Group No: G01

1
Module Name: ME1071
Semester: 2

BASIC MACHINING OPERATIONS USING METAL

LATHE

By

Index No. Name Marks

200756B DE SILVA T.D.H

Instructor’s name

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
 INTRODUCTION

Machining is the process that remove the material from a workpiece to obtain desirable shape and size.
Machining is a one of the most using manufacture process now. Machining processes can be used on
metals, wood, plastic, ceramic, and composite material. The man who specializes in machining is
known as machinist. There are many machines that are used to manufacture Application in many
industries. Such as building construction, automobile, aero industry, road, and transport industry, etc.

lathe machine is one of the most common machines that use in metal working sector. In these there
are rotating workpiece and a fixed cutting tool. Even though there are numerous machine tools
accessible for machining, the fundamentals of the process stay the same. Simple and quick metal
product can be created by using lathe machine. Lathe machine can perform varies type of operations
such as drilling, tapering, thread cutting etc.

TOOLS AND EQUIPMENT USED

• The central drilling tool

• Turning tool
• U cut cutting tool
• Knurling tool
• Lathe dog
• Thread cutting tool holder
• Thread cutting tool
• Micrometer screw gauge
• Chuk
• Lathe machine
• Workpiece (cylindrical rod)
 STEPS FOLLOWED IN PRODUCING THE SHAFT
In the beginning, the tool was prepared perpendicular to the line along the spindles and levelled to
the line for avoid unnecessary brakes in the tool due to the workpiece rotation over the tool. Also,
the workpiece was set to the chuck properly to avoid movements.

After that, the machine was turned on and the facing tool was fixed to the tool post. Then the facing
tool was brought near the far end of the workpiece and let the tool to go perpendicular to the axes of
the workpiece until it reaches the centre. The same steps were followed to face the other side also.
Make sure to maintain the length 140mm of the workpiece.

Then both sides of the workpiece were drilled by using the drilling tool. To drill the centres, the
tailstock must be set up with a drill chuck, locked in the appropriate position, and the drill bit driven
back and forth using a handwheel.

Then, the diameter of the workpiece was measured by using the micrometer screw gauge and the
diameter was reduced until it reaches to 23mm by using turning cutting tool. For that turning tool was
mounted to the tool post and positioned parallel to the axis. The decreasing process was done in two
steps. First, the maximum length of the workpiece was marked from the corner of the headstock end,
and straight turning was then begun from the tailstock end to the mark. Then the step was repeated to
the other side as well.
Then, the following diameter reducing processes were performed as above mentioned to obtain the
shape as follows.

Then, from the first 20mm to second 20mm mark, the diameter was linearly reduced. To obtain this
shape, the required angle was calculated by using tan(angle) = (23- 16)/2*20 formula. Then the angle
was set using rest screws and required tapping was created.

The carriage hand wheel and cross slide hand wheel can be turned to be adjusted in accordance with
it. The tool was then moved forward using the cross-slide wheel to complete the U cut after the
machine had been turned on. This was carried out up until the U cut's 2mm depth.

Then a thread cutting tool was used in place of the cutting tool. As before, get the lathe machine
ready for action. The machine was then turned on and self-action mode was turned on after the
spindle speed of the lathe was set to a standard setting. During this operation, a drop of lubricating
oil was also administered. The tool was then brought back to its initial position once the machine
had been switched off. The top slide and cross slide hand wheels were then turned until their values
rose by one. After restarting the machine, thread cutting was carried out till thread was produced.
The thread was flattened and checked using a screw pitch gage.
Using finely sharpened, hardened metal wheels, knurling is the process of imprinting a diamond
shape or straight-line pattern into the surface of a workpiece to enhance its appearance and offer a
stronger gripping surface. Choosing the placement and size of the knurl is the first step in the
knurling process. Next, the machine is set up for knurling.

GENERAL SAFETY PRECAUTION FOLLOWED IN A LATHE MACHINE

• Always concentrate on the work while using the lathe machine and keep alert on emergency
situations.
• Before starting the work, check whether all the safety methods are properly work
• Wear proper to avoid unnecessary accidents.
• Should wear safety shoes, goggles, and clothes
• Don’t wear jewellery, bangles, and rings.
• Use brush to clean the metal chips.
• Long hair should be tied back
• Be careful when handling work piece as it may be hot after performing a task
• After finished, place all tools in their specific places.
• Don’t use the lathe machine if you are the only one in the machine shop.
• Always remove the chuck key immediately after clamping a workpiece.
• Machine should be stopped before making measurements or adjustments on the workplace

IMPORTANCE OF USING CUTTING FLUID

The temperature of the workpiece is always high after using it in high-speed rotation and cutting for
a long time. This heat may cause fractures in the workpiece and decrease the hardness. To avoid such
a unnecessary conditions it is very essential to use cutting fluid. The cutting fluid absorb some amount
of the heat from the workpiece and cooldown the workpiece. Also, it reduce the friction between
workpiece and machine. It also helps to decrease the heat generation.

Cutting fluids also have several benefits, including the ability to flush away chips, small abrasive
particles, dust, and swarf from the work area, protect machined surfaces from corrosion, extend tool
life, and produce a superior surface finish.

