Mechanical work shop

Assignment#1

2019-CH-35

Huda shah

Chemical engineering

Submitted to: - Sir Ashraf Ali

University of engineering and technology

 LATHE SAFETY
As always we should be aware of safety requirements and attempt to observe safety rules in order
to eliminate serious injury to ourselves or others.

Wear glasses, short sleeves, no tie, no rings, no trying to stop the work by hand. Stop the machine
before trying to check the work. Don’t know how it works? –“Don’t run it.” Don’t use rags when the
machine is running.

1. Remove the chuck key from the chuck immediately after use. Do not turn the lathe on if the
chuck is still in the chuck key.

2. Turn the chuck or faceplate through by hand unless there are binding or clearance issues.

3. It is important that the chuck or faceplate is securely tightened onto the lathe’s spindle.

4. Move the tool bit to a safe distance from the chuck, collet, or face plate when inserting or
removing your part.

5. Place the tool post holder to the left of the compound slide. This will ensure that the compound
slide will not run into the spindle or chuck attachments.

6. When installing and removing chucks, face plates, and centers, always be sure all mating
surfaces are clean and free from burrs.

7. Make sure the tool bit is sharp and has correct clearance angles.

8. Clamp the tool bit as short as possible in the tool holder to prevent it from vibrating or breaking.

9. Evenly apply and maintain cutting fluids. This will prevent morphing.

10. Do not run a threaded spindle in reverse.

11. Never run the machine faster than the recommended speed for the specific material.

12. If a chuck or faceplate is jammed on the spindle nose, contact an instructor to remove it.

13. If any filing is done on work revolving in the lathe, file left handed to prevent slipping into the
chuck.

14. Always stop the machine before taking measurements.

15. Stop the machine when removing long stringy chips. Remove them with a pair of pliers.

16. Make sure that the tailstock is locked in place and that the proper adjustments are made if the
work is being turned between centers.

17. When turning between centers, avoid cutting completely through the piece.

18. Do not use rags while the machine is running.

19. Remove tools from the tool post and tailstock before cleaning.

20. Do not use compressed air to clean the lathe.

21. Use care when cleaning the lathe. The cutting tools are sharp, the chips are sharp, and the
workpiece may be sharp.

22. Make sure the machine is turned off and clean before leaving the workspace. Always remove
the chuck wrench after use, avoid horseplay, keep floor area clean. Use care when cleaning the
lathe, the cutting tools are sharp, the chips are sharp, and the workpiece may be sharp.
 Topic: 1 Lathe Construction
1. The Working of Centre Lathe Machine and its parts.
The lathe machine is one of the oldest and most important machine tools. As early as 1569,
wood lathes were in use in France. The lathe machine was adapted to metal cutting in England
during the Industrial Revolution. Lathe machine also called “Engine Lathe” because the first
type of lathe was driven by a steam engine Lathe machine is also known as “the mother/father
of the entire tool family”. Lathe Machines are used in metalworking, woodturning, metal
spinning, thermal spraying, glass working, and parts reclamation. The various other operations
that you can perform with the help of Lathe Machine can include sanding, cutting, knurling,
drilling, and deformation of tools that are employed in creating objects which have symmetry
about the axis of rotation.

What is Lathe Machine?

A lathe is a machine tool which is used to rotate a workpiece to perform various operations such
as turning, facing, knurling, grooving etc., with the help of tools that are applied to the workpiece.
Working Principle of Lathe Machine

The function of a lathe is to remove metal from a piece of work to give it a desired shape and size.
In a lathe machine, the workpiece rotates against the tool. The tool is used to remove material
from the workpiece. The direction of the motion of the tool is called a feed.
Feed
The tool movement relative to the work is known as feed. There are three types of feed:-
 Longitudinal feed :- When tool moves away or towards the head stock parallel to the axis of
the work.
 Cross feed:- When the tool moves away from the or towards from the operator
perpendicular to work.
 Angular feed:- By swivelling the compound rest the tool is made to move at any angle to the
work.
Schematic diagram of the lathe machine:

Parts of the Lathe Machine and their functions:

A lathe machine tool consists of several parts like:

1. Headstock
2. Bed
3. Tailstock
4. Carriage
5. Saddle
6. Cross-slide
7. Compound rest
8. Toolpost
9. Apron
10. Lead Screw
11. Feed rod
12. Chuck
13. Main spindle
14. Leg

Head Stock:
Head Stock is situated at the left side of the lathe bed and it is the house of the driving mechanism
and electrical mechanism of a Lathe machine tool.

