POLITEKNIK KUCHING SARAWAK

MECHANICAL ENGINEERING DEPARTMENT

CODE : J4102

COURSE : MECHANICAL WORKSHOP

PRACTICES 4 (MACHINE)

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 KUCHING POLYTECHNIC, SARAWAK
DEPARTMENT OF MECHANICAL ENGINEERING

J4102 – MECHANICAL WORKSHOP PRACTICES 4 (MACHINE)

1.0 LEARNING OUTCOMES:

At the end of this practice, the student should be able to:

1.1 conduct basic machinery works with lathe machine such as facing, turning
and tapering.
1.2 use the index head and conduct the method of simple indexing.
1.3 operate a cylindrical grinding machine.
1.4 practice the safety precaution when entering the workshop and when
handling the machines as well.

2.0 EQUIPMENT / APPARATUS :

2.1 Workpiece (Mild Steel with length of 103 mm, diameter of 40 mm)
2.2 Vernier Caliper
2.3 Tool bit (Lathe machine only)
2.4 Lathe Machine
2.5 Horizontal Milling Machine
2.6 Cylindrical Grinding Machine
2.7 Table Grinder
2.8 Hydraulic Power Hacksaw
2.9 Safety Goggle

3.0 SAFETY AND HEALTH :

3.1 General Safety Precaution

a) Think about what you are going to do before you do it.

b) Make sure all the safety procedures for the machine had been
done. Go over a safety checklist.
c) Wear a short sleeve or roll up long sleeves above the elbow.
d) Keep you shirt tucked in. It is recommended that you wear a shop
apron. Do not wear fuzzy sweaters around lathe.
e) If you have long hair, keep it secured properly to avoid your hair
being entangled in a moving machine.
f) Remove your wristwatch and rings before operating the lathe.
g) Do not use gloves when the lathe is running.
h) Please wear your safety glass when operating the machine.

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3.2 Operating Safety Precaution

a) Keep the machine and work area neat, clean and orderly.
b) Ensure all guards and cover plates are in place and all machine
cabinet doors closed before starting machine.
c) Never lay anything on the working surfaces of the machine, or
inside the machining chamber, where it may foul with rotating or
moving parts.
d) Do not touch or reach over moving or rotating machine parts.
e) Ensure you know how to stop the machine before starting it.
f) Do not operate the machine in excess of its rated capacity.
g) Stop machine immediately if anything unexpected happens.
h) Do not change speed of the spindle when the machine is turning
on.
i) Stop motors and switch off isolator when leaving machine
unattended.

3.3 Lathe Machine Safety

a) Pinch points due to lathe movement. Keep your hands away from
dangerous positions, such as gears, chuck jaws or between
compound rests.
b) Heavy chucks or workpiece can be dangerous when accidentally
dropped. Care must be used when handling them. Always remove
the chuck wrench immediately after using it.
c) Beware from flying chips due to injury result especially to your
eyes. Always turn off the lathe before attempting to remove chips.
Stringy chips must not be removed with bare hands; wear heavy
gloves and use hook tools or pliers or brush.
d) Beware from sharp edges, corners and projection.
e) When workpiece are clamped, their components often extend
beyond the outside diameter of the holding devise.
f) Workpiece extending out of the lathe should be supported by a
stock tube.
g) The spindle or workpiece should never be slowed or stopped by
hand gripping or by using a pry bar. Always use lathe controls to
stop or slow it.
h) Other safety aspects should be considered.

3.4 Horizontal Milling Machine Safety

a) On a milling machine the cutter is out in the open. This creates a

situation where your hands can come in contact with the cutter
quite easily. Always turn the machine spindle off when clearing
away chips or taking a measurement on the part.
b) Stop the spindle completely before you load or unload a workpiece.
c) When making adjustments to the work-head remove the cutting tool
from the spindle. Never loosen all of the clamping bolts on the tool
head at one time.

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 d) Never leave a running machine unattended.
e) When cleaning the milling machine; do not use compressed air.
Compressed air will blow chips back into your face and eyes.
Compressed air can also blow fine chips past the wipers on the
ways of the machine. Fine chips between mating surfaces of
machine will ruin the accuracy of the machine.
f) Do not use your hands to remove chips. Do not allow the chips to
pile up. When they pile up, it is hard to resist the urge to remove
them. When that urge is satisfied incorrectly, you may be hurt. After
stopping the spindle, use a stout brush or chip scraper to clear the
chips away.

