Errors in machining

operations:
Causes and remedies.
Errors may cause inaccurate dimensional accuracy and surface
roughness of the feature in the machining operations. Some possible
causes of such defects and their remedies in lathe, milling and
shaping operation are discussed below:

 Incorrect cutting parameters - If the cutting

parameters such as the feed rate, spindle speed or depth of
cut are too high, the surface of the workpiece will be rougher
than desired and may contain scratch marks or even burn
marks. Also, a large depth of cut may result in vibration of
the cutter and cause inaccuracies in the cut.
 Neglecting optimum cutting speed: Higher feed
rate and cutting speed will decrease the tool life and tool cost will
be increased. And lower feed rate and cutting speed will minimize
the production rate. So, an optimum cutting speed and feed rate is
a must to achieve the minimum tool cost and maximum
production.

 Dull cutter: As a cutter is used, the teeth will wear down

and become dull. A dull cutter is less capable of making precision
cuts.
 Unsecured work-piece: If the work-piece is not securely
clamped in the fixture, the friction of milling may cause it to shift
and alter the desired cuts.

 Alignment Error: The alignment between two centers (live

and dead center) is very essential during lathe operations. Otherwise,
the work piece will be dumbbell shaped. To eliminate this, the work
piece must hold carefully between two centers & the two centers
must be aligned and true with the center of the job.
Lubricants- Types &
applications:
What Is Lubricant??

-A lubricant is a substance introduced to reduce

friction between surfaces in mutual contact, which
ultimately reduces the heat generated when the surfaces
move. It may also have the function of transmitting
forces, transporting foreign particles, or heating or
cooling the surfaces.
Types Of Lubricants:

Lubricants can be subdivided into three major types depending

on their application on the machine tool:

Coolant Fluids
Lubricant Fluids
Cutting Fluids
Coolant Fluids:

A coolant is a fluid which flows through a device in

order to prevent its overheating, transferring the heat
produced by the device to other devices that utilize
or dissipate it.
Lubricant Fluids:
A lubricant is a substance (usually a l liquid)
introduced between two moving surfaces to reduce the
friction and wear between them.

Applications:
 Keep Moving parts Apart: A lubricant provides
a protective film which keeps apart two moving
parts.
Continued...
 Reduce Friction: Typically the lubricant-to-surface friction is
much less than surface-to-surface friction in a system without
any lubrication. Thus use of a lubricant reduces the overall
system friction. Reduced friction has the benefit of reducing
heat generation and reduced formation of wear particles as well
as improved efficiency.

 Transfer Heat: Both gas and liquid lubricants can transfer heat.
However, liquid lubricants are much more effective on account of
their high specific heat capacity. Typically the liquid lubricant is
constantly circulated to and from a cooler part of the system.
Continued…
 Transmits power: Lubricants known as hydraulic fluid are
used as the working fluid in hydrostatic power transmission.

 Prevent Corrosion: Good quality lubricants are typically

formulated with additives that form chemical bonds with
surfaces, or exclude moisture, to prevent corrosion and rust. It
reduces corrosion between two metallic surface and avoids
contact between these surfaces to avoid immersed corrosion.

 Seal for gas: Lubricants will occupy the clearance between

moving parts through the capillary force, thus sealing the
clearance. This effect can be used to seal pistons and shafts.
Cutting Fluids:
Metal Cutting Fluids are liquids used to cool and lubricate the
cutting edges of machine tools and the pieces they are shaping. It’s is
pumped over the cutting site of machines such as lathes, milling machines,
grinding machines or saws.
Benefits of using cutting Fluids:

The use of cutting fluids reduces friction and heat. The removal of the heat
Improve Part prevents the work piece from expanding during the machining operation,
Quality which would cause size variation as well as damage to the material’s
microstructure.
Proper use of cutting fluids increases tool life, which reduces the tooling
Reduce tooling
costs. Increased tool life also reduces tool changes and downtime which
costs
decreases labor costs.
Increase Cutting Cutting tools reduce friction and heating a machining operation. This
Speeds and allows high speeds and feeds to be used to achieve optimal cutting
Feeds conditions.
Effective use of cutting fluids helps remove the chips. This prevents the
Improved
chip from being caught between the tool and work piece where it causes
Surface Finishes
scratches and a poor surface finish
Bacteria can drastically affect cutting oils. Bacteria growth can turn a
Reduces
cutting fluid rancid. Additives in coolants help reduce the effects of
Bacterial Growth
bacteria, but it is important that pure water is used for coolant mixing.
Rust and Cutting fluids should protect the tooling, machine, and work piece against
Corrosion rust and corrosion. Cutting fluids should leave a small residual film that
Prevention remains after the water has evaporated.
-The End