First: Longitudinal Turning: As in figure Turn-5.
Figure Turn-5: a longitudinal turning process Steps of longitudinal turning on a lathe are as follows:
1. Determine the appropriate cutting conditions (cutting speeds, feeding and cutting depth).
2. Turret must be away than the operating environment by pulling the carriage away than the chuck.
3. Select and fix a suitable chuck -according to raw material dimensions- on the main spindle. See figure Turn-6.
Figure Turn-6: a chuck
4. As in figure Turn-7, feed the raw material, and adjust an appropriate machining length with an additional length to prevent a collision between cutter and chuck.
Figure Turn-7: feed the raw material with a suitable length
5. Hold the raw material with the chuck jaws in an appropriate and safe manner. See figure Turn-8.
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Figure Turn-8: hold the workpiece on a chuck
6. Choose an appropriate cutting tool which will be hold on turret. See figure Turn-9.
Figure Turn-9: hold the tool on a turret
7. Move the carriage to be close to the raw material face. So, use the compound rest to get a traverse movement.
8. Adjust an appropriate cutting depth. See figure Turn-10.
Figure Turn-10: cutting conditions 9. Run the machine to rotate the main spindle.
10. Start slow and manual contact between the cutter and raw material face 11. Manually or automatically, feed the cutting tool along the machining length.
12. Repeat steps 7 - 11 to get the desired product diameter.
13. Last cutting depth must be small to get a smooth surface.
14. During the machine turn off, workpiece surface can be inspected to verify the dimensions accuracy and surface alignment. See figure Turn-11.
Figure Turn-11: inspection steps
15. Cutting tool must be away than the product surface to help in product removing.
16. Close the machine.
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17. Take the final product. See figure Turn-12.
Figure Turn-12: remove the final product 18. Remove the chip.
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Second: Facing: As in figure Turn-13.
Figure Turn-13: a facing process Steps of facing process on a lathe are as follows:
1. Determine the appropriate cutting conditions (cutting speeds, feeding and cutting depth).
2. Turret must be away than the operating environment by pulling the carriage away than the chuck.
3. Select and fix of a suitable chuck -according to the raw material dimensions- on the main spindle.
4. As in figure Turn-14, feed the raw material and adjust an appropriate machining length to prevent a collision between cutter and chuck.
Figure Turn-14: feed the raw material with a suitable length 5. Hold the raw material with chuck jaws in an appropriate and safe manner.
6. Choose an appropriate cutting tool which will be hold on the turret.
7. Move the carriage to be close to the raw material face.
8. As in figure Turn-15, adjust the height of cutter to be in the middle of raw material face to get a right facing process.
Figure Turn-15: adjust cutter at the middle of face 9. Cutting tool must be away than the workpiece.
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10. Move the carriage to be close to the raw material face. So, use the compound rest to get a traverse movement.
11. Determine an appropriate cutting depth.
12. Run the machine to rotate the main spindle.
13. Start slow and manual contact between the cutter and the longitudinal raw material surface.
14. Manually or automatically, feed the cutting tool until reaching to the middle of raw material face. See figure Turn-16.
Figure Turn-16: cutting conditions in the turning process 15. Repeat steps 9 - 14 to cut the required depth of cut.
16. Last cutting depth must be small to get a smooth surface.
17. During the machine turn off, workpiece surface can be inspected to verify the surface accuracy.
18. Cutting tool must be away than the product surface to help in product removing.
19. Close the machine.
20. Take the final product.
21. Remove the chip.
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Third: Drilling: As in figure Turn-17.
Figure Turn-17: a drilling process Steps of drilling process on a lathe are as follows:
1. Determine the appropriate cutting conditions (cutting speeds, feeding and cutting depth).
2. Turret must be away than an operating environment by pulling the carriage away than the chuck.
3. Select and fix of a suitable chuck -according to the raw material dimensions- on the main spindle.
4. Centering the machined workpiece face to get an accurate machining without any deviation. As in figure Turn-18.
Figure Turn-18: a centered workpiece
5. Feed the raw material and adjust an appropriate machining length to prevent a collision between cutter and chuck.
6. Hold the raw material with the chuck jaws in an appropriate and safe manner.
7. Remove the center from tail stock.
8. Select an appropriate drilling tool, and hold it inside the tail stock instead of center. See figure Turn-19.
Figure Turn-19: a drilling tool inside the tailstock
9. As in figure Turn-20, move the tail stock to make the distance between the cutter and raw material face is close.
10. Run the machine to rotate the main spindle.
11. Use the tail stock handle to start slow contact between the cutter and raw material face.
12. Manually, feed the drilling tool to get the appropriate hole depth. See figure Turn-21.
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Figure Turn-20: a drilling tool close to the workpiece
Figure Turn-21: a drilling tool fed inside the workpiece 13. If hole depth is large, the hole can be carried out in several stages.
