i

Bachelors Degree
In
Industrial & Manufacturing Engineering



This report is submitted to
Department of Industrial & Manufacturing Engineering,
Rachna College of Engineering and Technology, Gujranwala

This is declared that work submitted in this report is my own, and any work that is
not mine has been quoted and acknowledged in the references.



Student Name:

Muhammad Yasin Farooqi
2009-IM-106

Internal Examiner:

Name: Engr. Qurrat-ul-ain Signature: ------------------------------



External Examiner:

Name: Engr. Shoab Kokab Signature:------------------------------





Department of Industrial & Manufacturing Engineering,
Rachna College of Engineering and Technology, Gujranwala
(A Constituent College of UET, Lahore)





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DEDICATION

To my beloved family especially my parents, this project is the
result of their prayers.....


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Preface:

The purpose of this report is to elaborate the work and the task which has been
performed during my final year project. It was a wonderful experience which was a
combination of having a professional environment as well as working with good people.

The main purpose of this report is to fulfil the requirement of the UNIVERSITY
OF ENIGNEERING AND TECHNOLOGY LAHORE to submit a report which is all
about the major tasks which I have performed in my final year project.

I would like to give my sincere gratitude to my supervisor ENGR. QURRAT-
UL-AIN for his engagement, enthusiasm and support during my thesis.



MUHAMMAD YASIN FAROOQI

JUN 2013









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Acknowledgment


Glory is to ALLAH ALMIGHTY for all His blessings and mercy. In His Name, we
begin, and in His Name we end. Endless peace and countless blessings of Allah be upon
the final Messenger Muhammad (S.A.W).
I want to express my deep sense of gratitude and indebtedness to my thesis supervisor
engr. Qurrat ul ain lecturer RCET, Department of Industrial and Manufacturing
Engineering, for providing precious guidance, inspiring discussions and constant
supervision throughout the course. His timely help, constructive criticism, and
conscientious efforts made it possible to present the work contained in this thesis.
I am really thankful to engr. Irfan lab engineer RCET and engr. Shehzad assistant
professor RCET for helping me in this thesis.




















v


Abstract:

This project report deals with problems in turning operation for the conventional lathe
machine. Vibrations during turning process cause chatter in the tool and the product and
affects the outcome of product. This study is to find a correlation between lathe machine
vibrations, the cutting tool material, and the weight of the work part. In this thesis, the
impact of these parameters on the surface roughness of the machined part, is also
examined. I have used two different tools to observe this effect, that are high speed steel
tool and a carbide tip tool. I have used two workparts with different weights. In this
thesis, I have combined two different approaches that are the vibration analysis with a
vibration analyzer and the surface roughness by profilometer. From which I have got the
impact of workpart weight and tool material on both the vibrations and surface
roughness at a time. Due to this correlation this can easily found that how one can
minimize vibrations by using appropriate tool according to the workpart weight.




Keywords:

Vibrations, turning operation, surface roughness, tool vibrations



vi

Contents
CHAPTER 1 INTRODUCTION ...................................................................................................................... 9
1.1 MOTIVATION ......................................................................................................................................... 9
1.2 PROBLEM STATEMENT ......................................................................................................................... 10
1.3 RESEARCH OBJECTIVES ....................................................................................................................... 10
1.4 REPORT STRUCTURE ............................................................................................................................ 10
CHAPTER 2 LITERATURE REVIEW ......................................................................................................... 11
2.1 VIBRATION: ......................................................................................................................................... 11
2.1.1 VIBRATION DISPLACEMENT: ............................................................................................................. 11
2.1.2 DIFFERENT CAUSES OF VIBRATION: .................................................................................................. 12
2.1.3 VIBRATIONS AND MACHINERY HEALTH: ........................................................................................... 12
2.2 MAINTENANCE: ................................................................................................................................... 13
2.2.1 BREAKDOWN MAINTENANCE: .......................................................................................................... 13
2.2.2 PREVENTIVE MAINTENANCE: ............................................................................................................ 13
2.2.3 PREDICTIVE MAINTENANCE: ............................................................................................................. 14
2.3 HOW DOES VIBRATION TRANSMIT? .................................................................................................... 14
2.4 THE METHODOLOGY OF PREDICTIVE MAINTENANCE: ........................................................................... 14
2.4.1 DETECTION: ...................................................................................................................................... 14
2.4.2 ANALYSIS: ........................................................................................................................................ 15
2.4.3 CORRECTION: ................................................................................................................................... 15
2.5 VIBRATION ANALYZER: ....................................................................................................................... 16
2.5.1 PANELS OF VIBRATION ANALYZER ................................................................................................... 16
2.5.2 TAKING THE READING: ..................................................................................................................... 19
2.5.3 PRECAUTIONS ................................................................................................................................... 25
2.5.4 DISCONNECTION AND CONNECTION ................................................................................................. 25
2.5.5 READINGS ......................................................................................................................................... 25
2.6 LATHE MACHINE .................................................................................................................................. 25
2.6.1 PRINCIPAL PARTS .............................................................................................................................. 27
2.6.2 MAINTENANCE ................................................................................................................................. 29
2.6.3 MAJOR SOURCES OF LATHE VIBRATION: ........................................................................................... 29
2.6.3.1 THE COMMON FIXES: ..................................................................................................................... 30
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2.6.4 CHATTER .......................................................................................................................................... 30
2.6.5 TURNING .......................................................................................................................................... 31
CHAPTER 3 METHODOLOGY .................................................................................................................. 32
3.1 WORKPIECE SPECIFICATIONS: .............................................................................................................. 32
3.2 TOOLS: ................................................................................................................................................ 32
3.3 SURFACE TEXTURE TEST: ..................................................................................................................... 32
3.4 COMPARISON: ...................................................................................................................................... 32
CHAPTER 4 EXPERIMENTS AND RESULTS .............................................................................................. 33
4.1 FIXED PARAMETERS IN THE MACHINING: ............................................................................................. 33
4.2 COMPARISON OF SAME WORKPARTS USING DIFFERENT TOOLS: ........................................................... 33
4.3 COMPARISON OF WORKPARTS WITH DIFFERENT WEIGHT BUT WITH SAME TOOL: ................................. 35
4.4 SURFACE ROUGHNESS TEST: ................................................................................................................ 37
4.4.1COMPARISON OF WORKPARTS WITH DIFFERENT WEIGHT BUT WITH SAME TOOL: ............................... 37
4.4.2 COMPARISON OF SAME WORKPARTS USING DIFFERENT TOOLS:......................................................... 37
CHAPTER 5 CONCLUSIONS ...................................................................................................................... 38
5.1 EFFECT OF WEIGHT OF THE WORKPART: ............................................................................................... 38
5.2 EFFECT OF TOOL MATERIAL: ................................................................................................................ 38
REFERENCES ............................................................................................................................................ 39
















