EMM3812

MECHANICAL
ENGINEERING
LABORATORY (IV)

Semester 1, 2019/2020

Title: Turning
Group: 2A (A)

No. Matric No. Name

1 192396 LUQMAN HAKIM BIN DZULKARNAIN
2 193498 NUR AFIQAH BINTI ADNAN
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TABLE OF CONTENTS

CONTENT PAGE

1.0 INTRODUCTION ………………………………………………………...…… 3

2.0 THEORETICAL BACKGROUND ………………………………………… 4

3.0 EXPERIMENTAL APPARATUS …………………………………………… 6

4.0 PROCEDURE ………………………………………………………………… 7

5.0 RESULT AND DISCUSSION ………………………………………………… 9

6.0 CONCLUSION ………………………………………………………………… 11

7.0 REFERENCES ………………………………………………………………… 11

8.0 APPENDIX …………………………………………………………………….. 12

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1.0 INTRODUCTION
The machine is an exceptionally adaptable and significant machine to realize how to work. This
machine pivots a round and hollow item against a device that the individual controls. The lathe is the
forerunner of all machine tools. The work is held and rotated on its axis while the cutting tool is
advanced along the line of a desired cut. The lathe is one of the most versatile machine tools used in
industry. With suitable attachments, the lather may be used for turning, tapering, form turning, screw
cutting, facing, dulling, boring, spinning, grinding, polishing operation. Cutting operations are
performed with a cutting tool fed either parallel or at right angles to the axis of the work.

The cutting tool may also be fed at an angle, relative to the axis of the work, for machining taper and
angles. On a lathe, the tailstock does not rotate. Instead, the spindle that holds the stock rotates. Collets,
centres, three jaw chucks, and other work-holding attachments can all be held in spindle. The tailstock
can hold tools for drilling, threading, reaming, or cutting tapers. Furthermore, it can bolster the part of
the bargain utilizing an inside and can be changed in accordance with adjust to various workpiece
lengths. Parts that are fabricated completely through turning often include components that are used in
limited quantities, perhaps for prototypes, such as custom designed shafts and fasteners. Turning is
likewise normally utilized as an optional procedure to include or refine highlights parts that were
fabricated utilizing an alternate procedure.

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2.0 THEORETICAL BACKGROUND

The lathe is a machine tool used for shaping pieces of metal (and sometimes wood or other materials)
by causing the work piece to be held and rotated by the lathe while a tool bit is advanced into the work
causing the cutting action. The basic lathe that was designed to cut cylindrical metal stock has been
developed further to produce screw threads, tapered work, drilled holes, knurled surfaces, and
crankshafts. Modern lathes offer a variety of rotating speeds and a means to manually and automatically
move the cutting tool into the work piece. The lathe cutting tool or tool bit must be made of the correct
material and ground to the correct angles to machine a work piece efficiently. The most common tool
bit is the general all-purpose bit made of highspeed steel. These tool bits are generally inexpensive, easy
to grind on a bench or pedestal grinder, take lots of abuse and wear, and are strong enough for all-
around repair and fabrication. High-speed steel tool bits can handle the high heat that is generated during
cutting and are not changed after cooling. These tool bits are used for turning, facing, boring and other
lathe operations. Tool bits made from special materials such as carbides, ceramics, diamonds, cast alloys
are able to machine work pieces at very high speeds but are brittle and expensive for normal lathe work.
Highspeed steel tool bits are available in many shapes and sizes to accommodate any lathe operation.

Figure 2.1: Turning operation.

The headstock is located on the operator's left end of the lathe bed. It contains the main spindle and oil
reservoir and the gearing mechanism for obtaining various spindle speeds and for transmitting power
to the feeding and threading mechanism. The headstock mechanism is driven by an electric motor
connected either to a belt or pulley system or to a geared system. The main spindle is mounted on
bearings in the headstock and is hardened and specially ground to fit different lathe holding devices.
The spindle has a hole through its entire length to accommodate long work pieces. The hole in the nose
of the spindle usually has a standard Morse taper which varies with the size of the lathe. Centers, collets,
drill chucks, tapered shank drills and reamers may be inserted into the spindle. Chucks, drive plates,
and faceplates may be screwed onto the spindle or clamped onto the spindle nose. The tailstock is
located on the opposite end of the lathe from the headstock. It supports one end of the work when
machining between centers, supports long pieces held in the chuck, and holds various forms of cutting
tools, such as drills, reamers, and taps. The tailstock is mounted on the ways and is designed to be
clamped at any point along the ways. It has a sliding spindle that is operated by a hand wheel and
clamped in position by means of a spindle clamp. The tailstock may be adjusted laterally (toward or
away from the operator) by adjusting screws. It should be unclamped from the ways before any lateral
adjustments are made, as this will allow the tailstock to be moved freely and prevent damage to the
lateral adjustment screws.

