(Workshop Lab Manual )

Workshop and Manufacturing Practices

LABORATORY MANUAL

NAME OF THE SHOP

Machine Shop

PREPARED BY
Mrs. Vaishali Dogra Mr. Tarun Dhiman

CHECKED BY
Dr. Manish Kumar Lila

APPROVED BY
Dr. Raghubeer Singh Bangari

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LATHE MACHINE
A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform
various operations such as cutting, sanding, knurling, drilling, deformation, facing,
and turning, with tools that are applied to the workpiece to create an object
with symmetry about that axis.
Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, and
glass-working. Objects that can be produced on a lathe include screws, candlesticks, gun
barrels, cue sticks, table legs, bowls, baseball bats, pens, musical instruments
(especially woodwind instruments), and crankshafts.

Types of Lathe Machine:

➢ Speed Lathe Machine
➢ Center Lathe or Engine Lathe Machine
➢ Turret Lathe Machine
➢ Toolroom Lathe Machine
➢ Bench Lathe Machine
➢ Automatic Lathe Machine
➢ Special Purpose Lathe Machine
➢ CNC Lathe Machine

Fig.1: Lathe machine

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Fig. 2: Different Parts of Lathe Machine (For Reference only)

Major parts of a lathe machine
Headstock: The headstock houses the main spindle, speed change mechanism, and
change gears. The headstock is required to be made as robust as possible due to the
cutting forces involved, which can distort a lightly built housing, and
induce harmonic vibrations that will transfer through to the workpiece, reducing the
quality of the finished workpiece.

Bed: The bed is a robust base that connects to the headstock and permits the carriage
and tailstock to be moved parallel with the axis of the spindle. This is facilitated by
hardened and ground bed ways which restrain the carriage and tailstock in a set track.

Feed and lead screws: The feed screw is a long driveshaft that allows a series of gears
to drive the carriage mechanisms. These gears are located in the apron of the carriage.
Both the feed screw and leadscrew are driven by either the change gears or an
intermediate gearbox known as a quick-change gearbox. These intermediate gears allow
the correct ratio and direction to be set for cutting threads or worm gears. Some lathes
have only one leadscrew that serves all carriage-moving purposes.

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Carriage: The carriage holds the tool bit and moves it longitudinally (turning) or
perpendicularly (facing) under the control of the operator. The operator moves the
carriage manually via the handwheel or automatically by engaging the feed shaft with the
carriage feed mechanism. The handwheels on the carriage and its related slides are
usually calibrated, both for ease of use and to assist in making reproducible cuts. The
carriage typically comprises a top casting, known as the saddle and a side casting, known
as the apron

Cross-slide: The cross-slide rides on the carriage and has a feed screw which travels at
right angles to the main spindle axis. This permit facing operations to be performed, and
the depth of cut to be adjusted.

Compound rest: The compound rest is usually where the tool post is mounted. It
provides a smaller amount of movement (less than the cross-slide) along its axis via
another feed screw. The compound rest axis can be adjusted independently of the carriage
or cross-slide. It is used for turning tapers, to control depth of cut when screw cutting or
precision facing, or to obtain finer feeds (under manual control) than the feed shaft
permits.

Tailstock: Located opposite the headstock, tailstocks are used to secure and support the
free end of a workpiece while it is being machined. A tailstock ensures the work piece's
longitudinal rotary axis is held steady and fixed precisely parallel to the lathe bed.

Chuck: Lathe chucks are essential components in machining processes, used to hold and
secure workpieces firmly on a lathe machine. They come in various types, including three-
jaw chucks, four-jaw chucks, and collet chucks, each suited to specific applications. Three-
jaw chucks are commonly used for round or symmetrical workpieces, while four-jaw
chucks offer versatility in clamping irregularly shaped objects. Three jaw chuck is usually
called a self-centering chuck, as while tightening, it keeps the workpiece in the centre.
Four jaw chuck is referred as Universal Chuck as it accommodate all types of cross
sections

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Spindle: Lathe spindles are used for machine-cutting of workpieces. They can also be
referred to as workpiece spindles, as the workpiece is clamped via the chuck of the lathe
spindle.

