JJ103 Mechanical Workshop Practice 1

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Experiment outcomes After following this practical work students should be able to: 1.1 1.2 1.3 Explain safety procedure in the workshops according to the workshop safety regulation Perform machining works according to Standard Operation Procedure (SOP) Practice correct safety procedures and working techniques in the workshop

2.0

Theory

The lathe is a machine tool used principally for shaping pieces of metal (and sometimes wood or other materials) by causing the work piece to be held and rotated by the lathe while a tool bit is advanced into the work causing the cutting action. The basic lathe that was designed to cut cylindrical metal stock has been developed further to produce screw threads, tapered work, drilled holes, knurled surfaces, and crankshafts.
Cutting speed (KP) may be

defined as the rate (or speed) that the material moves past the cutting edge of the tool, irrespective of the machining operation used the surface speed. For a given material there will be an optimum cutting speed for a certain set of machining conditions, and from this speed the spindle speed or revolution per minute (RPM) can be calculated. The cutting speed is given as a set of constants that are available from the material manufacturer or supplier. For each metal that using for lathe

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machine has different cutting speed. The following table gives the cutting speeds for a selection of common materials under one set of conditions.

The spindle speed is the rotational frequency of the spindle of the machine, measured in revolutions per minute (RPM). The preferred speed is determined based on the material being cut. Cutting speed (KP) unequal with spindle speed or revolution per minute (RPM). To calculate RPM, diameter (d) and cutting speed work piece need to be known. Formula used is RPM =

KPx100 d

RPM is the rotational speed of the cutter or work piece. KP is cutting speed Diameter of work piece in millimeters or inches is the constant pi (3.142 or

22 ) 7

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3.0

Apparatus/Equipments

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15

Center lathe machine Mild steel Tool bit holder Cutting tool holder Tool bit Spanner Allen key Chuck lock Ball bearing live center Center drill Chuck drill Vernier Caliper Steel Ruler Cooler Lubricant

4.0

Safety Precautions

4.1

Correct dress is important, remove rings and watches, roll sleeves above elbows.

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EXPERIMENT TITLE DURATION PAGE 4.2 4.3 4.4 4.5 4.6 4.7 4.8

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Always stop the lathe before making adjustments. Do not changes spindle speeds until the lathe comes to a complete stop. Handle sharp cutters, centers, and drills with care. Remove chuck keys and wrenches before operating Always wear protective eye protection. Handle heavy chucks with care and protect the lathe ways with a block of wood when installing a chuck. Use pliers or a brush to remove chips and swarf, never your hands.

5.0

Procedure

5.1 5.2 5.3 5.4 5.5

Clean and lubricate the machine. Be sure all guards are in position and locked in place. Turn the spindle over by hand to be sure it is not locked nor engaged in back gear. Move the carriage along the way. There should be no binding. Check cross slide movement.

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EXPERIMENT TITLE DURATION PAGE 5.6 5.7 5.8 5.9

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Mount the desired work holding attachment. Adjust the drive mechanism for the desired speed and feed. If the tailstock is used, check it for alignment. Clamp the cutter bit into an appropriate tool holder and mount it in the tool post. Do not permit excessive compound rest overhang as this often causes tool chatter and results in poorly machine surface. Mount the work. Check for adequate clearance between the work and the various machine parts.

5.10

*Students are advised to make the step-by-step procedure with the help of diagram

6.0

Result/Data

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JJ103 Mechanical Workshop Practice 1

EXPERIMENT TITLE DURATION PAGE 7.0 Discussion

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Your discussion should be related to the problems related during the process. It is advised to discuss about: 7.1 7.2 7.3 The cutting tool (angle, shape and process) Material used (hardness, shaping, knurling) Problems faced during the practical task and how you solve it

8.0

Conclusion and Recommendation

Your conclusion should be related to your practical and theoretical understanding on the related topic.

9.0

References Minimum of three different resources

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