 It holds the job on its spindle nose having external screw threads and internally Morse taper for
holding lathe center. And it is rotating at a different speed by cone pulley or all geared drive.
There is a hole throughout spindle for handling long bar work.
 Head Stock transmit power from the spindle to the feed rod, lead screw and thread cutting
mechanism.

Accessories mounted on headstock spindle:

1. Three jaw chuck

2. Four jaw chuck
3. Lathe center and lathe dog
4. Collect chuck
5. Faceplate
6. Magnetic chuck
A separate speed change gearbox is placed below headstock to reduce the speed in order to have
different feed rates for threading and automatic lateral movement of the carriage. The feed rod is
used for most turning operation and the lead screw is used for thread cutting operation.

Lead screw:
A lead screw is also known as a power screw or a translation screw. It converts rotational motion
to linear motion. Lead Screw is used for Thread Cutting operation in a lathe machine tool.

Feed Rod:
Feed rod is used to move the carriage from the left side to the right side and also from the right
side to the left side.

Chuck:
Chuck is used to holding the workpiece securely.

There are generally 2 types of chucks:

1. 3 jaw self-centering chuck

2. 4 jaw independent chuck

 Three jaws and three square slots or holes are provided on the circumference of the body.
 By inserting the key in any one slot, all jaws can be moved simultaneously.
 Speedy centering of the work piece.
 Cannot hold large size of work piece.

Main Spindle:
The spindle is a hollow cylindrical shaft in which long jobs can pass through it.

It is designed so well that the thrust of the cutting tool does not deflect the spindle.

Bed:
It is the base of the lathe machine. It is made of single piece casting of Semi-steel ( Chilled Cast
Iron). The bed consists of two heavy metal slides running lengthwise, with ways or ‘V’ formed upon
them and rigidly supported with cross girths.

 It is sufficiently rigid and good damping capacity to absorb vibration.

 It prevents the deflection produced by the cutting forces.
 It supports the headstock, tailstock, carriage and other components of the lathe machine.
Tail Stock:
Tail Stock is situated on the right side above the lathe bed.

it is used for :

 Support the long end of the job for holding and

minimizes its sagging.
 It holds the tool for performing different operations like
drilling, reaming, tapping, etc.
 And it is also used for a small amount of taper for a long job by offsetting the tailstock.

Carriage:
The carriage is used for support, guide and feed the tool against the job when the machining is
done.

 It holds moves and controls the cutting tool.

 It gives rigid supports to the tool during operations.
 It transfers power from feed rod to cutting tool through apron mechanism for longitudinal cross-
feeding.
 It simplifies the thread cutting
operation with the help of lead
screw and half nut mechanism.

it consist of

1. Saddle
2. Cross-slide
3. Compound rest
4. Toolpost
5. Apron

It provides three movements to the tool:

1. Longitudinal feed-through carriage movement

2. Cross feed-through  cross slide movement
3. Angular feed-through top slide movement

I. Saddle:
Generally, it is made up of ‘H’ shaped casting and it has a ‘V’ guide and a flat guide for mounting it
on the lathe bed guideways.

II. Cross-slide:
It is assembled on the top of the saddle. The top surface of the cross-slide is provided with T-slot.

III. Compound rest:

It supports the tool post and cutting tool in its various positions. It can be swiveled at any desired
position in the horizontal plane. It is necessary for turning angles and boring short tapers.

IV. Tool post:

It is the topmost portion of the carriage and it is used to hold various cutting tools or tool holders.

I. Fitted on top slide and carries the cutting tool or the cutting tool holder

II. Can adjust the height on some types

III. Can carry 4 different tool holders

There are three types of tool post commonly used and those are:

1. Ring and rocker tool post

2. Squarehead tool post
3. Quick change tool post

V. Apron:
An apron is a house of the feed mechanism. It is fastened to the saddle and hangover in front of
the bed.

Types of Lathe Machines (Capstan Lathe, Turret Lathe, CNC Lathe)

Types of Lathe Machine

Lathe machine tool which is used for removing the excess material from the workpiece to give
required shape and size to the workpiece.

