INTRODUCTION

Lathe is a tool that used to create an object which has symmetry about an axis of
rotation. It can perform various operations such as cutting, knurling,drilling, facing ,
turning,sanding and deformation. This machine just operate round workpiece but it
can accommodate with the varying workpiece lenghts. The workholding method used
was clamping the work using a chuck or collet for the short workpiece and rotating
lathe center was used in addition for the long workpiece.
Lathe are used in woodturning, metalworking, metal spinning, thermal spraying,
parts reclamation, and glass-working. Examples of objects that can be produced
using the lathe include chess, baseball bats, candlestick holders, a shafts , bowl and
table legs. Today, both manual and CNC lathes machine coexist in the manufacturing
industries.

OBJECTIVE
To practice the theory.
To increase understanding by using the practical method.
Know how to operate and create the object manually using the lathe machine
Enhance the skill on lathe machining operation.

MATERIAL
1

Table 1
Raw material of Aluminium.
A silvery white , soft and ductile metal.
The chief ore of aluminium is bauxite.
Low density of metal and can resist the
corrosion. Widely used in cooking
utensils, transportation and packaging.

TOOL AND MACHINES

Table 2

Tool/ Machine

Explanation
Lathe machine
Machine used to produce the part where
the turning, facing, taper, grooving and
knurling process operation can be done.

Bench saw machine

Cut the aluminium rod continuosly where
the speed of cutting can be adjusted.

Vernier calliper
Measure the object/ part produce with
0.02 mm precision.

Rotating lathe center

Ensure that the workpiece was hold at
the center and used as a support for the
long work piece.
Knurling tool
A tool used to make a pattern on the
work piece surface, where it make the
round part easy to hold.
Drill chuck
Used to make a hole in the work piece
with various kind of diameter .

Cutting tool
Sharp tool bit used to remove the
unwanted surface to produce a part

Chuck key
Used to tighten the chuck for clamping
process.

Spacing
Used to add the height of the knurling
tool.

Continue from table 2.

3

PROCEDURE
1. Cut the aluminium rod with the length given using the bench saw machine.
Measurement of the work piece to cut:
I.
Length = 74 cm
II.
Diameter = 54 cm
2. Turn on the lathe machine
3. Set up the work piece at the lathe machine. Make sure that the work piece
was placed at the center of the chuck.
4. Measure the length and the diameter of the work piece before any cutting
processes was made.
5. Facing process
I.
Set up the cutting tool for facing process where the tool bit height was
at the center of the work piece to get a smooth cutting surface without
leaving any outer surface.
II.
Then set the spindle speed with the suitable speed to feed the
aluminium material:
Formula to calculate the spindle speed:
V=n
1000
Where , V = cutting speed of the material
n = rpm
= diameter of material
III.
IV.
V.

After that measure the depth of material to remove.

Then, on the machine and control the speed of the cutting tool feed.
For the rough cut, the cutting tool speed can be faster, and for the
finishing low speed of feeding are recommended to get a smoother
surface.

Figure 1.Example of Facing Process.

6. Turning process

I.
II.
III.

For the turning process, the cutting tool was set same as the facing
processes.
Remove the outer surface using rough cut method and finish the cut
with low speed of feeding.
During this process, the shape of the work piece starting to show up.

Figure 2 Example Of Turning Process

7. Since the other side of the work piece are clamped, rotate the work piece after
the facing / turning process was done at the other side.
8. Chamfer process
This process is used to make two chamfer at the work piece, 15 and 45
I.
Loosen the screw of the tool holder and rotate it at 15 and tighten it
back.
II.
Then as the work piece rotate, move the cutting tool and feed the
material little by little.
III.
After that, rotate the tool holder for 45, to make the another chamfer.

Figure 3 :Chamfer Process.

9. Grooving process
I.
Change the cutting tool with the groove tool bit.
II.
Set the tool holder 90 with the work piece.
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III.
Then groove the work piece by 3mm depth.
10. Since the diameter of the work piece clamped was small than the other side,
the work piece become unbalanced when rotated and need support. So
I.
Ensure that the work piece was centred with the tailstock center.
II.
Replaced the center at the tailstock with chuck drill.
III.
Then drill the bottom of the work piece to make a hole about 0.8mm
depth
IV. Replaced the drill back with the center and placed the top of the center
in the hole to support the work piece

Figure 4 : Grooving Process

11. Knurling process
I.
Change the cutting tool with the knurling tool / turning tool.
II.
If the height not enough, use the plate spacing to increase the tool
height.
III.
Adjust the height until it is centred with the tailstock quill.
IV. Change the speed to 85 rpm.
V. Then placed the knurling tool on the work piece and on the machine to
produce a pattern.

Figure 5 : Knurling Process

12. Clean the machine and turn off the machine power supply after the work
done.

RESULT

Figure 6 : Final Result

DISCUSSION
During the practical on machining, some problem were faced, and we will discuss
how to overcome it.
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1.) Measurement of the work piece uneven/ consistent.

The uneven measurement of the work piece can create a confusion. The
problem was detected due to the several checking on the work piece
measurement. The problems occur:
I.
when the work piece slightly move during the rotation. To overcome
this, half of the work piece was clamped.
II.
The vernier calliper not in good condition. So ,need to find a good one
where the measurement can be locked.
III.
Digital reader of the lathe machine doesnt precise. Do the measuring
manually using the good vernier calliper.
2.) Clamping leave marks on the work piece.
When the clamp was too tight, it will leave marks on the work piece. Those
marks affect the finishing process or maybe the measurement of the work
piece diameter. To avoid it, use some paper and fold the work piece before
clamping it. This way the pressure of the clamp can be reduce since the
aluminium is soft.

CONCLUCION
Lathe mchine was used a decades ago, where its function was releven until
nowadays. From manual operation until the automatic CNC machine was build, this
machine tool had contribute largely in the industrial industries manufacturing
processses.
Having a chance to learn in how to operate this machine was a good experience.
Through this workshop practical learning,it improve the understanding on how
actually lathe machine operate to produce a part of things/ object.

REFERENCES
People

I.

II.
III.

Mr. MUHAMMAD SYAFIK BIN JUMALI, Teaching Engineer of manufacturing

processes subject, Manufacturing Engineering Technology Department.
(Lecture Session)
ENGR.ZOLKARNAIN BIN MARJUM, Senior Lecturer of Manufacturing
Engineering Technology Department. (Workshop Session)
Mr. MOHD FAIZ BIN WAHID, Lecturer of Manufacturing Engineering
Technology Department.(Workshop Session)

Web
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VIII.
IX.

http://en.wikipedia.org/wiki/Lathe
http://www.google.com
http://en.wikipedia.org/wiki/Aluminium
http://www.diracdelta.co.uk/science/source/v/e/vernier
%20caliper/image001.jpg
http://www.baileighindustrial.co.uk/media/catalog/product/cache/5/image/9df78
eab33525d08d6e5fb8d27136e95/b/a/band-saw-bs712m.jpg
http://1.imimg.com/data/2/9/MY-959991/Aluminium_Rods_250x250.jpg
http://img.directindustry.com/images_di/photo-g/rotating-lathe-centers-271502417549.jpg
http://img.alibaba.com/img/pb/541/240/515/515240541_946.jpg
http://littlemachineshop.com/Products/Images/480/480.1768.jpg