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OBJECTIVES
To identify parts of a lathe machine and other related equipments
used in handling the machine.
To learn and master the skills of handling the machines, and the
purposes of the important components of the machine in producing
an article.
To produce a complete turning article involving facing, turning,
drilling, grooving, tapering, knurling and chamfering operations.
To understand the theory of turning and operations.
To identify and learn the basic operation of turning machine.
To learn the safety guide lines in handling the tools and turning
machine.
To shape a cylindrical metal into a usable object.

APPARATUS

Modern center lathe machine

Chuck wrench
Tool post chuck
Drill chuck
Tool holder bracket
Goggle
Drills (centre drill, 6mm, 8mm, 12mm and 14mm)
Grooving tool holder
Knurling tool holder
Facing tool holder
Chamfering tool holder
Double sided spanner (6-8mm and 24-27mm)
Spanner (17mm)
Vernier caliper
Hammer
L-Square

PROCEDURES
This workshop activity is comprised of two parts, which are Turning 1
and Turning 2.
Turning 1
1. In the beginning, the demonstrator introduced us to the components
of the lathe machine and explained the application of each. Then, he
showed us how to operate the machine correctly and also he safety
precautions to be taken when around the machine.

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2. A cylindrical aluminium ( 30 x 75mm) was given to each student
and is clamped into the 3 jaw-clamp chuck, with a length of 55mm
from the tip of the chuck, using the chuck wrench to open and tighten
the jaw. It must be tightly clamped so that it does not vibrate when
the chuck is rotating.

3. Then, the tool bit is fixed to the tool post. Before any operation is
carried out, the cutting tool should be set to the center of the work
piece. To do so, the edge of the cutting tool is adjusted until it was in
the same level with the sharp edge of the tailstock center.
4. Then the tool bit is brought close to the work piece and the facing
operation is begun to obtain a smooth surface. The spindle is always
switched on first before letting the cutting tool touches the work piece.
Facing is generally a process where the length of the piece is reduced
by cutting its flat surface. For rough turning, spindle speed is set at
860 rpm. Then, this point is set as the zero-point by placing the
0mm graduate to the zero indicator.

5.

The cross handwheel (x-axis) was used during this facing process.
The tool bit is moved to the zero point of x-axis and y-axis. After that,
the clutch is pulled upward to start the spindle. Slowly, the tool bit is
driven in y-axis direction until it reached to the center of the work
piece. From this point, the bit is taken off by moving the cross slide
into the right direction.
6. Rough turning was done to obtain the dimension of 21 x 49mm.
Both the x and y axis was set to zero so that it will be easier to
determine the amount that was needed to be removed.

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7.

After rough turning, the finishing was done. To obtain a smooth and
fine surface, the spindle speed was set to 430 rpm and the x-axis
wheel was rotated slowly and continuously until the dimension of the
work piece becomes 20 x 50mm. Vernier calliper was used to check
the diameter and length of the work piece.

8. For drilling, the tail stock was changed to a drill chuck. The drill was
held in the drill chuck in the tail stock and locked firmly. First, the
center drill was used to set the point of drilling. Coolant was allowed
to flow on the work piece at the point where drilling is happening.
9. The center drill was driven through the work piece until the depth is
two third of flute length. It is then followed by the 6.5mm drill and
the8.5mm drill. The finishing drilling is performed with the10mm
drill at the speed of 430 rpm, also slowly and continuously.

10.Then, the grooving process was done. The tool bit is changed to the
groove tool to obtain a 15 x 5mm (2.5mm depth) dimension. The
groove tool is set at its datum point of grooving and as the work piece
is turning, the tool is brought to the positive y axis direction and
pulled out after the required depth was obtained.

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11.To perform tapering, the groove tool was changed back to the tool bit.
Tapering is done at the open end of the work piece. The compound
slide is tilted to +8.5 and only the hand wheel at the compound slide
(the z-axis) is moved. Tapering is done until the dimension of 14 x
20mm x +8.5 is obtained.