Lathe machine has been categorized into the following types:

 Center or Engine Lathe

 Capstan and Turret Lathe
 CNC Lathe Machine
 Speed Lathe
 Tool Room Lathe
 Bench Lathe
 Automatic Lathe

Center or Engine Lathe Machine:

Center or Engine Lathe Machine is the most widely used lathe machine and still, it is, in every
workshop, this machine is present.The operation like Turning, facing, grooving, Knurling, threading
and more, such operations are performed on this type of machine.Engine lathe machine has all
the parts such as bed, Saddle, headstock, and tailstock, etc. The headstock of an engine lathe is
rigid and tailstock is moveable which is further used to support an operation like knurling.It can
easily feed the cutting tool in both directions i.e. longitudinal and lateral directions with the help of
feed mechanisms.Center Lathe machines are driven by the gear mechanism or pulley
mechanism.It has three types of driven mechanisms, and those are Belt-driven, Motor-driven,
Gearhead type.

 In starting it was driven by steam engine, So it is called as Engine lathe.

  Not production lathe, found in school shops, tool rooms, and job shops.

 Primarily for single piece or short runs.

 Manually operated.

Capstan and Turret Lathe:

This is an advanced technology of the manufacturing industry.The capstan and turret lathe
machine used for Mass production (large Quantity) and it is a modified version of the engine
lathe machine.This machine is used where their sequence of operation is performed on the
workpiece, there is no alternative operation performed on this machine.These machines provided
by hexagonal turret head instead of the tailstock in which multiple operations (Turning, facing,
boring, reaming) performed in a sequence without changing its tool manually, after each operation
the turret rotated.It also consists of three tool post. It requires more floor space than other lathe
machines.Capstan and turret lathe is using for only large jobs.The main advantage of using
capstan and turret lathe is even less skilled operators can do a job.

CNC Lathe Machine:

CNC stands for Computerized numerically controlled.This is widely used as a lathe in the
present time because of its fast and accurate working. It is one of the most advanced types.It uses
computer programs to control the machine tool. Once the program is fed into the computer as per
the program it starts operation with very high speed and accuracy.Even do preplanned
programmed machine is there in which once code is set for the various operations it can starts
operation without changing code in the next time.A semi-skilled worker can easily operate this
after the initial setup is done.These types of lathes are also used for mass production like capstan
and turret but there is no programmed fed system.The components manufactured by these lathes
are very accurate in dimensional tolerances.
Tool Room Lathe:
The toolroom lathe machine operates to speed up to 2500 rpm.The parts are almost the same
similar to engine lathe machine but the parts are built very accurately and should be arranged in
proper sequence because this lathe is used for highly precious work with very fewer tolerances.It
is mainly used in grindings, working on the tool, dies gauges and in machining work where
accuracy is needed.

Bench Lathe:
Bench lathe machines are mounted on the bench.This type of lathe machine is small in size and
use for very small precision work. It has all the similar parts of engine lathe and speed lathe.

Automatic Lathe:
As the name indicates “Automatic lathe” performs work automatically.Standard lathes have some
drawbacks i.e. they are not used for mass production. But automatic lathes are used for mass
production. Some mechanisms are responsible for the automation in it.Here there is no need to
change the tool manually because it changes automatically.Having this machine the main
advantage is that a single operator can handle machines more than 4 to 5 machines at a
time.These types of lathes are high speed and heavy-duty.
 Topic: 2 Cutting Tools for Lathe Machine

 Single Point Cutting Tool Definition:

This tool consists of a sharpened cutting part called its point and the shank.The point of
the tool is bounded by the face (along which the chips slides as they are cut by the
tool), the side flank or major flank the end flank or minor flank and the base.As we know
we perform several operations on the lathe (like turning, facing)  from the single-point
cutting tool.Design and fabrication are very easy for this tool.This tool can be made at a
very cheaper rate as compared to others.