Lathe operations
A variety of operations can be performed on lathe machine, which are:

Fig. 3: Different operations carried on lathe machine

Turning: Cylindrical shapes, both external and internal, are produced by turning
operation. Turning is the process in which the material is removed by a traversing cutting
tool, from the surface of a rotating work piece. In turning operation, the diameter of the
workpiece is reduced. Longitudinal feed is used for plane turning as well as step turning
operations. When there is a difference in diameter is required at some length gap, the
operation is termed as step turning.

Taper Turning: A taper is defined as the uniform change in the diameter of a work
piece, measured along its length. It is expressed as a ratio of the difference in diameters
to the length. It is also expressed in degrees of half the included (taper) angle. Taper
turning refers to the production of a conical surface, on the work piece on a lathe.
Compound rest is used for taper turning, in which the tool is

Facing: Facing is a machining operation, performed to make the end surface of the work
piece, flat and perpendicular to the axis of rotation. For this, the work piece may be held

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in a chuck and rotated about the lathe axis. A facing tool is fed perpendicular to the axis
of the lathe. The tool is slightly inclined towards the end of the work piece. In facing, the
length of the workpiece is reduced. Cross feed is used in facing operation by using hand
wheel.

Chamfering: It is the operation of beveling the extreme end of a work piece. Chamfer is
provided for better look, to enable nut to pass freely on threaded work piece, to remove
burrs and protect the end of the work piece from being damaged.

Threading: Threading is nothing but cutting helical groove on a work piece. Threads
may be cut either on the internal or external cylindrical surfaces. A specially shaped
cutting tool, known as thread cutting tool, is used for this purpose. Thread cutting in a
lathe is performed by traversing the cutting tool at a definite rate, in proportion to the
rate at which the work revolves. Half nut mechanism is used for threading, which engage
and disengage the carriage with the screw feeder.

Knurling: It is the process of embossing a diamond shaped regular pattern on the

surface of a work piece using a special knurling tool. This tool consists of a set of hardened
steel rollers in a holder with the teeth cut on their surface in a definite pattern. The
purpose of knurling is to provide an effective gripping surface on a work piece to prevent
it from slipping when operated by hand.

Drilling: Holes that are axially located in cylindrical parts are produced by drilling
operation, using a twist drill. For this, the work piece is rotated in a chuck or face plate.
The tail stock spindle has a standard taper. The drill bit is fitted into the tail stock spindle
directly or through drill chuck. The tail stock is then moved over the bed and clamped on
it near the work. When the job rotates, the drill bit is fed into the work by turning the tail
stock hand wheel.

Boring: Boring is enlarging a hole and is used when correct size drill is not available.
However, it should be noted that boring cannot make a hole.

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Fig. 4: Some operations on Lathe a) Threading and Knurling b) Bevel and Chamfering

CUTTING TOOLS
Mainly, a single point cutting tool is used in common lathe operations, i.e. Turning,
Facing, chamfering etc. but knurling and drilling operation comprises of use of multipoint
cutting tool.

Fig. 5: Cutting tools used for Lathe operations

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INTRODUCTION TO CNC LATHE

CNC Lathe is the advanced version of conventional lathe machine. In lathe machine, the
main objective is to move the tool at desired speed and desired location as per the part
geometry using the right tool. CNC stands for computer numerical control and refers to a
machine operated by a computer system. In CNC, the movement and selection of the tool
is done by program for precise control of machining. A CNC lathe is operated with precise
design instructions to machine parts with precise specifications.

