JOB REPORT

ON
MACHINE SHOP
1. NAME OF THE JOB. Straight, step and taper turning, facing, centre drilling
and drilling practice.

2. OBJECTIVE. The objective of this job is to practice the preparation of a

straight turning, step turning, taper turning, facing, centre drilling and drilling operation
with the help of a lathe machine.

3. THEORY.

Machine Tools. A machine which performs the material removal with tools to
produce desired shape and size of the work piece is known as a machine tool.

Types of Machine Tools. There are various types of machine tools

commonly used in workshops. They are as follows:
 Lathe Machine.
 Shaper Machine.
 Planer Machine.
 Drilling machine.
 Grinding machine.
 Milling machine.

Lathe Machine.

The lathe is one of the most important machines in any workshop. Its main
objective is to remove material from outside by rotating the work against a cutting tool.
It is a power driver, well purpose machine tool, which is used for producing cylindrical
work piece.

An engine lathe is a power-driven, general-purpose machine tool used for

producing cylindrical work-pieces. As the piece of metal to be machined is rotated in the
lathe, a single-point cutting tool is advanced radically into the work piece a specified
depth and moved longitudinally along the axis of the work piece, removing metal in the
form of chips. Both inside and outside surfaces can be machined on a lathe by using
attachments and accessories. Other operations such as drilling, reaming, boring, taper
and angle turning, screw-thread chasing, form turning, knurling, milling, grinding, and
polishing may be performed.
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Types of Lathe Machine.

Speed lathe
Bench lathe
Engine lathe
Tool room lathe
Capstan and turret lathe
Automatic lathe
Special purpose lathe

Parts of Lathe Machine.

 Major parts.

Bed
Headstock
Tailstock
Carriage. Carriage have five major parts. They are as follows:
Saddle.
Cross-slide.
Compound rest.
Tools Post.
Apron.
Power feed and thread cutting mechanism.

 Other Parts.
 Carriage wheel
 Compound slide
 RPM selector dial
 Compound rest
 Apron
 Rack
 Tailstock spindle
 Lock lever
 Hand wheel
 Lead screw
 Set over screw
 Control rod
 Chip pan Parts of a Lathe Machine
 Tool holder
 Feed plate  Taper wheel

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  Spindle  Sliding gear
 Mandrels  Feed rod
 Lead Screw  Carriage stop
 Emergency stop  Feed compound
 Control handle  Follower rest
 Angle plate  Rests
 Carriage  Wheel

Working principles of Lathe Machine.

In a lathe machine the operations, which are done is defined as a job. The job is
held in a chuck or between centers and rotated about its axis at a uniform speed known
as RPM (Revolutions per minute). The cutting tool held in the tool post is fed into the
work-piece for a desired direction. Since there exists a relative motion between the work-
piece and the cutting tool, therefore the material is removed in the form of chips and the
desired shape is obtained.

Lathe Operations. The most common operations which can be carried out
on a lathe are:

 Straight Turning.

It is an operation of removing excess amount of material from the surface of the

cylindrical work piece. In this operation, the work is held either in the chuck or between
centers and the longitudinal feed is given to the tool either by hand or power.

 Step Turning.

It is an operation of producing various steps of different diameters in the work

place. This operation is carried out in the similar way as plain turning.

 Taper Turning.

It is an operation of producing an external conical surface on a work piece. A

small taper may be produced with the help of a forming tool or chamfering tool, but the
larger tapers are produced by swiveling the compound rest, at the required angle or by
offsetting the tailstock or by taper turning attachment.

If D is the larger diameter, “d” is the smaller diameter and “l” is the length of
taper, then,
Taper, θ= tan-1(D-d)/2l

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 Facing.

This operation is almost essential for all works. In this operation, the work piece
is held in the chuck and the facing tool is fed from the center of the work piece towards
the outer surface or from the outer surface to the center, with the help of a cross slide.

 Centre Drilling.

It is an operation of locating the centre of the job before proceeding for the
drilling operation. In this operation, the work piece is held in a chuck and the drill centre
is held in the tailstock. The drill is fed manually into the rotating work piece, by rotating
the tailstock hand wheel.

 Drilling.

It is an operation of making a hole in a work piece with the help of a drill. In this
operation, the work piece is held in a chuck and the drill is held in the tailstock. The drill
is fed manually into the rotating work piece, by rotating the tailstock hand wheel.

 Knurling.

It is an operation of providing knurled surface on the work piece. In this

operation, a knurled tool is moved longitudinally to a revolving work piece surface.

4. Apparatus Needed.

Adjustable wrench

Slide calipers

Cutting tool

Knurling tool

Chuck key

Facing tools

Turing tools

Taper Turing tools

Chamfering tools

Form or profile tools

Parting or necking tools

Drilling tools

External and internal threading tools

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5. Diagram of the Job.