Single Point Cutting Tool Types:

There are only two types of tool:

1. Single and
2. Multi-Point cutting tool.
1. Single Point cutting tool:

 One cutting point or tip is available

 Example: Lathe Machine, Planning
Machine tool
2. Multi-Point cutting tool:

 More than One cutting point or tip is available

 Example: Milling cutter, Grinding wheel, drill tool, extra.

 Knurling tool
A knurling tool is a manufacturing and repair tool on lathes to produce straight,
diagonal or diamond patterns, which presented as teeth of uniform pitch on the
exterior of the workpiece. The diamond pattern is also called the cross pattern.
Angular (diagonal) patterns can be left hand or right hand.

Knurling tools can be divided into various types. The tools refer to the toothed steel
wheels, rolls or knurls.
  Internal knurling tools: can knurl up to a depth in the
workpiece according to the toughness of the material
 Convex knurl tools: axial feed knurling tool
 Conical knurl tools: mainly generate radical face knurling
or conical surfaces
 Straight knurling holder: solid and have one wheel
 Spiral knurling holder: the head is tiltable, holds two
wheels
 Self-centering knurling tools: twin knurl wheels to cut
straight and diamond patterns
 Revolving self-centering knurling tool: three sets of twin wheels
 Shoulder self-centering knurling tool: knurl against a square shoulder

Parting tool
 Parting tools cut off the stock at a certain length. This tool requires a preformed blade
and holder.

Threading tool
 It is a type of single point tool fitted with a tool bit used for threading and grooving
operations. It basically forms threads on a part of metal surface
 Topic: 3 Precision Measuring Tool
Vernier Caliper, and its Applications.

What is a Vernier Caliper?

A vernier caliper is a dimension measuring instrument that is used to accurately measure not
only the internal and external dimensions of an object but also its depth. The instrument which is
equipped with a fixed jaw and a movable jaw that moves along a graduated scale can measure to
an accuracy of a hundredth of a millimeter. Owing to, both, its exceptional precision and accuracy,
the vernier caliper has found a great many uses in a variety of applications & settings.

How to read vernier caliper

A vernier caliper outputs measurement readings in centimetres (cm) and it is precise up to 2
decimal places

The measurement-reading technique described in this post will be similar for vernier calipers
which output measurement readings in inches.

Measurement Reading Technique For Vernier Caliper

In order to read the measurement readings from vernier caliper properly, you need to remember
two things before we start. For example, if a vernier caliper output a measurement reading of 2.13
cm, this means that:
 The main scale contributes the main number(s) and one decimal place to the reading (E.g.
2.1 cm, whereby 2 is the main number and 0.1 is the one decimal place number)
  The vernier scale contributes the second decimal place to the reading (E.g. 0.03 cm)

Let’s examine the image of the vernier caliper readings above. We will just use a two steps
method to get the measurement reading from this:

 To obtain the main scale reading: Look at the image above, 2.1 cm is to the immediate left
of the zero on the vernier scale. Hence, the main scale reading is 2.1 cm
 To obtain the vernier scale reading: Look at the image above and look closely for
an alignment of the scale lines of the main scale and vernier scale. In the image above, the
aligned line correspond to 3. Hence, the vernier scale reading is 0.03 cm.
In order to obtain the final measurement reading, we will add the main scale reading and vernier
scale reading together. This will give 2.1 cm + 0.03 cm = 2.13 cm.
In a nutshell

Use the following formula:

Obtained reading=Main scale reading+Vernier scale readingObtained reading=Main scale

reading+Vernier scale reading
Let’s go through another example to ensure that you understand the above steps:

Main scale reading: 10.0 cm (Immediate left of zero)

Vernier scale reading: 0.02 cm (Alignment of scale lines)
Measurement reading: 10.02 cm
List of Sectors Where Vernier Calipers are Used
Enlisted below are the top five sectors that rely extensively on the use of vernier calipers:-

#1)Machine Shop Applications

The machine shop is one of the most extensive users of the vernier caliper. The colossal looking
aircraft and ships have surprisingly got the most intricate of components that get them to function
the way they ought to. The automobile sector also employs the use of these calipers for a number
of reasons—from measuring the diameter of the automobile crankshaft to gauging the height of
the spring that the vehicle is set up with.

