COURSE NAME CONVENTIONAL MACHINING

COURSE CODE MMK 22104 LAB No. 2

LAB MODULE
TURNING OPERATION

PREPARED BY:

Name Matric No. Group

FARIS IZZUDDIN BIN AMRAN 231311024 A (MONDAY)

Section Marks
Objective /2
Introduction /4
Procedure /5
Results / 70
Discussions / 10
Conclusion /5
References /2
Appendix and formatting /2
TOTAL MARKS /100
FACULTY OF MECHANICAL ENGINEERING
TECHNOLOGY
 1. OBJECTIVE

1) To run a lathe for the purpose of straight turning.

2) To become familiar with the impact of machining on accuracy and surface polish.
3) To produce a machine part by using lathe machine from a mild steel.
2. INTRODUCTION

1.1 Turning machine

1.1.1 Principle of turning machine
Turning is a type of machining, also known as material removal, that is used to create
rotating parts. The process of turning involves rotating the cutting tool in tandem with the
work piece's linear motion to create cylindrical parts. Turning, which is often done with a
lathe machine, decreases a workpiece's diameter to a set of dimensions and produces a
smooth component finish. Turning is frequently employed as a secondary procedure to
assemble or improve the performance of a component that was installed earlier using a
different technique. In the metalworking business, one of the most popular machine tools is
the lathe. Round workpieces and a stationary cutting tool are the basis of its operation. After
the cutting tool is introduced, the workpiece spins on its own axis to take on the required
shape by turning the workpiece in opposition to a fixed lathe. Chip removal is the machine's
primary function when it comes to superfluous material. This is accomplished by fastening
and firmly gripping the workpiece on the machine, then rotating it in opposition to the
cutting tool to extract the metal. The instrument must be tougher than the material of the
work piece that is firmly mounted on the machine and feed or advance in a specific way in
relation to the work in order to cut the material correctly. Each component of a lathe machine
carries out crucial functions as listed below:

Figure 1: Turning Machine

 3. RAW MATERIAL, EQUIPMENT AND SAFETY ATTIRE

1. Raw material: Mild steel workpiece diameter Ø 50 mm x 90 mm.

2. Equipment: Lathe machine with accessories, cutting tools, hand tools, vernier caliper.

3. Safety attire: Safety goggle, safety shoe, protective shop caps.

4. PROCEDURE

1) Precautions for safety during machine operations.

i. Remove any watches, rings or bracelets that may become entangled in the machine.
ii. Long hair must be covered with a hair net or certified store hats. Unprotected hair being
entangled on a turning machine is one of the most prevalent mishaps stuck in the whirling
machines.
iii. When using the machine, always use authorized safety glasses or goggles. Make certain the
glasses are in fantastic condition and clean.
iv. Always wear appropriate footwear; no slippers are permitted in the workplace.
v. Keep your hands away from moving parts. It is unsafe to 'feel' the surface of a spinning
workpiece or to manually stop a machine.
vi. Always turn off a machine before measuring, cleaning, or adjusting it. Any form of labour near
moving parts of a machine is hazardous.
vii. Keep the floor clean and free of oil and grease. Grease and oil on the floor can lead to deadly
slips and accidents.
viii. Seek medical attention quickly for any injuries, no matter how minor. Report the damage and
ensure that even the smallest cut is treated to avoid dangerous infection.
ix. After machining, clean the machine, the floor, and the tool rack. Report any broken items and
repairs that are required.

2) Check the condition of your machine. Check first! Do not use any equipment unless you
understand its functioning and know how to swiftly stop it using the emergency stop button.
Knowing how to rapidly stop a machine might help you avoid a major disaster.
3) Clamp the workpiece to the chuck jaws at the headstock.
4) Attach the appropriate cutting tool to the tool holder. Insert the tool holder into the tool post
and adjust the cutting tool to meet the stock slightly above the stock's centerline.
 5) Set the machine's spindle speed and feed rate.
6) Begin machining operations for the centre hole, face, and straight turning to the desired
dimension. Surface roughness of the component for rough cut of straight tuning operation
should be seen, checked, and recorded.
7) Unclamp the workpiece and clean up any sharp edges.
8) Observe, verify, and document the measure the portion with a Vernier caliper and surface
roughness of the finished component.
9) Clean the machine using the correct tools.

5. PRODUCT DRAWING

Figure 2: Product Drawing

 6. RESULTS

1. Submit your final product to the instructors.

2. The final measurement of the product will be evaluated by the instructors. Please leave
blanks in the Table below.

ACTUAL
NO. DIMENSION MARKS
DIMENSION
Dia 0 1 2 3 4 5
1 Dia.26 X 25mm
Length 0 1 2 3 4 5
Dia 0 1 2 3 4 5
2 Dia.30 X 20mm
Length 0 1 2 3 4 5
Dia 0 1 2 3 4 5
3 Dia.26 X 20mm
Length 0 1 2 3 4 5
Dia 0 1 2 3 4 5
4 Dia.22 X 25mm
Length 0 1 2 3 4 5
Dia 0 1 2 3 4 5
5 Dia.18 X 20mm
Length 0 1 2 3 4 5
Dia 0 1 2 3 4 5
6 Dia.10 X 10mm
Length 0 1 2 3 4 5
7 15° X 25mm Length 0 1 2 3 4 5
8 145mm Length 0 1 2 3 4 5

TOTAL / 70

Measurement
0 - Exceed 0.6 mm 1 - Between +- 0.6 mm 2 - Between +- 0.5 mm
3 - Between +- 0.4 mm 4 - Between +- 0.3 mm 5 - Between +- 0.2 mm
7. DISCUSSIONS

1. Make a discussion about the result. Elaborate the result and give a reason or explanation for
any observation and data that you achieved.

