MANUFACTURING PROCESS-II

Lab Manual 8

Submitted to
Sir Farhan Raza
Submitted by
Abdul Rehman (2019-IM-37)
 UNIVERSITY OF ENGINEERING &
TECHNOLOGY, LAHORE

Manufacturing Process - II
Lab Manual 8

Department: Industrial & Manufacturing Engineering

Registration No: 2019-IM-37
Submitted By: Abdul Rehman
Submitted To: Dr. Syed Farhan Raza
Objective:-
To perform turning and taper turning operations on a cylindrical job using Lathe Machine

Problem Statement:-
Sometimes, we need to machine the small diameter within the same shaft or work-piece (WP)
for our convenience. And this turning is frequently converted into taper ones as per the
requirements. So, this experiment helps us understand the procedure and analysis of both
turning and taper turning operations.

Apparatus:-
• Lathe Machine
• Mild steel cylindrical workpiece
• Single point cutting tool made up of ______
• Shims used for leveling
• Tool For cutting material
• Vernier Calipers

Theory:-
Turning operation:-

This operation is carried out in order to cut the metal with feed direction parallel to the axis of
rotation of WP. Turning is performed to decrease the diameter of the metal. It also used to
produce a smooth surface finish on the metal. We can create different diameters on a same WP
with the turning operations.
 Fig. 1 Turning operation

Types of turning process:-

1. Straight Turning
2. Rough Turning
3. Shoulder Turning
4. Taper Turning

Straight Turning:

The workpiece is held on the chuck and it is made to rotate about the axis, and the tool is fed
parallel to the WP axis of rotation. The straight turning procedures are used for a cylindrical
surface by removing excess metal from the work piece.

Fig.2
Rough Turning:

It is the process of removal excess material from the work piece in a minimum time by applying
both higher feed rates and depth of cuts.

Shoulder Turning:

When the workpiece has different diameters and is it to be turned, the apparent surface forming
steps in terms of one diameter to other is called shoulder and turning of this part is called
shoulder turning.

Fig. 3

Taper Turning:

It is the process to cut the metal to nearly a cone shape with the help of the compound slide.

Fig. 4 Tapering Operation

Turning Tool:-

Turning tool are used for cutting diameters. The cutting edge is on the side of the tool and tool
is fed parallel to the axis of work piece.

Right Hand Turning:

Right Hand turning tool cuts from tailstock to headstock

Left Hand Turning:

Left Hand turning tool cuts from headstock to tailstock.

Fig. 5

Advantages of Taper Turning operation:-

• Lathe centers remain in alignment

• Setup is simple and permits changes from taper to parallel turning
• Length of work piece does not matter
• Wider range of taper may be produced

Advantages of Turning operation:-

• All types of materials are used for the process.

• Short lead times
• Precise

Disadvantages of Tuning operation:-

• If the cutting parameters such as the feed rate, spindle speed or depth of cut are too high,
the surface of the workpiece will be rougher than desired.
• Also a large depth of cut may result in vibrations leading to chattering and further causing
inaccuracies in the machined surface.
• As the tool is used, the sharp edge will wear down and become dull. A dull tool is less
capable of making precise cuts.
• Scrap content is large
 • Limited to rotational parts

Procedure of Turning Operation:-

➢ The workpiece is placed in the chuck and the chuck is tightened using a chuck key.

Fig. 6
➢ The cutting tool is placed in the tool post and the screws are tightened. The cutting point of
the tool is matched with the center of the workpiece.

➢ Then the tool’s tip is touched on the surface of the work piece and the reference is set on the
cross – slide’s hand wheel.

Fig. 7
➢ The carriage is brought to the point from which turning begins. With the tool away from the
work piece, the lathe is turned on.
➢ Cross – Slides is moved to the reference on the scale and then give a 1mm depth. The carriage
is moved to the end of work piece and the tool cuts through the work piece to a 1mm depth.
 Fig. 8
➢ This is repeated for as long as the required depth of material is removed.

Fig. 9

➢ The movement of the carriage may be automated with a suitable mechanism i.e. either by
lever or by pressing a button.

Fig. 10
 Fig. 11

Fig. 12

Procedure of Taper Turning Operation:-

➢ The workpiece is placed in the chuck and the chuck is tightened using a chuck key.
➢ The cutting tool is placed in the tool post and the screws are tightened. The cutting point of
the tool is matched with the center of the workpiece.
➢ Rotate the compound slide of the required angle say 10o.
➢ Then the tool’s tip is touched on the surface of the work piece and the reference is set on the
cross – slide’s hand wheel (this is actually the depth of cut).
➢ The carriage is brought to the point from which taper turning begins. With the tool away from
the work piece, the lathe is turned on.
➢ Rotate the compound slide handle and you see taper turning of the tool is starting.
➢ This is repeated for as long as the required depth of material is removed.
➢ Can taper turning be automated? (Provide an answer to this question)

Observations:-

Material of the work piece

Material of the tool SS
Depth of Cut
Rotational speed (rpm) (nw)
Tool angle w.r.t to compound rest
Taper Angle
Cutting Speed
Feed Rate (mm/rev)

Average Cutting Speed for turning operation =

Average cutting Speed for taper turning operation = ?

Where,

dw = WP Diameter

dm = Machined Surface Diameter

Material Removal Rate (MRR) for simple turning = Depth of Cut x Feed x Cutting Speed

Material Removal Rate (MRR) for taper turning = Depth of Cut x Feed x Cutting Speed

=
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