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E2.11 Hands-On Machining Using Lathe

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15 views7 pages

E2.11 Hands-On Machining Using Lathe

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crtve
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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NANYANG TECHNOLOGICAL UNIVERSITY

SCHOOL OF MECHANICAL AND AEROSPACE ENGINEERING

E2.11/E2.11AE HANDS-ON MACHINING PRACTICE- LATHE

PRECISION ENGINEERING LAB

Venue: N3-B4c-03

Name of student: _____________________________ Lab Sub-Group:___________________

Matric No: _______________________________________ Date: _________________________

Name of Supervisor:_______________________________________________________________

Grade: ______________________________
E2.11/E2.11AE HANDS-ON MACHINING PRACTICE- LATHE

1. INTRODUCTION

Material removal processes are a family of shaping operations that are appropriately selected to produce the
desired final geometry. Turning is a machining process in which a single-point tool removes material from
the surface of a rotating cylindrical workpiece. Turning is traditionally carried out on a machine tool called a
lathe.

2. OBJECTIVES

(i) To learn machining practices on a variety of machining o perations, such as internal &
external diameter turning, drilling, facing and parting off .
(ii) To learn tool setting and how to machine to the desired geometry.
(iii) To learn how to select appropriate tools and machining conditions.

3. SCOPE

3.1. Workshop Safety

Safety procedures must be observed at all times. Trained technical staff will assist student in following safe
working practices for workshop operations. PPE will be provided for each and every student.

a) Read the operating instructions carefully.


b) Don't wear loose clothing.
c) Long hair must be tied up or enclosed in a hair net.
d) Always wear safety glasses.
e) Wear ear protection especially for operations that generate high level of noise.
f) Footwear such as flip flops and sandals are prohibited.

3.2. Machining conditions in turning

In machining a turned part, relative motion is required between the single-point tool and the rotating
workpiece. The primary motion is accomplished at a certain rotational speed, N (rev/min) as shown in
Figure 1. In addition the tool must move laterally across the work for turning. This is a much slower
motion and called the ‘feed’ f (mm/rev). The penetration of the cutting tool to reduce the diameter of the
original workpiece is called the ‘depth of cut’ d (mm).

3.3. Machining Operations

The schematic of a lathe machine with its principle components are shown in Figure 2. A variety of
machining operations can be performed on a lathe. These operations include facing, taper turning, drilling,
outside & inside diameter turning and parting off (see Figure 3).

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Fig. 1 Schematic of the tool motion during turning of a workpiece

The operations require the use of appropriate cutting tools, work holding devices, measuring instruments,
testing devices, gauges, and other accessories as and when needed. Table 1 is a sample list of such
accessories and tools.
Table 1 Tools and accessories
Name Type Uses
For measuring length, outside & inside
Digital Vernier Caliper Measuring instrument
diameter and depth
Parallel bars Gauge For adjustment of height and parallelism
External carbide cutter Cutting tool For cutting outside shapes
Boring bar Cutting tool For cutting inside shapes
For cutting off the finished workpiece from
Parting off cutter Cutting tool
the raw material

Fig. 2 Nomenclature of a lathe machine

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Fig. 3 Example of various machining processes that can be performed on a lathe (a) facing, (b) taper turning,
(c) parting off, and (d) internal diameter turning (a.k.a. boring)

3.3. Experimental procedure for lathe work


(Note that all drawings provided have a nominal tolerance of ± 0.01 mm.)

Machining of the Frame, Axle and Flywheel of a Gyroscope (refer to Fig. 4 & 5)

1. Only the relevant portions of the 3 components will be used for the lathe operations.
2. The operations for the Frame consist of:
a. Facing operation of raw material
b. Turning of external diameter to 78 mm and to a length of 13 mm
c. Boring operation of internal diameter to 62 mm and to length of 13 mm
d. Chamfering operation to remove sharp edges on machined workpiece
e. Parting-off operation of Frame to a length of about 12 mm
f. Facing operation of Frame to the required length of 10 mm
g. Chamfering operation to remove any sharp edges of machined workpiece
3. The operations for the Flywheel consist of:
a. Facing operation to the required length of 12 mm
b. Spot (center) drilling
c. Drilling operation with a 5.8 mm drill
d. Reaming operation of 6.0 mm hole in the workpiece
4. The operations for the Axle consist of:
a. Tapering operation to produce a sharp cone on both ends of Axle
b. Deburring operation to remove sharp edges
5. Note that details of the process plan are provided in given the Lab course portal.

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Fig. 4 Gyroscope Frame and Axle

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Fig. 5 Gyroscope Flywheel

3.4 Assembly of Gyroscope

There is a separate instruction sheet (in the lab session) to guide you on how to assemble the gyroscope as
shown in Fig. 6. Assembly of the Gyroscope is only relevant if you have completed E2.12.

Fig. 6 Gyroscope Assembly

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4. OUTCOME

(i) Learn the importance of safety aspects to handle equipment


(ii) Students would be able to gain a basic knowledge on machining operations with a lathe
(iii) Learn various types of tooling and various machining parameters
(iv) Learn how to mount a workpiece rigidly as well as to secure a cutting tool in position
(v) Learn about correct tool setting
(vi) Learn to measure and to machine a part to the desired dimension

5. ON-LINE QUIZ

Students who have completed the hands-on machining will be given access to perform the quiz consisting
of ten questions randomly generated from a question pool.

REFERENCES

1. S. Kalpakjian, S. Schmid, Manufacturing Engineering & Technology, 7 th ed, Pearson, 2013.

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