PROGRAMME : CEEM222

COURSE : MEM460
INSTRUCTOR : Encik Thoha bin Subhi

LABORATORY REPORT
LABORATORY: SHEET METAL

NO NAME STUDENT ID GROUP

NO
1. MUHAMMAD ANIQ ABQARI BIN
SALLEHSHAHIBBUDIN 2022464556 A
2. ADAM BIN MOHD SHAHRIZAN
2022453412 A
3. QURRATUL NADJWA NURAISYAH
BINTI NADZRI 2022464476 A

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Table of Contents
1.0 Title................................................................................................................................................... 3
2.0 Objective .......................................................................................................................................... 3
3.0 Introduction ..................................................................................................................................... 3
4.0 Experimental Procedure ................................................................................................................. 4
4.1 Apparatus Setup .......................................................................................................................... 4
4.2 Material Used .............................................................................................................................. 7
4.3 Procedure and Setup .................................................................................................................. 9
a) Facing Process ..................................................................................................................... 10
b) Parallel Turning .................................................................................................................. 11
c) Taper Turning ...................................................................................................................... 12
d) Chamfering .......................................................................................................................... 13
4.4 Safety and Precautions ................................................................................................................. 13
5.0 Result and Discussion ................................................................................................................... 14
5.1 Result ......................................................................................................................................... 14
5.2 Discussion................................................................................................................................... 14
6.0 Recommendations ......................................................................................................................... 15
7.0 Conclusion ..................................................................................................................................... 15
8.0 Question ......................................................................................................................................... 15

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1.0 Title
Turning process (Lathe Machine)

2.0 Objective

The primary purpose of the lathe machine is to cut away extra material and produce the
appropriate form and size for the job by rotating the workpiece on a spindle against the tool at
a specific speed. A symmetrical object can be created by using cutting tools and drill bits of
various diameters. The 'Mother of All Machines' is another name for this. Because it enables
a wide range of operations, the lathe machine has evolved into a general-purpose machine
tool used in manufacturing and repair work.

3.0 Introduction
Lathe machine is one of the most important machine tools which is used in the metalworking
industry. It was invented by DAVID WILKINSON (05 Jan. 1771 – 03 Feb. 1852). Lathe
machine is also known as “Center Lathe” because of two centers between which the job can
be held and rotated. To make working with tools easier, those before us developed the lathe,
the earliest machine tool prototype, almost 2,000 years ago. The development of machine
tools proceeded during the 13th century, and it was important to come up with alternate ways
to use them because hanging them from trees was no longer an option. As a result, the "pedal
lathe" was developed, which utilised a foot pedal to turn the crankshaft and propel the
flywheel. This was also referred to as a flexible bar lathe and powered the spindle, which
rotated as a result.

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4.0 Experimental Procedure
4.1 Apparatus Setup
To setup a Cutting Tool for Machining

1.Move the toolpost to the left-hand side of the compound rest.

2.Mount a toolholder in the toolpost so that the set screw in the toolholder is about 1 inch
beyond the toolpost.

3.Insert the proper cutting tool into the toolholder, having the tool extend .500 inch beyond
the toolholder.

4.Set the cutting tool point to center height. Check it with straight rule or tailstock.

5.Tighten the toolpost securely to prevent it from moving during a cut

Figure 4.1.1 Toolpost and Toolholder

To Mount Workpiece in Lathe

1.Check that the line center is running true. If it is not running true, remove the center, clean
all surfaces, and replace the center. Check again for trueness.

2.Clean the lathe center points and the center holes in the workpiece.

3.Adjust the tailstock spindle until it projects about 3 inch beyond tailstock.

4.Loosen the tailstock clamp nut or lever.

5.Place the end of the workpiece in the chuck and slide the tailstock up until it supports the
other end of the workpiece.

6.Tighten the tailstock clamp nut or level.

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 Figure 4.1.2 Workpiece in Lathe

Installing a Cutting Tool

1.Tool holders are used to hold lathe cutting tools.

2.To install, clean the holder and tighten the bolts.

3.The lathe’s tool holder is attached to the tool post using a quick release lever.

4.The tool post is attached to the machine with a T-bolt.

