Safety Precautions of Machine Lab

Mentioned below are some of the necessary measures that students

must abide by to maintain a safe and secure environment of studying
inside the laboratory. These precautions include:

Never Use a Machine If You Are NOT Trained – Always Get

Training Before Operating Any Machinery.
You must attend general safety training and specific training on the
machine you intend to use. If you are unfamiliar with a particular tool
or instrument, do not use it until you are properly trained on its
usage.

Never Work Alone – Always Use “Buddy System.”

At least two adults must be in the shop when power tools are being
used. You must get permission from your Supervisor for off hours and
weekend work if the shop permits off hour work.

Never Use Machine When Impaired - Be Sober and Smart.

This includes when you are sick, too tired, stressed or hurried to

work carefully or on medication that could make you drowsy.

Never Start Work If You Cannot Do The Job Safely- Just Don’t Do It.

There are limits to what we can build here, and how safely you can do it in

hurry.

Never Wear Open Toe Shoes - Use Closed-Toe Shoes in the Shop.

Tools, chips and fixtures are sharp, and often hot. Shoes will help
protect your feet from injury. Leather shoes are preferred when

welding.

Never Work Without Proper Eye Protection -Always Wear

Appropriate Safety Glasses or Goggles When Working or

Cleaning Tools.

Prescription glasses with plastic lenses must meet ANSI Standard Z87.1 for

safety.

Never Work With Loose Hair, Jewelry, etc. –Always Remove or

Secure Anything That Might Get Caught in Moving Machinery.

Long hair, necklaces, ties, dangling ID badge, jewelry, loose clothes,

watch or Rings, may get caught in tools can drag you along resulting in

serious injury or death.

Never Bring Hands Close to Sharp Objects – Always Keep

Your Hands At a Safe Distance From Sharp Tools.

Make sure that nothing that you do will cause you to be cut.
Never Create a Dusty and Smoky Environment - Dust, Chemicals

and Smoke Can Be Dangerous to Your Health, so Work in Well-

Ventilated Areas, Minimize Contamination and Use Appropriate

Protective Equipment (PPE).

Ensure the shop is well ventilated and appropriate PPE is used when

working with machines.

Never Be Shy To Seek Help –Always Ask

If You’re Unsure About The Safe Operation of a Tool or Any Aspect of a

Job – Have Shop Staff Check The Tool or Work With Which You Are

Unfamiliar.

Exercise common sense and clarify before starting wor

 LATHE MACHINE
Topic 1: Lathe Construction
Lathe Machine Definition:
A lathe machine is a machine tool that is used to remove metals from a
workpiece to give a desired shape and size. Lathe Machines are used in
metalworking, woodturning, metal spinning, thermal spraying, glass
working, and parts reclamation.
The various other operations that you can perform with the help of Lathe
Machine can include sanding, cutting, knurling, drilling, and deformation of
tools that are employed in creating objects which have symmetry about the
axis of rotation.

Working Principle: The lathe is a machine tool which holds the

workpiece between two rigid and strong supports called centers or in a chuck
or face plate which revolves. The cutting tool is rigidly held and supported in
a tool post which is fed against
the revolving work. The normal
cutting operations are
performed with the cutting tool
fed either parallel or at right
angles to the axis of the work.
The cutting tool may also be
fed at an angle relative to the
axis of work for machining
tapers and angles.
The function of Lathe is to remove the metal in the form of chips from a
piece of work by mounting the same rigidly on a machine spindle and
revolving at the required speed and the cutting tool is fed against the work
either longitudinally or crosswise to make the work to the required shape
and size.
Parts of the Lathe Machine and their Functions:
The main parts of the lathe are the bed, headstock, quick changing gear
box, carriage and tailstock.

1. Bed: The bed is a heavy, rugged casting in which are mounted the
working parts of the lathe. It carries the headstock and tail stock for
supporting the workpiece and provides a base for the movement of
carriage assembly which carries the tool.
2. Legs: The legs carry the entire load of machine and are firmly secured to
floor by foundation bolts.
3. Headstock: The headstock is clamped on the left-hand side of the bed
and it serves as housing for the driving pulleys, back gears, headstock
spindle, live center and the feed reverse gear. The headstock spindle is a
hollow cylindrical shaft that provides a drive from the motor to work
holding devices.
4. Gear Box: The quick-change gear-box is placed below the headstock and
contains a number of different sized gears.
5. Carriage: The carriage is located between the headstock and tailstock
and serves the purpose of supporting, guiding and feeding the tool
against the job during operation. The main parts of carriage are:
a. The saddle is an H-shaped casting mounted on the top of lathe
ways. It provides support to cross-slide, compound rest and tool
post.
b. The cross slide is mounted on the top of saddle, and it provides a
mounted or automatic cross movement for the cutting tool.
c. The compound rest is fitted on the top of cross slide and is used to
support the tool post and the cutting tool.
 d. The tool post is mounted on the compound rest, and it rigidly
clamps the cutting tool or tool holder at the proper height relative to
the work center line.
e. The apron is fastened to the saddle and it houses the gears,
clutches and levers required to move the carriage or cross slide. The
engagement of split nut lever and the automatic feed lever at the
same time is prevented she carriage along the lathe bed.
6. Tailstock: The tailstock is a movable casting located opposite the
headstock on the ways of the bed. The tailstock can slide along the bed to
accommodate different lengths of workpiece between the centers. A
tailstock clamp is provided to lock the tailstock at any desired position.
The tailstock spindle has an internal taper to hold the dead center and the
tapered shank tools such as reamers and drills.