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The carriage is driven by a lead screw that rotates at the proper speed to obtain the desired feed rate.
The cross-slide is designed to feed in a direction perpendicular to the carriage movement. Thus, by
moving the carriage, the tool can be fed parallel to the work axis to perform straight turning; or by
moving the cross-slide, the tool can be fed radially into the work to perform facing, form turning, or
cutoff operations.

Figure 2.2: Diagram of an engine lathe, indicating its principal components.

The carriage includes the apron, saddle, compound rest, cross slide, tool post, and the cutting tool. It
sits across the lathe ways and in front of the lathe bed. The function of the carriage is to carry and move
the cutting tool. It can be moved by hand or by power and can be clamped into position with a locking
nut. The saddle carries the cross slide and the compound rest. The cross slide is mounted on the dovetail
ways on the top of the saddle and is moved back and forth at 90° to the axis of the lathe by the cross
slide lead screw. The lead screw can be hand or power activated. A feed reversing lever, located on the
carriage or headstock, can be used to cause the carriage and the cross slide to reverse the direction of
travel. The compound rest is mounted on the cross slide and can be swiveled and clamped at any angle
in a horizontal plane. The compound rest is used extensively in cutting steep tapers and angles for lathe
centers. The cutting tool and tool holder are secured in the tool post which is mounted directly to the
compound rest. The apron contains the gears and feed clutches which transmit motion from the feed
rod or lead screw to the carriage and cross slid

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3.0 APPARATUS AND EXPERIMENTAL SETUP

Figure 1 shows the turning machine.

Bed -The bed of the turning machine is simply a large base that sits on the ground or a table and
supports the other components of the machine.

Headstock assembly - The headstock assembly is the front section of the machine that is attached to
the bed. This assembly contains the motor and drive system which powers the spindle. The spindle
supports and rotates the workpiece, which is secured in a workpiece holder or fixture, such as a chuck
or collet.

Tailstock assembly - The tailstock assembly is the rear section of the machine that is attached to the
bed. The purpose of this assembly is to support the other end of the workpiece and allow it to rotate, as
it's driven by the spindle. For some turning operations, the workpiece is not supported by the tailstock
so that material can be removed from the end.

Carriage - The carriage is a platform that slides alongside the workpiece, allowing the cutting tool to
cut away material as it moves. The carriage rests on tracks that lay on the bed, called "ways", and is
advanced by a lead screw powered by a motor or hand wheel.

Cross slide - The 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. As with the carriage, the cross slide is powered
by a motor or hand wheel.

Compound - The compound is attached on top of the cross slide and supports the cutting tool. The
cutting tool is secured in a tool post which is fixed to the compound. The compound can rotate to alter
the angle of the cutting tool relative to the workpiece.

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4.0 PROCEDURE
1. Work piece is given by the assistant engineer.

Figure 4.1 shows the workpiece before undergoes turning process.

2. Brief explanation by assistant engineer on how to operate the lathe machine.

Figure 4.2 shows the lathe machine that is used in this experiment process.

3. Take a dimension of the workpiece and compare with given dimension and drawing.

4. Apply safety tools.

5. Start operating the lathe machine.

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6. Design the work piece according to the instruction

Figure 4.3 shows the workpiece after undergoes turning process

7. Take a final measurement.

8. Do finishing for the work piece.

Figure 4.4 shows the finishing of turning process that used low rpm to get smooth surface

9. Keep tools in safety tool box.

10. Clean the metal pieces around the machine with brush & broom.

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5.0 RESULT AND DISCUSSION

RESULT
During the process cycle, a variety of operations may be performed to the workpiece to yield
the desired part shape. These operations may be classified as external or internal. External
operations modify the outer diameter of the workpiece, while internal operations modify the
inner diameter. The following operations are each defined by the type of cutter used and the
path of that cutter to remove material from the workpiece.

Figure 5.1 shows the workpiece before undergoes turning process.

Figure 5.2 shows the workpiece after turning process

The workpiece is a piece of pre-shaped material that is secured to the fixture, which itself is attached to
the turning machine, and allowed to rotate at high speeds. The cutter is typically a single-point cutting
tool that is also secured in the machine, although some operations make use of multi-point tools. The
cutting tool feeds into the rotating workpiece and cuts away material in the form of small chips to create
the desired shape.