Figure 4.1.3 Installing a Cutting Tool

Positioning the Tool

To reposition the cutting tool, move the cross slide and lathe saddle by hand. Power feeds are
also available. Exact procedures are dependent on the machine. The compound provides a
third axis of motion, and its angle can be altered to cut tapers at any angle.

1.Loosen the bolts that keep the compound attached to the saddle.

2.Swivel the compound to the correct angle, using the dial indicator located at the
compound’s base.

3.Tighten the bolts again.

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4.The cutter can be hand fed along the chosen angle. The compound does not have a power
feed.

5.If needed, use two hands for a smoother feed rate. This will make a fine finish.

6.Both the compound and cross slide have micrometer dials, but the saddle lacks one.

7.If more accuracy is needed when positioning the saddle, use a dial indicator that is attached
to the saddle. Dial indicators press against stops.

Figure 4.1.4 Positioning the Tool

Centering the Workpiece

Steel Rule

1. Place the steel rule between the stock and the tool.

2. The tool is centered when the rule is vertical.

3. The tool is high when the rule is lean forward.

4. The tool is low when the rule is lean backward.

Figure 4.1.5 Steel Rule

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Tailstock Center

1. Reference the center of the tailstock when setting the tool.

2. Position the tip of the tool with the tailstock center.

Figure 4.1.6 Tailstock Center

4.2 Material Used

Aluminium workpiece A silvery-white, lightweight metal. It is soft
and malleable. Commonly used due to its
excellent resistance to corrosion, can be
easily machined, formed and strong.

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 Hex key A simple driver for screws and bolts with
internal hexagonal recesses head.

Vernier Calliper Used to measure the diameter of the

workpiece

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4.3 Procedure and Setup
Lathe machine,

A lathe with the following specifications was used: overall length 60mm,

List of tools includes a thread gauge, threading tool, parting tool, lathe dog carrier, flat
smooth file, single point cutting tool, knurling tool, centre drill, drill chuck 12", and a
spanners set.

Materials: Mild steel bars, 40 mm in diameter.

Steps to take:

1. Before deciding on a course of action, the workpiece drawing was carefully analysed and
comprehended.

2. A bar with a 10 mm diameter was cut into a 15 mm long piece.

3. Drilling operations for facing and the central hole were carried out while the workpiece
was secured in the lathe chuck. The process was carried out once more on the other side

4. Between live and dead centres, the workpiece was positioned.

5. Plain turning was done (L=30mm), along with chamfering and knurling on one side and
axial face switching.

6. The compound rest was swivelled at an angle of 45°to turn the plane.

7. Levers were set according to specifications, and threading was completed.

8. The workpiece was filed to remove the sharp edges.

9. To protect it from dust, the workpiece was removed from the lathe and oiled.

Security Measures

1. When operating a machine, loose clothing is not permitted.

2. The workpiece needs to be carefully held between the live and dead centres.

3. Prior to use, the machine must be cleaned.

4. The tool holder should be used to securely hold cutting tools.

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a) Facing Process
The tool will start to detach the metal from the end as soon as it hits the workpiece.
When the tool has reached the centre of the workpiece, turn it anticlockwise (in your
direction) until it returns from the edge. Use the compound handwheel to spin the
tool's tip until it reaches the end of the workpiece before turning the machine on. The
tool can extend past the diameter of the workpiece by rotating the cross-feed crank
back.

The lathe should now be turned on, and the speed control knob should be turned up to
a few hundred RPM. Turn the cross-feed handwheel slowly in the direction of the
workpiece once the machine is running.

You might observe that a tiny quantity of metal is removed on the return pass if you
crank the tool backward after it has reached the workpiece's center. This is because
there are high areas where the surface is not completely smooth, which is losing metal
from.

- Return pass
By inserting the tool only slightly into the workpiece on the return pass, you can
remove a lot of metal on a return cut. It works best with a tool that has a reasonably
sharp pointed tip because the tool must sink into the face of the workpiece.

It may take three or more passes to get a nice smooth finish across the face of your
workpiece, depending on how rough the end was, to begin with. These initial passes
are called roughing passes and cut relatively large amounts of metal.

