Mizan Tepi University

College Of Engineering and Technology

Department Of Mechanical Engineering

TITLE OF THE PROJECT: ANALYSIS OF TOTAL PRODUCTIVE

MAINTENANCE (TPM) IMPLEMENTATION USING OVERALL EQUIPMENT
EFFECTIVENESS (OEE) IN LATHE MACHINE

GROUP 2 SUB GROUPS

By:

1. Bizuayehu Damtew…………………………………..ETR/0263/10
2. Temesgen Mathewos… ……………………………ETR/ 0963/10

3. Natinael Abel ………………………………………..ETR/ 0786/11

 CHAPTER ONE

1. INTRODUCTION TO LATHE MACHINE

Lathe is the machine tool which is used to perform several operations on the work piece. Lathe is
useful in making several parts which is further assembled to make new machine. Hence lathe is known

as “mother of machines”. The function of Lathe is to remove the metal in the form of chips from a
piece of work by mounting the same rigidly on a machine spindle and revolving at the required speed
and the cutting tool is fed against the work either longitudinally or crosswise to make the work to the
required shape and size.

1.1. BASIC WORKING PRINCIPLE OF LATHE

In lathe, the work piece is held in the chuck, a work holding device. The cutting tool is mounted in the
tool post. The chuck is rotated by means of power. When the chuck rotates, the work piece also rotates.
The tool is moved against the rotating work piece by giving small amount of depth of cut. The material
is removed in the form of chips. Continuous feed and depth of cut is given until the required
dimensions are obtained in the work piece.

1.2. TYPES OF LATHE MACHINES

There are different types of lathe machines, they are

 Centre lathe
 Tool room lathe
 Bench lathe
 Capstan lathe
 Turret lathe
 Automatic lathe
 Figure1.1 center lathe

1.3. DESCRIPTION OF LATHE

Lathe is a machine which has several parts in it. They are

1. Bed

It is the base of the machine. On its left side, the head stock is mounted and on its right it has movable
casting known as tailstock. Its legs have holes to bolt down on the ground.

2. Head stock

It consists of spindles, gears and speed changing levers. It is used to transmit the motion to the job. It
has two types one is the headstock driven by belt and the other one is the gear driven.

3. Carriage

Carriage is used to carry a tool to bring in contact with the rotating work piece or to with draw from
such a contact. It operates on bed ways between the headstock and tail stock.

4. Saddle

It is an ‘H’ shaped part fitted on the lathe bed. There is a hand wheel to move it on the bed way. Cross
slide, compound rest, tool post is fitted on this saddle.

a) Cross slide

It is on the upper slide of saddle in the form of dove tail. A hand wheel is provided to drive the cross
slide. It permits the cross wise movement of the tool (i.e.) movement of tool towards or away from the
operator.

b) Compound rest
It is fitted over the cross slide on a turn table. It permits both parallel and angular movements to cutting
tool.

c) Tool post

It is fitted on the top most part of the compound rest. Tool is mounted on this tool post. Cutting tool is
fixed in it with the help of screws.

5. Apron

It is the hanging part in front of the carriage. It accommodates the mechanism of hand and power feed
to the cutting tool for carrying out different operations.

Figure1.2 apron mechanism

6. Lead screw

It is a long screw with ACME threads. It is used for transmitting power for automatic feed or feed for
thread cutting operation.
7. Tail stock
It is located at the right end of the lathe bed and it cn be positioned anywhere in the bed. It is used for
supporting lengthy jobs and also carries tool to carry out operations such as tapping, drilling, reaming.
 Figure 1.3 tailstock

1.4. WORK HOLDING DEVICES

 Lathe centers

They are used to support work. It has two categories of centers. Live center is one which is fitted in the
headstock spindle. Dead is another one which is fitted in the tail stock.

 Chuck

It is a device used to hold a job. It is easily fitted on the thread cut on the end of head stock spindle.
Various types of chuck are:

 Two jaw chuck

 Three jaw chuck
 Four jaw chuck
 Collet chuck
 Magnetic chuck.
 Face plate
 Catch plate
 Lathe carriers or dog’s
 Steady rest
 Mandrel
 Follower rest

1.5. CUTTING TOOLS USED

For making a finished job on lathe machine, various types of cutting tools are used. One of them is
single point cutting tool which is used to perform several operations on the work piece. Various types
of cutting tools are:
1. Facing Tool

2. Rough Turning Tool

3. Finishing Tool

4. Radius Tool

5. Parting Tools

6. Form Turning Tool

7. Thread Cutting Tool

8. Drill Tool

9. Boring Tool

10. Knurling Tool [2]

The leg of lathe machine is made of cast iron through the casting process since cast iron has high
shock absorbance and wears resistance capacity.

The bed of lathe is made of by single piece casting of semi steel due to its high compressive strength,
shock absorbance and high lubrication quality [4].

