Name of the Experiment:

Objectives:
i. To learn how to operate the lathe machine which requires turning, boring, facing
operations.
ii. To understand and undergo the turning, boring, facing process.
iii. To perform turning, boring, facing operation on a given cylindrical work-piece using
lathe machine

Machine: Lathe or Milling machines

Tools: sine bar, gage blocks, 6 inch dial caliper, steel ruler, fly-cutter (3’’ diameter)
high-speed end mill (1/2"), edge-finder (0.2’’).

Material: Aluminum block (approximately 2"x3")

Introduction: About lathe or Milling machine

The lathe is a machine tool used for shaping pieces of metal (and sometimes wood or other
materials) by causing the work piece to be held and rotated by the lathe while a tool bit is
advanced into the work causing the cutting action. The basic lathe that was designed to cut
cylindrical metal stock has been developed further to produce screw threads, tapered work,
drilled holes, knurled surfaces, and crankshafts. Modern lathes offer a variety of rotating speeds
and a means to manually and automatically move the cutting tool into the work piece. The lathe
cutting tool or tool bit must be made of the correct material and ground to the correct angles to
machine a work piece efficiently. The most common tool bit is the general all-purpose bit made
of high-speed steel. These tool bits are generally inexpensive, easy to grind on a bench or
pedestal grinder, take lots of abuse and wear, and are strong enough for all-around repair and
fabrication. High-speed steel tool bits can handle the high heat that is generated during cutting
and are not changed after cooling. These tool bits are used for turning, facing, boring and other
lathe operations. Tool bits made from special materials such as carbides, ceramics, diamonds,
cast alloys are able to machine work pieces at very high speeds but are brittle and expensive for
normal lathe work. High-speed steel tool bits are available in many shapes and sizes to
accommodate any lathe operation.

Figure

Operations/Methods:

1. Work piece is given by the assistant engineer.

2. Brief explanation by assistant engineer on how to operate the lathe machine.
3. Take a dimension of the work-piece and compare with given dimension and drawing.
4. Apply safety tools.

A. Secure the work-piece in the table of the milling machine/…………………………. using the
vice.
1. Clean milling machine /……………………………..vise thoroughly.
2. Place parallels under the work-piece to raise the surface to be milled above the level of the
vise jaws.
3. After the work-piece is in place, tighten the vise securely, then tap the work-piece lightly
with a dead blow hammer to seat it. Do not tighten the vise again because this would alter
the position of the work-piece and tightness of the parallels.

5. Design the work piece according to the given drawing and given measurement including
turning, milling ………………………….
6. Start operating the lathe/…….. machine.

B. Machine Setup
 1. Check the diameter of the cutter with vernier calipers.
2. Calculate RPM for cutting speed = 140 ft/min.

3. When using the White Chevalier Mills.

Set the speed of mill by adjusting the RPM knob and reading the speed on the analog meter.
“H” and “L” scales represent high and low gear ranges.
Note: do not cut at a speed lower than 500 rpm while in the high gear range.
(Check with the lab instructor to verify your setup before you continue).

4. Calculate feed (in inch/min) for a feed per tooth = 0.003".

Feed= feed per tooth x no. of cutter teeth x RPM
Note: Power feed: speed is displayed on the digital readout. Adjust with the dial

while moving away from your part.

If power feed is not available, use handles for manual feed.
Note: The direction of feed is optional on a vertical milling machine.

C. Milling the top surface using fly (face milling) cutting

1. Before starting the machine, be sure the cutting tool is clear of the work-piece. If not, lower
the work-piece by lowering the knee.
2. Move the table with the x and y axis handles to position the workpiece under the cutter.
3. Lower the cutting tool or raise the table using the crank until it touches the top surface of the
work-piece gently.
4. Set the micrometer dial on the knee to zero.
5. Lower the table by 0.020”, by turning the knee handwheel counters clockwise.
6. Move the table longitudinally so that the cutter is clear of the work-piece at either end.
7. Turn the machine on.
8. Raise the table (or lower the cutter) 0.030" (1 graduation is 0.001") from zero so that the
final thickness of the work-piece is 0.970"±0.002". Use multiple cuts and monitor the
thickness of the work-piece.
 9. Engage the power feed with the lever. Note: Table travels in the direction of the feed
engagement lever.
10. After work-piece has been milled on the top surface, disengage power feed and turn spindle
off.