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 - Finishing cut
A last finishing cut of roughly.001 to.003 inches of metal can be made once a
reasonably smooth surface has been obtained to produce an even better smooth
surface. To get a smoother finish, the finishing cut can also be made at a higher RPM.

A last finishing cut of roughly.001 to.003 inches of metal can be made once a
reasonably smooth surface has been obtained to produce an even better smooth
surface. To get a smoother finish, the finishing cut can also be made at a higher RPM.

b) Parallel Turning
Parallel turning is the process in which the cutting tool is fed parallel to the axis of the
workpiece. Since parallel turning is the fundamental lathe operation and most other
operations only slightly alter it, this operation is particularly crucial.

1. To create an exact cylindrical diameter.

2. To create a diameter that is desired.

In most cases, parallel turning is done in two cuts, the roughing cut and the finish cut.
The cross slide's graded collar helps the operator remove the right quantity of material
precisely. Only the tool's movement toward the work is shown by this collar.
Consequently, on rotating-task machines (such as lathes, cylindrical grinders, boring
mills, etc.),

a) From the tool crib, choose a turning and end-facing tool bit.
b) Place the workpiece inside the chuck's three jaws.
c) Insert the tool bit into the proper tool holder, leaving about a finger's width of space
exposed.(Only finger tighten)
d) Install a tool holder in the tool post on top of the rocker. About two finger widths
should be exposed.

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 e) Set the rocker so that the tool bit's cutting tip is parallel to the centerline of the
lathe. To find this center line, use the live center's point.
f) Rotate the tool holder such that the bit of the tool that touches the work only makes
contact at its point. Set the tool holder and bit of the tool in place. View diagram.
g) Adjust the lathe's workpiece-specific rpm.
h) Turn the carriage hand wheel to bring the cutting tool nearly but not quite in
contact with the workpiece.
i) Start the lathe, then place the tool bit against the workpiece.(by use of the cross
slide)
j) Move the carriage till it is free of the work by moving it to the end of the
workpiece.
k) Set the graduation collar on the cross slide to zero.
l) Adjust the cross slide dial as necessary. Don't forget to turn the dial in by half.
m) For a delicate cut, set the carriage power feed to.005", and for a rough cut, to.016".
n) Shut off the lathe and use a micrometer to measure the diameter.
o) Continue making rough cuts if more machining is necessary until a finish cut may
be utilized to attain the desired dimension.

c) Taper Turning

To position the workpiece, first loosen the chuck key's jaws; after that, tighten the jaws.The
cutting tool should be fixed in the tool holder.

Activate the lathe, then advance the carriage toward the workpiece. After a brief cross-feed,
progressively extend the carriage's longitudinal movement to the desired length.

Return the carriage holder to its starting position before feeding the pen holder vertically after
a brief horizontal feed. Till the desired diameter is reached, repeat this step.

A modest quantity of feed should be provided to achieve a smooth surface when the diameter
is nearly at the desired value.

Move the tool holder such that the tool contacts the end face of the workpiece to face it.

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 d) Chamfering
A particular kind of edge is called a chamfer. Chamfering is the technique for creating
the edge, which one could say is a distinctive yet typical application. A flat edge that
forms a 45-degree angle is known as a chamfer edge.

Although a chamfer edge enhances visual qualities, it is also a useful option for
purposes other than aesthetics. This particular edge makes it more durable and less
prone to damage than a filet and bevel edge. Chamfering is also excellent for
producing edges that can fit together smoothly. For instance, chamfering the edges of
two workpieces makes it easier for them to come together during welding while yet
maintaining the necessary dimensional precision.

4.4 Safety and Precautions

1. Wearing loose clothing, jewellery, watches, or gloves is prohibited. Constrict and tie back
lengthy hair.

2. Never lean on the machine. Stay upright. Stay away from flying chips with your face and
eyes.

3. Do not alter the machine while it is running. Hold off until the machine has completely
stopped.

4. Avoid touching the lathe's rotating work with your hands.

5. Use of callipers or gauges on a workpiece while a machine is running is not advised.

6. Avoid making deep cuts on long, thin parts since they may flex and fly out of the lathe.

7. When the lathe is running, do not leave it unattended.

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5.0 Result and Discussion

5.1 Result

Figure 5.1.1 Lathe’s Result

5.2 Discussion

A lathe machine may create a wide variety of items, including parts for equipment, musical
instruments, and other items we use every day. The lathe machine can perform a wide range
of tasks. Along with drilling and knurling, these operations also include facing, turning, and
taper turning. We successfully completed this machine pin job thanks to our proficiency in
this operation.

