The internship opportunity I had with Plasser India was a great chance for learning and professional development. Therefore, I consider myself as a very lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and professionals who led me though this internship period.

1. 1
HIGH CAPACITY | PRECISION | RELIABILITY
Internship Report

2. 2
Acknowledgment
The internship opportunity I had with Plasser India was a great
chance for learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with
an opportunity to be a part of it. I am also grateful for having a
chance to meet so many wonderful people and professionals who
led me though this internship period.
Bearing in mind previous I am using this opportunity to express
my deepest gratitude and special thanks to Mr Dharmendra Kumar
who in spite of being extraordinarily busy with his duties, took
time out to hear, guide and keep me on the correct path and
allowing me to carry out my internship at their esteemed
organization and extending during the training.
I perceive this opportunity as a big milestone in my career
development. I will strive to use gained skills and knowledge in the
best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to
continue cooperation with all of you in the future.
Sincerely,
Rishikesh Trivedi
Place: Plasser India Sector 38, Faridabad, Haryana 121003
Date: 20/07/2018

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Contents
1. About the company 4
2. Hydraulics Department 5
2.1. Hydraulics- Description 5
2.2. Components of Hydraulic System 6
2.3. Hose 6
2.3.1. Hose Assembly 7
2.3.2. Crimping 10
2.4. ISO Symbols of Hydraulics 13
3. Welding -Types 16
3.1. MIG or GMAW 16
3.2. Arc or SMAW 17
3.3. TIG or GTAW 18
3.4. FCAW 19
4. Raw Material preparation Department 20
4.1. Grinding Machine 20
4.2. Circular Saw 20
4.3. Metal sheet cutting machine 21
4.4. Metal sheet bending machine 22
4.5. CNC cutting and welding machine 23
4.6. Pug cutting machine 23
4.7. Drilling Machine 24
5. Machine Shop 25
5.1. VMC 25
5.2. Multi-Purpose Drilling machine 26
5.3. Radial Arm Drill 27
5.4. CNC Turning machine 28
5.5. Centre Lathe 29
5.6. Milling Machine 31
5.7. Grooving machine 36
5.8. Horizontal Boring Machine 36
5.9. CNC Lathe machine 38

4. 4
About the company:
Plasser India manufactures the most up-to-date high performance and
highly sophisticated machines for track maintenance, track laying as well as
track renewal.
The machines for Indian Railways are tailor-made designs with special
emphasis on applying the technology most appropriate for the local
conditions.
Production in India ensures a high indigenous content and by engaging a
large number of Indian suppliers they are generating value and ensuring
that “Make in India” is implemented in word and spirit. Machines and
components are not only manufactured for the Indian market, also foreign
Railway systems have already received high quality products from Plasser
India.
Following Plasser’s general policy, special emphasis is given to efficient
after-sales service, spare parts supply and prompt availability of technical
expertise as and when required.
Furthermore, there is continuous training of specialized and qualified
workers who are employed in the field not only in India but also in other
parts of the world where their knowledge and skills are being made use of.
Through Plasser India, the know-how and experience of Plasser & Theurer,
the largest manufacturer of track machines in the world, has been made
available to the Indian market.
There’s a story behind every organization. The story of Plasser India is one
of quality, innovation and trust.
Starting delivery of first track maintenance machine to Indian Railways in
1965 was the first step in their new beginning in India. They’ve been
setting technological milestones, enabling higher working speeds, higher
quality and economic advantages for their customers and the railways.
For over 50 years, Plasser India has concentrated on the development,
manufacturing and export of track maintenance machines. They’ve become
a part of railway system and have made great contribution towards its
safety, reliability and cost efficiency.