The diagram shows the process carried out when using a turning machine

The workpiece was inserted into the Clean the surface of the workpiece
workpiece holder at the spindle
 Analysis and final product:

EXPERIMENT 1 EXPERIMENT 2

EXPERIMENT 1 EXPERIMENT 2
1) Spindle speed (RPM) 870rpm 870rpm
2) Roughness medium medium
3) Initial Diameter (mm) 20 mm 30 mm
4) Initial Length (mm) 95 mm 90 mm
5) Final Diameter (mm) 26 mm 25 mm
6) Final Length (mm) 145 mm 140 mm
Table 1: Result obtained from the experiment
From this table, there are some errors when making experiments which are measurement
inaccuracies where the work material may be thicker or less due to measurement factors and cuts that
are not accurate and do not follow the specifications set by the table.

Discussion:

The primary goal of this workshop is to familiarize students with fundamental mechanical
machine techniques. Additionally, it teaches students to follow all rules during the workshop
and to put their own safety first at all times. The turning process went without a hitch and didn't
result in any issues that could have led to workpiece defects because safety precautions are
followed in the workshop. Prior to using the machine, students should clean and lubricate it to
ensure that it is appropriate and safe. Verify that every guard is positioned and secured. Turn
the spindle over by hand to be sure it is not locked nor engaged in back gear. Then move the
carriage along the ways. There should be no binding. Check cross slide movement. Mount the
desired work holding attachment. Adjust the drive mechanism for the desired speed and feed.
Due to low hardness level in aluminum the turning speed is set to low to make sure workpiece
is at smooth finishing.
2. Identify the defects on your product and discuss what are their possible causes.

Workpiece defects during the lathe turning operation can be caused by a several of
factors, such as material characteristics, tool wear, machine settings, and operator
skills. Defect identification is a must for quality control and troubleshooting. These
are a few common defects that can happen during turning operation.

1. Chatter or Vibrations
Vibration or chatter can cause surface irregularities on the workpiece and, in
the worst cases, even cause damage to the workpiece or the lathe. Chatter may
be caused by an improper tool setup, excessive cutting forces, or a lack of
rigidity in the lathe or workpiece setup. Optimizing tool geometries, lowering
cutting forces, and making sure the setup is stable are all necessary to reduce
chatter.
2. Surface Cracks
Surface cracks might occur during turning, especially when working with
brittle metals and other materials that are prone to cracking. Improper cutting
speeds or high cutting temperatures typically leads to crack.
3. Workpiece Damage
The workpiece damage occurs when the workpiece is not clamped properly,
the grip of the jaws of the chuck cannot withstand the weight of the material.
The workpiece then may experience the positional changes and no longer well
centered or aligned with the lathe's axis of rotation.
4. Tool Damage
Improper clamping can cause the unintentional contact between the cutting
tool and the workpiece. This may lead to breakage or chipping of the tool. It
may also lead to dimensional errors and poor quality of the surface finishes.
5. Tool Marks
Poor clamping can cause the workpiece to vibrate or shift during machining,
which could bring it into unexpected contact with the cutting tool and leave
visible tool marks on the surface.
 8. CONCLUSION

At the end of this project, I will be able to understand how a lathe machine operates. Work is defined
as what gets done on an operating lathe. The work is rotated on its axis at a constant speed while being
held in a chuck or between centers. The cutting tool is inserted into the workpiece in the desired
direction while it is held in the tool post. The material is removed as chips and the desired shape is
achieved because of the relative movement between the workpiece and the cutting tool. We should be
aware of the most frequently performed lathe operations, which include facing, drilling, turning,
boring, knurling, chamfering, taper turning, and tapping. Facing is necessary for nearly all tasks. Using
a cross slide, the facing tool is fed either from the outer surface to the center of the workpiece or from
the center to the outer surface while the workpiece is held in the chuck. The lathe is composed of five
main parts: the bed, headstock, tailstock, and carriage. Saddles, tool posts, aprons, compound breaks,
and cross slides are some of them. Lastly, the thread cutting and power feed mechanism. I carefully
measure it to ensure that the measurements are correct and what I want in order to get the best results.
To get the best results, I need more time to finish the project. I will gain more knowledge about the
turning process as a result of this.

9. REFERENCES

1. https://www.scribd.com/document/402282704/Turning-Report

2. https://www.xometry.com/resources/machining/types-of-turning-operations/

3. https://www.slideshare.net/sitikhairiyahsulaiman/lab-report-1-turning

4. https://www.custompartnet.com/wu/turn
10. APPENDIX