1

MECHANICAL MAINTENANCE OF
MACHINES
(A MINI PROJECT REPORT SUBMITTED FOR THE AWARD OF
B.TECH DEGREE)

DEPARTMENT OF MECHANICAL
ENGINEERING

PRRM ENGINEERING
COLLEGE
(Affiliated to JNTU University Hyderabad)

SHABAD, R.R DIST

V.NAVEEN KUMAR (09611A0351)

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By

G.SURESH YADAV (09611A0335)

MINISTRY OF LABOUR &

EMPLOYMENT
DIRECTORATE GENERAL OF EMPLOYMENT &
TRAINING

ADVANCED TRAINING INSTITUTE

MINI PROJECT REPORT ON

MECHANICAL MAINTENANCE OF
MACHINES

PROJECT
SUBMITTED BY:

GUIDE

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(11-06-2012 TO 22-06-2011)

Mr.
V.NAVEEN KUMAR
(ASSISTANT

DIRECTOR)

G.SURESH YADAV
(B.TechMechanical engineering)
PRRM
Engineering College

TABLE OF CONTENTS

1. ACKNOWLEDGEMENT
2. ABSTRACT
3. ADVANCED TRAINING INSTITUTE
4. INTRODUCTION
5. CATEGORIZATION OF EQUIPMENT
6. MAINTENANCE RECORD
7. MAINTENANCE PLANNING
8. MEASURING

INSTRUMENTS

USED

FOR

9. MAXIMIZING EQUIPMENT EFFECTIVENESS

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GEOMETRICAL TESTING OF MACHINE TOOLS

10.

CONCLUSION

ACKNOWLEDGEMENT
A visit to the Workshop 01 of ADVANCED TRAINING INSTITUTE(ATI),
Hyderabad was carried out for information regarding Mechanical Maintenance
of machines. As the first step the different machining processes carried out in
the workshop were observed. In the second step information regarding the different
machines, their specifications, types of tools used etc was collected. In the third step
a detailed study of the manufacturing processes of various components of the plant
and machinery tools with the required specifications was made.
We are very thankful to ATI VIDYANAGAR Unit for permitting and providing
all the requisite facilities to carry out this project in the maintenance tool work
shop department.

for his valuable guidance in our project.

(DIRECTOR I/C )
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We are extremely grateful to MR.

We are extremely grateful to Mr.

(ASSISTANT

DIRECTOR, PROJECT GUIDE ) for his valuable guidance in our project.

ABSTRACT
New mechanical maintenance strategies such as TPM and preventive maintenance
are placing new demands on mechanics, technicians, and other mechanical systems
specialists to upgrade their skills as quickly and efficiently as possible in order to
maintain job security and enhance their chances for career advancement.
Industrial Mechanics introduces trainees to what they need to know to perform
well on the job immediately, with minimal learning curve. Key subjects include:
bearings, seals, and lubrication; hydraulics and pneumatics; mechanical power
transmission systems; and robotics.

Manufacturers are very averse to down time. Any downtime in plant is direct
production loss which nobody want .Every factory manager wants the downtime to
minimum .To achieve this you require skilled manpower in your maintenance
department. Normally a gang of four to five people including a foreman, an
electrician, a fitter and one or two helpers are minimum requirement for shift
coverage.

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You and your employees can choose from a variety of self-paced topical programs
that group together related coursework and are designed for flexibility, addressing
the professional and personal needs of each student. Like all Penn Foster training
systems, Industrial Mechanic courses are available in print, video or via Computer
Based Training (CBT and CD).

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Plant manager along with his engineer schedules a maintenance plan which can be
implemented on weekly/fortnightly/monthly basis.

ADVANCED TRAINING INSTITUTE:

The Advanced Training Institute for Electronics and Process Instrumentation
was setup in the year 1974 by Directorate General of Employment &
Training (DGET) under Ministry of Labor, Government of India with the
assistance of ILO/Swedish International Development Agency (SIDA) to
cater to the needs of the industries for training and developing their
manpower in the field of Electronics and Process Instrumentation. This
institute is situated on the sprawling 20 acres of land near, Shivam road,
Vidyanagar, Hyderabad.
Our institute has well equipped laboratories with state of the art training
equipments and modern lecture halls providing air conditioned comforts to
make learning a pleasant experience.
We also offer project based learning in the areas of Microcontrollers.
Under World Bank aided VTIP programs, we have opened Center of
Excellence in the Instrumentation sector. Under this we have also introduced
many refresher programs of two weeks duration for government ITI
instructors.
Incidentally in the present scenario, we are one of the few nations to have
large young population. By training them vocationally, we will be able to
create young and talented work force to cater to the global needs.
With this in view, we invite the Industries / Institutions / Organizations and
Students to avail these training facilities in large numbers.

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We are also looking forward to your valuable suggestions and feedback to

further improve our activities.

INTRODUCTION:
MAINTENANCE:
Maintenance is the combination of all technical and associated
administrative actions intended to retain an item in, or restore it
to, a state in which it can perform its required function. Many
companies are seeking to gain competitive advantage with
respect to cost, quality, service and on-time deliveries. The effect
of maintenance on these variables has prompted increased
attention to the maintenance area as an integral part of
productivity improvement. Maintenance is rapidly evolving into a
major contributor to the performance and profitability of
manufacturing systems. In fact, some see maintenance as the
"last frontier" for manufacturing.

OBJECTIVE OF MAINTENANCE:

The objectives of maintenance are to ensure the desired plant

availability at an optimum cost within the safety prescription. In
other words, it may be mentioned that the objective of
maintenance is to minimize the total cost of unavailability and
resources.
Whenever the plant is not available either due to breakdowns or
due to planned stoppages, the following costs are incurred.
1) Loss of earnings due to stoppage of equipment
2) Loss of in service materials.
In addition the following costs are incurred on resources:
1) Labour of overhead expenses
2) Materials in spares and consumables
3) Cost of storage of spares and facilities.
Hence, maintenance functions are so organized as to minimize
the total cost of unavailability and resources.

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1.

2.MAINTENANCE FUNCTIONS:
The above mentioned objectives are attained by taking certain
action illustrated below:
ACTION
PURPOSE
a. Lubrication
b. Cleaning
c. Adjustments
the process

Return or slow down

of deterioration or

wear .
d. Application of
Protective coatings
e. Examination of the
wear and
State of the
basis, the
Components.
check a

Assess the extent of

determine, on that
action required to
break-down and the

time when
such action

Restore the original

tional capacity of
and prevent
Affect

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should be taken.
f. Analysis of history
of behaviour of the
machine and its
components.
g. Replacement of worn
out component.
h. Repair of cracks or
operaother repairable
the machine
damages .
further damage .
i. Modification of design
improvements to reduce