3.5 Cylindrical Grinding Machine Safety

a) Wear goggles for all grinding machine operations.

b) Check grinding wheels for cracks before operating.
c) Never operate grinding wheels at speeds in excess of the
recommended speed.
d) Never adjust the workpiece or work mounting devices when the
machine is operating.
e) Do not exceed recommended depth of cut for the grinding wheel or
machine.
f) Remove workpiece from grinding wheel before turning machine off.
g) Never leave a running machine unattended.

4.0 THEORY

A lathe is a machine tool which rotates the workpiece on its axis to

perform various operations such as cutting, sanding, knurling, drilling, or
deformation with tools that are applied to the workpiece to create an object
which has symmetry about an axis of rotation. The design of lathes can vary
greatly depending on the intended application; however, basic features are
common to most types. These machines consist of (at the least) a
headstock, bed, carriage, and tailstock. Better machines are solidly
constructed with broad bearing surfaces (slides or ways) for stability, and
manufactured with great precision. This helps ensure the components
manufactured on the machines can meet the required tolerances and
repeatability.

A milling machine is a machine tool used to machine solid materials.

Milling machines are often classed in two basic forms, horizontal and
vertical, which refers to the orientation of the main spindle. Both types range
in size from small, bench-mounted devices to room-sized machines. Unlike
a drill press, which holds the workpiece stationary as the drill moves axially
to penetrate the material, milling machines also move the workpiece radially
against the rotating milling cutter, which cuts on its sides as well as its tip.

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 Milling machines can perform a vast number of operations, from
simple (e.g., slot and keyway cutting, planing, drilling) to complex (e.g.,
contouring, diesinking). Cutting fluid is often pumped to the cutting site to
cool and lubricate the cut and to wash away the resulting swarf.

An indexing head, also known as a dividing head or spiral head is a

specialized tool that allows a workpiece to be circularly indexed; that is,
easily and precisely rotated to preset angles or circular divisions. Indexing
heads are usually used on the tables of milling machines. They are
commonly used to machine the flutes of a milling cutter or reamer or the
teeth of a gear.

Cylindrical grinding machine is a machine tool used for producing

very fine finishes or making very light cuts, using an abrasive wheel as the
cutting device especially for cylinder work pieces. It can be also used to
reduce particle size in materials. The workpiece is rotated and fed past the
wheel/s to form a cylinder. Therefore, it is used to make precision rods.

Cylindrical grinding is defined as having four essential actions

a) The work (object) must be constantly rotating

b) The grinding wheel must be constantly rotating
c) The grinding wheel is fed towards and away from the work
d) Either the work or the grinding wheel is traversed with the
respect to the other.

(Adapted from Wikipedia, the free encyclopedia, http://en.wikipedia.org)

5.0 PROCEDURES :

5.1 Part 1: Lathe Machine Operation

STEP WORK STEP FIGURE

1 Cut solid mild steel bar (as a 103 mm

workpiece) of 103 mm in length and 38
mm in diameter by using Hydraulic
Power Hacksaw. Ø 38 mm

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2 Clamp the workpiece with 70 mm
length out of the chuck at lathe
machine.
Ø 38 mm

70 mm

3 Do the facing at the end of workpiece

until you get the flattened surface.
Ø 38 mm

4 Touch the tool bit 60 mm from the end

of the workpiece and do the turning
marking.
Ø 38 mm

60 mm

5 Do the straight turning on the

workpiece for the length of 60 mm and
diameter of 25 mm.
Ø 38 mm Ø 25 mm

6 Set the tool post to 450 and do the 450

taper turning about 2 mm length on the
end of workpiece.
Ø 38 mm Ø 25 mm

2 mm

0
45 2 mm

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 Release the workpiece from chuck.
7 Turn it over and clamp it again into the
chuck. Do the facing at the other end of Ø 38 mm
workpiece until you get the flattened
surface and also until the length is 40
mm.

40 mm

8 Do the straight turning on the

workpiece (length of 40 mm) and make
sure until the diameter is 36.2 mm.
Ø 36.2 mm
Do not lathe the diameter until the
actual size of 36 mm. At least 0.2 mm
of the diameter is reserved for
cylindrical grinding operation.

Set the tool post to 1.50 and do the

9 taper turning along the length of 40 mm
on the workpiece.
Ø 36.2 mm
Caution: You must run this operation
manually. No automatic operation is
allowed.
1.50

5.2 Part 2: Horizontal Milling Machine Operation (Indexing

process)

For the taper part of 1.50 on the workpiece, does the gear cutting by using
Horizontal Milling Machine. Simple indexing will be applied here.

