1. TOPIC 2: MACHINING OPERATIONS: TURNING By: Suziyana Mat Dahan Manufacturing Technology (BPT 4413) 1

2. LESSON OUTCOMES By: Suziyana Mat Dahan 2 Manufacturing Technology (BPT 4413) LO1 Able to describe components and cutting principles of turning/lathe machine LO2 Able to discuss main operations that can be performed on lathes

3. TOPIC OUTLINE By: Suziyana Mat Dahan 3 Manufacturing Technology (BPT 4413)  Turning operations  Machine layout  Work holding devices  Types of operation  Cutting tool geometry  Principles of cutting  Turning methods and main operations

4. TURNING OPERATIONS By: Suziyana Mat Dahan 4 Manufacturing Technology (BPT 4413) Machining operations performed to produce circular, conical, flat or spherical components. E.g. small as miniature screws for hinge of eyeglass frames and as large as turbine shafts for hydroelectric power plants. Carried out on a lathe – versatile and can produce wide variety of shapes. The spindle carrying the work is rotated whilst a cutting tool, which is supported in a tool post, is made to travel in a certain direction depending on the form of surface required. Typical type – centre lathe which used in a jobbing (one off) situation or for small batch work.

5. Machine Layout (Centre Lathe) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 5

6. HeadstockTailstockSaddle Machine Layout Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 6

7. Speed Selector On / Off Switch Chuck Headstock Machine Layout (Headstock) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 7

8. By: Suziyana Mat Dahan 8 Manufacturing Technology (BPT 4413) Headstock Fixed to the bed. Supply power to a spindle at various rotational speeds. Have speed selector and on/off switch button. Have hollow spindle to which work holding devices (such as chucks and collects) are mounted.

9. Tool Post Compound Slide Lathe Bed Lead Screw Feed Shaft Switch Lever Cross Slide Rev - Off - On Handle Machine Layout (Saddle) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 9

10. Carriage Slides along the ways. Consists of a) to e). Cutting tool is mounted on the tool post with compound rest (swiveled for tool positioning and adjust ment). Cross-slide – move radially in and out for controlling radial position of tool. Apron – movement of carriage and cross slide. a) Saddle b) cross slide c) compound slide d) tool post e) apron Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 10

11. Compound Slide Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 11

12. Slide along the ways and supports the other end of workpiece. Equipped with center – fixed (dead center) or rotates (live centre). Used to mount drills and reamers to drill. Machine Layout (Tailstock) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 12

13. By: Suziyana Mat Dahan 13 Manufacturing Technology (BPT 4413) Work Holding Devices To hold workpiece securely during turning operation. One end of the workpiece is clamped to the spindle of the lathe by a: 1. Chuck 2. Collect 3. Face plates 4. Mandrel Chuck Equipped with three or four jaws. Three-jaw chucks -have a geared-scroll design that makes the jaws self- centering. -used for round workpieces (such as bar stock, pipes and tubing) and hexagonal stock.

14. Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 14

15. By: Suziyana Mat Dahan 15 Manufacturing Technology (BPT 4413) Four-jaw chucks -have jaws that can be moved and adjusted independently of each other. -used for square, rectangular, odd–shaped and heavy workpieces.

16. By: Suziyana Mat Dahan 16 Manufacturing Technology (BPT 4413) Power chucks -actuated pneumatically or hydraulically are used in automated equipment for high production rates including Computer Numerical Control (CNC) machines and loading of parts using industrial robots.

17. By: Suziyana Mat Dahan 17 Manufacturing Technology (BPT 4413) Collect A longitudinally-split, tapered bushing. The workpiece (generally with a maximum diameter of 25 mm) is placed inside the collect. 2 types – draw-in collect (pulled) and push-out collect (pushed). Tapered surfaces shrink the segments of the collect radially, tightening onto the workpiece. Used for round and other shapes of workpiece and available in a wide range of sizes. Advantage – grips nearly the entire circumference of the part making the device well suited for parts with small cross sections.

