LAB SESSION 01

OBJECTIVE

To evaluate the effect of precision in turning operation.

APPARATUS

Lath machine, Vernire caliper, Steel ruler, Work piece (Mild Steel) 25 mm diameter, HSS single
point tool

THEORY

Introduction

Turning is a lathe operation in which an external cylindrical surface is produced by generating.

The cutting tool is first adjusted for the desired depth of cut, using the cross slide. Then as the
work piece rotates, the cutting tool is advanced relatively slowly a direction parallel to the
rotational axis of the spindle. The motion is known as the feed. These combined motions cause
the work piece by adjusting the feed so that the helical path of the tool tip overlaps and generates
a cylindrical surface on the work piece. A spindle rpm which gives a desired cutting speed at the
circumference of the cylindrical surfaces should be reflected.

Lathe safety

As always we should be aware of safety requirements and attempt to observe safety rules in
order to eliminate serious injury to ourselves or others.

Wear glasses, apron, safety shoes, short sleeves, no tie, no rings, no trying to stop the work by
hand. Stop the machine before trying to check the work. Don’t know how it works? –“Don’t run
it.” Don’t use rags when the machine is running.

 Remove the chuck key from the chuck immediately after use. Do not turn the lathe on if
the chuck is still in the chuck key.
  Move the tool bit to a safe distance from the chuck, collet, or face plate when inserting or
removing your part.
 Place the tool post holder to the left of the compound slide. This will ensure that the
compound slide will not run into the spindle or chuck attachments.
 Never run the machine faster than the recommended speed for the specific material.
 If a chuck or faceplate is jammed on the spindle nose, contact an instructor to remove it.
 If any filing is done on work revolving in the lathe, file left handed to prevent slipping
into the chuck.
 Always stop the machine before taking measurements.
 Use care when cleaning the lathe, the cutting tools is sharp, the chips are sharp, and the
work piece may be sharp.
 Make sure the machine is turned off and clean before leaving the workspace. Always
remove the chuck key after use, and keep floor area clean.

Parts of lathe

A lathe (shown in fig.) basically consists of a bed to provide support, a head stock, a cross side to
traverse the tool, a tool post mounted on the cross slide. The spindle is driven by a motor through
a gear box to obtain a range of speeds. The carriage moves over the bed guide ways parallel to
the work piece and the cross slide provides the transverse motion. A feed shaft and lead screw
are also provided to power the carriage and for cutting the threads respectively.
The Bed:

The lathe bed is a mounting and aligning surface for the other machine components. Viewed
from the operating position in front of the machine, the headstock is mounted on the left end of
the bed and the tailstock on the right. The bed must be bolted to a base to provide a rigid and
stable platform. The bed ways are a precision surface (or surfaces) on which the carriage slides
left and right during machining operations. The ways are machined straight and flat and are
either bolted to the top of the bed or are an integrally machined part of the bed.

Headstock:

The headstock holds the spindle and drive mechanism for turning the work piece. The spindle is
a precision shaft and bearing arrangement rotated directly by a motor or through a motor driven
belt. Gears or sliding pulleys mounted at the rear of the headstock allow spindle speed
adjustment. A work piece is held in the spindle for turning or drilling by a jawed chuck or a
spring collet system. Large, unusual shaped, or otherwise difficult to hold pieces, can be attached
to the spindle with a face plate, drive dogs and special clamps.

Tailstock:

The tailstock supports long work that would otherwise sag or flex too much to allow for accurate
machining. Without a tailstock, long pieces cannot be turned straight and will invariably have a
taper. Some tailstocks can be intentionally misaligned to accurately cut a taper if needed. The
tailstock has a centering device pressed into a shallow, specially drilled hole in the end of the
work piece. The center can be either "live" or "dead." Live centers have a bearing, allowing the
center to rotate along with the work piece. Dead centers do not rotate and must be lubricated to
prevent overheating due to friction with the work piece. Instead of a center, a drill chuck can be
mounted in the tailstock.

Carriage:

The carriage provides mounting and motion control components for tooling. The carriage moves
left and right, either through manual operation of a hand wheel, or it can be driven by a lead
screw. At the base of a carriage is a saddle that mates and aligns with the bed ways. The cross-
slide, compound rest and tool holder are mounted to the top of the carriage. Some carriages are
equipped with a rotating turret to allow a variety of tools to be used in succession for multi-step
operations.

Cross Slide:

The cross-slide is mounted to the top of the carriage to provide movement perpendicular to the
length of the bed for facing cuts. An additional motion assembly, the compound rest, with an
adjustable angle, is often added to the top of the cross slide for angular cuts. The cutting tools
that do the actual metal removal during turning are mounted in an adjustable tool holder clamped
to the compound rest.

Lead Screw:

The lead screw provides automatic feed and makes thread cutting possible. It is a precision-
threaded shaft, driven by gears as the headstock turns. It passes through the front of the carriage
apron and is supported at the tailstock end by a bearing bracket. Controls in the apron engage a
lead nut to drive the carriage as the lead screw turns.
PROCEDURE

 Measure initial dimensions of work piece by using Vernier caliper.

 Clamp work piece in the 3-jaw chuck of lathe
machine by using chuck key.

 Center the work piece by placing the steel rule

between work piece and tool. The tool is centered
when steel rule is vertical otherwise it will be high or
low depending upon steel rule direction (shown in
figure)
 Clean the tool post, properly place the tool in the
tool post and tight the bolt.

 The cutting tool is first adjusted for the desired depth

of cut, using the cross slide. Depth of cut will be
given by reading the value on the scale of cross slide

 Set the required value of feed rate by selecting the value given in machine table. Lever
position show the value in row A,B, C while column values a,b,c,…. will be selected by
changing the tabular lever (Shown in figures below).

Hand lever (postions A,B,C) Tabular lever (positions a,b,c…)

  Select the value of spindle rotation (RPM) by
positioning the two RPM knobs on machine.

 Once you set all parameters on machine

(above steps), turn on your machine by
moving ON/OFF lever (switch) toward right
or left and perform turning operation.
Spindle will move clockwise by moving the
lever in right direction and vice versa.

 After every reading measure new dimensions (diameter) of work piece.

 Repeat the experiment until unless you get the precise dimensions.

REQUIRED DEIMENSIONS

For getting precise part, the tolerance in each dimension should be from + (0.05-0.1) to – (0.05-
0.1)

22mm 18mm 15mm

5mm
10m

20mm
Student lab report will consist of following:

 Objective
 Apparatus/ materials
 Procedure
 Observations and Calcluations
 Results and discussions
1. What is the difference between rough and finish cut? What are the values you used
and why?
2. What will be happened on too high spindle speed and depth of cut?
3. How will you select appropriate tool for given material? Give some examples
4. What will be the effect of auto feed and manual feed on the surface of work piece?
5. Do you get precise part within the tolerance? If NO? Than tell the reasons.
 Precautions
 Comments
OBJECTIVE

APPARATUS

PROCEDURE
OBSERVATIONS AND CALCULATIONS

Depth of cut RPM Feed Initial Final

Sr # Error
(mm) (mm/rev.) Diameter Diameter
DISCUSSION
What is the difference between rough and finish cut? What are the values you used and why?

What will be happened on too high spindle speed and depth of cut?

How will you select appropriate tool for given material? Give some examples

What will be the effect of auto feed and manual feed on the surface of work piece?
PRECAUTIONS

CONCLUSION

COMMENTS