D. End milling of slots

1. Replace the face mill cutter with an edge finder (run the edge finder above 1K rpm)
2. Touch the corners of the workpiece to set the origin of the workpiece (the lab instructor will
demonstrate the procedure). Consider the diameter of the edge finder and offset the zero
point accordingly.
3. Replace the edge finder with a 1/2" end mill.
4. Make a slot 1 (through slot) as shown in Figure using the same procedure in C.2-C.10. The
cutting speed should be 50 ft/min and depth of the slot should be 0.10". You will need
multiple cuts.
5. Make the slot 2 as shown in Figure using the same procedure in C.2-C.10. The depth of slot
should be 0.050".
E. Slope machining

1. Use a sine bar to set up the workpiece to be tilted at 100.

2. Use the 1/2" end mill or a fly cutter to generate the slope using multiple path cuts.

7. Take a final measurement.

8. Do finishing for the work piece.

9. Keep tools in safety toolbox.

10. Clean the metal pieces around the machine with brush & broom.

Results
1. When we compare the length sample of the product with the product produced , there are
slightly differences in the result.

2. In length A the sample of product is 60 mm but the length of product produced is

59.4mm and the tolerances is 0.6mm which is considered as medium class. In C , the
diameter should be 10mm but the product produce that we did is 11mm. Meanwhile in
D , the length should be 30mm but the product produce is 30.6mm and the tolerance is
consider as medium class. The rest, which is length B , E , F, G, and H tolerances is
consider as fine class for there is no differences when we compare to the product
produced with the sample product.
Discussion

As we can see there are some differences in the length and the surface of the product produced
when we compare with the sample product. There can be some of reasons or errors why there
some differences. Firstly, the rotating speed, it is highly advised to ensure the material
thickness , tool and the speed compatibility to achieve accuracy. Secondly, human error where
human do make mistakes when they read or take the measurement using vernier calliper. Other
than that, there are some possibilities of lack of sharpness of the cutting tools which makes the
surface a bit rough. Finally , lack of experience using turning machine, this is also the cause of
the differences between the product produced with sample product. There are also some
problems occurs during the process which is , we accidentally overcut the product which causes
differences in the length. We also have to use a another specimen to cut the angle just to ensure
we don’t make mistakes on the real specimen we did due to lack of experiences .

Conclusion

In conclusion, the project has provided us the knowledge regarding the turning process which is
a form of machining and removing several parts of a material by cutting away unwanted parts in
a rotational motion way. This process involved a machine called turning machine or lathe
machine. During the workshop session, we have been taught on how to use and handle the
machine properly and safely.

Many things we learnt while carrying out the turning process including the cutting parameters of
the process. These parameters are listed as the cutting feed, cutting speed, spindle speed, feed
rate, axial depth of cut and the radial depth of cut. These specification aspects are highly
essential as it will determine the value of the end product of out workpiece. Furthermore, we also
have been told the right techniques to handle the components of the lathe machine and the
correct way of using the tools in the tool box. The most important thing is the safety of the
student while handling the machine. We have been briefed about the safety measures that took
place during the finishing of our product and asked to strictly follow the instruction given by the
assistant engineers. Lastly, we suggest that in the future the details about the importance of
turning process and the usage of lathe machine should be taught in a more specific ways. Also
we hope that with the knowledge obtained during workshop, we can manage to use effectively
the skills so that we can manufacture a more accurate and valuable product in the future.

Safety Precautions

• Correct dress is important, remove rings and watches, roll sleeves above elbows.
• Always stop the lathe before making adjustments.
• Do not change spindle speeds until the lathe comes to a complete stop.
• Handle sharp cutters, centers, and drills with care.
• Remove chuck keys and wrenches before operating
• Always wear protective eye protection.
• Handle heavy chucks with care and protect the lathe ways with a block of wood when installing
a chuck.
• Know where the emergency stop is before operating the lathe.
• Use pliers or a brush to remove chips and swarf, never your hands.
• Never lean on the lathe.
• Never lay tools directly on the lathe ways. If a separate table is not available, use a wide board
with a cleat on each side to lay on the ways.
• Keep tools overhang as short as possible.
• Never attempt to measure work while it is turning.
• Never file lathe work unless the file has a handle.
• File left-handed if possible.
• Protect the lathe ways when grinding or filing.