Schematic Diagram of Lathe Machine:

Types of Lathe Machine:

There are 3 main types of Lathe Machines:
1. Capstan Lathe
2. Turret Lathe
3. CNC Lathe
Capstan Lathe
In capstan lathe, the ram slides longitudinally on a saddle positioned and
clamped on the bed ways. This type of machine is lighter in construction and
is suitable for machining bar of smaller diameters. The tools are normally
mounted on the square turret and 6 faces of the hexagonal turret. The
feeding movement is obtained when the ram moves from left to the right
and when the ram is moved backwards the turret indexes automatically and
the tool mounted on the next face comes into operation.
Turret Lathe
The turret lathe is mounted directly on a saddle and the whole unit moves
back and forth on the bed-ways to apply feed.  The movement of the turret
may be affected by hand or power. The turret has a hexagonal shaped tool
holder intended for holding six or more tools. Moreover, the machine is
heavier in construction. It is particularly adapted to larger diameter bar work
and chucking work.  
After one operation is completed, as the turret is brought back away from
the spindle nose, the turret index automatically by a mechanism
incorporated on the bed and in turret saddle, so that the tool mounted on
the next face is aligned with the work.

CNC Lathe
Computer numerical control, popularly referred to as CNC is a method for
automating control of machine tools through the use of software embedded
in a microcomputer attached to the tool. A CNC machine can process a piece
of material to meet specifications by following a coded programmed
instruction and without a manual operator. This process is suitable for a wide
range of materials including metals, plastics, wood, glass, foam and
composites and finds application in a variety of industries such as large CNC
machining and CNC machining aerospace parts.

Topic 2: Cutting Tools for Lathe Machine

0.Single-Point Cutting Tool:

Single point cutting tool consists of only one main cutting edge that can
perform material removal action at a time in a single pass. It is to be noted
that in insert-based cutting tools, multiple cutting edges may present in a
single tool; however, only one cutting edge can engage in material removal
action at a time.
1. Single Knurling Tool:
A knurling tool is a manufacturing and repair tool on lathes to produce
straight, diagonal or diamond patterns, which presented as teeth of uniform
pitch on the exterior of the workpiece. The diamond pattern is also called the
cross pattern. Angular (diagonal) patterns can be left hand or right hand.
2. Compound Knurling Tool:
The knurling tool is used to press or impact regular patterns onto a round
section of the machined parts for gripping or aesthetic purposes, to provide
a patterned handle for better grip or serration surfaces where components
are locked or keyed together in unit assemblies. 
3. Threading Tool
Thread cutting on the lathe is a process that produces a helical ridge of
uniform section on the workpiece. This is performed by taking successive
cuts with a threading toolbit the same shape as the thread form required.
4. Parting Tool
Parting uses a blade-like cutting tool plunged directly into the workpiece to
cut off the workpiece at a specific length. It is normally used to remove the
finished end of a workpiece from the bar stock that is clamped in the chuck.

Topic 3: Precision Measuring Tool

Vernier Calipers:
A measuring instrument consisting of an L-shaped frame with a linear scale
along its longer arm and an L-shaped sliding attachment with a vernier, used
to read directly the dimension of an object represented by the separation
between the inner or outer edges of the two shorter arms.
Applications:
 to measure Internal, External Diameter of an object.
 to measure depth or height of an object.
 in Science Labs
 in Medical Purposes
 in Steel Industries
 in Aerospace Industries
 in Educational Sector
 Topic 4: Lathe Operations
1. Facing:
It is the first operation that is done on the workpiece. It is a machining
operation that is done to produce flat surfaces at the ends of the workpiece.
This operation is performed by feeding the tool perpendicular to the axis of
rotation of the chuck.

2. Step Turning:
Step turning is an operation performed on lathe machine where the excess
material is removed from the work piece to obtain various steps of different
diameters. Different lathe cutting tools for external threading may have
different maximum and minimum pitch variations.