18. By: Suziyana Mat Dahan 18 Manufacturing Technology (BPT 4413) Face plates -Used clamping irregularly shaped workpieces. -The plates are round and have several slots and holes through which the workpiece is bolted or clamped.

19. By: Suziyana Mat Dahan 19 Manufacturing Technology (BPT 4413) Mandrels -Placed inside hollow or tubular workpieces. -Used to hold workpieces that require machining on both ends or on their cylindrical surfaces. -Some mandrels are mounted between centers on the lathe.

20. Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 20

21. By: Suziyana Mat Dahan 21 Manufacturing Technology (BPT 4413) Types of operation 1. Turning – to produce straight, conical, curved, or grooved workpieces. 2. Facing – to produce a flat surface at the end of the part. 3. Profiling – to produce various axis symmetric shapes for functional or aesthetic purposes. 4. Parting – to cut a piece the end of a part. 5. Threading – to produce external or iternal threads. 6. Knurling – to produce a regularly shaped roughness on cylindrical surfaces. 7. Boring – to enlarge hole or cylindrical cavity made by a previous process or to produce circular internal grooves. 8. Drilling – to produce a hole.

22. By: Suziyana Mat Dahan 22 Manufacturing Technology (BPT 4413)

23. R.H.S. TURNING TOOL L.H.S. TURNING TOOL FINISHING TOOL 45° FORM TOOL EXTRA THREADING TOOL PROFILE TOOL PARTING OFF TOOL PROFILE TOOL Types of Turning Tool Different types of operations performed using different kind of cutting tools: Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 23

24. Types of Turning Tool Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 24

25. RIGHT HAND SIDE CUTTING TOOL Cutting Tool Geometry Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 25

26. Cutting Tool Geometry Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 26

27. By: Suziyana Mat Dahan 27 Manufacturing Technology (BPT 4413) Various angles played various functions: 1. Rake angle -Controls direction of chip flow and strength of the tool tip. 1) Side Rake angle : provides a cutting edge to allow chips to escape during cutting. 2) Back Rake angle : promotes smooth chip flow and good finishing 2. Cutting edge angle (around 15 ◦ ) -Controls chip formation, tool strength and cutting forces. 3. Relief/clearance angle (around 5 ◦ ) -Controls interference and rubbing at the tool- workpiece interface. 1) End Relief angle : prevents tool end from rubbing 2) Side Relief angle: allows the tool to feed into the work 4. Nose radius -Affect surface finish and tool-tip strength.

28. SINGLE POINT CUTTING TOOL Principles of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 28

29. CUTTING EDGE Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 29

30. CUTTING POINT Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 30

31. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 31

32. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 32

33. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 33

34. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 34

35. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 35

36. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 36

37. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 37

38. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 38

39. WORKPIECE TOOL WORKPIECE Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 39

40. WORKPIECE TOOL Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 40

41. WORKPIECE TOOL CUT FLOW DEPTH OF CUT RELIEF ANGLE RAKE ANGLE Principle of Cutting Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 41

42. Swing & Tool Height Swing = Maximum diameter of the work which can be rotated in a Centre Lathe Rotating Direction Tool Height = Cutting tool is set to the centre level of the rotation Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 42

43. Tool Height & Rake Angle Correct Tool Height & Correct Rake Angle Above Tool Height Increase Top Rake Angle Lower Tool Height reduce Top Rake Angle Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 43

44. Tool Height Packing Tool Height Setting Tail Stock Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 44

45. Speed and Feed Table WORKPIECE MATERIALS FEED (mm/rev)CUTTING SPEED (m/min) Aluminium 0.2 – 1.070 – 100 Brass (Alpha, Ductile) 0.2 – 1.050 – 80 Brass (free-cutting) 0.2 – 1.570 – 100 Bronze (phosphor) 0.2 – 1.035 – 70 Cast iron (grey) 0.15 – 1.025 – 40 Copper 0.2 – 1.0 35 - 70 Steel (mild) 0.2 – 1.0 35 - 70 Steel (medium carbon) 0.15 – 0.7 30 - 35 Steel (alloy, high- tensile) 0.08 – 0.35 – 10 Thermo-setting plastic 0.2 – 1.0 35 - 50 Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 45

