Manufacturing processes

Experiment # 2
Experiment Title:
To perform knurling, parting off, drilling and boring operations on a given workpiece using lathe
machine.

Objectives:
 To understand the three operations (knurling, Drilling and parting)

Lathe Machine:

Figure 1: Lathe Machine

Operation Perform at Lathe Machine:

Knurling:

This is not a machining operation at all, because it does not involve material removal. Instead, it
is a metal forming operation used to produce a regular crosshatched pattern in the work surface.
It is done on certain components for effective gripping to prevent it from slipping while handling
it, example is thumbscrews, etc. The knurling process is shown in Figure 3. The knurling tool
consists of a set of hardened steel rollers in a holder with the teeth cut on their surface in a
definite pattern. The tool is held rigidly on the tool post and the rollers are pressed against the
revolving workpiece to squeeze the metal against the multiple edges. The speed used during
knurling should be very low and plenty of lubricant should be used. [1]

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Figure 2: Knurling [1]

Drilling:

Drilling is the operation of production of holes in a workpiece. Figure 11 shows how drilling
operation is performed on a lathe.

Figure 3: Drilling [1]

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While doing the drilling operation on a lathe, the workpiece is held in a chuck or on a faceplate.
The drill (the cutting tool) is held in the tailstock and is positioned near the workpiece by moving
the tailstock along the guideways. The tool is fed against the workpiece (the feed motion) by
rotating the handle of the tailstock in clockwise direction, Once the hole is drilled, the tool is
withdrawn by rotating the tailstock handle in the anti-clockwise direction. It should be noted that
in drilling on lathe the job is rotating while the tool remains stationary. [1]

Parting:
As the name itself indicates, parting is the operation of cutting a workpiece into two. The
operation is carried out with a tool called parting tool. The parting operation is shown in Figure
6. For parting operations, the workpiece is rotated at a low speed and the parting tool is fed in a
direction normal to the axis of rotation of the job. Ample amount of feed should be employed to
provide a continuous chip. If slow feed is used, the tool will not cut continuously but will ride on
the surface for a revolution or two, and then bite in suddenly. This phenomenon is known as
hogging, and is undesirable. Since, high feed rates are used, to compensate for the heat generated
during the operation an abundant supply of coolant should be used. [1]

Figure 4: Parting [1]

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Procedure:
Knurling operation:
 Choose a workpiece with a diameter suitable for the knurling tool.
 Install the knurling tool on the tool post of the lathe, making sure it is perpendicular to the
workpiece.
 Adjust the knurling tool so that the knurls (the raised lines on the tool) are aligned
parallel to the length of the workpiece. This will ensure that the knurling pattern is
consistent and uniform.
 Position the workpiece in the lathe chuck, making sure it is secure.
 Adjust the tool height so that the knurling tool contacts the workpiece at the desired
height.
 Start the lathe and bring the knurling tool into contact with the workpiece.
 Apply pressure to the knurling tool by turning the cross-slide handwheel, which will
cause the knurls to press into the surface of the workpiece.
 Move the knurling tool along the length of the workpiece, making sure to maintain
consistent pressure and speed.
 Once the knurling is complete, stop the lathe and remove the workpiece from the chuck.
 Inspect the knurling pattern to ensure that it is consistent and uniform. If necessary, adjust
the tool height and repeat the process.
 Finally, finish the workpiece according to your desired specifications.

Figure 5: knurling operation [2]

Boring Operation:
 Secure the workpiece in the lathe chuck or collet and ensure that it is properly centered
and aligned.
 Choose the appropriate boring tool based on the size and depth of the hole you need to
create. Make sure the tool is sharp and properly mounted in the tool post.
 Adjust the height of the tool to ensure that it is at the centerline of the workpiece
 Set the depth of cut by moving the cross-slide or compound rest. Take light cuts to avoid
damaging the tool or workpiece.

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 Turn on the lathe and set the speed to the recommended cutting speed for the material
you are machining.
 Gently feed the boring tool into the workpiece, using the hand crank or power feed. Take
care to maintain a consistent feed rate and avoid chatter or excessive vibration.
 Use a micrometer or dial bore gauge to measure the diameter and depth of the hole as you
bore. Stop periodically to check your progress and make any necessary adjustments to the
tool or cutting depth.
 When the hole is the desired size and depth, reduce the feed rate and take a final pass to
ensure a smooth surface finish.
 Turn off the lathe and carefully remove the workpiece from the chuck or collet.