There are 7 teeth to be milled here. So, the calculation for selecting an index
plate is shown as follow:

Brown and Sharpe type consists of 3 plates of 6 circles each drilled as follows:

Plate 1 - 15, 16, 17, 18, 19, 20 holes

Plate 2 - 21, 23, 27, 29, 31, 33 holes

Plate 3 - 37, 39, 41, 43, 47, 49 holes

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The formula for calculating the most suitable number of turn of index crank and
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the number of holes on the index plate used is which N is refer to the number
N
of equal divisions or teeth required to cut.

In this student project, a gear of 7 teeth is going to be cut, so the calculation is

shown as below:

40 40 5 15
= =5 =5
N 7 7 21

This means that five full turn is required for each division, 40/7 of a turn to be
exact. Since a 7-hole circle is not available, so the remaining of 5/7 must be
converted to 15/21 because there is a plate, the plate 2 with 21 holes is
available. Therefore, 5 full turn and 15 holes on a 21-hole circle is the correct
indexing for 7 equal teeth.

Hole-21 Hole-1

Sector arms

15th hole on
a 21-hole
circle

Hole-15

The sector indicates the next hole in which the pin is to be inserted and makes it
unnecessary to count holes when moving the index crank after each cut. It
consists of two radial, beveled arms which can be set at any angle to each other
and then moved together around the center of the index plate. Suppose that, as
shown in above figure, it is desired to make a series of cuts, moving the index
crank 5 15/21 turns after each cut. Since the circle illustrated has 21 holes, turn
the crank five full turn plus 15 spaces after each cut, Set the sector arms to
include the desired fractional part of a turn or 15 spaces between the beveled
edges of its arms, as shown. If the first cut is taken with the index pin against the
left-hand arm, to take the next cut, move the pin once against the right-hand arm
of the sector. Before taking the second cut, move the arms so that the left-hand
arm is again against the pin; this moves the right-hand arm another 15 spaces
ahead of the pin. Then take the second cut, and repeat the operation until all the
cuts have been completed.

NOTE: It is good practice always to index clockwise on the plate to eliminate

backlash.

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STEP WORK STEP FIGURE
Clamp the workpiece (from Part 1
above) into the chuck on the
1
Horizontal Milling Machine. Do the
indexing (7-gear cutting) on the 1.50 Do gear
cutting on
taper part of the workpiece.
this part

1.50

0
Horizontal, 00
2 Adjust the 1.5 taper part so that it
will be leveled horizontally. Use dial
indicator to check the correct
leveling of that part.

3 Adjust the milling cutting tool until Center axis of milling cutter
its position is perpendicular with the
horizontal axis of the workpiece and
parallel with the center, vertical axis
of the workpiece as well.
Vertical axis

Center

Horizontal axis

Touch the workpiece to the edge of

Touch only
4 the cutting tool to set 0 mm position.

5 Move the workpiece to the edge of

the cutting tool and set the depth of
cut is 2 mm. After this, lock the
vertical column of the milling
machine.
2mm

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 6 Do the first cutting by feed the End Begin
workpiece towards the cutting tool.
The cutting is only completed when
cutting tool traverse from one end to
another end of workpiece (cutting
through).

First through
cutting
7 Count the 15th hole on a 21-hole
circle. Set the sector arm on the
index plate so that it can mark the
section in between these two sector
arms is 15 holes. Tighthen the View of
sector binding screw. index plate
with its
8 For the second cutting, turn the sector on it
index crank for 5 full turn. Then, put
the index pin into the hole-15. Hole-1
Hole-21
Before start the second cut, move
the arms so that the left-hand arm is
again against the pin; this moves 15th hole on
the right-hand arm another 15 holes a 21-hole
circle
ahead of the pin. Then take the
second cut.
Hole-15
9 Repeat the Step 8 above until all
the cuts (7 cuts) have been Left-hand
Right-hand
sector arm
completed. sector arm

Front view

View of the workpiece after milling process

(indexing).

Side view
(show only
the 7 cuts)

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 5.3 Part 3: Cylindrical Grinding Machine Operation

STEP WORK STEP FIGURE

Swivel and set the table to 1.50

1
shown at the taper scale.

Note:
Your project is in the category of Do
“Conical Grinding For Slow Tapers”. this:
So, you only need to swivel and set Swivel
the table to 1.50 which shown at the and
taper scale. set to
1.50
For the category of “Conical
Grinding For Steep Tapers”. So,
you need to swivel headstock, not
the table.