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HYDRAULICS
Hydraulics is a technology and applied science using engineering,
chemistry, and other sciences involving the mechanical properties and use
of liquids. You can even say force transmitted by liquid.
The principle is based on closed system
with pistons, cylinders and special liquid.
Liquid has one very special physical
characteristic, they are incompressible
unlike air that’s why hydraulic systems
must be free of air. Within a hydraulic
system pressure is exerted on a liquid by
means of this force the space within a
cylinder is reduced and the liquid is
displaced. The resulting pressure acts the
same at any point in the system retaining its magnitude.
If two cylinders of equal size are connected to each other the liquid
transmits the exerted force while maintaining the ratio.
The force continues to
be transmitted
uniformly, however
it’s divided into four
equal parts
proportionally
reducing the distance
moved by the four
Pistons.
The hydraulic system works with a special liquid to ensure reliable
operation it has to meet certain requirements. It should work equally well at
low temperatures as at high temperatures. That’s why the brake fluid must
be exchanged regularly. The fluid is transported via steel pipes and hoses
from the master cylinder to the pistons.

6. 6
COMPONENTS OF HYDRAULIC SYSTEM
Hose: A hose is a flexible (used at movable areas) hollow tube designed to
carry fluids from one location to another. Hoses are also sometimes
called pipes (the word pipe usually refers to a rigid tube, whereas a hose is
usually a flexible one), or more generally tubing. The shape of a hose is
usually cylindrical (having a circular cross section).
SIMPLE HYDRAULIC SYSTEM

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Hose Assembly
1. Selecting the correct hose and fittings
This can be done by referring to the manufacturer specification or
using the hose layer line. Layer lines are the text printed or moulded
onto the hose often featuring part numbers, size, standards and
working pressures required to make hose selection simple.
From here we need to identify the required fittings-
Different types of threads are used depending on different application:

8. 8
2. Measuring & Cutting the Hose
Once we have our hose and fitting we must measure and cut the hose.
To accurately measure the original assembly, it is industry measure
cone to cone to ensure the correct cut-off length.
Once the hose is marked, we cut it using a dedicated hose cutting
machine. Using a cutting machine ensure the square cut necessary to
ensure a perfect seal when switching the fittings. This is aided by
serrated disk blade cutting efficiently and smoothly through the hose.
Then we need to make sure the hose is pushed on all the way, this is
done by marking the point where ferrule (cap/ring) will push to
known as the insertion depth, this makes easy to tell the fitting is fully
inserted.
We can even set any angle between fittings on both sides of the hose
if required.
MACHINE USED FOR INSERTING
FITTINGS TO HOSE

9. 9
3. Swaging the Hose Assembly
First we the correct swage
dimensions which is provided by
the supplier. Here pallet swage
machine (hose crimping machine)
is used. Once we know the
dimensions required we set the
nearest dye set without going
over our required final swage.
This is because when the dies are
closed together the hole in the
middle measures what the die
says.
HOSE CUTTING MACHINE

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Effects of Over and Under Crimping
a) Correctly Swaged Hose
Here is the picture of correctly swaged hose allowing unrestricted flow of
oil.
CLOSED OPEN
BEFORE CRIMPING AFTER CRIMPING

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b) Under crimped Hose
If the hose is under crimped then the compression seal is not formed by the
forced tail and the ferrule, this allow leak paths to formed behind the hose
tail and oil is forced through the wires of the hose and can cause blistering
leading to hose bursts.
c) Over crimped Hose
If the hose is over crimped then it compresses the ferrule and distorts the
hose tail this can reduce the flow rate as well as it can cause blockages in
small hose.
After assembling the fittings to the hose it is tested
by applying pressure that the hose will have to go
through it functioning.

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HOSE TESTING MACHINE

13. 13
ISO Symbols:

14. 14

15. 15
f vdf bdbf bdf df df dbdf
dv

16. 16
WELDING - Types
MIG (Metal Inert Gas) Welding or GMAW (Gas Metal Arc Welding)
The concept of combining two pieces of metal together with a wire that is
connected to an electrode current, is referred to as Metal Inert Gas (MIG)
welding.
In this type of welding process, a shielded gas is used along the wire
electrode, which heats up the two metals to be joined. A constant voltage
and direct current power source is required for this method, and this is the
most common industrial welding process. The MIG or GMAW process is
suitable for fusing mild steel, stainless-steel as well as aluminium.

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Arc Welding or SMAW (Shielded Metal Arc Welding)
Arc welding is also called as Shielded Metal Arc welding, or simply referred
to as ‘Stick’. This is the most basic of all welding types.
The welding stick uses electric current to form an electric arc between the
stick and the metals to be joined. To weld iron and steel, this type of welding
is often used in the construction of steel structures and in industrial
fabrication. Stick welding can be used for manufacturing, construction and
repair work.

