchet screwdriver.