The document is a lab report for an experiment on turning. It includes an introduction describing turning operations, theoretical background on lathe components and their functions, and descriptions of the experimental apparatus including the bed, headstock, tailstock, carriage, cross slide, and compound. Safety procedures and the experimental steps are outlined. Results and conclusions from measuring dimensions of turned parts are presented.
The document is a lab report for an experiment on turning. It includes an introduction describing turning operations, theoretical background on lathe components and their functions, and descriptions of the experimental apparatus including the bed, headstock, tailstock, carriage, cross slide, and compound. Safety procedures and the experimental steps are outlined. Results and conclusions from measuring dimensions of turned parts are presented.
The document is a lab report for an experiment on turning. It includes an introduction describing turning operations, theoretical background on lathe components and their functions, and descriptions of the experimental apparatus including the bed, headstock, tailstock, carriage, cross slide, and compound. Safety procedures and the experimental steps are outlined. Results and conclusions from measuring dimensions of turned parts are presented.
The document is a lab report for an experiment on turning. It includes an introduction describing turning operations, theoretical background on lathe components and their functions, and descriptions of the experimental apparatus including the bed, headstock, tailstock, carriage, cross slide, and compound. Safety procedures and the experimental steps are outlined. Results and conclusions from measuring dimensions of turned parts are presented.
1 192396 LUQMAN HAKIM BIN DZULKARNAIN 2 193498 NUR AFIQAH BINTI ADNAN [LAB EXPERIMENT: TURNING] SEPTEMBER 20, 2019
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.