14. During the machine turn off, workpiece surface can be inspected to verify the surface accuracy.
15. Cutting tool must be away than the product face to help in product removing. This can be done by dragging the drilling tool inside tail stock with a suitable handle, and then drag the tail stock.
16. Close the machine.
17. Take the final product.
18. Remove the chip.
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Fourth: Internal Turning: As in figure Turn-22.
Figure Turn-22: an internal turning Steps of internal turning on a lathe are as follows:
1. As in figure Turn-23, drill a suitable hole in the required surface to make an easy entry to the internal turning tool (this can be done on a drilling machine or lathe).
Figure Turn-23: drill a hole before an internal turning
2. Determine the appropriate cutting conditions (cutting speeds, feeding and cutting depth).
3. Turret must be away than an operating environment by pulling the carriage away than the chuck.
4. Select and fix of a suitable chuck -according to the raw material dimensions- on the main spindle.
5. Feed the raw material and adjust an appropriate machining length to prevent a collision between the cutter and chuck.
6. Hold the raw material with the chuck jaws in an appropriate and safe manner.
7. Choose the appropriate cutting tool which will be hold on the turret. See figure Turn-24.
8. Move the carriage to be close to the hole surface.
9. Adjust an appropriate cutting depth.
10. Run the machine to rotate the main spindle.
11. Start slow and manual contact between the cutter and raw material face.
12. Manually or automatically, feed the cutting tool along the machining length.
13. Repeat steps 8 - 12 to get the desired hole diameter.
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Figure Turn-24: hold tool on the turret 14. Last cutting depth must be small to get a smooth surface.
15. During the machine turn off, workpiece surface can be inspected to verify the machining accuracy.
16. Cutting tool must be away than the product surface to help in product removing.
17. Close the machine.
18. Take the final product.
19. Remove the chip.
39 | P a g e Fifth: Grinding:
Grinding is limited to the external surfaces, and it uses an attachment part to a lathe. Steps of grinding on a lathe are as follows:
1. Turret must be away than an operating environment by dragging the carriage away than the chuck.
2. Remove the turret.
3. As in figure Turn-25, a grinding device -with a special electric motor- must be fixed on the carriage instead of the turret as shown in following figure.
Figure Turn-25: hold a grinding wheel on the turret
4. Select and fix a suitable chuck -according to the raw material dimensions- on the main spindle.
5. Feed the raw material and adjust an appropriate length to prevent a collision between the grinding wheel and chuck.
6. As in figure Turn-26, hold the raw material with chuck jaws in an appropriate and safe manner.
Figure Turn-26: hold the raw material with the chuck
7. Manually, move the carriage to make the grinding wheel be close to the raw material face.
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8. Run the machine in low speed in the same direction of main spindle rotation.
9. Start slow and manual contact between the grinding wheel and the raw material face.
10. Manually and slowly, feed the grinding wheel to make a contact with the workpiece surface.
11. Use the compound rest to get a grinding wheel traverse movement along a machined surface.
12. If it is required, gradually, feed can be increased.
13. Repeat steps 10 - 12 to get a required surface finishing.
14. When the grinding process is finished, turn off the grinding wheel motor.
15. During the machine turn off, workpiece surface can be inspected to verify the machining accuracy.
16. Grinding wheel must be away than the product surface to help in the product and grinding wheel removing.
17. Close the machine.
18. Take the final product.
19. Remove the chip.
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Sixth: Tapering: As in figure Turn-27
Figure Turn-27: a tapering Process Steps of tapering on a lathe are as follows:
1. Determine the appropriate cutting conditions (cutting speeds, feeding and cutting depth).
2. Turret must be away than an operating environment by pulling the carriage away than the chuck.
3. Select and fix a suitable chuck -according to the raw material dimensions- on the main spindle.
4. Feed the raw material and adjust an appropriate machining length with an additional length to prevent a collision between cutter and chuck.