3. Straight Turning:
Straight turning, sometimes called cylindrical turning, is the process of
reducing the work diameter to a specific dimension as the carriage moves
the tool along the work. The work is machined on a plane parallel to its axis
so that there is no variation in the work diameter throughout the length of
the cut.
 4. Core Dia (Throat Dia):
It is the smallest diameter of the thread of a screw or a nut. The term
“minor diameter” replaces the term “core diameter” as applied to
the thread of a screw and also the term “inside diameter” as applied to
the thread of a nut.

5. Taper / Angular Turning:

It is the process in which a conical shape is produced on the workpiece.
During taper turning the feed is set at an angle to the workpiece.

6. Knurling:
It is the process of making indentations (recess or sharp depression) on the
border of a workpiece. The knurling operation is done to provide a better
grip to the job. It is performed by the knurling tool. The knurling tool is
pressed against the job to perform the knurling operation.

7. Threading:
The process of making threads on a cylindrical job is called threading.

Topic 5: Work piece / Job

Preparing the Work Piece

To prepare my final work piece I performed following operations on work
piece with the help of lathe machine:

Holding:
The first step is to hold the work piece in chuck with the help of chuck key to
perform the job on work piece. For this we first open the chuck with the help
of chuck key and then insert ¾ work piece into the chuck and close the
chuck with the help of chuck key. Hold the work piece and apply maximum
pressure to hold the work piece firmly. Then as mentioned in ABC rules,
removed the chuck key and then with the help of another key opened the
tool post and inserted the basic cutting tool in it and then given an angle so
that the face of cutting tool must not touch the sides of work piece. Before
doing that, I corrected the center position of cutting tool with the help of tail
stock point and hence completed the very first holding operation.

Facing:
After holding the work piece I performed the facing operation and for this I
again verified the angle adjustments and remaining all adjustments and
started the machine in Anticlockwise manner and then given the first feed
and performed a complete cut of 1 mm length for this I first adjusted the
horizontal position with the help of horizontal screw and then given the feed
with left hand through vertical screw while holding the horizontal screw with
the help of right hand and performed the first cut very carefully and hence
repeating this several times performed the first operation.

Straight Turning:
After performing the first facing operation very nicely I moved on and
started performing straight turning operation to adjust the diameter of my
work piece, I repeated this many times to get my required dimensions of my
work piece. So I first adjusted the diameter of one end according to my own
need and for this this time I just adjusted the vertical position of cutting tool
with the help of vertical screw and then hold it with the help of left and
started giving feed with the help of horizontal screw and right hand and
hence performed the first cut and hence by repeating this step several timer
I got the required diameter and then moved on and performed the same
operation on the other end and got the required diameter and hence
performed the straight turning operation. It is noted that in this operation I
also used the tail stock to support the work piece as while performing
turning on other end we adjust it such that ¾ of the work piece was outside
the chuck, whereas the end to be turned must be facing toward tail stock.
Parting off:
After beautifully completing the turning operation I moved toward another
operation which was actually not the complete parting off but it was a
depiction of parting tool, this time I used a special tool for this purpose to
part off my work piece. This time I kept on supporting the work piece and
just after taking the measurements and marking it on work piece I
performed a cut as I performed before in straight turning that kept on
holding vertical screw while giving the feed with the help of horizontal screw
and hence performed the first cut, but in this one thing must be noted that
utmost care must be taken otherwise this may cause loss to previous turning
operation as this operation involves a decrease in diameter. In this way after
doing this again and again performed the parting off operation.

Taper Turning:
After performing Parting off operation, I performed the most interesting and
important operation, the tapper turning operation, in this operation I
retained the adjustments with the chuck and work piece as such and
performed some changings with the Compound Rest. I opened the nut inside
the compound rest with the help of key and given an angle of 5° and again
tighten the compound rest with the help of key again and this time with
moved the cutting tool after giving an angle with it to the end from where
we started the parting off operation and then after adjusting the vertical
screw hold it with left hand and moved the horizontal screw with right hand.
Gradually a slop will start appearing and finally when after doing it again and
again the required length at other end reached, I stopped repeating and
hence completed the operation.

Threading:
Then moving ahead performed the second last operation which was
threading, this operation must be performed automatically with the help of
built in speed control and automatic operating functionality I performed
threading but one thing must be noted that before doing this angle of
Compound rest must be re adjusted to 0°.

Knurling:
Finally, the final step, knurling, in which I
again used a special type of tool know as
Knurling too, I just mounted this tool in
tool post and this time used both the
vertical screw and horizontal screw. To
perform this, I started the machine and
then moved tool vertically by vertical
screw and then moving horizontal screw
while applying pressure vertically with the

help of vertical screw and this way completed the final operation.