ME1071: Manufacturing Technology

Semester: 2

Coursework title here

By

Index No. Name Marks

220695E Wickramage YN

Date of commencement 26/04/2024

Date of submission 10/05/2024

Instructors’ name and affiliation

Mrs Maleesha
Department of Mechanical Engineering, University of Moratuwa
Thennakoon

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
Table of Contents
Table of Contents ................................................................................................................... 1

1 Introduction ........................................................................................................................ 2

2 Part ..................................................................................................................................... 3

3 Part 2 .................................................................................................................................. 4

4 Part 3 .................................................................................................................................. 7

5 Conclusions ........................................................................................................................ 9

6 Worksheets ....................................................................................................................... 10

7 References ........................................................................................................................ 14

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1 Introduction
Lathes play a important role in metalworking, shaping materials by rotating them against a
cutting tool. The engine lathe, historically powered by engines, remains a foundational tool. It
drills holes, enlarges objects, and adds threads for screws. Lathes are available in different
sizes, each adhering to the same operational principles. They firmly secure workpieces to
ensure precision during cutting. Across workshops globally, these machines are vital for
crafting complicated components with accuracy and efficiency. From delicate benchtop
variants to robust machines, lathes cater to diverse needs while maintaining consistent
operational standards. Each rotation ensures precise cuts, sculpting metal with meticulous
detail and reliability, reaffirming their indispensable status in the metalworking industry.

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2 Part

Micrometer Turning tool

screw gauge

Lathe dog
Centre drill

• First the centre axis of the 3-jaw jack and turning tool’s tip was aligned.
• After securing the centre drill tool in the tailstock, the workpiece was gently shifted
along the bed and positioned at its freshly faced end. The lathe was turned on and
both ends were drilled to the same depth after being fastened with the tailstock lock.
• The centres of both end of the work piece were marked and centre punched. Then it
was mounted in the machine’s 3 jaw jack by those 2 centre punched dents.
• Then outer layer of the workpiece was removed to get an even surface using auto feeder.
• Then according to the dimensions, it was faced, then on the other side 2 marks were marked
from 20mm and 40mm. and from that end we remove the material such that diameter is
16mm. until first 20mm mark.
• Then the workpiece was tapered from 40mm to 20mm mark, then the correct angle was
calculated, and tool rest was adjusted to the correct angle.
• Then with compound slider feed screw, workpiece was tapered according to dimensions.
• Following that, using U-shaped cutting tool a u-shaped groove was made in 20mm mark to
2mm depth, the coolant was applied.
• To get the desired shape, the metal workpiece was carefully turned on a lathe. This required
drilling the centres, rotating a portion to a smaller diameter, cutting, and facing the ends.
• a U-shaped cut, and lastly inserting one end through. A micrometre was used to verify
measurements throughout the procedure, and tool adjustments were performed at each stage.

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 • Then To increase grip, the workpiece was threaded to produce a rough surface. To get the
correct diamond or straight pattern, this required first deciding on the length and position of
the knurled pattern and then making precise machine changes.

3 Part 2
Safety precautions [1]

• Lathes have several quickly rotating pieces that can be dangerous to come into touch
with or entangle in. Every bodily portion should stay away from any rotating parts.
When using a lathe, never wear jewellery or loose-fitting clothing. Hold all long hair
back and secure. Guards can be used to prevent unintentional contact with rotating
parts.
• In an emergency, the spindle of the lathe will take longer to cease turning if the RPM
is adjusted too quickly. Use the lowest RPM appropriate for the operation and limit
the spindle to 1000 RPM.
• Pinch points can be produced by rotating and other moving components. Body parts
can be amputated, crushed, bruised, or lacerated by pinch points. Make use of guards
and stay away from these points.
• Cut and laceration hazards include cutting tools, drill bits, machined edges, chips, and
cutoffs. Use caution when handling any tools or sharp objects. Avoid using your
hands to remove chips. Use pressurized air (less than 30 psi) or a brush.
• A lathe may present many risks related to flying objects. Ensure that the cutting tool
and workpiece are securely fastened. Make sure the chuck key is taken out of the
chuck. Ensure that there are no tools, chips, or debris on the work area.
• Burn risks can arise from high-speed metalworking due to increased friction.
Workpieces, cutoffs, and cutting chips may feel hot to the touch both during and right
after the work process. Before handling any object, give it enough time to cool.

