Title: TURNING OPERATIONS ON MILD STEEL

Abstract:
This report is about the different turning processes or operations performed on mild steel using a lathe
machine.
A lathe machine is a machine used to perform turning processes such as Facing, straight turning, Taper
Turning, Thread Cutting, etc. These processes are carried out on the work piece to achieve a good surface
finish and dimensional accuracy.
Good surface finish and dimensional accuracy are important because they help the work piece to fulfill its
functional requirements, improve its performance and prolong its service.
Therefore, this paper will talk more about how to carry out these processes and the objective of the machining
process, steps involve, Methodology and analysis, and the calculations based on findings of a practical
conducted.
 Introduction
It is known that most metals undergo different types of defects (ME 322 lecture notes) and wear out easily
when they are in use. This leads to mechanical structures break down and lives being lost.
Therefore, to avoid such defects and structural worn out, different manufacturing processes are put in place
to assess material properties and life. Even though there are many processes used to strengthen engineering
materials, do surface finishing and achieve accurate dimensions on the work piece, this paper will be more
specific about a machining process known as turning.
The turning process is one of the processes carried out in the workshop using a lathe machine. Turning is
normally done to give a good surface finish and achieve dimensions' accuracy on the work piece.
Turning processes are further classified into four (4) categories, namely facing, straight turning, Taper Turning,
and Thread Cutting. Facing is the process of shortening the length of the work piece to find its diameter and
center. Straight turning is done using a lathe machine so that the diameter is constant over the length of the
work piece. Taper turning is a machining operation where the diameter of the work piece id gradually reduces
from one end to another. Tapering can be external or internal. Thread cutting is a process for generating a
thread or is a process used for the production of threads on the outer surface of a cylinder or the inner surface
of a bore. Tools used for thread cutting are the thread cutting die, the screw tab or for serial production, a
process called cold or hot forming.
Now, the rest of this paper will talk more about the logical steps involved in each process, the methodology of
the work (lab practical), and the analysis of the outcomes

AIM:
To perform various turning operations known as Facing, straight turning, Taper Turning, and Thread Cutting on the given
Mild Steel Workpiece as per the given drawing employing Lathe Machine. Find out the effect of lathe machine velocity,
temperature, and cutting fluid affect the workpiece.

Materials
1. Mild Steed – is used as the work piece
2. Lathe Machine- is a machine use for performing the turning processes.
 3. Cutting tool(feed)- is used to cut threading, straight turning, tapering and facing
4. Cutting fluid- is used as a lubrication for cutting and control friction temperature between cutting tool
and work piece. It also avoids tool teeth from cracking and give good surface finish.
5. Drill- is used to make possible of the work piece to best fit.
6. High Speed Still- use on cutting tool since it is strong.
7. Vanier Caliper- is used to measure the diameter of the work piece to locate the center of the work
piece.
Apparatus;

Figure 1: lathe Machine

Figure 2:
facing Figure 3: Drilling Figure 4: Knurling
Procedures:
Generally, the turning processes were done in the following sequence, Facing, straight turning, Taper Turning
Thread Cutting, and finally knurling. But to be more specific, firstly, prepare the working piece by cutting it to
150 mm long and 23mm diameter and then do facing to prepare the working piece to best fit the stocks.
Measure the facing edge of the working piece using a vainer caliper to find its diameter and locate its center
then find the radius of the workpiece and drill the center to best fit on the stock. Inset the working piece to
the stock on the lathe machine and tighten up the screws. Set the velocity of feed to 425 rpm and perform
plain turning and step turning (straight turning). Reset the velocity of feed to 570 rpm and perform tapering
also the taper angle is 4 degrees. Reset the velocity of feed to 175 rpm and then cut threads. Reset the
velocity of feed to 425 rpm and do profile turning. After profile turning, do knurling at a feed speed of 98 rpm.
RESULTS:
Cutting tool and turning tool Dimension and Speed used
1 feed o.5mm/revolution
2 Depth of cut 1 mm
3 Cutting speed 425 rpm
4 Plain turning 425rpm
5 Step turning 425 rpm
6 Taper turning 570 rpm and 4 degrees
7 Thread cutting 175 rpm and 9 degrees
8 Profile turning 425 rpm
9 Knurling turning 98 rpm

SAMPLE CALCULATIONS:
To save time and make things easier for some cases, there are standards set to do machining easily as shown
below.

But for accuracy, calculations can be done as follows:

FEED SPEED: Vf = s × f × N
Where; s = spindle speed,
f= feed per tooth and
N=number of fluites
SPINDLE SPEED: VS = V ÷ π ÷ D × 1000
Where; Vs = spindle speed
V=cutting speed
D= Diameter
TAPERING ANGLE:
D−d 23−19 4 -1 4
t an ∅=
2L
= 2 ×25
= 50 ∅ = tan ( 50 )= 4.57 0 ≈ 40
πdn
Cutting Speed(V)= 1000 m /min
(23)(425) π
= 1000 = 30. 7m/min or 31 m/min

d 1−d 2
Depth of cut:
2
= 23−19
2
= 4
2
= 2mm
Cutting Time: 1. Find the number of revolution.
N# rev =length of work piece divide feed speed
102
N= = 204 revolutions
0.5
2. time required for a complete cut:
number of revolution ( N ) 204
T=
angular velocity( n)
= 0.5 =0.48 minutes

DISCUSSIONS:
Based on the practice of turning operations done, it was identified that the speed of each turning process
varies with respect to turning processes and material type (i.e. the work piece) used. In terms of work piece,
the velocity of the chuck and spindle decreases with increasing hardness, that is, the stronger the material the
slower the cutting speed and turning speed. Regarding the speed calculated (i.e. 424.7 rpm), the rounded
speed is because the speeds on the lathe machine are standardized and were not equal to those calculated.
Tool life is also vital in metal cutting. Therefore, to prevent cutting tool teeth from damage or cracking, it is
important to control the turning speed and use cutting fluids such as oil and grease to reduce heat, friction,
and cracking of the tool.
In addition, there are four (4) important factors to consider when dealing with a lathe machine. The cutting
speed, feed speed, depth of the cut, and the cutting time as shown or calculated above.
Also, the cutting angle is important in the cutting of taper and thread. Pythagoras Theorem or trigonometric
are used to calculate these angles.

RECOMMENDATION:
Generally, the practice was carried out successfully, and all the results were obtained. This type of practical
given out is good for the students to learn things practically.
However, there were two problems that we faced during the practical. Some of the values of the speed and
angles calculated were not on the machine and we used the rounded data and, the machine used was
outdated and without a proper cooling system and cutting fluids to protect the cutting tools.
However, regardless of the problems and difficulties faced, the lab instructors help us to complete the
practical well and neither the cutting tool nor machine have been damaged.
CONCLUTION:
In any machining process, it is vital to consider important parameters such as cutting speed, material
properties, feed speed, cutting angles, cutting time, and the spindle to choose the right operation. The turning
process is done in many different ways on different materials. It is also important to note that lubrications
such as cutting fluids and coolants are also required to keep temperate at a reasonable level to get a good
surface finish and dimensional accuracy.
REFRENCE:
1. ME 322 lecture notes, Dr. Kamalakanta Muduli Associate Professor Mechanical Engineering Department,
Papua New Guinea University of Technology.
2. https:// CUTTING SPEED, FEED, DEPTH OF CUT, MACHINING TIME IN LATHE MACHINE
3. https: lathe Machine operations
4. ME 322 lab Manual.