Turning 2
12.In this part of the activity, the other end of the work piece was dealt
with. The finished end was fixed into the 3 jaw-clamp chuck and it is
made sure to be long enough to perform the next operation.

13.Facing was performed to obtain a length of 20mm.

14.Then, rough turning was done at 860 rpm to get the 29mm diameter
of the work piece.

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15.The finishing process was executed at the spindle speed of 430rpm to

obtain the dimension of 28 x 20mm.

16.The spindle was changed back to 860 rpm and rough turning was
done to acquire the 21 x 10mm dimension.

17.Then, finishing was performed at 430 rpm for the final dimension of
20 x 10mm.

18.The tool bit was then changed to the tool bit with an angle 45 x 45,
and is then centered at the machine for the chamfering process. This
is to obtain the dimension of 45 x 1.5mm at the selected edges of the
work piece.

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19.The knurling tool was used, after replacing the tool bit, and it is
centered at the machine using the tail stock center and L-square.
Before performing knurling, these steps were needed to be taken care
of:
a. Tool post is adjusted to +5
b. Spindle speed is changed to 30 rpm
c. The feed rate is set to 0.476
d. The opened end of the piece is supported with the tailstock.
20.Both the knurling wheels were made sure to be in contact with the
work piece. The spindle is switched on slowly until a pattern begins to
form.
21.The automatic feed was engaged so that it moves to the right and the
tool feed is let to cross the work piece until the entire work piece was
knurled.

The finished work piece is as following:-

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DISCUSSION
The modern center lathe machine is capable of generating a round or flat
surface. The work piece is revolved about its center line, while the tool, held
in a suitable tool post, follows a predetermined path. Therefore, all lathe
machine has the following attributes:
i.
ii.
iii.
iv.

Device for holding the work piece

Device for holding the tool
Rotation of the work or tool
Arrangement for movement of the work or tool

A cutting tool is used to remove metal in the form of small chips. The
process is termed machining and is perhaps the most versatile
manufacturing process. The machine that provides the necessary relative
motions between the work and the cutting tool is commonly known as the
machine tool. If a cutting tool is to shear or cut the metal efficiently, it is
important that angles have the correct values according to the machining
operation and the metal being machined.
Turning operations are entirely performed using the lathe machine. A
lathe is a machine tool used for producing surfaces of revolution and flat
edges.
The following is the picture of center lathe machine and its components:

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a) Headstock
- Contains the motor control, speed range selector, variable speed
control
b) Tailstock
- Contains ram, ram lock, bed clamp, ram hand wheel, lock stud, set
over screw
c) 4-way tool post
d) Contains tool holder
e) Compound slide
- contains tool post slide hand wheel
f) Cross slide
- Contains clutch and brake lever, cross feed hand wheel, power feed
lever, clutch kick-out, carriage hand wheel, half nut lever, thread dial
g) Feed box
- Contains sliding gear lever, gear election, thread/feed selector lever,
lead screw direction control
h) Lead screw
i) Feed shaft
- Contains clutch control bar
Basic turning operations are usually for generating round or flat
surfaces using a center lathe. The work piece is revolved about its centerline,
while the tool, held in a suitable tool post, follows a predetermined path.

Facing
If the tool follows a path at 90 degree to the lathe center line a plane surface
can be produced at the ends of the cylinder. This is achieved through the
movement of the cross slide. If the tools move towards the center line the
technique is known as surfacing inwards. If the tool moves away from the
centerline the technique is known as surfacing outwards.
Facing is done to produce a better finish at the end surface of the work piece.
This operation required the compound slide-to-slide about 45 degrees.

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Taper turning
It can be achieved only when the tool traverses a path not parallel with the
lathe center. There are two main methods, shown in figure below, for
producing a taper turning.
a) By tilting the compound slide.
b) By offsetting the tailstock.