5. Hold the raw material with the chuck jaws in an appropriate and safe manner.
6. As in figure Turn-28, adjust the compound rest with an appropriate tapering angle, as in next figures:
Figure Turn-28: compound rest adjustment 7. Choose an appropriate cutting tool which will be hold on the turret.
8. As in figure Turn-29, precisely , adjust the height of cutter to avoid curved sides of tapered surfaces.
9. Move the carriage to be close to the raw material face. So, use the compound rest to get a traverse movement.
10. Adjust an appropriate cutting depth (workpiece is machined to the larger diameter. See figure Turn-30).
11. Run the machine to rotate the main spindle.
12. Start slow and manual contact between the cutter and raw material face.
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Figure Turn-29: adjust the cutter height Figure Turn-30: workpiece diameters 13. Manually or automatically, feed the cutting tool along the specified machining length.
14. Repeat steps 12 - 13 to get a desired product diameter.
15. Regularly, adjust the cutter feeding for a good smooth surface
16. Cutting depths must be small to get a smooth surface and to decrease cutting forces.
17. During the machine turn off, workpiece surface can be inspected to verify the dimensions accuracy and tapering angle.
18. Cutting tool must be away than the product surface to help in product removing.
19. Close the machine.
20. Take the final product.
21. Remove the chip.
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Sixth: Parting off:
As in figure Turn-31, parting is the process of cutting off a piece from a stock while it is being held in the lathe. Also, it is used to cut off work after other machining operations have been completed.
Figure Turn-31: a parting off process Some precautions for parting off process:
1. As in figure Turn-32, this process uses a sharped tool with a 5° side rake and no back rake angle.
Figure Turn-32: a sharp parting off cutter 2. When parting off process, plenty of coolant must be used.
3. Length of the cutting portion of the cutter should be extend enough to be longer than the workpiece radius.
4. Work that is to be parted should be held rigidly in a chuck or collet, with the area to be parted as close to the holding device as possible.
5. Always, make the parting cut at a right angle to the centerline of the work.
6. Speeds for the parting should be about a half that used for the straight turning.
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7. Feeds should be light but continuous.
8. The parting tool should be positioned at the center height of workpiece.
9. Never try to catch the cutoff part in hand; it will be hot and could burn.
Steps of parting off on a lathe are as follows:
After finishing of all processes on workpiece, the follows will be start:
1. Turn off the machine.
2. Change the cutting tool with a suitable parting off tool. See figure Turn-33.
Figure Turn-33: a parting off cutter
3. Adjust the cutting tool in a right position for the workpiece surface.
4. Run the machine.
5. Slowly, feed the cutting tool toward the workpiece (use the compound rest to get a traverse movement).
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Seventh: Shoulders:
Frequently, it will be necessary to machine work that has two or more diameters in its length.
Workpiece may be mounted in a chuck or collet in straight turning. Shoulders are turned, or formed, to various shapes to suit the requirements of a particular part.
As in figure Turn-34, steps of shoulder process on a lathe are similar to the longitudinal turning process.
Figure Turn-34: a shoulder turning process
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Eighth: Angular Shoulders:
Sometimes, the angular shoulders are used to eliminate the sharp corners.
As in figure Turn-35, steps of shoulder process on a lathe are the same manner of the square shoulders by using a side turning tool which is set at the desired angle of the shoulder.
Figure Turn-35: using two tool to angular shoulders cutting processes
47 | P a g e Ninth: Grooves:
Grooving (or necking) is the process of turning a groove on workpiece. The shape of the tool and the depth to which it is fed into the work govern the shape and size of the groove. The types of grooves most commonly used are square, round, and V-shaped as in figure Turn-36.
Steps of the groove process on lathe are similar to steps of the parting off process, but the depth of cut is smaller.
Figure Turn-36: common grooves
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Machining Process:………….
Sheet number:……….. Date:………/…………/…….…
Semester:……… Academic year: ………/………
No. Process Sketch of Process Feed Speed Depth
of Cut
Machining Time
Material Removal
Rate
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Student name:………
Student ID:……….
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