FACULTY OF

ENGINEERING AND TECHNOLOGY

Workshop and CNC Technologies

LAB REPORT : LATHE TURNING

NAME STUDENT ID
introduction:

Lathe turning is essential to engineering, especially when producing mechanical parts and components. A variety of items, including shafts, gears,
bearings, and valves, among others, are produced using this method. Due to its adaptability, effectiveness, and accuracy, lathe turning is favoured in
engineering as a technique for producing complicated parts with precise tolerances.

In the lathe turning process, a workpiece is rotated around its axis while a cutting tool is used to mould it into the desired shape. This method is
frequently employed in the manufacturing and metallurgy sectors to produce exact cylindrical, conical, or spherical shapes.

A cutting tool that is fixed in a tool holder is used to remove material from the workpiece while the workpiece is mounted on the lathe machine and
rotates at a predetermined speed. Typically, a carriage moves along the length of the workpiece while controlling the cutting tool to produce the
required shape.[1]

Figure 1.0: Lathe Turning Machine

To form metal components to satisfy certain design criteria, engineers utilise lathe turning. Although it is possible to complete the operation
manually, computer numerical control (CNC) lathe turning has grown in popularity as a result of technological developments. Cutting tool
movements and speeds may be precisely controlled using a CNC lathe, producing products that are reliable and accurate.
Moreover, the repair and upkeep of mechanical components utilise lathe turning. For instance, lathe turning can be used to shape a new shaft to the
necessary dimensions when repairing or replacing a damaged one. Lathe turning can also be used to produce unique components for unique
applications or to swap out obsolete components.[2]

Overall, lathe turning is a crucial engineering procedure that aids in producing the mechanical parts and components required for diverse purposes. It
is essential to the creation, upkeep, and repair of mechanical systems, and its significance cannot be emphasised.

Bed The turning machine's bed is just a sizable base that rests on the floor or a
table and holds the other parts of the machine in place.

Carriage The cutting tool can remove material while moving along the carriage, which
is a platform that glides alongside the workpiece. The carriage is advanced by
a lead screw that is driven by a motor or hand wheel and sits on rails called
"ways" that are laid out on the bed.

Cross slide The tool can move towards or away from the workpiece, modifying the depth
of cut, thanks to the cross slide, which is fastened to the top of the carriage.
The cross slide is propelled by a motor or hand wheel, just as the carriage.

Compound The compound, which holds the cutting tool, is fastened on top of the cross
slide. A tool post that is affixed to the compound holds the cutting tool in
place. To change the cutting tool's angle with the workpiece, the compound
can rotate.

Headstock The machine's front portion, which is attached to the bed, is known as the
assembly headstock assembly. The motor and drive mechanism that powers the spindle
are contained in this unit. The workpiece is held in a workpiece holder or
fixture, such as a chuck or collet, and is rotated and supported by the spindle.

Tailstock The back portion of the machine that is fastened to the bed is called the
assembly tailstock assembly. This assembly's job is to hold up the opposite end of the
workpiece while allowing it to revolve under the spindle's power. In order to
remove material from the end of the workpiece during particular turning
operations, the tailstock is not used to support the workpiece.
Objectives:

1. To produce a workpart using lathe operations.

Procedure:

1. A piece of rod was selected with the suitable dimension.

2. The material was set on the lathe machine.

3. The lathe machine was operated and performed the turning operation according to the drawing dimension in Figure 1.1.

4. Guidance and supervision were provided by the laboratory technician.

5. The instructions given were followed properly when performing the turning process.

6. The quality part was inspected after turning and measurement was performed on the sample.

7. The sample was labelled by our programme, tutorial and laboratory group number.

8. A picture of the completed samples was taken and submitted as our work sample.
 Figure 1.0: Lathing Machining

Apparatus:

Figure 1.1: Lathe Machine

Figure 1.2: Metal file

 Figure 1.3: Sandpaper

Figure 1.4: Metal cylinder

 Figure 1.5: Chalk

Figure 1.6: Paint brush

 Figure 1.7: Vernier calliper

Figure 1.8: Steel protractor

Safety equipments:
 Figure 1.9: Safety goggle

Workflow:
1. A metal rod with a diameter of 32 mm was prepared and clamped properly on the turning machine.
2. The turning machine was then set to the turning speed of 450 rpm to smoothen the end surface of the rod.
3. A marking line was labelled on the rod with a length of 30 mm from the end of the rod.
4. Within this length, the rod was cut until a 20 mm diameter was achieved by a speed of 450 rpm.

Figure 2.0: Cutting Process

5. The machine was set to cut off the rod by 1 mm for 11 times to prevent the cutting from breaking and also to prevent overcutting.
6. A 29mm diameter within 4mm length was obtained by repeating the previous process.
7. The metal rod was then filed and the surface polished using sand paper. The process was performed at the speed of 750 rpm and 1000 rpm
separately.
 Figure 2.1: Before and After Smoothening the Surface

8. Take out the metal rod, rotate it 180° horizontally to expose the unprocessed part and put it back to the jaw chuck.
9. The finished surface was protected by wearing a sleeve outside.
10. Apron was adjusted and the angle is setted to a half angle which is 35° to obtain a 70° tapered cylinder.

Figure 2.2: Adjusting and Setting

11. The cutter was moved back and forth by rotating the apron manually multiple times until the rusted parts were totally removed.
 Figure 2.3: 70° angle of Tapered Cylinder was Shaped

12. Filing and polishing processes were conducted again.

13. The machine was stopped and the lathed metal rod was taken out. The lathing process was completed.

Figure 2.4: Before and After Lathing

Results & Discussion:

Our group was given a metal cylinder. The process of turning was done by 3 parts of the cylinder since each of the three parts have its specific
dimensions and method in the way the lathe operation is performed on the metal cylinder. The lathe was ensured to be stopped first whenever
adjustments were made from time to time in order to secure the safety of our members. Goggles are very important when the cutting is carried out
since the chips were aggressively flying off while the turning process is ongoing. Most of our members also got burned slightly at our hands as the
chips flew off since we were too close to the lathe machine when the process was going on.

Two types of turning were applied which are facing and taper. Facing was done to machine the end of the metal cylinder that is perpendicular to the
rotating axis. The taper turning was carried out to create a conical shape. During the cutting process, the technician stopped the machine to change
the cutting tool only to realise that the cutting tool has some wear. There are two types of wear which is crater wear and flank wear. Crater wear
occurs due to friction and pressure whereas flank wear occurs at the tip of the cutting tool due to friction between the chips and the surface of the
cutting tool. When the turning was carried out, a high pitched squeaking sound was produced by the lathe machine which was due to the vibration of
the cutting tool. Therefore, the chips should be removed from time to time as chips absorb heat. We were also taught by the technician that 98% of
the energy in turning is converted to heat. The remaining 2% of the energy is stored as elastic energy.

Figure 2.5: Top view of the metal cylinder after lathing process
References:

1. Xometry.[online]. Turning in Machining: Definition, Types, Advantages, and Disadvantages. Available at:
<https://www.xometry.com/resources/machining/what-is-turning-in-machining/#:~:text=Turning%20is%20a%20machining%20process,with
%20a%20CNC%20turning%20machine.>[Accessed 24 March 2023].

2. CustomPartNet.[online]Turning Process, Defects, Equipment. Available at:

<https://www.custompartnet.com/wu/turning> [Accessed 24 March 2023].