Figure 6: Boring Operation [3]

Drilling Operation:
 Choose the appropriate drill bit for the job at hand, based on the size and material of the
workpiece.
 Insert the drill bit into the drill chuck and tighten it securely using the chuck key. Make
sure the drill bit is centered in the chuck.
 Select the appropriate spindle speed for the drill bit and material being drilled. This can
usually be found in the machine’s user manual or on a chart near the machine.
 Securely mount the workpiece in the lathe’s chuck or on the lathe bed.
 Position the drill bit at the desired location on the workpiece using the lathe’s cross slide
and compound rest.
 Gradually lower the drill bit into the workpiece using the lathe’s tailstock.
 Turn on the lathe and engage the drill bit. Apply steady pressure to the tailstock lever to
feed the drill bit into the workpiece.
 Keep an eye on the drilling process to ensure that the drill bit is not overheating, and that
the chips are being properly cleared from the hole.
 Once the drilling process is complete, disengage the drill bit and turn off the lathe.
 Loosen the chuck and remove the drill bit.

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Figure 7: Drilling Operation [4]

Parting-of operation:
 Ensure that the lathe machine is set up properly and the workpiece is securely held in
place by the chuck or a center.
 Select a parting off tool that is appropriate for the size of the workpiece and the desired
cut.
 Adjust the height of the parting off tool so that it is aligned with the center of the
workpiece.
 Set the cutting speed based on the type of material being cut and the diameter of the
workpiece.
 Turn on the lathe machine and gradually increase the speed until it reaches the desired
cutting speed.
 Move the parting off tool towards the workpiece, making sure that it is aligned with the
center of the workpiece.
 Control the cut by applying pressure on the parting off tool and adjusting the cutting
speed as needed.
 Once the parting off cut is complete, turn off the lathe machine and remove the cut-off
part.
 Remove any chips that may have accumulated during the parting off process.
 Inspect the workpiece to ensure that the cut is clean and meets the required specifications

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Figure 8: Parting off [5]

Parameters for Knurling Operation:

 Workpiece: Mild Steel
 Tool: Knurling Tool (HSS)
 Pattern: Shank pattern
 Cutting Speed: 38 rpm

Parameters for Parting-Off Operation:

 Workpiece: Mild Steel
 Tool: High Speed Steel
 Cutting Speed: 375 rpm

Parameters for Boring Operation:

 Workpiece: Mild Steel
 Boring Tool: High Speed Steel
 Cutting Speed: 375 rpm

Parameters for Drilling Operation:

 Workpiece: Mild Steel
 Tool: High Speed Steel
 Drill bit diameter: 13mm
 Cutting Speed: 375 rpm

Comments:
 Make sure that the tool comes in between the center of the workpiece.
 Never stop the carriage while the tool is in contact with the work piece.
 Tighten the tool post securely to prevent it from moving during a cut.
 Always stop the lathe before adjusting.
 Make sure that the tool being used is harder than the material of the workpiece.

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 Check the cutting parameters before cutting to ensure dimensional accuracy.

 Always wear appropriate personal protective equipment (PPE), such as safety glasses and
ear protection, when using a lathe machine.

Conclusion:
In conclusion, this lab report has discussed the theory behind Universal Lathe Machines and their
applications in manufacturing. Through practical experimentation, we have demonstrated the
process of knurling, boring, drilling, and parting-Off on a Universal Lathe Machine and the key
considerations that need to be considered in order to achieve a successful result. We have shown
that choosing the right tool, setting the correct angle and depth of cut, using the correct speed and
feed rate, applying lubricant, and monitoring the workpiece are all critical factors in ensuring that
process is performed correctly on a Universal Lathe Machine.

References

[1] 04 04 2024. [Online]. Available: https://msvs-dei.vlabs.ac.in/mem103/Unit5lesson4.html.

[2] 04 04 2024. [Online]. Available: https://testbook.com/mechanical-engineering/lathe-machine-

operations-and-applications.

[3] 04 04 2024. [Online]. Available: https://testbook.com/mechanical-engineering/lathe-machine-

operations-and-applications.

[4] 04 04 2024. [Online]. Available: https://testbook.com/mechanical-engineering/lathe-machine-

operations-and-applications.

[5] 04 04 2024. [Online]. Available: https://testbook.com/mechanical-engineering/lathe-machine-

operations-and-applications.

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