CUTTING TOOLS MATERIALS USED ON LATHE MACHINES

• High carbon steel

high carbon steel that had been appropriately hardened and tempered was used to make all tool bits.
To refine the 0.6-1.5% carbon and grain size, these have trace levels of vanadium, silicon,
chromium, manganese, and chromium. About HRC 62 is the greatest hardness. Wear resistance and
hot hardness of this material are very low.
 • Cemented carbides

These are currently the most crucial tool materials because of their exceptional hot hardness
and hot state wear resistance. Cemented carbides have a drawback in that they are not very robust.
Powder metallurgy is used to create these materials, which are created by sintering tungsten carbide
grains in a cobalt matrix. The combination may also contain additional carbides besides tungsten
carbide, such as tantalum carbide and/or titanium carbide (TIC). Cemented carbide is offered as
inserts in a range of sizes. By using clamps or brazing, they are mechanically connected to the tool
holder.
• Stellite

It is a cast non-ferrous alloy containing 43 to 48% cobalt, 17 to 19% tungsten, 30 to 35% chromium,
and 2% carbon. Stellite is very hard and can be used for heavy cuts. Because of its temper does not
lose even at higher temperatures, we can use this tool in varies conditions. This material is very
expensive.

CHARACTERISTICS AND COMPARISON OF 3-JAW AND 4-JAW CHUCKS

3 jaw chuck 4 jaw chuck

The jaws move all at the same direction The jaws move independently

Can’t hold square bars but hex- stocks can be Can be hold square bars but can’t held hex-
held bars

Both the heavier job and the workpiece Heavy-duty tasks can be completed, and the
cannot be configured for eccentric turning. workpiece can be prepared for eccentric
turning.

Accuracy level is about 0.010 Accuracy level is between 0 and 0.001

3-Jaw chuck has one hole for the chuck 4-Jaw chuck has four holes for the chuck
key/wrench to tighten or release the jaws’ key/wrench to control each jaw, one at a
grip. time.
 MANUFACTURE THE GIVEN WORKPIECE

• Workpiece data: cylindrical rod made of mild-steel having length of 100 mm and 50 mm
diameter.
• Production data: Item is axisymmetric. General tolerance – 0.1 mm Roughness – 0.4
micrometres

First, lathe machine was prepared as given in above and workpiece should be mounted to the chuck
properly and then following steps are followed to obtain the given workpiece.
FACING
facing tool should be fixed to tool post. Then turn on the machine and the tool should be moved close
to one of the far ends of the workpiece and tool should be move perpendicularly until it reaches the
centre. And repeat the step for both sides until the length of the rod is reduced to 75mm.
DRILLING
First, the drilling tool should be attached to tail stock and move the tail stock near the workpiece and
then using hand wheel, both sides of the workpiece are drilled to same depth.
TURNING
Then the workpiece is mounted by using drill holes between the spindles of the headstock and tail
stock using lathe dog. Then the diameter should be reduced to 40mm by using the turning cutting
tool. The tool is arranged perpendicular to the axis of the workpiece and then the turning is done
until it reaches the mark then repeat the step to the other side of the workpiece also to obtain 40mm
diameter workpiece.

TAPER TURNING
To obtain the taper part, first calculate the angle by using tan(angle)= (40- 20)/2*10 formula. Then
the angle is ser by using screws. The relevant portion of the workpiece should then be tapered using
a rotating compound slider feed screw after the workpiece has been mounted to spindles using a work
career. Repeat until the depth of the bottom section of the taper matches the depth of the preceding
step-turned part.

PARTING OFF
Then u shaped cutting tool is used to obtain u shape. For that tool is set perpendicular to the centre
line and the carriage hand wheel and cross slide hand wheel can be turned to be adjusted in accordance
with it. then start the machine and keep cutting until the U cut is 2mm deep.

THREAD CUTTING
Then the thread cutting tool should be used to obtain thread. The cross-slide hand wheel should be set
to zero, as well as the top slide hand wheel. Start by making a mark 18mm from the side of the work
piece with the 20mm diameter. The cross slide should then be turned counter clockwise in order to
remove the cutting nose. While cutting thread, apply a drop of lubricant oil.
Then, the equipment and tool should be brought back to where they were. The top slide and cross
slide hand wheels should then be turned until their values have increased by one. Restart the device
and keep cutting thread until thread is produced as follows.

REFERENCES

• Dwivedi, K., 2022. Types of cutting tool materials and their properties. Mechical. Available at:
https://www.mechical.com/2021/01/types-of-cutting-tool-materials.html [Accessed September
27, 2022].
• Burke, T.R., Identifying 3-Jaw and 4-Jaw Chucks. Sabes. Available at:
https://www.sabes.org/content/skillscommons [Accessed September 27, 2022].
• Yeo, G.S., 2020. 10 turning operations you need to know - swiss-turning specialists. Turntech
Precision. Available at: https://turntechprecision.com/clueless-machinist/2020/8/25/10-
machining-operations-performed-on-a-lathe [Accessed September 27, 2022].