viii








9

Chapter 1
Introduction

An industrial sector especially in manufacturing most used conventional lathe machines.
The lathe machine in production line requires high precision for every single part of
product. It is important to make sure the part is standardized for every component. A
product having standardized and specific tolerance can be assembled easily. The
machining process is the starting time to maintain quality of product. Various types of
machines are used in the manufacturing industries. But for this thesis I have just only
focus on the conventional lathe machine. Here the conventional lathe machine is used to
investigate about the disturbed vibration. As, the advanced precision lathe machines
have very high prices compare with the conventional lathe machine. So, this project
comes out with an idea to implement some standard in the conventional lathe machine.
The basic concept of lathe machine is that it spins the workpiece and the cutting tool
remains static. Lathe machine can perform the machining processes such as cutting,
drilling, facing or turning with several shapes of cutting tools. The lathe operation is
suitable to apply for workpieces that have symmetrical shapes about an axis of rotation.
When the workpiece is not clamped well, it produces vibrations in the whole machine
body. So, the solution to this problem is to sense the vibrations and suppresses them to
get optimum conditions for machining. In the better machines, the body structure is
solidly constructed for stability and manufactured with great precision. It helps to
ensure that the components, manufactured on the machine, can meet the required
tolerances and quality.
In lathe turning operation the material is removed from a rotating workpiece with the help
of various cutting tools. In this process, frequently occurring problem is the relative
dynamic motion between cutting tool and workpiece. It causes chatter that ultimately
produces bad surface finish of the workpiece. From this study, the performance of lathe
machine and the accuracy of machine can be increased by overcoming the problem of
relative dynamic motion between cutting tool and workpiece.
This project has been done in order to suppress the vibrations that are generated in the lathe
machine. This study is carried out by vibration analyzer OneproD and XPR-300. And the
surface roughness is investigated by the profilometer.
1.1 Motivation

I have a deep entrust in the maintenance as well as in the machining processes. I found this
project producing a correlation between these two fields. Thats why I have taken that
project.

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1.2 Problem Statement

Most of mechanical component such as machines or structures face failures caused by
vibrations. This situation also happens in the lathe machine, that is the most widely used
machine in industry. Many problems have been found such as chatter. Chatter is a dynamic
instability of the cutting process (Hseih, 1996). Chatter is caused by the interaction of the
dynamic metal cutting process and the structural dynamic of the machine tool. If chatter
crosses a certain limit then it can easily spoil the surface accuracy, damage the cutting tool
and also produce irritating unacceptable noise.
Therefore, the typical techniques such as vibration analysis are used to investigate the
reduction of chatter in turning operations. There are two approaches that can be used for
that particular purpose. First is that we control the vibrations by changing our tool and 2
nd
is
that we compare vibrations for different weights of materials with different tools. Then the
optimized results can be used.

1.3 Research Objectives
The main objective of study is to suppress the lathe machine vibrations by using vibration
analysis technique.
1.4 Report Structure
Chapter 2 contains the whole work that has been done related to this problem.
Chapter 3 contains the approach that has been used in this project to solve this problem.
Chapter 4 contains the experiments that have been performed to get results.
Chapter 5 contains conclusions and my future perspective about this project.


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Chapter 2
Literature Review

This chapter is more to recognize the basic understanding of knowledge about the study.
The topics like vibrations, how they transmit, how they can be controlled, and also
about lathe machine.
2.1 Vibration:
Vibration is the response of a system to an internal or external stimulus causing
it to oscillate or pulsate. [1]
If two machines are subjected to the same dynamic force, the amplitude
responses from the machine which has greater dynamic resistance will be less than that
of the other machine.
Dynamic resistance within a machine or structure is proportional to the amount
of stiffness, damping and mass within the system.
Vibration amplitude response




Vibration has three important parameters which can be measured:
Frequency: How many times dose the machine or structure vibrate per minute or per
second. Frequency tells us about the type of fault that a particular machine has.
Different types of faults occur at specific frequencies. [2]
Amplitude: Is the size of the vibration signal. The amplitude of the vibration shows the
severity of the fault. It tells us about the machine condition that whether the machine
can run or we have to shut it down. [2]
Phase: How is the member vibrating in relation with a reference point. Phase provides
information on the balancing of shafts or other faults eliminations. [2]
2.1.1 Vibration displacement:
Displacement is a measure of the total travel of the mass- back and forth.
Vibration velocity:
The velocity of the vibration is a measure of the speed at which the mass is moving or
vibrating during its oscillations.
Vibration acceleration:
When a machine housing vibrates, it experiences acceleration since it continually
changes speed as it oscillates back and forth. The greater the rate of change of velocity,
the higher will be the forces and stresses on this machine due to the higher rate of
acceleration.
Vibration phase:
Phase is a measure of how one part is moving in relation to another part, or to a fixed
reference point.

