THERMODYNAMICS

MANUFACTURING RESOURCE CENTER (MRC)

LAB REPORT 2: LATHE AND MILLING MACHINES

Submitted by: Hamna Anwaar Registration no: 335763

TITLE: Lathe and Milling Machines

OBJECTIVE:

Lathe Machine:

1. To perform facing, turning and taper turning operations on lathe.

2. To perform Drilling, boring, parting off and knurling operation on lathe.
3. To perform Thread cutting on lathe machine.

Milling Machine:

1. To perform face milling and pocket milling operations on milling machine.

2. To perform Gear cutting on milling Machine using indexing head.

APPARATUS:

Lathe Machine:

1. Nylon rod
2. Lathe machine
3. Vernier caliper
4. Turning, parting and boring tool

Milling Machine:

1. Milling machine
2. Work piece
3. Vernier caliper
4. Vice on table
5. End milling cutters

PRINCIPLE:

Lathe Machine:

In a lathe, the work piece is held in chuck and rotates about its axis by means of power. A single point
cutting tool is mounted in tool post. When the chuck rotates the work piece also rotates. The tool moves
parallel to the axis of rotation of work piece to produce a flat surface. The tool moves at an angle to the
axis of work piece to produce a turn surface. The material is removed in the form of the chip from the
work piece by giving proper feed and depth of cut. So, the required size and shape of the work is
obtained.
Milling Machine:

The working principle of the milling machine, applied in the metal removing operation on a milling
machine. The work is rigidly clamped on the table of the machine and revolving multi teeth cutter
mounted either on a spindle.

The cutter revolves at a normal speed and the work fed slowly past the cutter. The work can be fed in a
longitudinal, vertical or cross direction. As the work progress further, the cutter teeth remove the metal
from the work surface to produce the desired shape.

THEORY:

Lathe Machine:

A lathe machine is a machine tool that removes the undesired material from a rotating work piece in the
form of chips with the help of a tool that is traversed across the work and can be feed deep into the
work.

Main Parts of Lathe Machine:

Bed: It is the base on which all the other parts of the lathe are mounted. The bed is made from Cast
iron or nickel cast iron alloy and is supported on broad box-section columns.

Headstock: It is present on the left end of the bed. The main function of the headstock is to transmit
power to the different parts of the lathe.

Tailstock: It is a movable casting located opposite to the headstock on the way of the bed.

Carriage: It is located between headstock and tailstock. The basic function of the carriage is to support,
guide, and feed the tool against the job during operation.

Saddle: It is an H-shaped casting mounted on the top of the lathe ways. It provides support to cross-
slide, compound rest, and tool post.

Cross Slide: It is provided with a female dovetail on one side and assembled on the top of the saddle
with its male dovetail.

Compound rest: It is present on the top of the cross slide. It supports the tool post and cutting tool in its
various positions. Compound rest is necessary for turning angles and boring short tapers and forms on
forming tools.

Tool Post: It is mounted on the compound rest. It is used to hold various cutting tool holders.
The Apron is fastened to the saddle and hangs over the front of the bed.

Chuck: It is basically used to hold the workpiece, particularly of short length and large diameter or of
irregular shape which can’t be conveniently mounted between centers. It can be attached to the lathe
by screwing on the spindle nose.
Feed rod: It is a power transmission mechanism used for precise linear movement of the carriage along
the longitudinal axis of the lathe. In some lathe machines instead of feed rod lead screws are used.

Lead screw: It is used mostly in the case when the threading operation is to be performed on a lathe.

Operations of Lathe Machine:

Turning: It is the operation of reducing the diameter of a work piece to produce a cone -shaped or a
cylindrical surface.

Taper Turning: A taper may be define as a uniform increase or decrease in diameter of a piece of work
measured along its length. In a lathe, taper turning means to produce a conical surface by gradual
reduction in diameter from a cylindrical work piece.

Step turning: It creates two surfaces with an abrupt change in diameters between them. The final
feature resembles a step.

Facing: It is an operation of reducing the length of a work piece to produce a flat surface square with the
axis.

Drilling: It is an operation of producing a cylindrical hole in a work piece by the rotating cutting edge of a
cutter known as the drill.

Knurling: It is the process of embossing a diamond shaped pattern on the surface of a work piece.

Threading: It is an operations to produce a helical groove on a cylindrical or conical surface by feeding

the tool longitudinally when the job is revolved between centers or by a chuck.