#2)Medical Applications

The medical industry resorts to the use of a plethora of tools and instruments in order to perform a
wide range of diagnostic as well as surgical procedures. It is, thus, paramount to know the exact
depths and thicknesses of the instruments that are to perform multifarious procedures on the
human body. The slightest mistake on the production end may result in the loss of a precious life.

#3)Research & Laboratory Applications

A vernier caliper is used for a multitude of laboratory-based applications. Take, for instance, the
use of a vernier caliper to gauge the expansions and contractions of metals and metallic products
as the temperature is raised and lowered respectively. The effect of gravity acting on a minuscule-
sized object as it rotates in a pendulum-like motion also requires the knowledge of its dimensions
and, thereby, its mass.

#4)Locksmithing Applications

The trade of locksmithing involves the use of intricate patterned keys and locking mechanisms.  It
goes without saying that locksmiths have to imperatively resort to the use of vernier calipers in
order to make precise and accurate cuts through the metallic lock surfaces so as to be able to turn
and un-turn them comfortably.  The use of vernier calipers helps measure thicknesses and
diameters with great precision.

#5)Educational Applications

Educational institutions and schools bestow their students with the opportunity to use the vernier
calipers hands on. Any physics laboratory in a school is likely to house vernier calipers to help
students grasp the basics of using a vernier caliper and get a practical demonstration of what is
only otherwise taught theoretically in the classroom.
 Topic: 4 Lathe Operations
Describe the Lathe / Manufacturing Operations
A Lathe Machine consists of the following operation:

 Facing
 Turning
 Knurling
 Thread cutting
 Tapping
 Parting off
 Drilling
 Boring

Before continuing any operation in lathe we have to load the job and center it on the head-stock
spindle.In lathe operations, the headstock spindle holds the job and it rotates with the same speed
as the spindle. The carriage holding the tool on the tool post, also the carriage gives the tool post
moves longitudinally or crosswise direction to give the desired feed on the job.These two motions
(longitudinally and crosswise) helps to remove the chips of the metal and giving the proper shape
of the job.The Lathe is such a versatile machine that it can produce another lathe.It is tough to
mentioned which operations are not performed in a lathe machine tool, though we discuss some
important lathe operations in detail.
 1. Facing operation in the lathe:
Facing operation is for making the ends of the job to produce a smooth flat surface with the axis
of operation or a certain length of a job.

In this operation,

1. Hold the job on Head-stock spindle using Three or four-jaw chuck.

2. Start the machine on desire RPM to rotate the job.
3. Give a desirable feed on the perpendicular direction of the axis of the job.
 2. Turning operation in the lathe:
The operation by which we remove the excess material from the workpiece to produce a cone-
shaped or a cylindrical surface.

There are several types of turning operations, those are:

1. Straight turning
2. Step turning
3. Taper turning

I. Straight turning:
This operation is done to produce a cylindrical surface by removing excess material from the
workpiece.

It is done in the following ways:

1. Mount the job by suitable job holding device and check the trueness of the job axis with the
lathe axis.
2. Hold the cutting tool on the tool post and set the cutting edge at the job axis or slightly above it.
3. Set the spindle as per the desired feed.
4. Give depth of cut as per finish or rough cut.
5. Start the machining.
6. Engage automatic feed to move the carriage with the tool to the desired length, then disengage
the feed and carriage is brought back to its starting.
7. The process is repeated until the job finished.
 II. Step turning:
A shoulder turning is called which has a different diameter to form a step from one diameter to
another.

There are four kinds of the shoulder.

1. Square
2. Beveled
3. Radius
4. Undercut

III. Taper turning:

A taper is defined as a uniform decrease or increase in the diameter of a workpiece along with its
length.

The operation by which a conical surface of the gradual reduction in diameter from a cylindrical
workpiece is produced is called taper turning.
Taper turning methods:
A tapering form may be done by anyone of the following methods.