10

of the components or
attention or
location of the
maintaining
equipment.
j. Capital replacement.
machine when

the frequency of
to reduce cost of
the equipment.
Replacement of the
the age of the

existing machine
requirements of
quality and
quantity of output
and
emergence of
better machines
make it economical
to dislodge
install a new machine
In these, the first four steps are taken with the sole purpose of
reducing friction, wear and effects of environment on the
individual parts of a machine. For example, lubrication reduces
friction; cleaning prevents corrosion and abrasion due to dust;
adjustment of level or alignments or by tightening the loose bolts
and nuts eliminates undue stresses; and preventive coatings
guard against rust and corrosion. These action increase the useful
life of parts and therefore, constitute an intrinsic part of
Preventive Maintenance.
The next two steps, inspection of parts and analysis of history, are
meant to assess the condition of the part, the extent of wear, the
action required to remedy the defect and the time when such
action should be undertaken. These activities are undertaken
essentially to be able to plan the remedial measures.
Inspection can be external for abnormal sound or temperature
which does not require a stoppage of the machine. It could even
be internal, requiring a machine to be stopped either purely for
inspection or at the time of some other repair or during
overhauling of the machine. Historical data on the other hand, is a

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the present and

11

chronological record of repairs and replacements carried out on a

machine during its life in the company. Analysis of such a record
helps to estimate the life span of various components and
establish the frequency of inspections, repairs, and replacements.
Replacement and repair of components can be undertaken on the
basis of inspection reports, analysis of history or complaints of
operating personnel.
Another important part of maintenance is the change in some
characteristics of the components which gives frequent trouble, to
avoid re-occurrence of that trouble with that frequency. Such an
action is taken on the basis of history of the equipment and
evaluation of costs involved. This step can be defined as
"Maintenance Prevention". Cost of maintenance of the machine
rises with the increase in its age. Moreover, passage of time also
affects the operational efficiency of the machine. Requirements of
quality and quantity of production go through a change making an
old machine more or less obsolete in relationship to the new
demands.
New and better machines emerge in the market. All these factors
make it necessary to replace the existing machines at some stage
in their lives by new machines. Maintenance is vitally linked with
such action. Analysis to determine the economics in replacement
of machines and their physical installation, therefore, becomes a
responsibility of the maintenance personnel.

Efficient
use of plant and equipment is a vital factor for
industrial growth, particularly in a developing economy like ours
plant and equipments besides being very expensive, are in many
cases imported involving foreign exchange. Further the cost of
plant and equipment forms a considerable portion of the total cost
of production. Thus it is imperative to look after them as
importance as it provides a means to maintain the plant and
equipment in a high state of operating efficiency and enhance its
productivity.

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EQUIPMENT MAINTENANCE SYSTEM:

12

Poor maintenance causes economic losses such as:

(a)
Increased down time
(b)
Poor efficiency
(c)
Declaration of equipment
(d)
Poor quality of product
(e)
higher labor costs
(f) Loss of material in process
(g)
Higher production costs
(h)
Increased hazards etc.

Systematic maintenance procedure offers tremendous

possibilities for savings in money materials and man
power .these savings come through:
(a)
Reduction in down time
(b)
Reduced losses of material in process
(c)
Increased life of the equipment
(d)
Reduction in over time
(e)
Optimum spares inventory
(f) Timely replacement of spares and machines
(g)
Maintenance of product quality
(h)
Proper running of the equipment
(i) Optimum operational costs of the machines.
Through proper maintenance the down time of equipment comes
down considerably. Machines are attended to before they break
down .spare parts are replaced before they fall. Lubrication is
down regularly and according to the time table, all these and
many other activities keep the equipment in good running
condition.

Maintenance practices can be broadly classified in to the

following types:

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TYPES OF MAINTENANCE:

13

1.
2.
3.
4.
5.
6.

Capital maintenance
Break down maintenance
Planned maintenance
Reactive maintenance
Total productive maintenance
Preventive maintenance

1. CAPTIAL MAINTENANCE:
A replacement is affected when
(a)
An equipment ages to the extent that the costs of
maintaining it in the required condition provides gains that
are less than those reliable from investment in a new unit.
(b)
A better machine emerges in the market rendering the
original unit obsolets.

2. BREAKDOWN MAINTENANCE:

In the case of break down maintenance the equipment is

generally attended only when it break down the maintenance
crew will carry out the necessary repairs, when the machine has
actually broken down and its able to function, in order to put it
back in to commission .such break downs may occur to any
machines at any time .there are many disadvantages in this
system.

(a)
There is always an urgency to put the machine back in
the working condition and hence the machine may not get
adequate maintenance.
(b)
Since the type and time of the break down is uncertain,
production plans completely get disrupted.
(c)
Planning of maintenance work Is not possible
(d)
Distribution of work load is difficult
(e)
Results in imbalanced utilization of maintenance staff
(f) May result is over staffing the maintenance department

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Some of them are:

14

(g)
Increased over time
(h)
Increased down time equipment due to non availability
of man power
(i) Excessive inventory of spares
(j) Waste of materials in process in continuous chemical
industries
(k)
Poor working conditions for maintenance staff

However, break down maintenance system may be

suitable in certain conditions such as:
(a)
Where plant capacity exceeds market demand
(b)
Standbys are available and quick switching over is
possible
(c)
Process is absolute and more modern equipment is
under consideration
(d)
May be economical for non critical equipment where
this type of maintenance is cheaper than any other system.

3. PLANNED MAINTENANCE:

Together with conditioned based maintenance, planned

maintenance comprises, preventive maintenance in which the
maintenance event is preplanned, and all future maintenance is
preprogrammed. Planned maintenance is created for every item
separately according to manufactures recommendation or
legislation. Plan can be based on equipment running hours, date
based, or for vehicle distance travelled. Good example of PM
program is car maintenance. After so many kilometers or miles oil
should be changed, parts renewed.

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Planned Preventative Maintenance ('PPM') or more usual just

simple Planned Maintenance (PM) or Scheduled Maintenance is
any variety of scheduled maintenance to an object or item of
equipment. Specifically, Planned Maintenance is a scheduled
service visit carried out by a competent and suitable agent, to
ensure that an item of equipment is operating correctly and to
therefore avoid any unscheduled breakdown and downtime.

15

ADVANTAGES:

Easier planning of maintenance and ordering spares,

Costs are distributed more evenly,

No initial costs for instruments for supervision of equipment.

DISADVANTAGES:

Less reliable than equipment with CBM

More expensive due to more frequent parts change.

Parts that have scheduled maintenance at fixed intervals, usually

due to wearout or a fixed shelf life are sometimes known as timechange interval, or TCI items.

4. REACTIVE MAINTENANCE:

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Reactive maintenance (also known as corrective maintenance)

involves all unscheduled actions performed as a result of system
or product failure. Basically, it is an attempt to restore the
system/product to a specified condition. The spectrum of
activities within this level are (1) failure identification, (2)
localization and isolation, (3) disassembly, (4) item removal and
replacement or repair in place, (5) reassembly, and (6) checkout
and condition verification. This approach is mainly a response to
machine breakdowns. Unfortunately, many manufacturers are still
in a reactive mode of operation. Their main objective is to ship
the product. If their manufacturing equipment breaks down, they
fix it as quickly as possible and then run it until it breaks down
again. This is an extremely unreliable process and is not the best
way to maximize the useful life span of one's assets. It leaves
machine tools in a state of poor repair and can cause the
production of out-of-tolerance parts and scrap. Because of its
unpredictable nature it can easily cause disruptions to the
production process.

16

5. TOTAL PRODUCTIVE MAINTENANCE:

Use appropriate technologies and standards to verify that

the equipment is in like-new condition after repair, overhaul,
or replacement.