A taper may be defined as a uniform increase in diameter on a work piece for

a given length measured parallel to the axis. To start, the compound slide had
to adjust for certain degree from the x-axis.
Knurling
The knurling operation consists of deformation of the workpiece using a
hardened knurling roller. The disadvantage of this tool is the fit has less
contact than the standard area.
Knurling provides a good gripping surface for levers and tool handlers. The
type of knurling used was diamond type and the tool holder was revolving
head knurling type.

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Drilling and Reaming
Drilling at the center lathe is achieved by using tailstock as tool holding
device. Twist drill is used for drilling and taper-shank reamer is used for
reaming operation.
Drilling is process to make a hole in the work piece.

Boring
When holes require accurate diameter the boring technique is often used.
The boring tool is held in the tool post. If a tapered hole is needed the
compound slide is indexed at one-half the included angle of the taper. Boring
is the enlarging of a hole by means of a single-point cutting tool. Boring may
be done to obtain a continuous inside diameter, or a stepped, tapered,
contoured or recessed diameter.
Grooving
This process produces a groove or drain on the work piece. It will remove a
portion of material at a specified location on the work piece. The cutting tool
suitable for this process is grooving tool.

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Chamfering
Chamfering will eliminate the sharp edge on the work piece. The cutting tool
used was 45 rougher.

1.5mm

90

Finishing
Finishing would make the outer surface of work piece fine and smooth. The
technique could be done manually by moving the knife tool slowly with
constant speed along the work piece. However, it would work better if the
automatic feed cut were applied. Thus, the suitable speed of the cross slide
is chosen at the feed box. Then, the cross slide would move by itself
according to the selected direction. The cut usually is done just several times
only.
Lathe operations:
Operation

Cutting Speed

Turning
(external)

V = (D
+2d)N

Boring

V = (D
+2d)N

Facing

Max. V =
DN
Min.V = 0
Mean V =
DN/2
Max. V =
DN
Min.V = 0
Mean V =
DN/2

Parting

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Machining
time
T = L / fN
where L=
length of
workpiece +
allowance.
T = L / fN

Material-removal
rate
MRR = (D+d)N.
f.D

T=D+
allowance
2fN

max MRR=
DN.f.d
mean MRR =
DN.f.d
2
max MRR=
DN.f.d
mean MRR =
DN.f.d
2

T=D+
allowance
2fN

MRR =
(D-d)N. f.D

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At first, while performing the facing process, I found a bump in the
middle of the work piece. Later on, I found out that was because the tool bit
was not center to the work piece. So, centering the tool bit was and always
will be a determining aspect in attaining a good work piece. Undeniably, I
experienced some problems initially because the briefing given at the
beginning of the session was too brief and fast. Since it was the first time I
was exposed to a lathe machine, it took quite some time for me to operate
the machine. Thankfully, the demonstrator was there to help.
In performing turning, we must always be alert and be aware of what
you are doing. A little mistake can cause a work piece. Below are some of the
safety precautions that should be taken when in the turning section.
i.
Do not attempt to operate the lathe on your own until you are
thoroughly familiar with its operation.
ii.
Dress appropriately. All neckties, watches and rings should be
removed. Instead a properly fitted coat and goggles should be
worn.
iii.
Works should be clamped properly and the correct size of tool
or work holding device should be used.
iv.
Stop the machine before making any measurements.
v.
Do not attempt to remove chips with bare hand and fingers.
Stop the machine and use pliers instead to remove them.
vi.
Plan the work thoroughly before starting. Have all the tools that
are need at hand before commencing work.
vii.
Do not fool around or permit anyone to interfere with the
machine while you are operating it.
viii.
Never leave the key in the chuck. Make it a habit never to let go
of the key until it is out of the chuck and clear of the work
area.
ix.
Check the work frequently for overheating or vibrations as it
could damage both the work and the machine.
x.
Stop the machine immediately if some odd noise or vibration
develops while operation. If the cause of trouble is not found,
get the instructor. Under no condition should the machine be
operated until the trouble has been found and corrected.
xi.
Return all necessary tools to the proper storage area. Remove
all other tools from the immediate work area.