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2.1.2 Different causes of vibration:
There are many causes of vibration as described below.
1. Misalignment of different components of machinery
2. Unbalance of rotating parts due to unequal weight distribution that creates flatter
3. Loose tightening of coupled parts also create significant value of vibration
4. Meshing of one part of the machine with others also create heat and vibration
5. When two power transferring gears wear out then they also create a huge
vibration
6. The wearing of balls and cylinders of bearings can also create vibration
7. Resonance is also an important factor that can create disastrous vibrations
2.1.3 Vibrations and machinery health:
Now the question that arouses in our minds is that how the vibrations impact the
health of machinery. Obviously vibrations create some extra force and generate some
extra loads onto the different machine components such as bearings and gears. These
two components are the major ones to operate a machine on the normal speeds. And a
fault within these two or anyone of them can create a lot of major problems in the
machinery. Some times by changing with the new ones can be handy but in some cases
the failure of these two important parts can lead to such disastrous problems that the
whole machine becomes waste, and a lot of capital and time flow away due to the
problem created by the unwanted vibrations. So it is very important for us to now that
after how much time we have to change these components to ensure the safe operation
of the machinery.



The waveform given in the above figure clearly shows that during the vibration
a continuous load is applied on the machine components periodically. These continuous
load reversals are the major reason of the failure of different parts of the machinery. So
vibrations in this respect are disastrous for any kind of machinery.
+ve load
-ve load
Figure 2.1 (load application on components of the machine due to the vibrations)

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Up till now we have concluded that vibrations are harmful for the machinery
because they lead to the different types of failures. Now we are in the position to
discover some more disadvantages of the vibrations. First of all, in the machines which
are used in the highly precised working the vibrations played a significant role in
defining the accuracy of the manufactured parts by that particular machine. If the
vibrations in that machine or equipment are too high then the accuracy of the parts,
being manufactured by that equipment, will be significantly disturbed. [3]
The vibrations in the machinery can also cause the other parts of the machine to
wear out in a very less time than the expected life of that particular part. So in this way
the vibrations are dangerous for the whole machine and affect the expected life of the
equipment.
Another important point about the vibrations and the machine health is that
vibrations badly affect the stiffness of the joints between the different parts of the
machine. Due to vibrations the parts of the machine began to disintegrate. So it badly
affects the stiffness of the machine.
2.2 Maintenance:
There are three different techniques of maintenance described below. [3][4]
Breakdown maintenance
Preventive maintenance
Predictive maintenance
2.2.1 Breakdown Maintenance:
This type of maintenance is actually not maintenance. In this type we do not
repair the machine rather we change the machine with some new equipment. In
breakdown maintenance we do not repair our equipment due to some small faults and
problems rather we let it in operation till the end of its life.
This type of maintenance has many disadvantages.
First is that there is no anticipation of these failures. So it can cause many
troubles if it occurs at a time when much high production is needed.
Second disadvantage of this type of maintenance is that it requires much more
capital than that required to detect and uproot the problems before the
breakdown occurs. It is estimated that it requires three times more money to get
rid of such problems.
Third problem that can happen is that very disastrous breakdowns can cause
safety problems. And they can damage the operator of that particular machine.
2.2.2 Preventive maintenance:
This type of maintenance consists of disintegration of parts after a specified period
of time and analysis of all the parts and then replacement of the effected or problem
creator parts. This type of maintenance has several advantages over the first one.
In this type frequent breakdowns are avoided.
The production at the critical situations is not disturbed.
Also from the safety point of view it is better than the first one
14

Preventive maintenance has also some disadvantages.
This method is very much costly and the wastage of time too.
It is very tough task to anticipate the time breakages between the every
maintenance.
If the time intervals are too short then we can avoid the failures but expenses are
very high.
If the intervals are larger then major disastrous faults cannot be avoided.
2.2.3 Predictive maintenance:
This is unique type of maintenance. In this type we use different methods to predict
the present condition of the machinery. And after detecting the problems we uproot
them and make our machines safe to use. This type of maintenance has a number of
advantages over the previous two types.
The sudden and untimely crackdowns can be avoided.
A huge capital can be saved by this method.
Machines are allowed to run and operate as far as any defect is detected.
2.3 How Does Vibration Transmit?
As described earlier that the vibrations transmit in the form of sine-waves from point to
point in a machine. There are two types of wave form: [5]
1. Time Wave Form: This wave form is between the amplitude (at y-axis) and
time (at x-axis).At a time it is only used to analyze one fault in a machine.