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Total productive maintenance (TPM) is preventive maintenance

plus continuing efforts to adapt, modify, and refine equipment to
increase flexibility, reduce material handling, and promote
continuous flows. It is operator-oriented maintenance with the
involvement of all qualified employees in all maintenance
activities. TPM has been described as preventive maintenance
with these three factors added: (1) involving machine operators in
preliminary maintenance activities by encouraging them to keep
machines clean and well lubricated; (2) encouraging operators to
report indications of incipient distress to the maintenance
department; and (3) establishing a maintenance education and
training program. Developed in Japan, TPM places a high value on
teamwork, consensus building, and continuous improvement. It is
a partnership approach among organizational functions,
especially production and maintenance. TPM means total
employee involvement, total equipment effectiveness, and a total
maintenance delivery system. In order to achieve this, machine
operators must share the preventive maintenance efforts, assist
mechanics with repairs when equipment is down, and work on
equipment and process improvements within team activities.
Tennessee Eastman found that another employee, such as an
equipment operator, with minimal training, could do 40 percent of
the traditional maintenance mechanic's work. Another 40 percent
could be performed with additional training, but still below the
certified level. Only 20 percent of the maintenance tasks actually
required a certified mechanic's skills. They also reported that as
much as 75 percent of maintenance problems can be prevented
by operators at an early stage. This frees maintenance personnel
to be responsible for the tasks that require their critical skills,
such as breakdown analysis, overhaul, corrective maintenance
and root cause analysis. This places them in a "consultant" role
with the operators allowing them to: Help the operator diagnose
problems and restore equipment to like-new condition.

17

Use this knowledge to assess the root cause of the problem

so that changes may be made to the design, operation, or
maintenance practices in the future.

Work with purchasing, engineering, operations, and

maintenance to modify procurement standards to assure
maximum reliability in future equipment.

Of course, for all of this to work, the firm must have an

organizational culture which supports a high level of employee
involvement. Businesses must be willing to provide the necessary
training in order to allow production personnel to perform the
required tasks.
TPM's focus is on elimination of the major losses or inefficiencies
incurred in production activities. These losses include those due
to obstruction of equipment efficiency, manpower efficiency, and
material and energy efficiency. Based on their link to corporate
goals, targets for eliminating or reducing these losses are
developed. Just as in activity-based cost accounting where cost
drivers are identified, the objective of TPM is to identify variables
that can demonstrate improved performance. All major
equipment losses are functionally related to availability,
performance, efficiency and/or quality rate so the improvement
resulting from the maintenance system can be measured by its
impact on overall equipment effectiveness (see below).

BENEFICIAL RESULTS OF TPM :

Overall equipment effectiveness and overall efficiency are

maximized.
It takes the guesswork out of determining which machine
needs major repairs or rebuilding.

It provides objectivity by converting the operator's intuition

into quantifiable values.

It pinpoints exact maintenance requirement. The operator

carries out only the needed corrective actions so no
unnecessary work, beyond routine maintenance, is done.

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18

It rapidly verifies the effectiveness of major corrective work.

Operators improve their job skills.

Operators are motivated by involvement in maintaining their

own machines and by involvement in team-based concepts.

Operator involvement in the process gives them ownership

of making the project a success.

A preventive maintenance program for the lifecycle of the

equipment is developed.

By getting everyone involved in equipment design and

selection, a better understanding of why certain decisions
and trade-offs is necessary results.

Equipment and maintenance management (inherent in a

reliability strategy) result.

Capacity is maximized.

Costs are minimized.

Product quality is improved.

Improved safety.

The manufacturing process is continually improved.

As a final note on TPM, another school of thought holds that TPM

can be adopted by continuous diagnostic monitoring of a
machine's conditions and establishing a trend line for it. Trend
lines approaching or veering into the domain that identifies poor
operating conditions will trigger maintenance action.

As the name itself indicates preventive maintenance is based on

the old age saying
Prevention is better than cure or a stick in time saves nine .
Preventive maintenance is a systematic maintenance procedure
where in the condition of the plant is constantly watched through
a systematic inspection and preventive action taken to reduce the

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6. PREVENTIVE MAINTENANCE:

19

incidence of break downs. The necessity for either major or minor

repairs is determined to prevent unscheduled interruptions to the
plant and equipment or any deterioration.

THE FUNDEMENTAL ACTIVITES ARE:

(1)
Periodical inspection of plant and equipment to discuss
the conditions of deterioration
(2)
Up-keep of an equipment to remove or repair such
conditions while they are still in a minor state. Thus the
essence of the preventive maintenance is a well planned
inspection system .proper inspection at right time is the crux
of the preventive maintenance system, the results of
inspection are used to analyze the problems of up keep,
replacement and modifications well in advance and thereby
to help proper planning and assessment of the work contents
of the jobs. It is off course necessary to determine with great
care what is to be inspected and when. Meticulous recording
of the facts revealed during such inspections is another
important point. Analysis of such records indicates the type
of work maintenance needed, replacements required,
planning of maintenance work and inventory of spares.
Preventive maintenance renders more effective use of man
power and materials and helps to attain greater efficiency in
plant operation.
Planning of maintenance work and optimum inventory of
spares and components became possible with the
introduction of this system. It will be possible to synchronize
the maintenance program me so that there is at least
interruption to continuous operation and production.

The various elements of a preventive maintenance

of a system in an industry are as follows:
An inventory of all plant and equipment that need to be
maintained.
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20

Categorization of equipments to assess the relative

importance and thereby determine the equipments
requiring preventive maintenance.
A well designed inspection system.
A good lubrication system.
Maintenance of adequate records and analysis of these
records.
Planning of maintenance work.
Control of maintenance stores and spares.
Organization for preventive maintenance work.

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21

PREVENTIVE MAINTENANCE ON
CENTRE
LATHE MACHINE:

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A lathe is a machine tool which spins a block of material to

perform various operation such as facing, taper turning,
threading, chamfering drilling, boring, knurling of deformation
with tools that are applied to the work piece to create an object
which has symmetry about an axis of rotation. Lathes are
manufactured in a wide range of sizes. The average metric lathe
used in school shops may have a 230 to 330 mm swing and have
a
bed
length
of
from
500
to
3000
mm.
The main parts of the lathe machine as shown in Figure are bed,
headstock, quick-change gearbox, carriage and tailstock. Besides
that, many lathe accessories are available to increase the
versatility of the lathe and the variety of work that can be
machined such as lathe centers, chucks, collets, mandrel, and
lathe dogs. Overall, lathe is the most commonly used machine in
the industry because it can be used for many types of operations.
Modern lathe machines have come with other types such as the
engine, turret, single and multiple-spindle automatic, tracer and
now computer numerical controlled.

22

LEVELING OF LATHE MACHINE:

Before the various tests on any machine tool are carried out,
it is very essential that it should be installed in truly
horizontal and vertical planes. In horizontal plane, both
longitudinal and transverse directions are equally important.
If, say, any long lathe bed is not installed truly horizontal the
bed will undergo a deflection, thereby producing a simple
bend and undesirable stresses will be introduced. If the bed
is not installed truly horizontal in transverse direction, twist
will be introduced. Thus the movement of the saddle cant
be in a straight line and true geometric cylinder cant be
generated. For proper installation and maintenance of its
accuracy, a special concrete foundation of considerable
depth must be prepared. Also this must be insulated from
the surrounding floor by introducing some form of damping.
The level of the machine bed in longitudinal and transverse
directions is generally tested by a sensitive spirit level. The
saddle is kept approximately in the centre of the bed support
feet. The spirit level is then placed at a-a (Fig. 16.1), ensure

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1.