CONCLUSION
Alhamdulillah, Im able to complete this activity without any big
problems. All in all, I would say that the objectives of this workshop activity
is successfully achieved as I can now understand and operate a lathe
machine. Hence, I have gained knowledge and valuable experience in doing
this activity. The practical work in using this machine gave an opportunity to

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me to practice the proper way in applying the basic operations besides
develop some skills and technique. I managed to produce the required work
piece, albeit with a little deviation from the correct dimensions. Im thankful
for that.

REFERENCES
-

Course manual
Machine Tool Practice (6th Edition) by Prentice Hall
Machinerys Handbook (26th Edition) by Industrial Press

ANSWERS TO QUESTIONS
1. Taper turning can only be achieved when the tool traverses a path not
parallel with the lathe centre. What are the limitation and advantages
of these two methods?
a) By tilting the compound slide
Advantages
Possible to cut any angle of taper
Simple setting of workpiece and cutting tool
Possible for internal and external tapering
Limitations
Length of taper is limited to the stroke of the compound slide
b) By offsetting the tailstock
Advantages
Possible to cut long, slight tapers
Possible to cut a short taper to a long workpiece
Limitations
The limitation of the taper due to the limited contact of the
center and the center hole.
Possible for external taper only
2. Sketch the knurling operation and find its limitation

Limitations :
If the wheels are not properly set, not properly facing
the surface of the piece, the knurling process is
considered not done properly.

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The feed rate mustnt be too much; roughly around
0.7mm, or otherwise it wont come out as what is
should be.
It is not a quick process as the motion of the knife
longitudinally must be done at a slow rate; 30 rpm.
3. Homework Problems
1) Determine the cutting speed for machining a work piece 120mm in
diameter at a spindle speed N= 500 rpm.
Cutting Speed = (120) (500) / 1000 = 188.5 m/min
2) Determine the rotational speed of the lathe spindle in machining a work
piece 80mm in diameter at a cutting speed 215 m/min.
Rotational speed of lathe spindle, N
rev/min.

= 215 . 1000 / (80 ) =

3) Determine the feed per minute required to turn a work piece on a lathe at
the spindle speed 1000 rpm; the tool feed is 0.26 mm/rev.
Feed per minute = (0.26mm/rev) (1000 rev/min) = 260mm/min
4) Determine the depth of cut in boring a hole 55mm in diameter to 60mm
by one pass on a lathe
Depth of Cut = (60 55) / 2 = 2.5 mm
5) Determine the depth of cut in turning a work piece 150mm in two passes.
The first pass is a roughening operation to 142 mm and the second pass
is a finishing to 140 mm diameter.
DoC (rough) = (150 142) / 2 = 4 mm
DoC (finishing) = (142 140) / 2= 1 mm
6) Determine the machining time for slide turning of a shaft from D= 70mm
to 64 mm over a length of 200mm. The lathe spindle speed is 600 rpm;
the tool feed = 0.4 mm/rev. Using tool approach of 3mm and over travel
2mm. What is the depth of cut?
Machining time, T = (200 + 2 +3) / (0.4 x 600)
= 0.083 min = 51 sec
DoC = (70 64) / 2 = 3 mm

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7) Determine the machining time in facing a work piece of a diameter
165mm on a lathe in one pass. The spindle speed is 480 rpm and feed is
0.3 mm/rev. Consider the depth of cut 3.5 mm, and both approach and
over travel are 5.5mm.
Length of travel, L = (165 / 2) + (2 x 5.5) = 93.5 mm
Machining time, T = (93.5 / (480 x 0.3) = 39 sec
8) Determine the machining time in parting off a tube like work piece with
outside diameter 100mm and inside diameter 84mm. The spindle speed
=250 rpm, the tool feed = 0.14mm/rev. The tool travel and approach equal
2mm.
Machining time, T = [(100 89) / 2 ] + 4 / 0.14 x 250
= 0.323 min
= 20.6 sec

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