DJJ3032 – MECHANICAL WORKSHOP PRACTICE 3 (MACHINING)

1.0 OBJECTIVES
At the end of this topic, you should:
a) Practice the safety precaution when enter the workshop and when handling the lathe and
milling machine.
b) Able to grind tool bit specially to cut metric V thread.
c) Able to select the feed, spindle speed and the types of cutting tools for lathe works.
d) Able to use milling machine for
e) Able to conduct various lathe processes correctly such as:
i. Facing
ii. Parallel turning
iii. Taper turning
iv. Fillet shoulders
v. Step turning
vi. Chamfering
vii. Grooving
viii. Milling
ix. Indexing

2.0 EQUIPMENT / APPARATUS

a) Workpiece
i) Part A: length: 44mm, diameter: 32mm
ii) Part B: length: 105mm, diameter: 20mm
iii) Part C: length:105mm, diameter: 9.5mm
b) Vernier Caliper
c) Single point cutting tool (HSS)
d) Parting tool (HSS)
e) Center drill
f) Twist drill (Ø 9mm, Ø 10.5mm, Ø 20mm)
g) Taps (M12 x 1.75)
h) Tap wrench
i) Conventional lathe machine
3.0 SAFETY AND HEALTH
Describe the safety precautions below:
i. General Safety Precaution
ii. Turning Machine Safety
iii. Operating Safety Precautions

4.0 THEORY
Lathe machine is one of the most important machines in any workshop. Its main objective is to
remove material by rotating the workpiece against cutting tool. Though a lathe machine is used
to produce cylindrical work, yet it may also be used for other purposes such as drilling,
threading, grinding, and milling. There are a variety of operations may be performed to the
workpiece to yield a desired shape of the products.
5.0 PROCEDURES
Explain in detail the lathe operation to product project in Figure 3.2

No. Work Step Figure

1.

Get first piece of workpiece with the

dimension of 43mm in length and 32mm
in diameter using hydraulic power saw.

2.
Lathe one end of the workpiece for
getting 22mm diameter with 16mm
length.

3.
Lathe the other end of workpiece for
getting 24mm diameter with 27mm
length. The total length of the workpiece
is 40mm.

4.

Drill a small hole on the face of 27mm

diameter workpiece using a centre drill.

5.
Drill a through hole on the workpiece
with 5mm diameter drill bit and
following with the 10.5mm diameter drill
bit.
6.
Drill a bigger hole with 16mm depth
on the workpiece using a 19mm
diameter drill bit.

7.
Bore the workpiece to get the hole
20mm diameter.

8.
Using milling machine, do a shape
milling process to get the shape of
hexagon on the workpiece. Lastly,
tap the workpiece with M12 x 1.75
tap bit.

9.
Lathe the second workpiece for the
length of 100mm and diameter of
9mm from one end to the other end
of workpiece.

10.
Grind the tool bit to become half
circle. Lathe both end of the
workpiece to become the shape of
hemisphere.
11.
Get third piece of workpiece with the
dimension of 105mm in length and
20mm in diameter using hydraulic
power saw, do the straight turning
72.5mm along the workpiece to have
12mm diameter. Then turn the tool
holder to 30° and do the taper turning
at the end of the workpiece.
12.

Do the straight turning 33.5mm along

the workpiece to have 19mm
diameter. Then lathe the end of
workpiece to become the shape of
hemisphere with curved tool bit.

13.
Do fillet shoulder on the workpiece.

14.
Grind a tool bit in V shape for thread
cutting on the workpiece.

15.
Lastly, drill a hole in 9mm diameter on
the workpiece using drilling machine.
Average = % of error =
NO PORTIONS R1 R2 R3 𝑨𝒄𝒕𝒖𝒂𝒍 − 𝑹𝒆𝒔𝒖𝒍𝒕
(R1+R2+R3)/3 × 𝟏𝟎𝟎%
𝑨𝒄𝒕𝒖𝒂𝒍

Part A
1. Turning length 24mm 24 24 24 24 0
2. Turning length 16mm 16 15.7 16.3 16 0
3. Turning Ø 32mm 32 32.5 31.5 32 0
4. Turning Ø 25.4mm 25 24.9 25.1 25 1.5
5. Drilling Ø 20mm 20 20 20 20 0
6. Hexagon shape (width 22 21.6 22.4 22 0
22mm)
7. Boring depth Ø 16mm 16 16 16 16 0
Part B
8. Turning Ø 19mm 19.2 19 18.8 19 0
9. Turning Ø12mm 12 12 12 12 0
10. Turning length 30mm 30 30 29.5 30 0
11. Turning length 76mm 76 75 76 76 0
12. Drilling Ø 9mm 9 9 9 9 0
Part C
13. Turning Ø 9mm 9 9 9 9 0
14. Turning length 100mm 100 100 100 100 0

7.0 DISCUSSIONS
A) Refer Figure 3.2
B) Factors cause dimensional inaccuracy
- Cutting parameters
- Machine Tool rigidity
- Workpiece

Methods to increase the dimensional accuracy

- Measure the material multiple times and take the average reading.
- Use both Vernier caliper and the machine built-in measuring instrument.
- Avoid human error and make sure the zero error have been included in calculation.

C) Describe the application of magneto puller in automotive industry.

- A tool which screws into the centre of the magneto to force the magneto away from the
shaft on which it rides. In short, it is use to remove magnetic material from where it’s
on.
D) How to reduce the manufacturing cost of magneto puller by reducing the machining step?
- Limit the part uses from three to two parts of material
- Limit the length of thread, by doing so the material does not have to be long
- Use material closes to the measurement of final product to avoid waste
- Limit the depth of cavities which will take a longer time to produce
- Add radius in internal vertical edges

E) Sketch the adjusted or modified design of magneto puller with fewer machining step and
state type of machining process involved.

8.0 CONCLUSION
The objective of turning and milling is to remove material from a work piece to obtain a specific
shape and improve surface finish. Before operation is done, several parameters need to be
determined. Tool geometry and material have a significant effect on the cutting operation. It is
important to use a material that is harder than the work piece material. During the actual operation,
there are also several important factors that determine the outcome of the operation. Important
factor is the stability of the work piece. If the work piece is not aligned properly, the work piece will
sit at an angle which will cause unwanted shape. Another factor is that excessive feeds and cutting
speeds are dangerous during turning and milling.

9.0 REFERENCES
Bawa (2004). Manufacturing Processes 1. McGraw Hill
Bawa (2004). Manufacturing Processes 2. McGraw Hill
Chapman, W.A.J (1996). Workshop Technology Part 2. ELBS
Lalpakjian (1992). Manufacturing Engineering Technology. Addision
S.f.Krar, J.W. Oswald (1976). Technology of Machine Tools. McGraw.