WORKSHOP REPORT

CODE &COURSE:

JJ103 MECHANICAL WORKSHOP PRATICAL 1

NAME/MATRIC: NUMBER

NAME MOHAMAD FADHIL BIN ZULKIFLI

MATRIC NUMBER 15DKM12F1011

CLASS:

DKM 1A

GROUP:

GROUP 1

EXAMINER:

ENCIK ZAHIRAN BIN HAMZAH

SUBMISSION: DATE

8 / 10 / 2012

MARKS:

RECEIVED:

TITLE: MACHINING A TAPERED SHAFT.

INTRODUCTION
Topic: Lathe Machine

Figure1: Lathe Machine

Lathe machine is a machine which rotates the work piece on its axis to perform various operation such as cutting, knurling, drilling, or deformation. The tools are applied to the work piece to create an object which has symmetry about an axis of rotation. The picture as show in figure 1.

The explain about lathe machine how to use with workpiece and keep safety:-

Machine tool which spins a block of material to perform various operations such as cutting, sanding , knurling, drilling or deformation with tools that are applied to the work piece to create an object which has symmetry about an axis or rotation.

Carriage is assembly that moves the tool post and cutting tool along the ways Carriage Hand wheel is a wheel with a handle used to move the carriage by hand by means of a rack and ponion drive. Apron is the front part of the carriage assembly on which carriage hand wheel is mounted. An adjustable horizontal metal rail the tool rest between the material and the operator accommodates the positioning of shaping tools, which are usually hand-held. With wood, it is common practice to press and slide sandpaper against the still-spinning object after shaping to smooth the surface made with the metal shaping tools. Metal is removed from the workpiece using a hardened cutting tool, which is usually fixed to a solid moveable mounting called the "toolpost", which is then moved against the workpiece using handwheels and/or computer controlled motors.

OBJECTIVE

At the end of the session the student will be able; i) To exposes the student to aperate the lathe maching for various machining processes and practice measuring skills.

ii) To exposes the students to tool bits grinding (off hand grinding). iii) To operate the lathe maching for various machining processes: iv) Facing. Centre drilling. Knurling. Straight turning. Chamfering. Tapered turning. Students need to keep safety in the workshop.

TOOLS EQUIPMENT

1. Table Grinder.

2. Cutting Tool Holder.

3. Knurling Tool.

4. Vernier Calliper.

5. Chuck Tightened.

7. Tool Holder Tightened.

8. Driling Tool.

9. 13mm Wrench.

10. Round Bar.

11. Toolbit Set 1/4 inch Square HSS.

12. Tool Holder.

SAFETY PRECAUTIONS

1. Before starts any work in the works, permission must b e obtained from the Lecturer. 2. Understanding its mechanism and knowing how to stop a machine quickly by using emergency stop button. 3. Wear a safety glasses for eye protection. 4. Wear a suitable clothes to avoid from injured. 5. Do not wear a ring or watches. 6. Make sure wear a safety shoes to protect from a small chip or sharp chips. 7. Never have more than one person operate a machine at the same time. 8. Use the machine very properly and keeps hands away from moving part. 9. Always stop machine before measuring, cleaning, or making adjustment. 10. Switch off mainsuis before leaving the workshop.

DISCUSSIONS
Here we discuss about lathe round bar and bar lathe ways round. To solve this problem we need to follow the following steps. If there are problems we can discuss the problem. For example, lathe right round bars with a diameter not be shared. We need to set the cross slide handwheel meter diameter shared the corresponding amount. in addition, the problem lathe tool is broken. We can use the remnants of the lathe tool. Then we sharpened again. apart from the above discussion, we can share to solve the problem. This is the case, we discuss the group. that is where we can share our incomes and skill that we can do. This discussion, we hope to solve the problem. We have to divide their work to each person. With this we can facilitate practical work.

CONCLUSIONS

Conclusion, we must be vigilant to the work of the workshop. Our own gain skills for heavy work. This is the training that we have to improve the skills individual. We get the facilities in heavy work. Then we can master the skills to us and we can quickly understand.