Fig. 6: CNC lathe Machine and its parts

A simple CNC lathe operates on two axes. The rotating action of the workpiece is called
"turning.” This is why certain types of CNC lathes are called CNC Turning Machines. CNC
lathes produce precise round shapes with an outer diameter (OD) and an inner diameter
(ID). Many different kinds of structures can be machined with this machine tool,
depending on their various industries’ needs.
They are commonly used in automotive, aerospace, steel and paper mills, and
shipbuilding industries
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MAIN PARTS OF CNC LATHE MACHINE

Headstock: Headstock of a CNC lathe machine has the main motor of the machine
which drives the spindle. Chuck is mounted on this main spindle.

CNC Lathe Bed: The tool turret travel over the CNC lathe bed, which is specially
hardened so that any kind of machining operations carried on the machine doesn’t affect
them.

Chuck: CNC lathe machine chuck grips the component which are to be machined. Chuck
itself has many parts. Jaws are mounted on the chuck to grip the part.

Tailstock: Tailstock are mostly used to give an extra gripping force for component
machining. For long components machining they provide extra force on the other end so
that machining process can be carried out smoothly.

Tailstock Quill: The whole tailstock is moved forward or reverse, but in that way, it is
not used to grip the part, but tailstock is travelled to a point near the component and then
it is set there, after that operator actuate the tailstock quill which travel either with
hydraulic pressure or pneumatic pressure to grip the component.

Foot Switch or Foot Pedals: Foot switches are used to actuate the chuck and tailstock
quill. Through these pedals CNC machinist’s open and close the chuck to grip the
component, the same way tailstock quill is taken to forward position or reversed through
theses pedals.

CNC Control Panel: The brain of the CNC machine, all the CNC program are stored
inside this panel, CNC operator controls the whole machine through the keys on this
panel. Operator can enter new program by using this panel, programs can be transferred
by using USB port on this panel as well. G-code and M-codes are used to feed the part
program to CNC lathe by control panel.
Tool Turret: The tools are mounted on the tool turret which are used for component
machining. Tool turrets vary in shapes and number of tools that can be mounted on them.
It is also referred as ATC (Automatic Tool Changer)

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DRILLING
Drilling is the process of creating a cylindrical hole of the specified diameter and depth by
removing metal with the rotating edges of a drill and to create a circular hole. In this, a
tool is used to drill holes of varying sizes and other operations called a drill bit. Holes can
be drilled on various surfaces from metal to wood. This operation is one of the most
important machining operations. A Typical drilling machine and drill bit are shown in
figures.

Fig. 7: a) Drilling machine b) Drill bit

A drill bit is a cutting tool used in a drill to remove material to create holes, almost always
of circular cross-section. Drill bits come in many sizes and shapes and can create different
kinds of holes in many different materials. In order to create holes drill bits are usually
attached to a drill, which powers them to cut through the workpiece, typically by rotation.
The drill will grasp the upper end of a bit called the shank in the chuck. Drills come in
standardized drill bit sizes.

Many different materials are used for or on drill bits, depending on the required
application. These are Tungsten Carbide (TC), low Carbon Steel (0.1-0.4 % C), high
Carbon Steel (0.75- 1.1% C), High Speed Steel, Cobalt Steel Etc.

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TAPPING
Apart from lathe, tapping process can also be used to produce threads. Tapping is the
process of cutting a thread inside a hole so that a cap screw or bolt can be threaded into
the hole. Also, it is used to make thread on nuts. Tapping can be done on the lathe by
power feed or by hand. The figure shows a tapping tool and the process of tapping in a
drilled hole.

Fig.8: a) Tapping Tool b) Tapping process

There are several different types of tapping operations, each suited to specific applications
and requirements. Some of the main types of tapping operations are hand/ manual
tapping, Machine Tapping, Blind Hole Tapping, Through Hole Tapping etc.
The choice of tapping method and tap type depends on factors such as the material being
tapped, the hole depth, thread size and pitch, production volume, and the desired thread
quality. Proper tool selection, cutting fluid application, and feed rates are critical for
achieving accurate and reliable threaded holes in machining operations.