Accuracy: 0.04 mm

Milling Machine:

The milling machine is a type of machine which removes the material from the workpiece by feeding the
work past a rotating multipoint cutter. The metal removal rate is higher very high as the cutter has a
high speed and many cutting edges.

Parts of Milling Machine:

Base: The base is the part upon which the whole machine parts are being mounted. It is a type of
foundation for the machine.

Column: The main supporting frame which consists of all the driving mechanisms and the motor is called
the column.
Knee: The knee shape is quite similar to that of the human body knee. This is an important part of this
machine that supports the other parts like the saddle and table.

Saddle: The saddle is present on the top of the knee which further carries the table. Its basic function is
to support the table.

Table: The table is present on the top of the saddle. The table consists of T-slots or sometimes fixtures
are used for holding up the work piece on the table. A table can travel longitudinally in a horizontal
plane.

Over-arm: It is also called the over-hanging arm. Overarm is present at the top of the column. The basic
function of the over-arm is to support the arbor and spindle.

Spindle or Arbor: The top portion of the column contains the spindle. The spindle is also an important
part of the machine as it is the part where the multipoint cutter is attached.

Operations of Milling Machine:

Face Milling: This operation makes flat surfaces at the face of work piece.

Side Milling: It is the machining process which produces flat vertical surface at the sides of a work piece.

Plain Milling: It is a Process of milling flat surfaces keeping the axis of the cutter parallel to the surface
being milled.

Straddle Milling: It is a process in which two side milling cutter are used to machined two opposite sides
of a work piece simultaneously.

Angular Milling: It is a process of milling flat surfaces which are neither Parallel nor perpendicular to the
axis of the milling cutter.

Gang Milling: It is the machining process in which two or more milling cutters are used together to
perform different milling operation simultaneously.

Form Milling: It is the process of machining special contour (outline) composed of curves, straight lines,
or entirely of curves, at a single cut.

Profile Milling: This milling operation is used to cut a profile on the work piece.

End Milling: It is the process of producing flat surfaces which may be horizontal, vertical and at any angle
taking worktable as a reference.

Saw Milling: It is machining process which is used to produce narrow grooves or slots on the work piece.

Milling Key Ways, Grooves and Slots: This milling operation is used to produce key ways, grooves and
slots on the work piece.
Gear Milling: It is the milling process which is used to cut gears on the work piece.

Helical Milling: This milling operation is done to produce objects having helical design such as helical
gears, twisted drills etc.

Cam Milling: It is a machining process which is used to make cams.

Thread Milling: It is the process of milling used to cut threads on the cylindrical work piece.

Accuracy: 0.02mm

PROCEDURE:

Lathe Machine:

1. Cut a stock metal out of a rod of nylon of dia 85 mm and dia 25 mm and above.
2. Fix it in a three jaws chuck in a lathe machine with at least 75mm protrusion.
3. Face the open end of the stock and fit the center of tail stock.
4. Turn the job to 18mm throughout.
5. Remove the job and fix it in the chuck from the other end.
6. Ensure that the fixing of chuck is at the solid portion of work piece. Do not over tight facing
other end.

Machine Machine:

1. To take piece of Acrylic plate as per given drawing.

2. The stock provided has right thickness of 6mm.
3. Mount the block on a machine table in a vice.
4. Machine one of the longer sides of the block from the sides by using end mill cutter 8mm.
5. Mark the other to confirm to the required dimension and inflect similar cuts on other three
sides.
6. Install a job horizontally in the vice on table. (Check by level)
7. Using 8mm end mill cutter the thickness of the work piece is machined to 6mm.
8. Mark the center line for the slot for the slot to be machined.

ENVIRONMENTAL SIGNIFICANCE:

Machining produces many by-products or wastes including metal chips/swarf impregnated with cutting
fluid, spent cutting fluid, oil contaminated water, oil mist, metal dust, and unnecessary energy usage.
OBSERVATIONS AND CALCULATIONS:

CONCLUSION:

Machining is a process in which a material (often metal) is cut to a desired final shape and size by a
controlled material-removal process. Machining is a part of the manufacture of many metal products,
but it can also be used on other materials such as wood, plastic, ceramic, and composite material.

A lathe machine is a heavy duty and high powered tools largely used in engineering. They are used to cut
and shape metals, woods or plastics and even drill holes with added parts.

Milling Machines provide the technology, precision, accuracy, and consistent flow of procedures for a
high production rate. They have the features that make them fast, with low to zero human errors. You
can save time and money and lessen the risk of wastage of materials.