Important of using cutting fluid.[2]

• Lowering energy expenses requires the cutting fluid's cooling property and lubricating
impact. The proper cutting fluid lowers wear and strain on equipment and machinery,
extending their lives and saving energy. Reducing corrosion to allowable levels
reduces energy use and, consequently, energy expenses. Using the proper cutting fluid
also results in fewer replacements of tools and machine parts. It is also reasonably
priced.
• Cutting fluids prevent corrosion on metals such as carbon steel, cast iron, stainless
steel, and wrought iron. Oxygen, moisture, and high temperatures provide the ideal
conditions for corrosion. On the other hand, cutting fluids with a pH of more than
nine can assist shield ferrous metals from corrosion. The pH level for non-ferrous
metals like brass, bronze, and aluminium will differ.
• The leftovers from the machining operation are metal chips. To prevent machine
malfunctions, this material needs to be flushed out and the chip-removal procedure
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 needs to keep up with the development of new chips. Metal shavings and excessive
tramp oil are troublesome. They gather within the apparatus and taint the cutting fluid.
It is necessary to remove and clear the machine's old cutting fluid. The growth of
bacteria in the cutting fluid is a serious issue. Metal chips are flushed out by cutting
oil to the "sump," where they can be routinely retrieved by hand or with the use of
"mobile sump suckers."
• By minimizing metal-to-metal contact, the proper cutting fluid minimizes friction. To
reduce the harm that friction causes to the metal workpiece, a film of fluid is
positioned between the tool and the metal. Cutting fluids that are soluble serve as a
cushion and ensure a smooth surface, which lessens tool wear and tear.
• Cutting fluids also have the benefit of reducing residue development, which is an
inevitable byproduct of machining. Every cutting fluid has a residue on it. Finding the
proper cutting oil that doesn't produce an excessive amount of the improper residue is
the secret. The liquid residue is the less toxic residue that remains. The machine's
operation is hampered by "slip-stick" issues brought on by the hard, filthy residue.

Cutting tool materials

• Carbon steel: The first steel used in machine tools had a carbon percentage of between
one and two percent. Although these carbon steel tools are reasonably priced, their
cutting power tends to diminish at temperatures beyond 400° F (205° C).
• High- speed steel: With the advent of high-speed steel around 1900, tool speeds could
be doubled or tripled compared to those possible with carbon steel, doubling or
tripling the capabilities of machine shops globally. Eighteen percent of one of the
most popular varieties of high-speed steel is made up of tungsten, four percent
chromium, one percent vanadium, and only five to eight percent carbon.
• Cast alloys: Many nonferrous alloys containing cobalt, chromium, and tungsten have
been developed as cast-alloy cutting tool materials. These alloys are very good at
piercing the strong skin of cast iron and maintaining their cutting ability even when
heated to a red temperature.

3- Jaw Jack 4- Jaw Jack

self-centering Not self-centering, requires manual
adjusting.

Can hold hex bar stock Can’t hold hex bar stock

Less gripping power Less gripping power

Because there is only one adjustment takes more effort and knowledge to
point, it is easy to use and fast. prepare for accurate centering.

Cannot hold square stock Can hold square stock

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 [3]

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4 Part 3
Workpiece data:
Mild steel cylindrical rod, measuring 100 mm in length and 50 mm in diameter.
Production data:

Item is asymmetric.

General tolerance – 0.1 mm

Roughness – 0.4 µm

Procedure:

• The face tool was secured to the chuck for a 75mm overall length after facing.

• Then the centres of the circular faces were drilled, to translate the rotational motion to
the workpiece, lathe dog was used.

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• the diameter of the workpiece reduced to 40mm using a turning tool using the same
technique described before in part2.
• Then 40mm marked in the workpiece then the diameter was reduce to 20mm until the

mark.

• Then the tapper angle was calculated, and tappers using taper turning tool.

• Using a parting tool work piece was parted, slow rpm and consumption fluid was
used, and the depth of cutting is 2mm. Commonly, the speed is set to 60 to 80 RPM,
while the feed is best from 0.04 mm to 0.08 mm revolution of the spindle

• Using a thread cutting tool, cut the threads where indicated. Carry out the initial
action again.

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 • Please use a tool for knurling. You can use a knurling tool to make a helical pattern.
Increase the tool's force to make the desired pattern and distribute it over the area.

5 Conclusions
To sum up, machining emphasizes how crucial it is to carefully choose cutting tools, speeds,
and feeds to attain desired results, minimize tool wear, and improve surface quality and
dimensional accuracy. Furthermore, it is critical to prioritize the exact setup and alignment of
workpieces in the lathe because it directly affects machining precision and reduces errors.
Manufacturers may optimize their machining processes and guarantee consistent, high-quality
outputs while optimizing productivity and decreasing costs by following these guidelines.
Machining operations may remain competitive in the current dynamic industrial landscape by
continuously improving their skills and adhering to best practices. This allows them to fulfil
the expectations for precision and reliability across a range of sectors.

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6 Worksheets

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7 References
[1]"Metalworking Lathe Safety Awareness Guide Print this page", Ehs, 2024. Available:
https://ehs.cornell.edu/campus-health-safety/occupational-safety/tool-and-machine-
safety/metalworking-lathe-safety#:~:text=Keep all body parts away,accidental contact with
rotating parts.

[2]"5 ADVANTAGES OF HAVING THE RIGHT CUTTING FLUID", Castrol, 2024.

Available: https://castrol.com/en_in/india/home/learn/industrial_resources/blogs/5-
advantages-of-having-the-right-cutting-fluid.html.

[3]"Three- vs. Four-Jaw Lathe Chucks - Make:", Makezine, 2011. Available:

https://makezine.com/article/digital-fabrication/machining/three-vs-four-jaw-lathe-chucks/.

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