2. Frequency Wave Form: This wave form is between the amplitude (at y-axis)
and frequency (at x-axis). The Fourier series is used to get a frequency wave
form. The Frequency wave form is also known as spectrum. So spectrum is used
to analyze different faults as of spectrum is different for different faults.
The amplitude is measured in displacement (mm), velocity (mm/s) &
acceleration (mm/s2)
The frequency is measured in Hz, cycle/sec (CPS) or cycle/min (CPM)

2.4 The methodology of predictive maintenance:
This consists of three major steps. [6]
Detection
Analysis
Correction
2.4.1 Detection:
In the detection, we normally different types of instruments to detect and
calculate the vibration intensity and trends at some specified locations and points. A
schedule is prepared that tells about the time after which the machine is will be checked
for errors and the detection of faults will be performed. Some machines are checked
after a month but on some important machines the test is performed after one or two
15

weeks. Some time we used to install the vibration analyzing equipment with the
machine to remain familiar with the condition of most sensitive machinery.
The vibration detection equipments may be of different types. They consist of a
transducer that is installed at the required position and that transducer after getting the
information in the form of vibrations transform these into some form of electrical
signals. These signals are sent to the computer where they are processed and graphs of
the vibration curves are obtained.
After getting the graphs or values of amplitudes and frequencies at different
locations of the machine we prepare the charts using all this information. In these charts
the machine health after different scheduled periods of time is compared. After the
comparison the vibration engineer anticipate the machine condition and detect the faults
present in the machinery based on this research.
2.4.2 Analysis:
After the problem in the machinery is detected, all the data is compared with
some standard graphs. Then an engineer, by observing the graphs shape, develop some
relation and use the unique property of vibration to know that at which location the
problem exists and which part is responsible for these vibrations.
This analysis of vibration graphs shows different types of problems such as,
Weight unbalance
Alignment problems
Problems in gears
Problems in bearing
Resonance
Problems in the shafts
Problems in the belts
2.4.3 Correction:
After the detection and analysis of the problems the machinery needs
maintenance. The schedule is prepared according to the spare time. Then the corrections
are made according to the prepared time table.










16

2.5 Vibration analyzer:
It is an instrument used to measure the vibration depending upon the frequency and
amplitude. It produces a spectrum which is compared with the standard spectrums
available and then the cause of vibration is diagnosed.
2.5.1 Panels of Vibration Analyzer
Mains
The instrument turns on automatically a few seconds after being connected to
the mains through the power supply module. If the battery level is too low, the charge
starts and goes on as long as the main screen is displayed.
When using a new battery, leave the battery in charge for about 10 hours in
order to achieve full charge. Do not use the instrument prior to 2-3 hours of charge.
To turn the instrument off, first disconnect it from the mains, and then press the
key.
The battery is not recharged when the instrument is turned off.
To start the instrument again, first disconnect it and then connect it again.
Battery
Once the battery is sufficiently charged, the instrument may operate on battery. Use the
key to turn the instrument on and off.
Keyboard

o On / Off key

The On/Off key enables the equipment to be switched on or off. Once this key
has been activated, a few seconds are necessary for the screen to display the first
message.
This key is not active when the instrument is connected to the mains. To start
again you should disconnect the instrument from the mains and then connect it again.
This key is also used to Reset OneproD MVP-2C
o Escape key

The Escape key enables the user to leave a screen without validating the
measurement or selection that he/she has carried out.
o Validation key

The Validation key enables the user to leave a screen whilst validating the
selection or measurement which he/she has just carried out.

17

o Alphanumeric keypad
The keyboard allows the input of numerical and alphanumeric data. Numerical
data can be entered directly without taking into account the other characters Decimal
point and sign are located on each side of 0 key.
Alphanumeric data can be entered in the following manner. Press the key once, the first
character assigned to this key will appear, by pressing twice, the second character will





be used, and so on, thereby allowing all the available characters to be selected. Once the
required character is displayed, press the key corresponding to the next character. If the
next character is located on the same key, then move on by pressing the cursor key.
o Help key

The Help key allows the user to gain access to help information at any time.
o Contrast key

Pressing the Contrast key modifies the contrast of the screen.
o Backlight key

It is used to select screen backlight intensity. Two levels are available. A
permanent use of the highest level reduces battery operating time.
o Function keys

Five keys are located below the screen. They are used to activate the icon
functions displayed on the screen.




18

o Additional functions key

This key enables the user to view all the icons relating to the function keys,
when these are not all displayed simultaneously.
o Cursor keys
These keys are used to:

Browse lists

Next line: Previous line:
Next page: Previous page:


Move cursor on spectrum or time wave display

Fast motion: and
Slow motion: and


o Electronic Tag identification

In Collector mode this key is used to read electronic tags.


o Software reset in Collector mode
Hold down the key for at least 10 s.
During this operation, OneproD MVP-2C should not be connected to the
mains. This operation may need to be repeated several times.
NOTE: this operation will not delete the stored data.





19

2.5.2 Taking the reading:
In order to take a reading following are the major steps,
Load a route
Disconnect the vibration analyzer from the host computer
Connect the vibration analyzer to the accelerometer
Select a point and get the reading

Load a route:
Steps to transfer Routes:

Three wires are connected with MVP-2C (vibration analyzer).
One is for charging MVP-2C. Its one end is connected with power
and second with MVP-2C
Second one is to connect MVP-2C with computer so that data can be
transferred to computer.
Third one is to connect the MVP-2C to equipment (wheels and shaft)
via magnetic, cone or nuts.
For transferring routes there is no need of connecting 3
rd
one wire.
Power on the computer.
Press the button on MVP-2C to switch on MVP-2C
Go to collector module. (by pressing the button right below collector
module )

By pressing YES enter to next page. In collector module there are off
routes shown on screen. Never delete them. This screen allows the user to select a
route from the list of available routes.