REFERENCES

1. http://www.americanmachinetools.com/lathe_diagram.htm . (6.10.2012) 2. http://www.technologystudent.com/equip1/mlathe1.htm . (6.10.2012) 3. http://www.slideshare.net/AZIZCO/lathe-machining-presentation. (6.10.2012) 4. http://www.lathes.co.uk/latheparts/index.html. (6.10.2012) 5. http://en.wikipedia.org/wiki/Metal_lathe. (6.10.2012)

PROCEDURE

PROCEDURES
Setting up the machine : 1. Switch on the main power supply. 2. Switch on the coolant of the machine. 3. Make sure the coolant flow is good. 4. Make sure the headstock assembly in the good order. 5. Make sure to pull up the movement knob so the chuck is moving in perfect order. 6. Check the angle of tool post and carriage in zero degree angles. Facing for cylinder ends : 1. Set up the machine. 2. The cutting tool is attached to the tool holder. 3. Set the speed up approximately 900rpm. 4. The work piece is attached to the chuck. 5. Start the facing process for the first side (right side) of the cylinder. 6. Take out the work piece and measure exactly 100mm length from the end of facing area. 7. Start the facing process for the second sides (left side) of the cylinder until the work piece are exactly 100mm. Straight turning for 22mm diameter : 1. Set up the machine and make sure in a good condition. 2. Attached the cutting tool on the tool holder. 3. Set the speed up to approximately 900rpm. 4. The work piece is attached to the chuck. 5. Start the straight turning process for the first (right side) of the cylinder until the diameter reach 22mm. Open the chuck and take out the work piece out. Fit in the work piece in to the chuck for the second side (left side) and repeat the straight turning (no 1 to 5) for it.

DIAGRAMS

Straight turning for 15mm diameter : 1. Set up the machine. 2. Attach the cutting tool to the tool holder. 3. Set the speed up to approximately 900rpm.

4. The work piece is attached to the chuck. 5. Start the straight turning process until
the diameter reach 15mm and length 20mm from the end of the facing face.

Straight turning for 10mm diameter : 1. Set up the machine. 2. Attach the cutting tool to the tool holder. 3. Set the speed up to approximately 900rpm. 4. The work piece is attached to the chuck. 5. Start the straight turning process until Knurling for 22mm diameter : 1. Set up the machine. 2. The knurling tool is attached to the tool holder. 3. Set the speed up to approximately 60rpm. 4. The work piece is attached to the chuck and make sure that the right side (the one with 10mm and 15mm diameter)is free around 65mm. 5. Knurling process is started until reach length 25mm from the knurling starting point. Center drilling process : 1. Set up the machine. 2. The drill tool is attached to the barrel of the tail stock. 3. Set the speed up to approximately 60rpm. 4. Make sure the work piece is attached to the chuck and make sure the right side and the 15mm diameter are been gripped by the chuck. 5. The center drill process is started until the whole length of the small drill is inside the work piece.

Chamfering for 6 degree angle : 1. Set up the machine. 2. The cutting toll is attached to the tool holder. 3. Set the speed up to approximately 900rpm. 4. The work piece is attached to the chuck and make sure that the right side and the 15mm diameter are been gripped by the chuck. 5. Adjust the cutting angle to 6 degree. 6. The chamfering process is started until the diameter reach 12mm.

PART BED

DESCRIPTION Base of the machine that sits on the ground or a table and supports the other components of machine.

HEADSTOCK A ASSEMBLY

The front section of the machine that is attached to the bed. This assembly contains the motor and drive system which powers the spindle.

TAILSTOCK A ASSEMBLY

The rear section of the machine that is attached to the bed. To support the other end of the workpiece and allow it to rotate that driven by the spindle.

CARRIAGE

Is a platform that slides alongside the workpiece, allowing the cutting tool to cut away material as it moves.

CROSS SLIDE

Is attached to the top of the carriage and allows the tool to move towards or away from the workpiece, changing the depth of cut.

COMPOUND

Is attached on the top of the cross slide and slide supports the cutting tool.