23

the level in the longitudinal direction. It is then traversed

along the length of bed and readings at various places noted
down. For test in transverse direction the level is placed on a
bridge piece to span the front and rear guide ways and then
reading is noted. It is preferable to take two readings in
longitudinal and transverse directions simultaneously so that
the effect of adjustments in one direction may also be
observed in the other. The readings in transverse direction
reveal
any

Fig. 16.1

twist or wind in the bed. It may be noted that the two guide
ways may be perfectly leveled in longitudinal direction, but
might not be parallel to each other. This is revealed by the
test
in
transverse
direction.
The straightness of bed in longitudinal direction for the long
beds can also be determined by other methods, e.g., using
straight edges, autocollimators or by taut wire method. But
the test in transverse direction can be carried out only by
spirit level. It is desired that the front guide way should be
convex only as the cutting forces and the weight of carriage
act downward on it. If the front guide ways are concave, then
the effect will be cumulative. The tendency of the carriage,
under cutting forces is to lift upwards from the rear and this
is prevented by a gib placed underneath the guide ways.
With the result, an upward force acts on the rear guide ways;
which must, therefore, be made concave. Transverse level
may be in any direction, but no twist can be tolerated.

LOCATION

Locating cylinder is provided to locate the chuck or face plate.

However locating surface cant be threaded one as threads get

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2.
TRUE
RUNNING
OF
CYLINDER OF MAIN SPINDLE:

24

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worn out soon and thus introducing play in face plate or chuck.
Thus locating surface is cylindrical and this must run truly; for
only then the face plate etc., can run truly. The dial indicator is
fixed to the carriage (or any other fixed member) and the feeler
of the indicator touches the locating surface. The surface is
then rotated on its axis and indictor should not show any
movement
of
needle.

25

3.
AXIAL SLIP OF MAIN SPINDLE AND
TRUE RUNNING OF SHOULDER FACE OF
SPINDLE NOSE:

Fig. 16.3

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Let us first distinguish between the axial play and the axial slip.
Axial play means the indispensable freedom of spindle
movement in axial direction to prevent it from seizing by
heating. The spindle is supported between two bearings. Due
to running of spindle, there will be a rise in temperature and
thermal expansion of spindle would be there. If no axial play is
allowed, it would try to bend. Thus there will be no adverse
effect of axial play if the direction of cutting forces remains
same. If the direction of cutting force changes, there would be
some error introduced due to movement of spindle axially in
either direction. Under such conditions, therefore, it is
advisable to cut threads in one direction only. Axial slip is
defined as the axial spindle movement which follows the same
pattern and is due to the manufacturing error. Actually this test
is meant to check this error. To test this the feeler of the dial
gauge rests on the face of the locating spindle shoulder and the
dial gauge holder is clamped to the bed (Fig. 16.3). The
locating cylinder is then rotated and the change in reading
noted down. The readings are taken at two diametrically
opposite points. The total error indicated by the movement of
the pointer includes three main sources of errors.

26

(i) Axial slip due to error in bearings supporting the locating

shoulder, i.e., the bearings are not perpendicular to the axis of
rotation and due to it a point on the shoulder will move axially
in
and
out
at
diametrically
opposite
points.
(ii) Face of the locating shoulder not in a plane perpendicular
to axis of rotation. (Hi) Irregularities of front face. Due to axial
slip, in screw cutting, the pitch will not be uniform due to
periodic movement of the spindle. This, however, is not
important while turning.

4. TRUE RUNNING OF HEADSTOCK CENTRE:

Headstock centre is live centre and the work piece has to
rotate with this centre. If it is not true with the axis of
movement of the spindle, eccentricity will be caused while
turning a work, as the job axis would not coincide with the
axis of rotation of main spindle. For testing this error, the
feeler of the dial indicator is pressed perpendicular to the
taper surface of the centre (Fig. 16.4), and the spindle is
rotated. The deviation indicated by the dial gauge gives the
trueness
of
the
centre.

This has to be checked in both vertical and horizontal planes.

In this we require the use of mandrel. An important
precaution in the use of mandrels and dial indicator is
mentioned here. The mandrel must be so proportioned that
its overhang does not produce appreciable sag, or else the
sag must be calculated and accounted for. The rigidity

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5.
PARALLELISM OF MAIN SPINDLE TO
SADDLE MOVEMENT:

27

indicator set up is also very important and must be carefully

watched. Otherwise variations in readings are recorded by
pointer may be solely due to deflection of the indicator
mounting in different positions and it becomes very difficult
to detect and isolate the spurious deflection from the true
variations. If axis of the spindle is not parallel to bed in
horizontal direction, a tapered surface is produced. Any
deviation from parallelism of spindle axis from bed in vertical
axis will produce a hyperboloid surface. For this test, a
mandrel is fitted in the taper socket of the spindle. Mandrel
has a concentric taper shank which is close fit to the spindle
nose taper. The feeler of the dial indicator is pressed on the
mandrel and the carriage is moved. The indication in
horizontal plane is given by dial (b) and in vertical plane by
dial (a) (Fig. 16.5). In vertical plane the mandrel should be
rising
towards

Fig. 16.5

the free end in order to counteract the weight of mandrel

and job. But for counter-acting cutting forces, it should be
lower towards free end. In horizontal plane, mandrel should
be inclined in a direction opposite to the direction of tool
pressure.

6.
TRUE RUNNING OF TAPER SOCKET IN
MAIN SPINDLE:

Page 30

If the axis of tapered hole of the socket is not concentric with

the main spindle axis, eccentric and tapered jobs will be
produced. To test it, a mandrel is fitted into the tapered hole
and readings at two extremes of the mandrel are taken by
means
of
a
dial
indicator
as
shown
in

28

FIG 16.6

7.
MOVEMENT OF UPPER SLIDE PARALLEL
WITH MAIN SPINDLE IN VERTICAL PLANE:
The dial indicator if fixed in the tool post. A mandrel is fitted in the
spindle.
The
feeler

Fig. 16.7
of the dial gauge is pressed against the mandrel in vertical plane
and the upper slide is moved longitudinally. This error is not
tested in horizontal plane because there is swivelling
arrangement for taper turning. Parallelism of tailstock sleeve to
saddle movement. If the tailstock sleeve is not parallel to the
saddle movement, the height of dead centre would vary as
varying lengths of sleeve are taken out. For the jobs held between
two centres, it is necessary that the central axis of the dead
centre be coaxial with the job axis in both the planes. If it is not
so,
the
job

PREVENTIVE MAINTENANCE ON

Page 30

may be tilted up or down or in sideways due to the support of the

dead centre. The test is carried out by fixing the dial indicator on
the tool post and pressing the plunger against the sleeves first in
vertical and then in horizontal plane (Fig. 16.9). The carriage is
moved along the full length of the sleeve and deviations as
indicated by dial indicator are noted down. Tailstock sleeve should
be rising towards the free end in vertical plane and should be
inclined towards the tool pressure in horizontal plane.