20

Enter into communication with PC mode indicated by pressing the button
right below

Then select YES

Open the software for vibration analyzer named XPR-300 v.3.05.





After opening, Right click on option Asset Hierarchy


21
















Then click on New and then click on Location
Then a dialogue box will open fill in the any location name.





Now right click on the Location that is newly built then click New and then
Equipment

22



A dialogue box will open fill in with the name of the equipment whose analysis is
required and then select Yes.
Now click on New Equipment and then right click on Measurement Points. A
dialogue box will open. Fill in.




23



Click on Operative Parameters, a dialogue box will open. Fill in the parameter
you want to measure like rotational speed.

Spectrum and Time Waves

Right Click. New signals Measurement Wave


24





Right click on Equipment and choose Create Selection.
Fill in Designation and Name.
Click Acquisition on menu bar and select Off Line from the drop down list.
Fill in Serial number.
Now select the route, you want to transfer to MVP-2C.
Click ok when transfer is completed.














25

2.5.3 Precautions
Never delete off routes in the collector module.
Beware of laser light.

2.5.4 Disconnection and Connection
Disconnect the host computer and connect the accelerometer to the vibration
analyzer, in order to start taking the readings.

2.5.5 Readings

1. Three wires are connected with MVP-2C (vibration analyzer).
One is for charging MVP-2C. Its one end is connected with power and
second with MVP-2C
Second one is to connect MVP-2C with computer so that data can be
transferred to computer.
Third one is to connect the MVP-2C to equipment (wheels and shaft) via
magnetic, cone or nuts. (As shown in figure below)





For taking readings in collector module only wire no. 1 & 3 have to be
attached.
2.6 Lathe machine
A lathe is a machine that removes material by rotating the workpiece against a cutter.
Although a lathe machine can be used for many purposes, it is particularly adapted for
turning operation of cylindrical workpieces which has got symmetry about an axis of
rotation. Other than turning, a lathe can also be used to perform drilling, boring and reaming
operations. In addition, it used for cutting threads and taper turning with appropriate
attachments. It can also be adapted for simple milling or grinding operations. Figure shows
a conventional lathe machine that is used in the industry. [7]
1
st
Wire for charging
2
nd
Wire for
connecting
With computer via
usb connector
3
rd
wire for connecting with
testing equipment
26




A lathe is probably the oldest of all the machine tools as well as the most important
in modern metal cutting practice. There are different types of lathes with different sizes,
design, method of operation, arrangement of gears and purpose. In general, they can be
classified as speed lathes, engine lathes, turret lathes etc.
Accurate positioning and holding of workpiece on lathe are critical requirements for
successful turning and other machining operations. Parameters used in this study are based
on the turning operation. Turning process involves the spinning of workpiece and static
cutting tools. A lathe is a machine that uses single-point cutting tools. A single-point cutting
tool is the static cutter with the rotating workpiece.
Lathes have been used widely in the industry. In the beginning of history, lathes
were commonly used in wood turning and also for making different shapes of pottery. Lathe
machines are usually used in woodturning, metalworking, metal spinning and glass
working. Metalworking lathes are standard terms for a large class of lathes designed for
machining hard materials. These rigid machine tools remove material from a rotating
workpiece via movements of various cutting tools such as tool bits and drill bits.
Lathe machines should be kept on improving to produce good products with high
accuracy and quality. The problem identified should be followed by the new solutions or
techniques to resolve it for the future. The new techniques are really helpful to ensure that
the components manufactured meet the required tolerances and quality.



Figure 2.2 (Conventional lathe machine)
27

2.6.1 Principal parts:
To learn the operation of the lathe, we must be familiar with the names and functions of
the principal parts. Lathes from different manufacturers differ somewhat in
construction, but all are built to perform the same general functions.
Bed and Ways: The bed is the base or foundation of the parts of the lathe. The main
feature of the bed is the ways, which are formed on the beds upper surface and run the
full length of the bed. The ways keep the tailstock and the carriage, which slide on
them, in alignment with the headstock.
Headstock: The headstock contains the headstock spindle and the mechanism for
driving it. In the belt-driven type, the driving mechanism consists of a motor-driven
cone pulley that drives the spindle cone pulley through a drive belt. The spindle can be
rotated either directly or through back gears. When the headstock is set up for direct
drive, a bull-gear pin, located under a cover to the right of the spindle pulley, connects
the pulley to the spindle. This connection causes the spindle to turn at the same speed as
the spindle pulley.
When the headstock is set up for gear drive, the bull-gear pin is pulled out,
disconnecting the spindle pulley from the spindle. This allows the spindle to turn freely
inside the spindle pulley. The back-gear lever, on the left end of the headstock, is moved
to engage the back-gear set with a gear on the end of the spindle and a gear on the end
of the spindle pulley. In this drive mode, the drive belt turns the spindle pulley, which
turns the back-gear set, which turns the spindle. Each drive mode provides four spindle
speeds, for a total of eight. The back-gear drive speeds are less slower than the direct-
drive speeds.
Tailstock: The primary purpose of the tailstock is to hold the dead center to support one
end of the work being machined. However, the tailstock can also be used to hold
tapered shank drills, reamers, and drill chucks. It can be moved on the ways along the
length of the bed and can be clamped in the desired position by tightening the tailstock
clamping nut. This movement allows for the turning of different lengths of work. The
tailstock can be adjusted laterally (front to back) to cut a taper by loosening the
clamping screws at the bottom of the tailstock.
Carriage: The carriage is the movable support for the crossfeed slide and the
compound rest. The compound rest carries the cutting tool in the tool post.
The carriage has T-slots or tapped holes to use for clamping work for boring or milling.
When the carriage is used for boring and milling operations, carriage movement feeds
the work to the cutting tool, which is rotated by the headstock spindle. We can lock the
carriage in any position on the bed by tightening the carriage clamp screw. But we do
this only when we do such work as facing or parting-off, for which longitudinal feed is
not required. Normally the carriage clamp is kept in the released position. Always move
the carriage by hand to be sure it is free before you engage its automatic feed.
28