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TIG (Tungsten Inert Gas) or GTAW (Gas Tungsten Arc Welding)
A non-consumable tungsten electrode is used in this type of welding process.
This tungsten electrode is made use of to heat the base metal and create a
molten weld puddle. By melting two pieces of metal together, an autogenous
weld can be created. For this type of welding, the welder needs to have a lot
of expertise as it’s a very complex process. This welding process is
employed to carry out high-quality work when a superior standard finish is
required, without making use of excessive clean up by sanding or grinding.

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FCAW (Flux-Cored Arc Welding)
As an alternative to shield welding, Flux-cored Arc Welding was developed.
This welding process is quite similar to MIG or GMAW process, except for
the fact that in FCAW a special tubular wire filled with flux is used and
shielding gas is not always needed, depending on the filler.
This type of welding is well-known for being extremely inexpensive and
easy to learn. However, there are several limitations in its applications and
the results are not often aesthetically pleasing as some of the other welding
methods. The semi-automatic arc is often used in construction projects,
thanks to its high welding speed and portability.

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Raw Material preparation Department
Grinding Machine (Grinder)
A grinding machine, often shortened
to grinder, is any of various power
tools or machine tools used for grinding,
which is a type of machining using
an abrasive wheel as the cutting tool.
Each grain of abrasive on the wheel's
surface cuts a small chip from the work
piece via shear deformation.
Grinding is used to finish work pieces
that must show high surface quality (e.g.,
low surface roughness) and
high accuracy of shape and dimension.
Circular Saw (Pipe Cutting Machine)
This machine is used to cut metal pipes into desired length.
In this machine a wheel blade is rotated with the help of electric motor and
the whole set is moved vertically (up and down) by hydraulics (containing
BELT GRINDER

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or operated by liquid under
pressure) or pneumatic
(containing or operated by air or
gas under pressure). It can be
automatic, semiautomatic or
manual.
Metal Sheet Cutting Machine (Shearing Machine)
This machine is used to cut metal sheet into desired size. It can be
mechanically operated with gears and can be hydraulics operated. It cuts
the sheet from one side to other like scissors.
MANUAL SEMI-AUTOMATIC
SHEARING MACHINE

22. 22
Which I saw was mechanically operated that can cut metal sheet with
thickness from 0.1 mm to 30 mm.
Working
Hydraulics is used to pull the blade upwards, while the blade is pulled the
operator places the metal sheet from where he has been instructed to cut it,
which he does with help of light projecting the shadow of blade on the
metal sheet to be cut. After the metal sheet is placed at the right place the
operator gives power to the blade. Before the blade touch the metal sheet,
very powerful holders holds the sheet so that while cutting it don’t move
and produce error. And then the blades cuts the sheet into two pieces and
again hydraulic pulls the blade upwards.
Metal Sheet Bending Machine
This machine is used to bend the metal sheet to desired angle. It uses dye of
different angles to bend the metal sheet. It is mechanically operated.
Hydraulics is used to pull the dye upward.
METAL SHEET BENDING MACHINE

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CNC Cutting and Welding Machine
This machine is used to cut or weld very thick metal jobs with up to 300
mm thickness. It is fully automatic machine. It works on two different
welding principles Plasma and gas.
Plasma is used for less thick metal and gas is used for thicker metals.
In this metal to be cut or weld is placed on a bed and then the operator feed
the machine the desired dimensions and operation and then the machine
does rest of the work itself. Operator just have to take care of refilling the
plasma and gas.
Pug Cutting Machine
These machines can produce straight
cuts on any length, square or bevel
edge. With the same precision these
machines can cut circles and also shape
with gradual curves, when hand-guided.
Can be swivelled to cut up to 45° with
Rack and Pinion.
Fuel Gas: Acetylene or LPG can be
used by selecting the appropriate nozzles.
CNC METAL CUTTING AND WELDING MACHINE
PUG CUTTING MACINE

24. 24
Drilling Machine
A drill is a tool fitted with a cutting tool
attachment or driving tool attachment,
usually a drill bit or driver bit, used for
boring holes in various materials or
fastening various materials together.
DRILLING MACHINE