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Practical 1

Objective: Study of Part Programming on CNC lathe for Plane Turning operation

TOOLS & EQUIPMENT:-

CNC Lathe machine, mild steel bar

Codes to be used:
G71 : Roughing cycle used for rough-material removal
G90 : Absolute Positioning mode
G95 : Feed in mm/Rev.
G64 : Continuous path mode
G00 : Rapid Traverse
G01 : Liner interpolation
G96 : Constant cutting speed on
T01 D1 : Loading of tool T1 and activation of the tool offset D1
S200 LIMS=2000 : Limit for main spindle.
M03 : Start Spindle turning clockwise
M06 : Tool change
M07 : Turn coolant on
M09 : Turn coolant Off
M05 : Spindle Stop
M30 : Main Program End

Main program

G71 G90 G95 G64

M06
T01 D1
G96 S200 LIMS=2000 M03
G00 X40 Z5
G00 X30
G01 Z -50 F 0.2 M07
G00 X 35
G00 Z 5
M09 M05
M30

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Fig. 9: Drawing for plain turning operation

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Practical 2
OBJECTIVE: -
To make a plumb bob on lathe machine as per the given dimensions

TOOLS & EQUIPMENT:-

Lathe machine, mild steel bar, right hand cutting tool, tool post key, chuck key, taps and
dies, drills, steel rule, outside callipers, vernier caliper

THEORY:-
A plumb bob is a simple tool that is used to establish whether something is “plumb:
(exactly vertical). When the string Is attached to a static object and the plumb bob weight
is suspended below, the laws of gravity will ensure that the string is both vertical and
perpendicular to any horizontal plane through which it passes. It is used in construction
and surveying to establish a vertical datum. It is typically made of stone, wood or lead but
can also be made of other metals.

PROCEDURE:-
1. The work piece is held in the 3-jaw chuck of lathe machine and tightened firmly
with chuck key
2. Right hand cutting tool is tightened in the tool post with the help of box key
3. Machine is switched on and the tool post is swivelled and cutting tool is adjusted
4. Drilling, tapping and threading operations will be done to obtain the required cap
dimensions as per the drawing for M10 bolt
5. Facing, taper turning and turning operations will be performed using general
running tool according to the sketch shown in figure
6. After completion of the job, it is inspected for the dimensions obtained with the
help of steel rule and vernier calliper

PRECAUTIONS: -
1. Make sure entangled hazards are removed
2. Keep the floor free from obstructions or slip hazards
3. Sufficient quantity of cutting fluid to be used during every machining process
4. Tool should be gripped rigidly in appropriate position in tool post

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5. Make sure that lathe has a start/stop button within easy reach of the operator

Fig. 10: Drawing of Plumb Bob

Fig. 11. Plumb Bob after Machining

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VIVA QUESTIONS FOR MACHINE SHOP

1. What are the different operations can be performed on the lathe?
2. What is the material of lathe bed?
3. Describe the different materials used for cutting tool.
4. What is percentage of carbon in mild steel?
5. State the different parts of the lathe.
6. How many kinds of chucks are used in lathe?
7. What are different gears used in the lathe?
8. Explain the utility of the feed bar?
9. When lead screw is used?
10. Which part of the lathe is used for tapper turning?
11. Describe the direction of rotation of chuck?
12. Explain the functions of tail stock?
13. State different types of chips produced while operating the lathe.
14. What is the name of the part of lathe on which the cutting tool is mounted?
15. What are different coolants can be used in machining?
16. What is the function of rail?
17. Which tool is used for centering purpose?
18. Describe the function of carriage wheel.
19. Explain the function of dead centre.
20. Which cutting tools are used for mild steel at high speed?
21. While machining a mild steel job, sometimes a chatter kind of heavy noise is
produced, why?
22. What is the main criterion taken care while selecting the material for the lathe bed?
23. What is the direction of motion of cutting tool in facing operation?
24. If the size of the job is too large, what problem may appear and how will you resolve
it?
25. Differentiate between turning and facing.
26. What Is full form of CNC?
27. What is the function of CNC Control Panel?

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