29

RADIAL
DRILLING MACHINE:

Page 30

A drilling machine, called a drill press, is used to cut holes into or

through metal, wood, or other materials (Figure 4-1).Drilling
machines use a drilling tool that has cutting edges at its point.
This cutting tool is held in the drill press by a chuck or Morse
taper and is rotated and fed into the work at variable speeds.
Drilling machines may be used to perform other operations. They
can perform counter sinking, boring, counter boring, spot facing,
reaming, and tapping (Figure 4-2).Drill press operators must know
how to set up the work, set speed and feed, and provide for
coolant to get an acceptable finished product. The size or capacity
of the drilling machine usually determined by the largest piece of
stock that can be center-drilled. For instance, 15-inch drilling
machines can center-drill a 30-inch-diameter piece of stock. Other
ways to determine the size of the drill press are by the largest
hole that can be drilled, the distance between the spindle and
column, and the vertical distance between the worktable and
spindle.When it comes to mechanical machining, radial drilling
machine is used for all functions such as drilling, counter boring,
spot facing, lapping, screwing reaming, tapping and boring. Radial
drilling machines work well with a variety of material such as cast
iron, steel, plastic etc. Drilling machines hold a certain diameter
of drill (called a chuck) rotates at a specified rpm (revolutions per
minute) allowing the drill to start a hole.
Radial drills are of three types. With the plain radial drill, the drill
spindle is always vertical, and may not swing over any point of
the work. The spindle in the half-universal drill may be swung over
any point of the work and it may swing in one plane at any angle
to the vertical up to complete reversal of the direction of the drill.
And the spindle in the full-universal drill can be swung in any
plane at any angle to the vertical.

30

1. FLATNESS
BASE:

OF

CLAMPING

SURFACE

OF

Page 30

The test is performed by placing a straight edge on two gauge

blocks on the base plate in various positions and the error is
noted down by inserting the feeler gauges. This error should not
exceed 0.1/1000 mm clamping surface and the surface should be
concave only.

31

2. FLATNESS
TABLE:

OF

CLAMPING

SURFACE

OF

This test is performed in the same manner as test (1), but on the
table. The permissible error is also same.

3. PERPENDICULARITY OF DRILL HEAD GUIDE

TO THE BASE PLATE:
The squarenesS (perpendicularity) of drill head guide to the base
plate
is
tested
:
(a) In a vertical plane passing through the axes of both spindle
and
column,
and
(b)
In
a
plane
at
90
to
the
plane
at
(a).
The test is performed by placing the frame level (with graduations
from
0.03
to
0.05
mm/m)
on
guide

Fig. 16.17. Checking flatness of clamping

surface of base.

4. PERPENDICULARITYOF DRILL HEAD GUIDE

WITH TABLE:

Page 30

column and base plate and the error is noted by noting the
difference between the readings of the two levels. This error
should
not
exceed
0.25/1000
mm
guide
column.

32

This test is performed exactly in the same way as (b). (Refer Fig.
16.18) and the permissible error is also same.

5. PERPENDICULARITY OF SPINDLE SLEEVE

WITH BASE PLATE:
This test is performed in both the planes specified in test (3) and
in the similar manner with the difference that the frame levels are
to be placed on spindle sleeve and base plate. The error (i.e., the
difference between the readings of the two levels) should not
exceed 0.25/1000 mm for plane (a) and the sleeve should be
inclined toward column only; and 0.15/1000 mm for plane (b).

6. TRUE RUNNING OF SPINDLE TAPER:

For this test, the test mandrel is placed in the tapered hole of
spindle and a dial indicator is fixed on the table and its feeler
made to scan the mandrel. The spindle is rotated slowly and
readings of indicator noted down. The error should not exceed
0.03/100 mm for machines with taper up to Morse No. 2 and
0.04/300 mm for machines with taper larger than Morse No. 2.

7. PARALLELISM OF THE SPINDLE AXIS WITH

ITS VERTICAL MOVEMENT:

Page 30

This test is performed into two planes CA) and (B at right angles
to each other. The test mandrel is fitted in the tapered hole of the
spindle and the dial indicator is fixed on the table with its feeler
touching the mandrel. The spindle is adjusted in the middle
position of its travel. The readings of the dial indicator are noted
when the spindle is moved in upper and lower directions of the
middle
position
with
slow
vertical
feed
mechanism.

33

Fig. 16.18. Test for perpendicularity of drill head

with table.

Fig. 16.19

Fig. 16.20
machines
with
taper
upto
Morse
No.
machines with taper larger than Morse No.

(Lower end of mandrel can be inclined towards column only).

2.
2.
Page 30

For
For

34

PREVENTIVE MAINTENANCE
MILLING MACHINE:

ON UNIVERSAL

Page 30

A milling machine is a machine tool used for the complex shaping

of metal and other solid materials. Its basic form is that of a
rotating cutter or end mill which rotates about the spindle axis
(similar to a drill), and a movable table to which the work piece is
affixed. That is to say the cutting tool generally remains
stationary (except for its rotation) while the work piece moves to
accomplish the cutting action. Milling machines may be operated
manually or under computer numerical control (see CNC).Milling
machines can perform a vast number of complex operations, such
as slot cutting, planning, drilling, rebating, routing, etc. Cutting
fluid is often pumped to the cutting site to cool and lubricate the
cut, and to sluice away the resulting swarf. A milling machine is a
power driven machine that cuts by means of a multi tooth
rotating cutter. The mill is constructed in such a manner that the
fixed work piece is fed into the rotating cutter. Varieties of cutters
and holding devices allow a wide range of cutting possibilities.
The mills in the Student Shop are vertical milling machines,
commonly called Bridgeport style mills. These versatile mills are
capable of performing many operations, including some that are
similar to those performed on the drill press like drilling, reaming,
countersinking, and counter boring. Other operations performed
on the mill include but are not limited to: side and face milling, fly
cutting, and precision boring. Mills are classified on the basis of
the position of their spindle. The spindle operates in either a
vertical or horizontal position. The amount of horsepower the mill
is able to supply to the cutter is also often important.

Machine tools are very sensitive to impact or shock, even heavy

cast inn standards are not always solid and rigid enough to
withstand stresses due to falling during transportation and
deformations may be set up. Although the machine is always
carefully adjusted and aligned when on the test stand or in the
assembly department of the manufacturer, it is well known from
experience that erection in the workshop of the user is not always
done with sufficient care and thus inaccuracies of the work may
result from the faulty erection of the machine. So the machine
should be carefully leveled up by means of a spirit level before
starting with the actual trial tests. Each trial measurement is
based on the correct erection of the machine. No upright, base
etc. can be made so rigid that it will be thoroughly free from
deformation resulting from faulty erection. Machine tools for the
workshop must be able to produce work pieces of given accuracy
within prescribed limits, consistently and without requiring artistic
skill on the part of the operator. For acceptance test of a machine,

Page 30

35

36

its alignment test is performed and to see its dynamic stability,

which may be poor though alignment tests are right, certain
specific jobs are prepared and their accuracy checked.

Fig. 16.15
The relative alignment of all parts of machine and the accuracy of
the control devices and driving mechanisms are measured under
no load condition. The result of these measurements must lie
within the prescribed limits given by the manufacturer depending
upon the grade of the machine tool.

