Lab Report 06

“Developing Operational Procedures for the various types of Machines in Machine

Tools & Machining (MTM) laboratory”

Turret Lathe

Tailstock replaced by “turret” that holds up to six tools

•Tools rapidly brought into action by indexing the turret

•Tool post replaced by four-sided turret to index four tools

•Applications: high production work that requires a sequence of cuts on the part

Machining

A material removal process in which a sharp cutting tool is used to mechanically cut away
material so that the desired part geometry remains

•Most common application: to shape metal parts

•Machining is the most versatile and accurate of all manufacturing processes in its capability to
produce a diversity of part geometries and geometric features

-Casting can also produce a variety of shapes, but it lacks the precision and accuracy of
machining.

Classification of Machined Parts

1. Rotational - cylindrical or disk-like shape

2. Non-rotational (also called prismatic) - block-like or plate-like

Figure 6.1 - Machined parts are classified as: (a) rotational, or (b) Non-rotational, shown here by block and flat parts
Machining Operations and Operational Procedures
Each machining operation produces characteristic part geometry due to two factors:

1. Relative motions between the tool and the work part

• Generating –part geometry is determined by the feed trajectory of the cutting tool

2. Shape of the cutting tool

• Forming –part geometry is created by the shape of the cutting too

Figure 6.2 - Generating shape: (a) Straight turning, (b) Taper turning, (c) Contour turning, (d) Plain milling, (e) Profile milling

Figure 6.3 - Forming to create shape: (a) Form turning, (b) Drilling,
Turning
A single point cutting tool removes material from a rotating workpiece to generate a cylindrical
shape
•Performed on a machine tool called a lathe
•Variations of turning that are performed on a Turret lathe:
Facing
Contour turning
Chamfering
Cutoff
Threading

Figure 6.4 - Turning operation

Facing

Tool is fed radially inward

Contour Turning

Instead of feeding the tool parallel to the axis of rotation, tool follows a contour that is other than
straight, thus creating a contoured form.

Chamfering

Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer".

Cutoff

Tool is fed radially into rotating work at some location to cut off end of part Figure.
 Figure 6.5 (a) Facing (b) Contour Turning (c) Chamfering (d) Cutoff

Threading

Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotation at
a large feed rate, thus creating threads.

Figure 6.6 - Combination of forming and generating to create shape: (a) thread cutting on a lathe

Methods of Holding the Work in a Lathe

•Holding the work between centers

•Chuck
•Collet
•Face plate
Holding the Work between Centers

Figure 6.7 (a) Mounting the work between Centers using a "Dog”
Chuck

Figure 6.7 (b) Three-Jaw Chuck

Collet

Figure 6.7 (c) Collet

Face Plate

Figure 6.7 (d) Face Plate for Non-Cylindrical Work Parts

Parts Produced on Turret Lathe

Figure 6.8 - (a) Part produced on a Turret Lathe; and (b) Sequence of Operations to produce the part:
(1) Feed Stock to Stop, (2) Turn main Diameter, (3) Form Second Diameter and Spot Face, (4) Drill, (5) Chamfer, and (6) Cutoff

Operating and Working Procedure

 Personal Protective Equipment (PPE)

Safety glasses and hearing protection, plus minimum shop PPE.

 Environmental/Ventilation Controls

Ensure equipment is secure so it doesn’t move when in use. A dust collection system
should be attached near the cutting area.

 Required training or approval {Supervisor’s approval or task-specific training}

1. Review and observe general safety practices outlined in the Machine Shop Equipment
Safety Guidelines. Refer to manufacturer’s operating manual for all operating procedures.
2. Ensure all safety shields and guards are in place prior to turning the machine on.
3. Ensure all body part, clothing, hair, jewelry and other objects are clear of the cutting area
and other moving parts before starting the machine and engaging its moving parts.
4. All stock must be properly secured in the lathe chuck or mounted prior to the machining
process taking place. Use the correct sized clamp or vise for the stock being machined.
5. Turn the chuck or faceplate by hand to ensure there is no binding or danger of the work
striking any part of the lathe.
  Inspection requirements before use

1. Before starting the lathe, ensure the spindle work has the cup center imbedded; tail, stock
and tool rests are securely clamped; and there is proper clearance for the rotating stock.
2. Prior to starting the lathe, ensure that small diameter stock does not project too far from
the chuck without support from the tail stock center.
3. When using wood, do not mount a split work piece or one containing knots.
4. When roughing stock, do not force the tool in the work piece or take too big a cut.
5. The operator must always be aware of the direction and speed of the carriage or cross-
feed prior to engaging the automatic feed.