25. 25
MACHINE SHOP
VMC (Vertical Machining Centre)
CNC vertical machining centres (VMCs) remain machine shop staples.
These milling machines have vertically oriented spindles that approach
work pieces mounted on their table from above. They are less costly than
horizontal machining centres (HMCs), which makes them attractive to
small job shops as well as larger machining operations. In addition, the
performance of these machines has increased over the years, leveraging
technologies such as high-speed spindles and advanced CNC capabilities
(including conversational control programming). Ancillary equipment is
also available to
increase the flexibility
and capability of these
machines, including
spindle speeders, angle
heads, tool- and part-
probes, quick-change
work holding devices,
and rotary indexers to
enable four- or five-axis
machining work.
Tools of the VMC automatically
changes according to the programme
is has been fed. Operator changes
tools from the side mount tool
changer when it gets blunt or breaks
into pieces.
SIDE MOUNT TOOL CHANGER
VMC

26. 26
Through spindle coolant throws jet of
coolant when the job is under
operation.
Multi-Purpose Drilling Machine
This machine is one of the most
common and useful machine
employed in industry for producing
forming and finishing holes in a work
piece. The unit essentially consists of:
1. A spindle which turns the tool
which can be advanced in the
work piece either automatically
or by hand.
2. A work table which holds the
work piece rigidly in position.
Working Principle
The rotating edge of the drill exerts a
large force on the work piece and the
hole is generated. The removal of metal in a drilling operation is by
shearing and extrusion.
COOLANT USED DURING PROCESS

27. 27
Radial Drilling Machine (Radial Arm Drill)
This type of drilling machines are
perfect for large-sized workpieces.
They are suitable for the reaming
and tapping of the materials. High
suitability made them exceedingly
productive.
The drilling machine have a thick
base plate and vertical column to
which a horizontal arm is
mounted.
Parts of the Radial Drilling
Machine:
Column- It is a piece of outspread arm drill which holds the radial arm
which can be moved around as indicated by its length.
Arm Raise- Adjusts the vertical height of the radial arm.
On/Off Button- Activates and deactivates the drill press.
Arm Clamp- It secures the column and arm in place.
Table- It is the place where the workpiece are fed and worked on.
Base- It is the part which is used to support the table and column.
Spindle- It is used to hold the cutting tool.
Drill Head- It is the part if drill press that penetrates through the material.
Radial Arm- Holds and supports the drill head assembly.

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CNC Turning Machine (Lathe)
This machine is used to
do Turning. Turning is
a machining process in
which a cutting tool,
typically a non-
rotary tool bit, describes
a helix toolpath by
moving more or less
linearly while the
workpiece rotates.
Parts:
Chuck- This is used for holding the cutting tool.
Guard- When the guard is closed it protects the person who is operating
the CNC.
Light- Used to light up the workpiece so that operator can keep an eye on
the job.
Motor- Used to rotate the chuck at high speed.
Cutter- Used to cut the material.
Vice- Used to hold the material.
Lathe Bed- This base of the CNC.

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Centre Lathe
Lathe machine is a basic machine which is used in every metal forming
industries. It is combination of many parts which works together to perform
a desire function. A lathe machine is used to machine cylindrical work
piece which is 360
degree symmetrical
form the axis of
rotation. It used to
perform turning,
chamfering,
boring, facing,
internal threading,
shaping, slot
cutting etc. on
cylindrical work
piece.
There are many types of lathe machine but each machine consist some
basic part which are essential for its proper working. These parts are bed,
tool post, Chuck, head stock, tail stock, legs, Gear chain, lead screw,
carriage, cross slide, split nut, apron, chip pan, guide ways etc. These parts
work together to obtain desire motion of tool and work piece so it can be
machined.
The lathe machine works on basic
principle that when the work piece
rotate at a constant speed and a tool
is introduce between its rotation, it
cut the metal. This is basic
fundamental of it. The working of
lathe machine is explained in later
section of this article.
CENTRE LATHE

30. 30
The lathe consist following parts:
1. Bed
It is the main body of the machine. All main components are bolted on it. It
is usually made by cast iron due to its high compressive strength and high
lubrication quality. It is made by casting process and bolted on floor space.
2. Tool post
It is bolted on the carriage. It is used to hold the tool at correct position. Tool
holder mounted on it.
3. Chuck
Chuck is used to hold the workspace. It is bolted on the spindle which rotates
the chuck and work piece. It is four jaw and three jaw according to the
requirement of machine.
4. Head stock
Head stock is the main body parts which are placed at left side of bed. It is
serve as holding device for the gear chain, spindle, driving pulley etc. It is
also made by cast iron.