SPECIFICATION
TESTS:

FOR

THE

ALIGNMENT

(1) The procedure for testing standard machine tools must not
require more than 6 to 8 hrs of work provided allthe tooling and
measuring
equipment
are
readily
available.
(2) The permissible limits of accuracy of individual measurements
must be wide enough to make economical manufacture possible
while on the other hand the cumulative error of number of
superimposed
details
should
not
be
excessive.
The various tests performed on the milling machine are shown in
(Fig. 16.16) and described below.

We have to distinguish between axial (or end) play and axial slip
of
the
spindle.
End play means the indispensable freedom of a spindle moving in
the axial direction to prevent it from seizing by heating. This end
play is specially important on high speed machines and it should
be
within
the
prescribed
limits.
Axial slip is denned as the axial spindle movement which may
repeat positively with each revolution as a consequence of
manufacturing errors. It is only this axial sliding movement which
is to be tested, and the specified tolerance applies only to this

Page 30

1.CUTTER SPINDLE AXIAL SLIP OR FLOAT:

37

movement. When testing the axial slip of a spindle the feeler of

the dial gauge rests on the face of the locating spindle shoulder
and dial gauge holder is clamped to the table. The locating
spindle shoulder is rotated and change in reading is noted. This is
done at the two spots diametrically opposite to each other. (i)
Axial slip due to error in bearing supporting the locating shoulder.
(ii) Face of the locating shoulder not in a plane perpendicular to
axis of rotation. (Hi) Irregularities of front face. Effects of this will
be that in cutting spirals, the pitch will not be constant and we will
get
irregular
pitch
helix.
If the feeler touches at the same spot where the turning tool on
the emery wheel has machined the spindle collar in the
assembled machine, then the feeler will not show any deviation.
Therefore axial slip must always be tested at two points 180
apart on the collar of the spindle.

2. ECCENTRICITY OF EXTERNAL DIAMETER:

The feeler is placed on the cylindrical surface of the shoulder. The
locating shoulder is rotated and any deviation in reading of dial
gauge
is
noted.
It is due to eccentricity of the spindle in the hole in which it fits.
Due to it, vibrations are produced and the cutter will float
sideways and cut over, or under-size. Face mills may dig in when
leading edges cease to cut.

3.TRUE RUNNING OF INTERNAL TAPER:

gauge from A to B cross-slide of the machine is operated to bring

the dial gauge at the bottom of the end of mandrel. There are can
be
two
errors
:

Page 30

The table is set in its main position longitudinally and the mandrel
300 mm long is fixed in the spindle taper. A dial gauge is set on
the machine table and feeler adjusted to touch the lower surface
of the mandrel. The mandrel is then turned and the dial readings
at two points are noted i.e., one at the place nearest to spindle
nose and other at about 300 mm from it. For shifting the position
of dial

38

(i) Axis of the spindle and the axis of taper may not be parallel.
(ii) Eccentricity of the taper hole which, if present, should indicate
same error at both the places. The error in first case will give
different readings at two places. Due to this error, cut will not be
shared equally between teeth of cutters, and therefore vibrations
and poor finish will result.

4. TABLE SURFACE PARALLEL WITH ARBOR

RISING TOWARDS OVER ARM:
In selecting the permissible errors of horizontal milling machines,
care is taken to the fact that in the direction parallel to the cutter
spindle, the work table extends towards the front face of the knee
only, and never slopes down. While working, the table tends to
incline downwards under the influence of the weight of work and
cutting pressure, while the cutter arbor tends to deflect upwards.
Great importance, therefore, has always been attached to the
necessity of having the direction of table tolerance opposite to
the deformation expected under cutting conditions. Parallelism
between table face and the axis of the main spindle is checked as
follows:
A dial gauge is set on the machine table.
A mandrel 300 mm long is fitted in the spindle taper.

The stand of the dial gauge is moved and not the table itself
remains stationary.

Page 30

The feeler of dial gauge is made to touch the lower surface

of the mandrel. With mandrel in position (mean) the readings
at the maximum travel of the table surface are observed.

39

Effect of this error will be that the milled surface produced

will not be square to the base and parallel cross ways.

5.SURFACE PARALLEL WITH LONGITUDINAL

MOVEMENT:
For this test the dial gauge is fixed to the spindle. Feeler is
directed upon the surface the machine table and latter moved
longitudinally. The deviations from parallelism between the table
surface and longitudinal motion are noted down. If the table is
uneven, a straight edge may be placed on the surface. Due to this
error the surface of the table will fluctuate up and down and
cutter will not take equal cuts on the job which is clamped on the
table and the milled surface will not be parallel to the base.

6.TRANSVERSE MOVEMENT PARALLEL WITH

SPINDLE AXIS:

Horizontal plane
Vertical plane.

The table is set in its mean position and dial gauge fixed on the
table. The table is moved crosswise and any deviation on reading
of dial gauge is noted with feeler on one side of mandrel in
horizontal plane and under the mandrel for error in vertical plane.
Due to this error, depth of cut will vary when cross slide is moved.

Concept of preventive Maintenance is presently accepted in most

of the industries in order to achieve their planned production.
Both production and maintenance have the same objective - to

Page 30

MAINTENANCE:

ECONOMICS OF

40

produce a quality product at maximum efficiency and minimum

cost.
Theoretically maintenance should aim at keeping the machines
and other facilities in a condition that allows them to be used
without any interruption and at their maximum profit making
capacity. Such a situation can be assured in practice only if
machines are replaced frequently or if a stand-by machine is
maintained which can be put into operation as and when the
original unit is stopped for checks, repairs and component
replacements.
But, no industrial unit can possibly afford to throw away its capital
resources by replacing machines frequently, nor can a company
block its money in equipment that will be only partially utilised by
having stand-bys.
An organisation has, under such circumstances, to accept a
certain loss in productive capacity of its investments to enable
maintenance, to examine the various equipment, repair if not in
order, and put them back in a condition as required by the users.

Before embarking on an elaborate preventive maintenance

programme,
the management will have to make a careful
analysis as to which type of equipment need preventive
maintenance. It may not be economical to have preventive
maintenance for each and every sundry machine. Even if it is
desirable to the preventive maintenance on all equipments, for
initial introduction of the system priorities will have to be decided,
as the company might like to bring in only the important
equipment within the frame work of preventive maintenance. As
discussed, in certain situations break-down maintenance may be
economical. There are various other systems of maintenance like

Page 30

CATEGORISATION OF EQUIPMENTS:

41

scheduled maintenance which may be desirable for certain type

of equipment.

Some of the factors that need to be taken into

considerations are:
(a)

(b)

(c)

(d)
(e)

Whether the equipment is continuous or intermittent

running equipment. An unscheduled or a sudden break
down of a continuous running machine with a high degree
of utilization, will obviously cause considerable production
loss.
In the event of failure of a particular machine, whether a
substitute or a standby is available. If there is a standby
the same can be lastly switched on without any delay and
mean while the machine can be repaired and put in
condition.
How important is the machine from the point of view of
quality of the product that is coming out of the machine.
On other words what could loss as a result of poor quality
or rejections.
What is the position with regard to availability of spares,
easy or difficult to obtain.
What are the likely hazards that the equipment can cause
on the workers and other employees, equipments which
have certain inherent hazards need meticulous care.

Inspection is the crux of preventive maintenance programmes.