Apron: The apron is attached to the front of the carriage and contains the mechanism
that controls the movement of the carriage and the crossslide.
Feed Rod: The feed rod transmits power to the apron to drive the longitudinal feed and
crossfeed mechanisms. The feed rod is driven by the spindle through a train of gears.
The ratio of feed rod speed to spindle speed can be varied by using change gears to
produce various rates of feed. The rotating feed rod drives gears in the apron; these
gears in turn drive the longitudinal feed and crossfeed mechanisms through friction
clutches.Some lathes do not have a separate feed rod, but use a spline in the lead screw
for the same purpose.
Lead Screw: The lead screw is used for thread cutting. It has accurately cut Acme
threads along its length that engage the threads of half-nuts in the apron when the half-
nuts are clamped over it. The lead screw is driven by the spindle through a gear train.
Therefore, the rotation of the lead screw bears a direct relation to the rotation of the
spindle. When the half-nuts are engaged, the longitudinal movement of the carriage is
controlled directly by the spindle rotation. Consequently, the cutting tool is moved a
definite distance along the work for each revolution that the spindle makes.
Crossfeed Slide: The crossfeed slide is mounted to the top of the carriage in a dovetail
and moves on the carriage at a right angle to the axis of the lathe. A crossfeed screw
allows the slide to be moved toward or away from the work in accurate increments.
Compound Rest: The compound rest mounted on the compound slide, provides a rigid
adjustable mounting for the cutting tool. The compound rest assembly has the following
principal parts:
1. The compound rest SWIVEL, which can be swung around to any desired angle and
clamped in position. It is graduated over an arc of 90 on each side of its center position
for easier setting to the angle selected. This feature is used for machining short, steep
tapers, such as the angle on bevel gears, valve disks, and lathe centers.
2. The compound rest, or TOP SLIDE, which is mounted on the swivel section on a
dovetailed slide. It is moved by the compound rest feed screw.
This arrangement permits feeding the tool to the work at any angle (determined by the
angular setting of the swivel section). The graduated collars on the crossfeed and
compound rest feed screws read in thousandths of an inch for fine adjustment in
regulating the depth of cut.
Accessories and Attachments: Accessories are the tools and equipment used in routine
lathe machining operations. Attachments are special fixtures that may be mounted on
the lathe to expand the use of the lathe to include taper cutting, milling, and grinding.
29

Tool post: The sole purpose of the tool post is to provide a rigid support for the tool. It
is mounted in the T-slot of the compound rest. A forged tool or a toolholder is inserted
in the slot in the tool post. By tightening a setscrew, we can firmly clamp the whole unit
in place with the tool in the desired position.
Toolholders: Notice the angles at which the tool bits are set in the various holders.
These angles must be considered with respect to the angles ground on the tools and the
angle that the toolholder is set with respect to the axis of the work. Two types of
toolholders that differ slightly from the common toolholders are those used for
threading and knurling.
The threading toolholder has a formed cutter which needs to be ground only on the top
surface for sharpening. Since the thread form is accurately shaped over a large arc of the
tool, as the surface is worn away by grinding, the cutter can be rotated to the correct
position and secured by the setscrew.
A knurling toolholder carries two knurled rollers which impress their patterns on the
work as it revolves. The purpose of the knurling tool is to provide a roughened surface
on round metal parts, such as knobs, to give a better grip in handling. The knurled
rollers come in a variety of patterns.
2.6.2 Maintenance
Every lathe must be maintained strictly according to requirements of the
Maintenance and Material Management Systems. The first requirement of maintenance
to your lathe is proper lubrication. Make it a point to oil your lathe daily where oil holes
are provided. Oil the ways daily-not only for lubrication but to protect their scraped
surfaces. Oil the lead screw often while it is in use; this is necessary to preserve its
accuracy, for a worn lead screw lacks precision in thread cutting. Make sure the
headstock is filled to the proper oil level; drain the oil out and replace it when it
becomes dirty or gummy. If your lathe is equipped with an automatic oiling system for
some parts, make sure all those parts are getting oil. Make it a habit to check frequently
to see that all moving parts are being lubricated. [1]
2.6.3 Major sources of lathe vibration:
1.) The stock you are turning is not centered properly. This has the same effect of too
much clothes on one side of your washing machine during spin cycle. You can cure this
by slowing down the speed you turn at until the roughed stock is more centered.
2.) Take a look at the head stock on your lathe, if it has worn bearings, if the pulleys are
out of line or your belt is worn, you will most likely get vibrations.
3.) Look at the floor your lathe is on. Is it solid? Cement is the best surface, an flex in
your floor will result in lathe vibrations.
30