31. 31
5. Tail stock
Tail stock situated on bed. It is placed at right hand side of the bed. The main
function of tail stock to support the job when required. It is also used to
perform drilling operation.
6. Lead screw
Lead screw is situated at the bottom side of bed which is used to move the
carriage automatically during thread cutting.
7. Legs
Legs are used to carry all the loads of the machine. They are bolted on the
floor which prevents vibration.
8. Carriage
It is situated between the head stock and tail stock. It is used to hold and
move the tool post on the bed vertically and horizontally. It slides on the
guide ways. Carriage is made by cast iron.
9. Apron
It is situated on the carriage. It consist all controlling and moving mechanism
of carriage.
10. Chips pan
Chips pan is placed lower side of bed. The main function of it to carries all
chips removed by the work piece.
11. Guide ways
Guide ways take care of movement of tail stock and carriage on bed.
12. Speed controller
Speed controller switch is situated on head stock which controls the speed of
spindle.
13. Spindle
It is the main part of lathe which holds and rotates the chuck.
Milling Machine
Milling is the machining process of using rotary cutters to remove material
from a workpiece by advancing (or feeding) in a direction at an angle with
the axis of the tool. It covers a wide variety of different operations
and machines, on scales from small individual parts to large, heavy-duty
gang milling operations.

32. 32
Milling machines are tools designed to machine metal, wood, and other
solid materials. Often automated, milling machines can be positioned in
either vertical or horizontal orientation to carve out materials based on a
pre-existing design. These designs are often CAD directed, and many
milling machines are CNC-operated, although manually and traditionally-
automated milling devices are also common. Milling machines are capable
of dynamic movement, both of the tool and the workpiece, and many
milling machines can perform multi-axis machining.
VERTICAL MILLING MACHINE
HORIZONTAL MILLING MACHINE

33. 33
1. Column & Base
Column including base is the main casting that supports all other parts of
milling machine.
 The column contains an oil reservoir and a pump which lubricates the
spindle.
 The column rests on the base and base contains coolant reservoir and a
pump which is used during machining operation that requires coolant.
2. Knee
It is a casting that supports the saddle and table. All gearing mechanism is
enclosed within the knee.
 It is fastened to the column by dovetail ways.
 The knee is supported and adjusted by a vertical positioning screw
(elevating screw).
 The elevating screw is used to adjust the knee up and down by raising or
lowering the lever either with the help of hand or power feed.
3. Saddle and Swivel Table
Saddle is present on the knee and supports the table. It slides on a
horizontal dovetail on the knee and dovetail is parallel to the axis of the
spindle (in horizontal milling m/c).

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4. Power Feed Mechanism
It is the knee which contains the power feed mechanism. It is used to
control the longitudinal ( left and right), transverse ( in and out) and vertical
(up and down) feeds.
 To get the desired rate of feed on the machine, the feed selection lever is
positioned as indicated on the feed selection plates.
 On some universal knee and column milling machine, the feed is obtained
by turning the speed selection handle until the desired rate of feed is
indicated on the feed dial.
 Most of the milling machines have a rapid traverse lever that can be
engaged when a temporary increase in the speed of the longitudinal,
transverse or vertical feeds is required. For example this lever would be
engaged when the operator is positioning or aligning the work.
5. Table
It is a rectangular casting which is present on the top of the saddle.
 It is used to hold the work or work holding devices.
 It contains several T-slots for holding the work and work holding devices
(i.e. jigs and fixtures).
 The table can be operated by hand or by power.To move the table by hand,
engage and turn the longitudinal hand crank. To move it through power,
engage the longitudinal direction feed control lever.
6. Spindle
It is the shaft which is used to hold and drives the cutting tools of the
milling machine.
 Spindle is mounted on the bearings and supported by the column.
 Spindle is driven by the electric motor through gear trains. The gear trains
are present within the column.
 The face of the spindle which lies near to the table has an internal taper
machined on it. The internal taper at the front face of the spindle permits
only tapered cutter holder or arbor. It has two keys at the front face which
provides positive drive for the cutter holder or arbor.
 The drawbolt and jamnut is used to secure the holder and arbor in the
spindle.

