FACULTY OF MECHANICAL AND MANUFACTURING
ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
Course Code & Name BDA 18201 MECHANICAL WORKSHOP 1
Code & Title of Experiment GROUP PROJECT (TURNING)
Date of Experiment
Programme
Group Members
ASSESSMENT
1
INTRODUCTION /5%
SAFETY PRECAUTIONs /5%
METHODS AND SOP /40%
ANALYSIS AND FINAL PRODUCT /40%
DISCUSSIONS /5%
CONCLUSION AND /10%
RECOMMENDATION
TOTAL /100%
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INTRODUCTION
A lathe /leɪð/ is a tool that rotates the workpiece about an axis of rotation to perform
various operations such as cutting, sanding, knurling, drilling, deformation, facing, turning,
with tools that are applied to the workpiece to create an object with symmetry about that axis.
Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, parts
reclamation, and glass-working. Lathes can be used to shape pottery, the best-known design
being the potter's wheel. Most suitably equipped metalworking lathes can also be used to
produce most solids of revolution, plane surfaces and screw threads or helices.
Lathes consist of components such as a tailstock, tool rest and headstock. The
material was placed in between the tailstock and the headstock. The material is then turned
and curved to make different shapes by controlling the shaping tool. Lathes are also used to
cut threads, drill different shapes like conical, cylindrical, mill ends, drill and bore openings
among many other functions. Lathes can be controlled manually or with auto-system.
Lathe is a machine tool that use to cut a work piece by turning process. Turning
typically involves roughing procedures followed by a finishing operation. Each component
has its function. Bed is use to support major components, carriage is use to slides along the
ways and it consist of the cross-slide, tool post, and apron. The headstock holds the jaws and
has various drives speed. The tailstock are used to support the other end of workpiece. In
lathe, there is many type of operation lathe which is:
Turning : produce straight, conical, curved, or grooved workpieces
Facing : to produce a flat surface at the end of the part or for making face grooves.
Boring : to enlarge a hole of cylindrical cavity made by a previous process or to produce
circular internal grooves.
Drilling : to produce a hole by fixing a drill in the tailstock
Threading: to produce external or internal threads
Knurling: to produce a regularly shaped roughness on cylindrical
Cutting off: to cut off a work piece
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SAFETY PRECAUTION
1) Proper PPE were used during operation on lathe machine
2) All loose wearing were removed
3) Materials to be machined shall be securely fastened or clamped to the working surfaces
before starting the machine.
4) Ensure machine is fully stopped before making speed adjustment
5) Ensure the workpiece is put centered in the faceplate
6) Ensure cutting tools is aligned and tightened
7) Use proper speed depends on type of material
8) Handle sharp cutters, centers, and drills with care.
9) Remove chuck keys and wrenches before operating
10) Know where the emergency stop is before operating the lathe.
11) Use pliers or a brush to remove chips and swarf, never your hands.
12) Never lean on the lathe.
13) 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.
14) Never make unwanted loud noise to avoid startling person nearby
15) Do not skylark
16) Never leave machine unattended when in operation
17) Do not attempt to screw chuck on lathe spindle with power on, as it may get cross-
threaded and cause an accident.
18) Do not attempt to adjust a tool while the
lathe is running.
19) Operators shall not attempt to use
micrometers on revolving work21)
20) Watch for hazard sign such as rotating
hazard.
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METHOD AND SOP
Measuring
Before start the process, the length, thickness and wide of the work piece given is
measured and recorded. The length of the work piece was measured for fifth times to
make sure that the workpiece given have the correct and accurate length, thickness
and wide. The length of the work piece had been measured for multiple time to make
sure the accuracy of measurement.
Turning Process
1) Each person is provided with 60mm tubular aluminum workpiece
2) Lathe machine layout were set up
3) The tools were set in the respective position and rotation were checked to
ensure rotate in balance motion
4) Drawing were referred to avoid any unwanted cut made
5) Motor were switched to start the cutting process.
6) The bottom part and top part were determined
7) Make the step turning operation as per the given dimension
8) For angled cutting part, cutting angle were adjusted to 15 Degree to give a
tilted cut at the top section.
9) Chamfer the corners and check the dimension.
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ANALYSIS AND FINAL PRODUCT
The final product is measured by using a vernier caliper to get the most accurate
reading and recorded in a table (Table 1)
ELEMENTS 1 2 3 4
Part Length 60mm ±0.3 60 59.95 60 59.98
Side (20mm) ±0.4 20.5 20 20 20
Side (23mm) ±0.4 23 22.9 23 23
Side (15mm) ±0.4 15 15 15.1 64
Angular 15⁰ 64 64 64 64
Table (1)
From this table, because of some parallax error or zero error not calculated when
using the vernier calliper, we will obtain some inaccuracy in the measurements.
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DISCUSSION
The main idea of doing this workshop is to expose student with the basic kind of mechanical
machine techniques. Turning is the most common form of machining, a material removal
process, which can create a variety of features on a part by turning the material on lathe
machine. The turning process requires a lathe machine, workpiece, fixture and cutting tools.
The workpiece is a piece of tubular type aluminium that is secured to the headstock, where
the workpiece will be rotated. The cutter is a cutting tool with sharp teeth that is also secured
at tool post and the rotated workpiece will be cut my moving the cutting tool
The main idea of doing this workshop is to expose student with the basic kind of
mechanical machine techniques. It is also train student to obey with the rule during the
workshop and always apply the individual safety first. Safety precaution in workshop is
followed and the turning process went smoothly without any problem that may produce
defects to the workpiece. Before operating the machine students should check the machine
whether it is safe and appropriate by clean and lubricate the machine. Be sure all guards are in
position and locked in place. 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 aluminium the
turning speed is set to low to make sure workpiece is at smooth finishing surface.
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CONCLUSION AND RECOMMENDATION
By the end of the project, we can know the working principles of the Lathe Machine.
In a lathe machine the operations, which are done is defined as a job. The job is held in a
chuck or between centres and rotated about its axis at a uniform speed. The cutting tool held
in the tool post is fed into the workpiece for a desired direction. Since there exists a relative
motion between the work-piece and the cutting tool, therefore the material is removed in the
form of chips and the desired shape is obtained. In our project, it was based on the lathe. The
most common operations which can be carried out on a lathe that we should know are facing,
drilling, turning, boring, knurling, chamfer ,taper turning and tapping. Facing is almost
essential for all works. In this operation, the work piece is held in the chuck and the facing
tool is fed from the centre of the work piece towards the outer surface or from the outer
surface to the centre, with the help of a cross slide. The major parts of lathe machine are bed,
headstock, tailstock, carriage, it have five major parts. They are a saddle, cross-slide,
compound rest, tools post, apron. Lastly, power feed and thread cutting mechanism. As
we know, practice made things perfect. To get the best result sof the project, we must practice
all out before starting our project. Besides, we needed extra time to finish the project to get
the best results. This will give us more experienced about lathe processes.
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