1. Taper turning by form tool

2. By swiveling the compound rest
3. Tail-stock set over method
4. By taper turning attachment

a) Taper turning by form tool:

It is used to form a short length of taper by using a form tool or broad nose tool.Any increase in the
length of taper will require the use of a wider cutting edge which may destroy the workpiece due to
the vibration and spoil the workpiece.In this operation, the tool angle must be half of the taper
angle.

b) Taper turning by swiveling the compound rest:

This method is used for turning step and short tapers.

It is done as follows:

1. Set the compound rest by swiveling it from the centerline of the lathe center through an angle
equal to a half taper angle.
2. Clamp the carriage in place.
3. After adjusting and setting the tool, feed is applied by the compound rest’s feed handle to
complete the taper.
 c) Tail-stock set over method:
Set over of tail-stock from its center-line is done equal to half taper.Job is held between the
centers. The length of the workpiece will be long enough. An only a small taper on a long job is
done by this process.It is used for external taper only.

d) By taper turning attachment:

It is done in the following ways:

1. The cross slide is first made free from lead screw by hinder screw.
2. The rear end of the cross slide is then tightened with a guide block by a belt.
3. Set the guide bar at an angle to the lathe axis. (Half taper angle)
4. The required depth of cut is given by the compound slide is at a right angle to the lathe axis.
 3. Knurling operation:
It is the process of producing a rough surface on the workpiece to provide effective gripping.

Knurling tool is held rigidly on the tool post and pressed against the rotating job so that leaving
the exact facsimile of the tool on the surface of the job.

4. Thread cutting operation :

It is the operation that is used to produce a helical groove on a cylindrical or conical surface by
feeding the tool longitudinally when the job revolved between the two centers.

i. Tool setting for thread cutting operation:

The tool should be set exactly to the height of the centerline of the job and at 90 degrees to the
job.

Tool setting gauge is used for this purpose.

ii. Feeding during thread cutting operation:

It is done in two ways.

1. The tool may be feed exactly at 90 degrees to the job axis but it does not have good cutting
action because only the front end of the tool does cutting.
2. The tool may be feed at an angle from 27-30 degrees at which the compound rest may be set
so that the complete side of the tool is used for cutting action which gives a better polish on the
threads.

iii. Job speed during threading:

The job speed will be 1/3 to 1/4 th of the job speed in turning operation.

5. Parting-off operation: (cross dia )

It is the operation of cutting off a bar type job after complete the machining process.

In this operation a bar type job is held on a chuck, rotates at turning speed, a parting off tool is fed
into the job slowly until the tool reaches the center of the job.
 6. Drilling operation:
Drilling is an operation by which we can make holes in a job.

In this operation, the job is rotated at the turning speed on the lathe axis and the drilling tool fitted
on the tail-stock spindle. And the tail-stock is moved towards the job by hand feed.
 7. Boring operation:
In this operation, we can enlarge the diameter of the existing hole on a job by turning inside with
some farm tool known as a boring tool.

The boring tool is also fitted on tail-stock.

Reference
1. . http://en.wikipedia.org/wiki/Lathe
2. Production Technology by R.B. Gupta
3. Workshop Technology - 1 by A.W. J. Chapman

4. Manufacturing process II by NPTEL

5. Lathe machine by DM Skoglund, PS Petersen, RJ Grimm – US Patent 3,121,357, 1964 
6. https://www.mechanicalbooster.com/2016/11/what-is-lathe-machine-main-parts-operations-working.html
7. https://openoregon.pressbooks.pub/manufacturingprocesses45/chapter/chapter-unit-1-the-engine-lathe/
8. https://www.zjcncmachine.com/knurling-tool-definition-types-how-does-knurling-work-cnc-knurling-tool/#:~:text=A%20knurling%20tool%20is
%20a,left%20hand%20or%20right%20hand.

Youtube videos for understanding

https://www.youtube.com/watch?v=XXpOwsD0fWM

https://www.youtube.com/watch?v=Cx0sau2dLRg&t=124s

https://www.youtube.com/watch?v=oK43dxJeH10&t=139s

https://www.youtube.com/watch?v=uQPCdwegXzc&t=73s

https://www.youtube.com/watch?v=8EsAxOnzEms

https://www.youtube.com/watch?v=MYhe3KSKKiU

https://www.youtube.com/watch?v=r7tvsqUIf2U&t=69s

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