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7. Over Arm / Overhanging Arm
It is a horizontal beam present at the top face of the column. It may be a
single casting which slides on the dovetail ways present on the top face of
the column.
 The overarm is used to fastened arbour support. It may consist of one or
two cylindrical bars which slide through the holes in the column.
8. Arbor Support
It is a casting with bearing that supports the outer end of the arbour. It also
helps in aligning the outer end of the arbor with the spindle.
 It prevents the springing of outer end of the arbor during cutting operations.
 There are generally two types of arbor supports used in the milling
machine. The first one has small diameter bearing hole, 1-inch in maximum
diameter. And the other one has large diameter bearing hole, usually up to
23/4 inches.
 The arbor support has an oil reservoir that lubricates the bearing surfaces. It
can be clamped anywhere on the overarm. The arbor support is used only in
the horizontal types of milling machine.
9. Ram
The overhanging arm in the vertical machine is called ram. One end of the
ram is mounted on the top of the column and on the other end milling head
is attached.
 The ram can be a moved transversally (in and out) on the column by a hand
lever.
Types of Milling Machine
1. Horizontal Milling Machine
In horizontal milling machine the axis of rotation of the spindle is
horizontal to the table. And due the axis of spindle horizontal, it is called as
horizontal milling machine.
2. Vertical Milling Machine
The milling machine in which the spindle axis is perpendicular to the table
is called vertical milling machine.

36. 36
3. Knee-Type Milling Machine
The milling machine which has a knee like projection at the middle is
called knee-type milling machine. It is characterised by a vertical adjustable
work table resting on a saddle supported by a knee.
4. Ram-Type Milling Machine
A milling machine which has a ram on the top of the column is called ram
type milling machine. Generally ram is used in vertical milling machine. It
can be moved on the column in transverse direction (i.e. in and out when
operated from the knee side).
5. Manufacturing or Bed -Type Milling Machine
6. Planer-Type Milling Machine
Grooving Machine
This machine is used to make
grooves and keys in shafts and
many different parts.
A groove is a long and narrow
indentation built into a material,
generally for the purpose of
allowing another material or part
to move within the groove and be
guided by it.
Horizontal Boring Machine/Mill
A horizontal boring machine is
a machine tool which bores holes in
a horizontal direction.
GROOVING MACHINE

37. 37
Boring machine has its work spindle
parallel to the ground and work table.
Typically there are three linear axes in
which the tool head and part move.
Convention dictates that the main axis
that drives the part towards the work
spindle is the Z axis, with a cross-
traversing X axis and a vertically
traversing Y axis. The work spindle is
referred to as the C axis and, if a
rotary table is incorporated, its centre
line is the B axis.
HORIZONTAL BORING MACHINE
TOOLS

38. 38
CNC Lathe Machines
Some view Lathes as the only universal CNC Machine tool because a lathe
can make all of the parts needed for another lathe. A lathe spins the
workpiece in a spindle while a fixed cutting tool approaches the workpiece
to slice chips off of it. Because of this geometry, lathes are ideal for parts
that have symmetry around some axis that could be chucked up in the
spindle.
CNC Lathes have at the very least the ability to drive the cutting tool under
g-code control over 2 axes, referred to as X and Z. They may have a
considerable amount of other functionality as well, and there are many
variations on lathes such as Swiss Lathes.
The act of cutting a workpiece on a lathe is called "Turning".
Uses of CNC Lathe Machines
With CNC lathe machines, the material being worked is slowly sheared
away. The result is a beautifully finished product or intricate part. Because
these machines are so versatile, they are used by many industries to include
automotive, electronics, aerospace, firearm manufacturing, sporting, and
much more.