θ
24 12 20

15
20 20 24
64 mm

Figure: Diagram of the Job

Note: All the dimensions are in mm.

Length of every section is equal.
Drill size is 6-7.5 mm.
Metal: Mild Steel.

6. Working Procedure. The job was prepared as per the following sequence:

 Facing.
 Straight Turning.
 Step Turning.
 Centre Drilling.
 Drilling.
 Taper Turning.
 Knurling.

 Facing.

 The piece of metal was supplied of 24 mm diameter.

 The work piece was held in the chuck and the facing tool was fed from the
lathe center of the work piece towards the outer surface with the help of a cross
slide.
 The machine was operated counter clockwise and the facing was done.

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 Straight Turning.

 The work piece was to reduce in its diameter by 2 mm.

 First, the entire length of 60 mm was measured with the help of the slide
calipers.
 The marking was done on the 60 mm position by the turning tools.
 This extra metal over the diameter was measured by the slide calipers and
adjusted to the machine.
 Then the work piece was held in the chuck and the machine was switched
on.
 Finally, the cross slide was operated towards the left and again towards the
right so long the entire work piece was reduced to 22 mm diameter.

 Step Turning.

 In this operation, first the 40 mm length was measured with the help of a
slide calipers, leaving the 20 mm portion intact of 22 mm diameter.
 Then the marking was done on the 40 mm position by the turning tools.
 The work piece was to reduce in its diameter by 2 mm in this length.
 The extra metal of 2 mm diameter was measured by the slide calipers and
adjusted to the machine.
 Then the work piece was held in the chuck and the machine was switched
on.
 Finally, the cross slide was operated towards the left and again towards the
right so long the 40 mm length of the work piece was reduced to 20 mm diameter.

 Centre Drilling.

 It is an operation of locating the centre of the job before proceeding for

the drilling operation.
 Here, the work piece was held in a chuck and the drill centre was held in
the tailstock.
 The drill centre was fed manually into the rotating work piece, by rotating
the tailstock hand wheel.
 Then the machine was switched on and centre drilling was done of near
about 02 mm length.

 Drilling.

 The diameter of the drill was given as 6-7.5 mm.

 A drill bit of 7 mm was selected for that purpose.
 The length of the drill 15 mm was adjusted to the machine.
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  Then the work piece was held in a chuck and the drill was held in the
tailstock.
 The drill is fed manually into the rotating work piece, by rotating the
tailstock hand wheel.
 And finally the drilling of desired diameter and length was done.

 Taper Turning.

 For taper turning, the larger diameter D was 20 mm, smaller diameter d
was 10 mm and length of the taper turning was 20 mm.
 So, as per the formula, the angle was found, 14.04 degree.
 The angle was set in the machine with the help of the adjustable range.
 Finally, the desired angled taper turning was done from the right towards
the left direction.

 Knurling.

 The knurling tool was set in the machine.

 The same was centred and knurling was done in the middle 20 mm portion
of the work piece.
 Here, a knurled tool was moved longitudinally to the revolving work piece
surface.

7. Discussions.

1. Lathe machine should be stopped before making adjustments to the tool

holder.
2. A short piece of winding wood may be used to push the winding chip
down into the lathe pan.
3. A lathe chip is both hot and sharp and should never be touched by hand.
4. Chuck key should not be leaved in the chuck.
5. It is bad practice to stop the lathe before the required length of knurl is
completed.
6. A brush should be used to remove the chips resulting from a knurling
operation.
7. In case of emergency, the emergency stop should be used to stop the
machine.
8. For smooth working and to prevent the job from becoming too much hot,
the cooling fluid should be used.
9. Care should be taken so that any time while turning is done, the marked
portion should not be crossed.

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 10. Extreme care should be taken so that the tool post is not colliding with the
head stock while the machine is on. In this case, there may be a damage of
the machine.
11. The slide calipers should be used accurately, otherwise the lengths and the
diameters may be varied.
12. Necktie, wrist watch and jewelry such as rings should not be wearing
during the operation.
13. The mechanist should wear an apron, shop coat, or coveralls.
14. Apron strings should be tied at the back, and bulging pieces of cotton
waste should be tied at the back.
15. The mechanist should not wear woolen sweater.
16. The mechanist should wear canvas shoes.
17. Gloves should be worn when the worker is moving sheet metal or large
pieces of stock.
18. The worker should wear goggles or safety glasses to save the eye from the
flying particles of metal.

8. Conclusions. Machine shop provides us the opportunity to learn how to

prepare different jobs on ground. This is of immense importance and of extreme
practical usefulness to prepare such jobs in the machine shop, which will make the
students beneficiary in the long run.

9. Remarks by the Instructor.

10. Grading Obtained.