 Safe operating Procedures or Precautions

1. Never leave the key in the chuck. Do not let go of the key until it is free of the chuck and
secured in its proper holding place.
2. Select turning speed carefully. Large diameter stock must be turned at a very low speed.
Always use the lowest speed to rough out the stock prior to final machining.
3. The correct speed and feed for the specific material and cutting tool must be used. Stop
the machine before making adjustments or measurements.
4. Never attempt to run the chuck on or off the spindle head by engaging the power.
5. Do not stop the rotation of the chuck by reversing power to the lathe unless tapping holes.
6. Do not stop the rotation of the any rotating or moving machinery parts by hand.
7. Do not leave tools, bits or excess pieces of stock on the lathe bed.
8. All belts and pulleys must be guarded. If frayed belts or pulleys are observed, the lathe
must be taken out of service and the belts or pulleys replaced.
9. Stop the machine immediately if odd noise or excessive vibration occurs.

Conclusion
The Turret lathe is a very versatile and important machine to know how to operate. This machine
rotates a cylindrical object against a tool that the individual controls. The Turret lathe is the
forerunner of all machine tools. The work is held and rotated on its axis while the cutting tool is
advanced along the line of a desired cut. The Turret lathe is one of the most versatile machine
tools used in industry. With suitable attachments, the machine may be used for turning, tapering,
form turning, screw cutting, facing, dulling, boring, spinning, grinding, polishing operation.
Cutting operations are performed with a 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 the work, for
machining taper and angles. On a Turret lathe, the tailstock does not rotate. Instead, the spindle
that holds the stock rotates. Collets, centers, three jaw chucks, and other work-holding
attachments can all be held in spindle. The tailstock can hold tools for drilling, threading,
reaming, or cutting tapers. Additionally, it can support the end of the workpiece using a center
and can be adjusted to adapt to different workpiece lengths.
Recommendation

A lubricant was used to

control component heating
and reducing friction
between the tool and the
metal rod being reduced,
and ultimately increasing
tool and part life span. But
the offset is that while the
coolant is spread it
distract eyes accuracy.
Furthermore, the quality of
the lubricant used is low
which in turn affected the
performance of both
machine and work piece.
The mild metal part had a
rough surface after
machining from using the
coolant which greatly
affected the reading
because the part was not
faced
and further smoothed
A lubricant was used to
control component heating
and reducing friction
between the tool and the
metal rod being reduced,
and ultimately increasing
tool and part life span. But
the offset is that while the
coolant is spread it
distract eyes accuracy.
Furthermore, the quality of
the lubricant used is low
which in turn affected the
performance of both
machine and work piece.
The mild metal part had a
rough surface after
machining from using the
coolant which greatly
affected the reading
because the part was not
faced
and further smoothed
Lubricants must be used to control the component heating and reduce the friction between the
tool and workpiece it will ultimately increase the tool and machine life. A way to avoid heavy
vibration during the cutting process is to place a damper to the machine to observe the vibration
this will greatly increase the smoothing of the operation performed on Turret lathe. During
performing the operation on Turret lathe machine the line of sight should be perpendicular to
avoid parallel error this will improve the quality of the product.

References
1. https://www.seasshops.ucla.edu/standard-operating-procedure-sop-lathe/
2. https://themechanicalengineering.com/lathe-machine/
3. https://mechanicalenotes.com/lathe-machine/
4. https://www.engineeringchoice.com/what-is-lathe/