1.6. TOOL MATERIALS

1. The single point cutting tools are made of high speed steel. (H. S. S)

2. The main alloying elements in 18 – 4 – 1 HSS tools are 18 % tungsten, 4% chromium and 1 %
Vanadium. 5 to 10 % cobalt is also added to improve the heat resisting properties of the tool.

3. General purpose hand cutting tools are usually made from carbon steel or tool steel.

4. Carbide tipped tools fixed in tool holders, are mostly used in production shops.

1.7. CUTTING TOOL ANGLES

1) Top rake angle (back rake angle)

a. If the slope is given to the face or surface of the tool and if this slope is along the tools length then it
is called top rake angle. It is usually 15° to 20°.

2) Side rake angle

a. If the slope is given to the face or top of the tool along the tools width then it is called side rake
angle. It lies between 6° and 15°.

3) Clearance angle (relief angle)

a. Types:

1. Side clearance angle

2. End clearance angle.

b. They are provided to keep surface of the tool clear of the work piece.

4) Cutting edge angle (Types)

1. Side cutting edge angle – (generally 15°) it is an angle, the side cutting edge makes with the axis of
the tool.

2. End cutting edge angle – (from 7° to 15°) it is an angle, the end cutting edge makes with the width
of the tool.

5) Lip angle (cutting angle)

a. It is the angle between the face and the end surface of the tool.

6) Nose angle

b. It is the angle between the side cutting edge and end cutting edge.

1.8. LATHE OPERATIONS

 Facing
 Plain Turning
 Step Turning
 Taper Turning
 Knurling
 Drilling

Important terms:

CUTTING SPEED

 It is the peripheral speed of the work past the cutting tool.

 It is the speed at which metal is removed by the tool from the work piece.
 It is expressed in meter / minute.
 π∗diameter∗R . P . M
Cutting speed =
1000

πDN m
¿
1000 min

Where, D – Diameter in mm

N – Spindle speed in rpm

FEED

 It is defined as the rate of tool travel across a surface cutting it.

 It is the distance of the tool advances for each revolution of the work piece.
 It is expressed in mm/revolution.

DEPTH OF CUT

 It is the perpendicular distance measured from the machined surface to the uncut surface of
work. It is expressed in mm.
d 1−d 2
depth of cut=
2

Where, d1 = diameter of work before machining

d2 = diameter of work after machining.

1.9. Objectives of the Project

1.9.1. General Objectives of the Project

 The main objective of this project is to analysis of total productive maintenance (TPM)
implementation using overall equipment effectiveness (OEE) in lathe machine.
 CHAPTER TWO

2. LITERATURE REVIEW
Lathe is a machine widely used for wood works and machining of metal parts. Lathe is a machine
which turns the work piece against a machine tool. The Lathe is used for facing, turning, knurling,
taper cutting, threading, gear cutting and many other metal and wood works.

2.1. History of Lathe

Lathe is a very ancient tool and its first use dates back to 1300 BC in Egypt. Lathe was also known and
used in Assyria and Greece. Ancient Romans came to know about this machine and they further
developed this machine. During the medieval period, the use of this machine had spread to most parts
of Europe and it was during the Industrial revolution when this machine gained popularity with its use
in all the industries. After the development of electronics, automated lathes have been developed.

2.2. Evolution of Lathe

The first lathe was a simple lathe which was is now referred to as two person lathe. One person would
turn the wood work piece using rope and the other person would shape the work piece using a sharp
tool. This design was improved by Ancient Romans who added a turning bow which eased the wood
work. Later a pedal (as in manual sewing machines) was used for rotating the work piece. This type of
lathe is called “spring pole” lathe which was used till the early decades of the 20th century. In 1772, a
horse-powered boring machine was installed which was used for making canons. During the Industrial
revolution, steam engines and water wheels were attached to the lathe to turn the work piece at higher
speed which made the work faster and easier. After 1950, many new designs were made which
improved the precision of work.

Lathes are classified depending upon their application and functionality as

 Light duty lathe – These machines find their application in automobile, electronic, electrical
industries and are manufactured from quality tested raw materials.
 Medium duty lathe – These machines are powerful than the light duty lathes and can work on
bigger work pieces and have more strength than the light duty lathes. Click Here to get more
information on medium duty lathe machine.
 Heavy duty late – These machines are manufactured from highest grades of materials like iron
and steel. They are designed for high precision heavy duty operations.
 All geared lathe – In all geared lathe, all the rotating components of the machine are driven by
the same source at different speeds by using gears to perform various operations.
 Imported lathe – Imported lathes are high quality lathes used for high precision operations.
Depending upon the modes of operation, the lathes can be classified as

 Manual lathe – In these lathes, the tool handling is done manually and so the precision of
work also depends upon the skill of the person handling the machine.
 CNC Lathe – CNC lathes are completely automated lathes. We just have to feed the
instructions into the computer and the lathe will perform the operations according to the data
fed to the computer