46. Turning methods of main operations Facing Parallel Turning Parting Off (Under-cutting) Forming (Chamfering) Taper Turning Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 46

47. Facing Purpose - Generating a Flat face) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 47

48. Rotating Direction Feed Direction Facing Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 48

49. Rotating Direction Facing Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 49

50. Rotating Direction Facing Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 50

51. Rotating Direction Facing Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 51

52. Rotating Direction Facing Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 52

53. Rotating Direction Facing Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 53

54. Direction of Tool Movement Relief/Clearance Angle Setting Up for Facing Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 54

55. Parallel Turning Purpose - Generating a Cylinder Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 55

56. Parallel Turning Rotating Direction Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 56

57. Parallel Turning Rotating Direction Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 57

58. Parallel Turning Rotating Direction Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 58

59. Parallel Turning Rotating Direction Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 59

60. Parallel Turning Rotating Direction Feed Direction Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 60

61. Direction of Tool Movement Setting Up for Parallel Turning Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 61

62. Parting off (under-cutting) Purposes: 1. Generating a Under - cutting 2. Or Parting Off the Material Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 62

63. Parting off (under-cutting) Using Parting Off Tool Set up perpendicular to the axis Lower spindle speed Zig - Zag feeding No Power Feed Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 63

64. Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 64

65. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 65

66. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 66

67. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 67

68. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 68

69. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 69

70. Tool Path Zig - Zag Feeding Parting off (Under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 70

71. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 71

72. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 72

73. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 73

74. Tool Path Zig - Zag Feeding Parting Off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 74

75. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 75

76. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 76

77. Tool Path Zig - Zag Feeding Parting off (under-cutting) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 77

78. Taper turning Purpose - Generating a Taper ( Cone ) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 78

79. Compound Slide Taper turning Using Compound Slide Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 79

80. Turning Tool Compound slide Lock Nuts Taper turning Compound Slide Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 80

81. Setting up angle =  2 Taper turning Set compound slide to required angle ◦ ( half of included angle ) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 81

82. Direction of Tool Movement Taper turning Feed direction move along the compound slide ◦ ( Don`t use power feed ) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 82

83. Taper turning Start at the end of the taper Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 83

84. Taper turning Cut along the compound slide Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 84

85. Taper turning Cut along the compound slide Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 85

86. Taper turning Cut along the compound slide Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 86

87. Taper turning Cut along the compound slide Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 87

88. Include angle =  Setting up angle =  2 Taper turning Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 88

89. Less than 3 mm Forming Taper turning using a form tool (Less than 3mm Chamfer) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 89

90. 45 Form tool ° Forming Using 45 ° Form tool Set up perpendicular to the axis Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 90

91. Direction of Tool Movement Forming Lower spindle speed Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 91

92. Direction of Tool Movement Forming Manual feed forward Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 92

93. Direction of Tool Movement Forming Manual feed forward Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 93

94. Forming Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 94

95. Forming Profile turning using a form tool ◦ ( Similarly to taper turning using a form tool ) Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 95

96. Safety Consult Staff Where are the Points Consult Staff Where are the Dangerous Points Familiar with the Controls Familiar with the Controls Stop the Machine in Stop the Machine in Emergency Only One Man operates One Machine Only One Man operates One Machine Suitable & safety protection of yourself Suitable & safety protection of yourself Don't leave the machine when it is running Don't leave the machine when it is running Don't touch the work while it is running Don't touch the work while it is running Don't operate the machine staff Supervised Don't operate the machine Without staff Supervised Manufacturing Technology (BPT 4413) By: Suziyana Mat Dahan 96

97. By: Suziyana Mat Dahan 97 Manufacturing Technology (BPT 4413)