Experiment No.

6: To perform Knurling Operation on Lathe

Theoretical Background
Knurling Operation:
Knurling is a manufacturing process, typically conducted on
a lathe, whereby a pattern of straight, angled or crossed lines is cut or rolled into the
material. The operation is performed for producing indentations on a part of a work
piece. Knurling allows hands or fingers to get a better grip on the knurled object than
would be provided by the originally smooth metal surface. Occasionally, the knurled
pattern is a series of straight ridges or a helix of "straight" ridges rather than the more-
usual crisscross pattern.
Knurling a simple operation performed after turning to improve the surface finish and
to provide grip to work piece. Usually for this operation the lathe is operated at its
minimum speed and desired knurling tool is fed into work piece.
The outer surface of the metal pin is knurled so that the raised detail 'bites' into the
plastic irrespective of whether the size of the hole in the plastic closely matches the
diameter of the pin.
Tool handles, mechanical pencils, barbell bars, and the control knobs on electronic
equipment are frequently knurled. Knurling is also used on the grips of dart-sand the
foot-pegs of bicycles. Aside from adding functionality to an object knurling also adds
a decorative pattern to the material.

Tool used:
Knurling is accomplished using one or more very hard rollers that contain
the reverse of the pattern to be imposed. It is possible for a "straight" knurl (not
crisscrossed) to be pressed with a single roller, however the material needs to be
supported adequately to avoid deformation. A crisscross pattern can be accomplished
using any of:
 A single roller that contains the reverse of the complete desired pattern. These
are available to form either "male" or "female" patterns,
 A left-handed straight roller followed by a right-handed straight roller (or vice
versa).
One or more left-handed rollers used simultaneously with one or more right-handed
rollers.
Procedure:
 Mount the work between centers and mark the required length to be knurled. If
the work is held in a chuck for knurling, the right end of the work should be
supported with a revolving tailstock center.
 Set the lathe to run at one-quarter the speed required for turning.
 Set the carriage feed to .015 to .030 in. (0.38 mm to 0.76 mm).
 Set the center of the floating head of the knurling tool even with the dead-
center point.
 Set the knurling tool at right angles to the work piece and tighten it securely in
this position.
 Start the machine and lightly touch the rolls against the work to make sure that
they are tracking properly. Adjust if necessary.
 Move the knurling tool to the end of the work so that only half the roll face
bears against the work. If the knurl does not extend to the end of the work
piece, set the knurling tool at the correct limit of the section to be knurled.
 Force the knurling tool into the work approximately .025 in. (0.63 mm) and
start the lathe.
 OR
Start the lathe and then force the knurling tool into the work until the
diamond pattern comes to a point.
 Stop the lathe and examine the pattern. If necessary, reset the knurling tool.
 If the pattern is incorrect, it is usually because the knurling tool is not set on
center.
 If the knurling tool is on center and the pattern is not correct, it is generally
because of worn knurling rolls. In this case, it will be necessary to set the
knurling tool off square slightly so that the corner of the knurling rolls can start
the pattern.
 Once the pattern is correct, engage the automatic carriage feed and apply
cutting fluid to the knurling rolls.
 Knurl to the proper length and depth.
Note: Do not disengage the feed until the full length has been knurled;
otherwise, rings will be formed on the knurled pattern.
 If the knurling pattern is not to a point after the length has been knurled,
reverse the lathe feed and take another pass across the work.
Calculations:
Material of work piece = Mild steel
Required RPM’s = Lowest possible rpms at lathe

Drawbacks and Improvements:

 Knurling is the operation mainly depends upon the condition of the tool and
the pattern on it. So, this operation can be made much correct by having true
tool without any errors in it.
 CNC and NC machines can be used for production purposes and much more
accurate machining. Which also decrease the time of the machining up to great
extent.
Precautions
 Always wear approved safety glasses. When operating a lathe, chips fly and it
is important to protect your eyes.
 Never wear a ring or watch because it can cause serious injuries.
 Always remove the chips with a brush and never with your hand or a cloth.
Steel chips are sharp and can cause cuts if handled manually or with a cloth
that has chips embedded in it.
 Whenever polishing, filing, cleaning, or making adjustments to the work piece
or machine, always remove the sharp cutting tool from the tool holder to
prevent serious cuts on your arms and hands.
  Always wear approved safety glasses. When operating a lathe, chips fly and it
is important to protect your eyes.
 Roll up your sleeves, remove your tie, and tuck in loose clothing. Short sleeves
are preferable because loose clothing can get caught by revolving lathe dogs,
chucks, and rotating parts of the lathe. You can be drawn into the machine and
be seriously injured.
Conclusions:
Experiment is conducted with great care and knurling of work material is done by
knurling tool as described above in theoretical background at required RPM’s that are
lowest possible on lathe machine and learn how to operate lathe machine for knurling
operations and how to deal with the quick gear box mechanism for the settings of
RPM’s and infers that the threading is usually done at lowest possible RPM’s.