Inspection of the equipment is carried out in a systematic way
periodically in order to determine the condition of the equipment.
Certain parts may wear out and deteriorate certain bolts and nuts
may become loose due to vibrations, certain surfaces may get
eroded, defects may occur as a result of overheating, alignment
may go out of order and host of defects may develop in any

Page 30

INSPECTION:

42

equipment. These defects if not corrected may result in

malfunctioning or breakdown of the machine or cause hazards.
Corrective action can be taken if they are noticed well in time and
break down can be avoided. In other words, through a process of
inspection it will be possible to check the condition and take
preventive measures, which may include repair, reconditioning or
replacement of defective parts. Hence, inspection is a very
important aspect of preventive maintenance.

METHODS OF INSPECTION :
There are
inspected.
(a)
(b)

different methods by which the equipment can be

They can broadly be classified into
External
Internal

REQUENCY OF INSPECTION:
When once the items to be checked have been listed out in detail,
the next logical questions will be to decide when or how often
it is to be inspected.
While every item needs to be
inspected, but all of them need not to be inspected at the same
interval or frequency. the importance and critically varies. Every
inspection is associated with a cost. Too frequent an a inspection
will increase the cost of inspection besides involving more down
time if inspection is to be carried out during shut down, while
under-inspection may result in frequent breakdowns.

Lubrication is an important activity in any system of maintenance.

The functions of a lubricant are many. They are to reduce and
wear and tear between the moving parts, to economies power

Page 30

LUBRICATION:

43

consumption, to keep the bearings within allowable temperature

limits to protect them from dust and erosion etc. correct
lubrication of all moving parts is necessary to ensure proper
running of the equipment, to maintain plant efficiency and to
prolong the life of the equipments and its components. A well
conceived lubrication programme should include selection of the
correct lubrication programme should include selection of the
correct lubrication, its application by the right method at proper
frequency. Storage, handling, identification and standardization of
lubricants are also to be covered in the programme.

CLASSIFICATION OF LUBRICATING OILS:

Spindle oils
Electric motor oils
Gear oils
General bearing oils
Turbine oils
Air compressor oils
Refrigeration compressor oils
Steam cylinder oils
Cutting oils
Hydraulic oils and
Greases

Lubricating oils are selected on the basis of physical properties

required for operating conditions.

CHARACTERISTCS:

Viscosity
Flash point
Fire point
Pour point
Carbon residue content
Emulsification

Lubricating methods have an influence on the efficiency of

lubrication and the selection of lubricant. The methods of applying

Page 30

LUBRICATING METHODS:

44

lubricating oils to moving parts may be classified into four groups.

They are:

Once through oiling

Oil reservoir
Circulating oil system and
Other oiling devices

STORAGE AND HANDLING OF LUBRICANTS:

MAINTENANCE RECORDS:

Page 30

Use of lubricants which are contained with dirt and other

foreign materials can cause great damage to costly machinery.
Utmost cars is therefore, necessary to be exercised in the main
storage and handling of lubricants. They must be stored in a clean
and dry place under cover to prevent deterioration and
contamination due to exposure to varying environments. The
transfer of lubricants from others should be kept clean.
Cleanliness in all aspects of storage and handling of lubricants
goes a long way in providing the efficiency of the lubrication.Color
and symbol codes are used to indicate the type of lubricant used
and the frequency of application. A particular color will indicate
the type of lubricant and specific symbol such as triangle, circle,
rectangle etc., will indicate the frequency of use. Right from the
containers in store including the handling and dispensing
equipment to the points of application will have the same color
code. The application points can have the symbol in addition, to
indicate the frequency alternatively a diagram on the machine
with color and symbol codes will indicate the points. Such a
system of coding will ensure use of the lubricant, at the right time
for the right point even by an illiterate worker.

45

Building up of data and an analysis of the same is one of the basic

aspects of preventive maintenance. Some data is normally
maintained in the forms of log books by every maintenance
department. But this is mostly incomplete and haphazard and
would not serve any useful purpose if any analysis is to be carried
out. Various decisions involved in respect of inspection to be
carried, repairs and replacements to be undertaken, man power
to be provided, spares to be stroked and schedules to be drawnup, are all dependent on an analysis of accurate data. Installation
of a preventive maintenance system and refinement of the
system for effective results calls for a proper data bank, while
paper work is essential, it should be reduced to the minimum.

INSTRUCTION,MANUALS,DRAWINGS:
Machinery manufactures supply the manuals along with the
equipment. The said manuals contain some very useful
information regarding the operation and maintenance of the
equipment. They are very valuable guides for installation,
commissioning and running of the equipment.

EQUIPMENT DATA:

(a)
Description of the equipment
(b)
Suppliers name
(c)
Data of installation
(d)
Cost of equipment
(e)
Physical dimensions
(f) Operating characteristics
(g)
Spare parts required
(h)
Type of lubricants etc.

Page 30

All relevant information about each and every equipment should

be available in the maintenance department. Equipment data
sheet will contain information like:

46

EQUIPMENT HISTORY CARD:

(a)
(b)

Defective design
Defective material

(c)

Poor maintenance

(d)

Improper operation

(e)

Environment and working conditions etc.

Page 30

This is a record of all the repairs, overhauls, modifications and

replacements done on an equipment. All the events that have
occurred during the life span of an equipment are chronological
and systematic recorded, giving complete history. The history
cards enables the maintenance man to study the behavior of the
equipment and analyze the life of parts determine and refine
inspection plans and decide modifications. A typical history card is
given.The data thus collected through history cards will have to
be further analyzed in detail in order to determine the causes of
failures and decide on the corrective action to be taken. The
possible causes of failure may be further classified:

47

MAINTENANCE PLANNING:
Planning of maintenance work involves deciding as to what jobs
are to be done, how they are to be carried out, when they should
be taken up and the various resources required to do the work.
Corrective measures are also to be taken up as and when there is
likely to be deviations from the plant during the actual execution
of jobs / woks. The objective of planning is to carry out all the jobs
in the most effective way using the correct amount of resources.

FEATURES:
Forecasting future work
Determine the best method of carrying out the work
Arranging for the spares and other maintenance materials
required
Working out a schedule in consultation with the production
departments
Deciding the number and type of people required to do the
job
Allocation of work to individuals
Follows up and control regarding progress of work

Scheduling is the preparation of a time table, showing the

allocation of the various jobs to specific time periods. In order to
prepare such a schedule the estimate of time required for various
jobs is necessary. The jobs to be done are all collected and the
total man hours required are estimated. Once the man hours

Page 30

SCHEDULING:

48

required are computed craft-wise, it is compared with the

available man-hours. The jobs are then scheduled according to
priority and the availability of man-hours. Scheduling of
maintenance work requires detailing of maintenance and
production schedules. Hence, it is necessary to involve production
personnel in decision making regarding jobs to be carried out,
priority of each job and the time when it is to be undertaken. It
may be available to prepare a tentative schedule for a period of 24 weeks and finalise it in consultation with production. Schedule
can be prepared in two stages, long term and short term schedule
will be a final and a detailed break-up of work for the next one
week.
The authorization for executing the work will
be through a work order which will give the details of work to be
done, estimated time, scheduled period, materials required,
labour requirement and the method of work. Materials required
for the work will be drawn against authorized material
requirements. Time spent on each job / work order will be booked
in the time cards by the foreman or the individual employees.