2.6.3.1 The common fixes:
1.) Bring your head stock and tailstock together until they touch. Do they line up
perfectly, if not you may have a lathe base or floor that is sagging under the weight.
2.) Spin the lathe by hand. Is it smooth? If its rough or bumpy, then there are chances
that you have worn bearings that need to be replaced.
3.) Use a straight edge to make sure all belts and pulleys are in line. Being off center
will cause vibration or can cause un-even wear of the belts which in turn will cause
whole machine vibrations. If the belt is worn replace it.
4.) Add some weight to the base of lathe. The lathe is heavy it means that vibration is
sent right through the base. Add weight makes it harder for the lathe to move around, it
will decrease vibrations of an out of round piece of stock.
2.6.4 Chatter
Chatter is vibration in either the tool or the work. The finished work surface appears to
have a grooved or lined finish instead of a smooth surface. The vibration is set up by a
weakness in the work, work support, tool, or tool support and is probably the most
elusive thing you will find in the entire field of machine work. As a general rule,
strengthening the various parts of the tool support train will help. It is also advisable to
support the work by a center rest.
The fault may be in the machine adjustments. Gibs may be too loose; bearings may,
after a long period of heavy service, be worn; the tool may be sharpened improperly,
and so on. If the machine is in excellent condition, the fault may be in the tool or tool
setup. Grind the tool with a point or as near a point as the finish specified will permit;
avoid a wide, round leading edge on the tool. Reduce the overhang of the tool as much
as possible. Be sure all the gib and bearing adjustments are properly made. See that the
work receives proper support for the cut and, above all, do not try to turn at a surface
speed that is too high. Excessive speed is probably the greatest cause of chatter. The
first thing you should do when chatter occurs is reduce the speed.







31

2.6.5 Turning
Turning is the machining of excess stock from the periphery of the workpiece to reduce
the diameter. In most lathe machining operations requiring removal of large amounts of
stock, a series of roughing cuts is taken to remove most of the excess stock. Then a
finishing cut is taken to accurately "size" the workpiece. There can be different types of
tuning.
Strraight turning
Taper turning
Profile turning
Groove turning
Cut off turning
Ruogh turning
Finish turning
Straight turning: In this type the tool feeds along a straight line.
Taper turning: Here the tool is fed at an angle to produce a conical geometry.
Profile turning: In this type, instead of feedin the tool along a straight line, the tool
follows a contour.
Groove turning: The tool creates a groove by moving along a straight line.
Cut-off turning: The tool is fed radially into the rotating work at same location.
Rough Turning: When a great deal of stock is to be removed, you should take heavy
cuts to complete the job in the least possible time. This is called rough turning. Select
the proper tool for taking a heavy chip. The speed of the work and the amount of feed of
the tool should be as great as the tool will stand.
Finish Turning: When one has rough turned the work to within about 1/32 inch of the
finished size, take a finishing cut. A fine feed, the proper lubricant, and above all, a
keen-edged tool are necessary to produce a smooth finish. Measure carefully to be sure
you are machining the work to the proper dimension. Stop the lathe when you take
measurements. If you must finish the work to close tolerances, be sure the work is not
hot when you take the finish cut. If you turn the workpiece to exact size when it is hot, it
will be undersize when it has cooled.



32

Chapter 3
Methodology

The approach used in this project is the vibration analysis by vibration analyzer
OneproD and XPR-300. With the help of this device the vibrations of the machine and
the tool chatter is analysed. And then by surface texture test the surface roughness is
examined. And then the effect of weight of the workpiece, by using tools of two
different materials, on the surface finish is examined.

3.1 Workpiece specifications:
Workpiece used for this thesis is of mild steel (MS). Dimensions of the workpieces are
given below,

Workpart
Initial dia.
(mm)
Final dia.
(mm)
Total length
(mm)
Machined
length (mm)
Weight (g)
W1 19.5 18.5 75 55 174
W2 25 24 75 55 223

3.2 Tools:
These workparts are turned on the conventional lathe machine by tools of two different
materials. The materials used are high carbon steel and carbide tip tool. And then the
vibrations are analyzed by the vibration analyzer. And the impact of these vibrations on
the surface finish of the turned part is then examined.

Tool Material
T1 High speed steel (HSS)
T2 Carbide tip tool
3.3 Surface texture test:
This test is performed to check the surface texture of the machined workpart. This test is
performed on the profilometer. Profilometer is the equipment that is used to analyze the
surface texture of any material.
3.4 Comparison:
After the experimentation, the comparison is done between the vibration models in
different conditions. And conclusions are extracted in terms of tool chatter and machine
vibrations in all these cases.
33

Chapter 4
Experiments and Results

This chapter is about the whole experimentation that is performed to approach the
optimum results. This all has been done to minimize the machine vibrations because
lathe machine is a very common tool for machining purposes. And the major issue of
the accuracy disturbance is due to the tool chatter and the whole body vibrations in the
machine.

4.1 Fixed parameters in the machining:
During machining of these workparts almost all the parameters that are governed by the
machine are kept constant. And by keeping machine parameters constant the effect of
tool and weight of the workpart on the machine vibrations is examined.

Parameter Value
Speed 125 rpm
Feed rate 150 mm/min.
Depth of cut 1 mm

4.2 Comparison of same workparts using different tools:
If we compare the machine vibrations during the machining of the same workparts
using two different tools then we can easily estimate from the acquired data that how
machine behaves by changing the tool.



Fig. 4.1 (vibration parameters for W2T1)
34


This can easily be seen from the fig. 4.1 and fig. 4.2 that by using the hard tool, the
carbide tool, the bearing defect is decreased. It means that the vibrations in the bearing
are decreased due to the less effort required for the machining of the workpart. While in
case of HSS tool the machine has to input more effort so the bearing vibrations are
increased.
Second parameter that can be compared is the vibration velocity. In case of the carbide
tip tool the vibration velocity will be more. While in case of the HSS tool this parameter
is less. But this difference is not much. It can be extracted from the spectra of these
vibrations that in which case the accuracy of the machined part will be high.