Remember when a workpiece is to

be conically ground, the workpiece
axis and the grinding wheel axis
must be at the same height.
Otherwise, the workpiece will not be
ground at the correct angle.

Clamp the workpiece (from Part 2

2
above) into the chuck on the
Cylindrical Grinding Machine.
Observe and ensure that the
workpiece is revolving uniformly
around its axis. In order to do it, you Workpiece
have to on the chuck by turning the Chuck
Chuck Switch on.

Adjust the table automatic-free-

3 Table
traverse from left to right and vice
versa by setting at the Limit Stopper
below the table. Ensure that all the
conical part of your workpiece to be
grinded is traverse pass the Limit stopper Limit stopper
grinding wheel with the traverse
limit range you had set. In order to Traverse limit range
do it, you have to on the Hydraulic
Switch and pull the Table Feed
Handle.

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 With the grinding wheel and chuck Grinding Wheel
on and conical part of workpiece Touching, “0 mm”
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facing perpendicularly to the
grinding wheel, set “0 mm” by Arbor
touching the surface of the grinding
wheel to the surface of the
workpiece. Traverse the grinding
wheel slowly towards the surface of
workpiece manually by turning the
Workpiece
Head Crossfeed Handwheel. Stop
the traverse when spark is being
observed. It means that the surface
of grinding wheel and the surface of
workpiece is touching.
Grinding Wheel
On the coolant Switch. Then start
5 Table (workpiece)
the grinding process by pulling the
Table Feed Handle to operate traverse cross the
grinding wheel
position. The table carried the
workpiece together will traverse to
and fro in front and crossing the
grinding wheel during the grinding
process.

After a few round of grinding 0.5 mm for each Feed Grinding Wheel
process (Hint: when you observe feed
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that less spark is being produced),
then feed the grinding wheel
towards the workpiece with the
depth of cut as 0.5 mm by turning
the Head Crossfeed Handwheel. Do
not feed too much at a time in order
to get a more smooth and precision
surface besides to prevent any
incident happened. Ø 36.2 mm

Repeat the Step 6 above until you

get the final bigger diameter of Get the final bigger Feed Grinding Wheel
7 diameter of conical
conical part is 36 mm.
part = 36 mm
Note:

The bigger conical diameter is 36.2

mm (from Part 2 above) while the
request bigger diameter for that part
is 36 mm only.
Ø 36 mm
So, 0.2 mm have to be removed by
grinding process. (Use the scale at
the Head Crossfeed Handwheel).

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6.0 RESULTS/DATA :

6.1 Project Diagram 1

Ø 36 mm

1.5˚ 6

2 40mm

3 60mm

45˚

2 mm
4
Ø 25mm

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 6.2 Data

Take the reading for the parts below and do the calculation for the
deviation and its percentage:

Part a. Project Dimension f. g.

Actual b. c. d. e. Mean Deviation Deviation
Dimension Reading Reading Reading (mm) (mm) Percentage
(mm) 1 (mm) 2 (mm) 3 (mm) bcd f  ae f
e g   100%
3 a

1 36
2 40
3 60
4 2
5 25
6 1.50

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 FORMAT OF WORKSHOP PRACTICE REPORT
[Submitted by Student]

FRONT PAGE OF REPORT

POLYTECHNIC NAME OF POLYTECHNIC

LOGO AND
DEPARTMENT
COURSE: NAME OF COURSE
CODE: JXXXX
TASK: PROJECT OF MACHINE WORKSHOP
LECTURER:

Submitted by :
Student Matrix No :
Date :

ASSESSMENT
Learning Outcomes (5%)
Equipments / Apparatus (5%)
Safety and Health (5%)
Theory (10%)
Working Procedures (20%)
Result / Data (10%)
Calculation (5%)
Discussion (15%)
Conclusion (15%)
Reference (5%)
Appendix (5%)
OVERALL MARKS ( 100% )

Name & Signature:

....................................
(Lecturer)
Date:

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 FORMAT OF WORKSHOP PRACTICE REPORT
[SUBMITTED BY STUDENT]
PROJECT:

1.0 LEARNING OUTCOMES :

2.0 EQUIPMENTS / APPARATUS :

3.0 SAFETY AND HEALTH :

4.0 THEORY:

5.0 WORKING PROCEDURES :

6.0 RESULTS/DATA :

7.0 CALCULATION :

8.0 DISCUSSION

9.0 CONCLUSION :

10.0 REFERENCES :

11.0 APPENDIX

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