The spindle rotation speed is dependent on the operation. The spindle's rotational frequency,
expressed in RPM, is known as its rotation speed. Drilling requires a higher speed while
knurling activity requires a slower turn speed. The type of materials and the quality of the
tool bits influence the rotation speed during the turning process.

In order to guarantee that the project's dimension is precise and accurate, periodic
measurements of the workpiece are required. To ensure that no mistake is made that could
jeopardize the project's outcome, constant surveillance of the workpiece is necessary.

There are no accidents occurred during the lathe workshop practice.

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6.0 Recommendations

Use a face mask or eye protection when operating the lathe machine because metal chips will
fly everywhere as the machine removes a piece of the metal. Make sure the machine's
rotation is compatible with the tool you are using; otherwise, the metal won't be cut. Make
sure that the machine's rotation is moving away from you while filing the metal's spherical-
shaped end so that the file can effectively smooth the metal. If not, both the file and the
rotation will move towards you and the file won't be able to smooth the metal.

7.0 Conclusion

Lathes are useful equipment for making precise parts fast and efficiently, especially in
production settings where time is a crucial consideration when evaluating cost reductions.
Before making a purchase, one must weigh the benefits and drawbacks of a certain
instrument or piece of equipment, including pricing factors and the need for ongoing
maintenance to keep the device in good operating order. Business owners can make the best
judgement possible when determining whether a lathe machine would be beneficial to their
operation by thoroughly analysing all the available options before making any decisions.

8.0 Question

Explain in details the turning process of bolt and nut

The turning process can be carried out manually or automatically using a variety of
techniques. The method generally includes the following steps:

Preparing the blank, which is the raw material that will be used to create the bolt or nut, is the
first stage in the turning process. The blank is typically cylindrical in shape and constructed
of metal.

Turning: The blank will now be turned on a lathe. A cutting tool is used to remove material
from the surface of the blank while the blank is rotating on a machine tool called a lathe. The
cutting tool is often designed to provide the correct thread profile and is composed of high-

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speed steel or carbide. Up till the desired depth of the thread is reached, the turning procedure
is repeated numerous times.

Thread rolling is another technique for producing threads. The blank is pressed between two
dies made of hardened steel that have the thread profile etched into them during this
operation. The metal flows and forms the threads as a result of the rotating dies' pressure on
the blank. This method is frequently utilized for high-volume production since it is quicker
than turning.

Heat Treatment: The bolt or nut is heat-treated to enhance its mechanical qualities once the
threads are created. The fastener is heated to a certain temperature during the heat treatment
process, then quickly cooled. The fastener's strength, hardness, and toughness can all be
increased by this technique.

Finishing: The fastener is lastly finished by being cleaned, deburred, and coated. The fastener
is cleaned to remove any dirt or debris, and it is deburred to remove any burrs or edges that
might have been left over after turning. A protective layer, such zinc or chromium, can be
applied to the fastener to increase corrosion resistance.

Briefly put, the turning process for bolts and nuts entails preparing the blank, rolling or
turning the threads, heat treating the fastener, and finishing the item. The procedure is crucial
to the fastener's quality and dependability and is necessary to provide a safe and sturdy
connection in a variety of applications.

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9.0 References

1) Conclusion lathe machine

https://www.studocu.com/my/search/conclusion-lathe-machine?institutionId=43438

2)Different Operations Performed on a Lathe Machine

https://themechanicalengineering.com/lathe-
machine/#Different_Operations_Performed_on_Lathe_Machine

3) Metalworking Machines – Lathes

https://www.ccohs.ca/oshanswers/safety_haz/metalworking/lathes.html

4) Aluminium

https://www.rsc.org/periodic-
table/element/13/aluminium#:~:text=Aluminium%20is%20a%20silvery%2Dwhite,It%20is%
20soft%20and%20malleable.&text=Aluminium%20is%20used%20in%20a,beer%20kegs%2
0and%20aeroplane%20parts.

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