Fig. 4.2 (vibration parameters for W2T2)
Fig. 4.3 (vibration spectrum for W2T1) Fig. 4.4 (vibration spectrum for W2T2)
35




It can easily be concluded from the above spectra that vibration level in using the HSS
tool is high as compared to the carbide tool. It means that the tool chatter is high in case
of HSS tool due to the less hardness of the material as compared to the carbide.
So due to more tool chatter the dimensional accuracy will obviously be less.

4.3 Comparison of workparts with different weight but with
same tool:

In this section the impact of the weight of workpart on the machine vibrations and the
tool chatter is examined.


Fig. 4.6 (zoomed spectrum for W2T2) Fig. 4.5 (zoomed spectrum for W2T1)
Fig. 4.7 (vibration parameters for W1T1)
36

If we compare fig. 4.7 with fig. 4.1 then we can see that the weight of the workpart
plays an important role in the machine vibrations. From these figures it is clear that in
case of W1, that is a light weight part, the bearing defect shown by the vibration
analyzer is 0.0171. But in case of W2, that is a heavy weight part, bearing defect climbs
up to 0.356.That is a big change in vibrations with just 49 gm change in the weight of
the workpart.
So, for a big change in the workpart weight there might be chances of some drastic
accident or occurrence of some serious failure of the machinery. It also produces a huge
amount of heat. Due to that heat, sometimes, the workpart is tempered and hardened,
due to which further machining becomes very much difficult. And we have to use most
hard tool to cut that material.
To avoid this type of serious problem we must slow down the speed of the machine. By
doing this we can avoid the generation of a huge amount of heat and thus avoid the
tempering of the workpart.
Second parameter on the basis of which we can compare these two situations is
vibration velocity. It has also the same trend as the bearing defect. It can be observed
that vibration velocity in case of W1 is just 0.0008 mm/s, but in case of heavier part it
appears with a big change and the value in this case is 0.0022 mm/s. This is a very big
change in the vibration velocity and this is the parameter that defines the accuracy of the
workpart. So we can conclude that accuracy can be disturbed in case large and heavy
weight parts.





It is quite clear from figures 4.8, 4.9, 4.3 & 4.5 that the amount of vibrations is much
greater in case of the heavier workpart as compared to the lighter one. So, we can say
that when using same cutting tool the accuracy of the lighter part will be better as
compared to the heavier workpart.



Fig. 4.8 (vibration spectrum for W1T1) Fig. 4.9 (zoomed spectrum for W1T1)
37

4.4 Surface roughness test:

Surface roughness is checked on the profilometer. Comparison table is given below,

Workpeice
Surface Roughness
Average (R)
R1 R2
W2T2 6.0 7.2 6.6
W1T2 4.2 4.0 4.1
W2T1 6.0 6.2 6.1
W1T1 4.0 3.6 3.8

4.4.1Comparison of workparts with different weight but with
same tool:

It is clear from the table, given above, that in case of larger workpiece due to greater
vibrations we have got larger value of surface roughness. There is a huge difference
between the surface roughness values, so the weight factor is very important in case of
conventional lath machine.

4.4.2 Comparison of same workparts using different tools:

In case of carbide tip tool the surface roughness value is low as compared to the HSS
tool. So, we can conclude that in case of hard tool the accuracy is more due to lesser
amount of vibrations. So, to get higher accuracy we have to use harder tools.














38

Chapter 5
Conclusions

In this chapter we are in a position to conclude all the discussion that is carried out in
the first 4 chapters.

5.1 Effect of weight of the workpart:
It wouldnt be wrong if I use the word deriving parameter for weight factor in the
conventional lathe machines. We see a huge change in the vibrations of the machine by
increasing the weight of the workpart in our experimentation with a little change in the
weight. For a big change in the workpart weight there might be chances of some drastic
accident or occurrence of some serious failure of the machinery. It also produces a huge
amount of heat. Due to that heat, sometimes, the workpart is tempered and hardened,
due to which further machining becomes very much difficult. And we have to use most
hard tool to cut that material.
To avoid this type of serious problem we must slow down the speed of the machine. By
doing this we can avoid the generation of a huge amount of heat and thus avoid the
tempering of the workpart.
Due to this change in vibrations it would also has a great impact on the surface texture
of the workpart.

5.2 Effect of tool material:
Using a hard tool can lessen the amount of vibrations. So, using a hard tool also can
increase the accuracy of work. But in case of hard tools we have to closely control the
feed rate. Feed rate becomes more important for good accuracy in case of hard tools.
Because in case of hard tools large amount of heat is generated, due to which after
machining a shrinkage effect is produced. Thus the accuracy of the workpart is
disturbed.














39

References:

[1] Machine tool vibrations by E.I. Rivin.
[2] Vibration diagnostic guide by SKF reliability systems.
[3] Introduction to vibration technology by Dennis h. Shreve Director of marketing Ird
mechanalysis, inc.
[4] Maintenance Engineering Handbook by R. Keith Mobley.
[5] Control of vibration and resonance in aero engines and rotating machinery-An
overview by D.J. Ewins, Imperial College London, United Kingdom.
[6] Industrial Machinery Repair: Best Maintenance Practices Pocket Guide by Ricky
Smith and R. Keith Mobley
[7] Fuzzy active vibration control for lathe machine by Muhamad faisal ezuarie bin
draman, Faculty of Mechanical Engineering, universiti malaysia Pahang.