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DISCUSSION
Elaborate the effect of the following process parameters on turning process: (i) feed rate, (ii)
spindle speed and (iii) depth of cut.
Cutting speed is defined as the speed (usually in feet per minute) of a tool when it is cutting the work.
Feed rate is defined as tool’s distance travelled during one spindle revolution. Feed rate and cutting
speed determine the rate of material removal, power requirements, and surface finish. Feed rate and
cutting speed are mostly determined by the material that’s being cut. In addition, the deepness of the
cut, size and condition of the lathe, and rigidity of the lathe should still be considered. Based on search
on the Internet, roughing cuts (0.01 in. to 0.03 in. depth of cut) for most aluminum alloys run at a
feedrate of .005 inches per minute (IPM) to 0.02 IPM while finishing cuts (0.002 in. to 0.012 in. depth
of cut) run at 0.002 IPM to 0.004 IPM. As the softness of the material decreases, the cutting speed
increases. Additionally, as the cutting tool material becomes stronger, the cutting speed increases. For
each thousandth depth of cut, the diameter of the stock is reduced by two thousandths.

A lathe work cutting speed may be defined as the rate at which a point on the work circumference
travels past the cutting tool. Cutting speed is always expressed in meters per minute (m/min) or in feet
per minute (ft/min.) industry demands that machining operations be performed as quickly as possible;
therefore current cutting speeds must be used for the type of material being cut. If a cutting speed is too
high, the cutting tool edge breaks down rapidly, resulting in time lost recondition the tool. With too
slow a cutting speed, time will be lost for the machining operation, resulting in low production rates.
Based on research and testing by steel and cutting tool manufacturers, see lathe cutting speed table
below. The cutting speeds for high speed steel listed below are recommended for efficient metal
removal rates. These speeds may be varied slightly to shift factors such as the condition of the machine,
the type of work material and sand or hard spots in the metal.

The feed of a lathe is the distance the cutting tool advances along the length of the work for every
revolution of the spindle. The feed of a lathe is dependent upon the speed of the lead screw or feed rod.
The speed is controlled by the change gears in the quick change gearbox. Only two cut should be taken
to bring a diameter cut. Since the purpose of a rough cut is to remove excess material quickly and
surface finish is not too important. A coarse feed should be used. The finishing cut is used to bring the
diameter to size and produce a good surface finish and therefore a fine feed should be used.

Identify three advantages of the turning process for product fabrication.

Three advantages of the turning process for product fabrication are good surface finish. It also
requires less energy and strength than other processes. Lastly, chips collecting is easier.
Are there any difficulties that can be found during turning process?

Yes, there are difficulties during turning process. The first difficulty is how to handle the machine
properly to prevent injuries or any safety issues, therefore, we need to follow the instruction from the
lab instructor. Next, we need to always follow the safety rules during handling the machine such as
wear goggles and aprons. Besides, we need to focus on our experiment to make sure the cutting
dimension is accurate. We need to always make sure that the coolant disperse to the cutting tip and
specimen, if the toolholder doesn’t have coolant either running through it or running on top of the
assembly while it’s in operation, heat will build up and can have negative effects on tool life, surface
finish and part quality.

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7.0 CONCLUSION
The turning procedure requires a turning machine or machine, workpiece, installation, and cutting
apparatus. The workpiece is a bit of pre-moulded material that is verified to the apparatus, which itself
is joined to the turning machine, and permitted to pivot at high speeds. The shaper is ordinarily a solitary
point cutting device that is additionally verified in the machine, albeit a few activities utilize multi-point
devices. The cutting device sustains into the turning workpiece and removes material as little chips to
make the ideal shape.

Turning is utilized to create rotational, ordinarily axis-symmetric, parts that have numerous highlights,
for example, openings, grooves, strings, decreases, different breadth steps, and even moulded surfaces.
Parts that are manufactured totally through turning frequently incorporate segments that are utilized in
constrained amounts, maybe for models, for example, hand crafted shafts and latches. Turning is
likewise regularly utilized as an optional procedure to include or refine highlights parts that were made
utilizing an alternate procedure. Because of the high resilience and surface completes that turning can
offer, it is perfect for adding accuracy rotational highlights to a section whose essential shape has just
been framed.

8.0 REFERENCES
[Book]: LamNgeun Virasak (2017). Manufacturing Process 4-5. Chapter 2: Lathe Machine. Page

6.

[Book]: Callister, W.D. (2005). Fundamentals of Materials Science and Engineering – An

Integrated Approach. John Wiley & Sons, Inc.

[Book]: Niebel, B., & Draper, A. (1989). Modern manufacturing process engineering (pp. 148-
153). New York: McGraw-Hill.

[Journal]: Ismail, M.I.S., Bahari, M.J., Shuib, N. (2018). Thermal Deformation of Gas Metal Arc

Welding on Aluminum Alloy T-Joints, Engineering Solid Mechanics, Vol.6, pp.21-26

[Website]: CustomPart.Net (2019). Turning. Retrieved from:

https://www.custompartnet.com/wu/turning#top

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9.0 APPENDICES

Figure 9.1 shows the lathe machine that is used in this experiment process.

Figure 9.2 shows the workpiece before undergoes turning process.

Figure 9.3 shows the workpiece after turning process

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