SPARES AND MAINTENANCE MATERIAL:

A proper control of spares and stores is an essential feature of any
maintenance plan. Planning and scheduling of maintenance work
to be effective, the spare parts should be made available as and
when required. At the same time, over stocking of materials
results in
(1)
(2)

Un-necessary blocking of valuable capital

Wastage of storage space

(3)

Deterioration and obsolescence materials.

Inventory control-general concepts :: ABC and VED analysis :

Page 30

Hence, it is necessary to control and regulate the material

inventory.

49

The two types of analysis that are suitable to

maintenance items are:
(a)
(b)

ABC analysis and

VED analysis (vital, essential and desirable).

In the former the emphasis is an inventory value, whereas in the

latter the basis is critically of the item.

ECONOMIC ORDER QUALITY

(EOQ):
Economic order quality is that size of the order which gives
maximum economy in purchasing any material and ultimately
contributes towards maintaining the materials at the optimum
level and at the minimum cost.

The quantity to order at a given time must be determined by

balancing two factors: (1) the cost of possessing or carrying
materials and (2) the cost of acquiring or ordering materials.
Purchasing larger quantities may decrease the unit cost of
acquisition, but this saving may not be more than offset by the
cost of carrying materials in stock for a longer period of time.

The carrying cost of inventory may include:

Page 30

In other words, it is the amount of inventory to be ordered at one

time for purposes of minimizing annual inventory cost.

Interest on investment of working capital

Property tax and insurance

Storage cost, handling cost

Deterioration and shrinkage of stocks

Obsolescence of stocks.

Page 30

50

51

MEASURING INSTRUMENTS USED FOR GEOMETRICAL

TESSTING OF MACHINE TOOLS IMPORTANT SHEET:
1. DIAL GAUGE:
A dial gauge or indicator consists of components such as
bezel, indicating pointers, tool post and clamp, magnetic
tool holder and sensor button. Dial indicators are available
in many physical sizes and ranges. For most alignment
applications the smaller sized indicators should be used to
reduce indicator bar sag. Dial indicators should be chosen
that have a range of 0.100 inch and accurate to 0.001
inch.

Page 30

Indicator readings, and many other types of readings, are

expressed in several units. A reading of 1/1000" is
equivalent to 0.001 inch and is commonly expressed as 1
mil. The dial gauge have two scales, One outer scale
marked (0-100) and second inner scale marked (1000).The outer scale (0-100) is to be used when dial gauge
needle moves clockwise and inner scale (100-0) when dial
gauge needle moves anticlockwise. When sensor of dial
gauge is pushed upwards towards dial then needle on the
dial
moves
clockwise
and
when
sensor
is
moved downwards away from the dial then needle on dial
gauge moves in anticlockwise direction. The dial gauge
readings when needle moves clockwise are +ve where as
when needle moves anticlockwise are - ve (Fig.-2). The
movement of the needle should be watched.

52

for clockwise or anticlockwise rotation throughout the move

to avoid any confusion of +ve orve sign.

2. TEST MANDRELS:
Two types of test mandrels are used. They are:
Mandrels are used in alignment tests to represent the
axis and are of two types:

In construction the test mandrels with taper shank & conical

shank for inserting in the socket of the machine to be tested,

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1. TEST MANDRELS WITH TAPER SHANKS:

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and a cylindrical body which is used as a reference surface

for the measurements. In alignment tests, the cylindrical
surface of the mandrel represents the axis desired to be
checked, either for out of true running or for position in
relation to other elements of the machine tool. These are
made of hardened and stabilized steel left either unplanted
or plated with hard chromium. The mandrels of such type
having relatively slow and steep tapers are shown in Fig.
The deflection of free ends of mandrels should be less than
0.65 um for those having working length of 75 mm and than
5.8 um for those having working length of 505 mm. These
should be free from errors of roundness and the axes of the
conical and cylindrical portions be straight and coincident.
The cylindricity should be perfect over the whole of the
measuring length.

The nut operated between-centers expanding mandrel is

generally mounted between 60 degree centers, and can be driven
from the drive flat with a carrier or drive plate. It is possible to
attach a simple component end locator, if required, at diameter L.
There is a ground diameter G to adapt this mandrel to face-plate
mounted, if required, by use of an adaptor plate. Adaptor plates
made to suit the machine mounting can be manufactured by PTG

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2. MANDRELS BETWEEN CENTRES:

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Work holding Ltd., or the customer. Component end locators,

solid-type or compensating (for out-of-square locating faces) can
also be supplied, or manufactured by the customer. These
mandrels are generally used for small-batch grinding operations.
These mandrels are hand-operated by use of conventional
spanners, and are often used for inspection purposes. For
maximum efficiency, expansion sleeves should be pre-loaded to
maintain contact with. Mandrels mounted between centers
represent simply a straining line passing between two points. The
axis of mandrel shall be straight and is surface truly cylindrical.
Typical test mandrel between centers is shown below

3. STRAIGHT EDGES:
A straightedge is a tool with an edge free from curves, or
straight, used for transcribing straight lines, or checking the
straightness of lines. If it has equally spaced markings along its
length it is usually called a ruler.
Straightedges are used in the automotive service and machining
industry to check the flatness of machined mating surfaces.

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True straightness can in some cases be checked by using a laser

line level as an optical straightedge: it can illuminate an
accurately straight line on a flat surface such as the edge of a
plank or shelf.

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The height of the edge should be considerably bit in order to

provided resistance to bending in measuring plane. Precision
straight edges are generally hardened and tapered on reference
surfaces. The error of the surface should be less than :
(a)
(b)

+0.01mm in standard edge

+0.05mm in precision straight edge

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On the full length straight edges are used for checking

straightness and flatness of the surface.

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4. MASTER CYLINDER:

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The master cylinder is a control device that converts nonhydraulic pressure (commonly from a driver's foot) into hydraulic
pressure, in order to move other device(s) which are located at
the other end of the hydraulic system, such as one or more slave
cylinders. As pistons move along the bore of the master cylinder,
this movement is transferred through the hydraulic fluid, to result
in a movement of the slave cylinder(s). The hydraulic pressure
created by moving a piston (inside the bore of the master
cylinder) toward the slave cylinder(s) compresses the fluid evenly,
but by varying the comparative surface-area of the master
cylinder and/or each slave cylinder, one will vary the amount of
force and displacement applied to each slave cylinder (relative to
the amount of force and displacement that was applied to the
master cylinder).

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MAXIMIZING EQUIPMENT EFFECTIVENESS:

MEASURING AVAILABILITY:
It is the ratio of operation time to loading time
Availability

= operation time / loading time

= loading time down time / loading time

In this case, loading time or the available time per day is derived
Loading time = total available time per day (or) month planned
down time
Planned down time = the amount of down time officially
scheduled in the
production plan.
Ex:
Working shaft per day is 8 hrs or 480 min
If the planned down time per day is 20 min
Then the loading time per day will be
Equipment down time involves equipment stoppage losses
resulting from failures setup/adjustment procedures exchange of
dies etc
Down time
Due to break down
Set up

Adjustment
Total down time

=
=
=
=

20 min
20 min
20 min
60 min

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CONCLUSION:

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Preventive maintenance is required to keep the machine in order

for production and safety. The advantages of preventive
maintenance are reliability, safety and above all the availability of
right machine at the right point of time.