LAPORAN PRAKTIKUM PROSES MANUFAKTUR

MODUL 1
TURNING

OLEH :

KELOMPOK : 28
ANGGOTA : 1. Astrid Parama Ningrum (13406026)
2. Bona Mangkirap (13406043)
3. Irma Sofiani (13406049)
4. Nadia Fadhilah Riza (13406069)
5. Prila Sista Lilly Jane (13406080)
6. Ira Wulandari (13406094)

LABORATORIUM TEKNIK PRODUKSI

PROGRAM STUDI MESIN
INSTITUT TEKNOLOGI BANDUNG
2007
Purpose

1. Participants understand the construction of a lathe and how to operate it

2. Participants understand the processes of turning
3. Participants understand the parameters of turning process and how to
determine them.

Basic Theory

Turning is a machining process in which a single point tool removes material from
the surface of a rotating cylindrical workpiece. The tool is fed linearly in a
direction parallel to the axis of rotation, as illustrated below.

Turning is traditionally carried out on a machine tool called lathe, which provides
power to turn the part at a given rotational speed and to feed the tool at a
specified rate and depth of cut.

Principal components of an engine lathe:

 Headstock contains the drive unit to rotate the spindle, which rotates the
work
 Tailstock, opposite the headstock in which a center is mounted to support
the other end of the workpiece
 Tool post is where the cutting tool is held
 Cross-slide is where the tool post is fastened, designed to feed in a
direction perpendicular to the carriage movement
 Carriage is designed to slide along the ways of the lathe in order to feed
the tool parallel to the axis of rotation
 Ways are like tracks along which the carriage rides, and they are made
with great precision to achieve a high degree of parallelism relative to the
spindle axis
 The Bed of the lathe provides a rigid frame for the machine tool
 Leadscrew drives the carriage rotating at the proper speed to obtain the
desired feed rate
Equation for turning parameters:
 .d .N
 Cut rate vc 
1000

 Feed rate v f  f .N

(d 0  d m )
 Depth of cut d  d0
2
lt
 Cutting time tc 
vf

 Material Removal Rate MRR  f . A.vc

where: d0 = original diameter of the part (mm)

dm = final diameter of the part (mm)
f = feed rate (mm/r)
lt = length of the cylindrical workpart (mm)
A = Area of the workpart
N = rotational speed (rev/min)
MRR = material removal rate(mm3/min)
tc = cutting time (s)
vf = cutting speed (mm/rot)
Operations related to turning:

 Facing
The tool is fed radially into the rotating work on one end to create a flat
surface on the end
 Taper turning
Instead of feeding the tool parallel to the axis of rotation of the work, the
tool is fed at an angle, thus creating a tapered cylinder of conical shape.
 Contour turning
The tool follows a contour that is other than straight, thus creating a
contoured form in the turned part
 Form turning
In this operation, sometimes called forming, the tool has a shape that is
imparted to the work by plunging the tool radically into the work
 Chamfering
 The cutting edge of the tool is used to cut an angle on the corner of the
cylinder, forming what is called a chamfer
 Cutoff (parting)
The tool is fed radially into the rotating work of some location along its
length to cut off the end of the part
 Threading
A pointed tool is fed linearly across the outside surface of the rotating
workpart in a direction parallel to the axis of rotation at a large effective
feed rate thus creating threads in the cylinder
 Boring
A single-point tool is fed linearly, parallel to the axis of rotation, on the
inside diameter of an existing hole in the part
 Drilling
Drilling can be performed on a lathe by feeding the drill into the rotating
work along its axis
 Knurling
Metal forming operation used to produce a regular cross-hatched pattern
in the work surface
Analysis
Astrid Parama Ningrum (13406026)

 In our practicum, we did turning process and there are processes that
we try, such as facing, centre boring, diameter reducing, grooving and
threading.
 We set the lathe in zero coordinate to avoid backlash that will affect the
turning processes.
 In facing processes, the surface of specimen have a coarse. It might
because of the cutting tool have defect.
 Cutter which used for facing, centre boring and diameter reducing
processes is different with cutter in grooving and threading processes.
Cutter that practican used be changed to avoid damage on cutter. But
it is better to change the cutting tool in every process.
 In centre boring processes we make the space for the holder to reduce
vibration in the work piece
 Turning processes with lathe did not used backlash compensator, but
we did alternative ways such as turning the hand wheel unto the
opposite direction two times to reduce the gap between gears.
 The speed of spindle must be higher so lathe can make better surface
finish and to treat the cutter tool better. Because in low rate, the spindle
will damage the cutter.
 The turning processes wil have bad result if the feed rate higher. It
means the workiece move faster and would make the surface not flat

 In turning processes needed the concentration of operator to make

sure the result is as it wants. The dimension of specimen is depending
with the operator, so it is not good to producing.
  In reducing diameter the specimen will be cut off if the operator let the
lathe keep running.

Bona Mangkirap (13406043)

- While doing facing process, the zero position of the cutting tool and cutting
placement will affect facing result. a bad facing result twill have scrap on it
surface and it will affect on centre boring and centre drilling process.
- In the observation ,the centre boring process mean to give place for the
nipper so the work piece will have no vibration caused by threading
process that can make the result bad. The other reason of the flanking is
to reduce the resulted moment.
- The work piece must not be nip to long from the spindle because it will
increase the moment which means the work piece will be more unstable.
- Cutter must be changed in every process because each process need
different cutter. If a wrong cutter used in wrong process it will damaged the
cutter.
- Higher spindle rate will produced a better surface finish and longer cutter’s
life. Because low spindle rate will make greater impact for the cutter which
will damage the cutter greater.
- Higher feed rate will make the turning result worse. Because which means
the work piece will move fast and maybe skip the cut, so the surface result
will not flat.
- A bad result in threading process happened in the observation, it because
when locate the zero position for threading process there’s an error so
depth of cut become to deep and the threading result become unarranged
and full of chip left. While a good one will provide a better surface (without
chip) with good thread result.
- In reducing diameter process, we cannot cut the work piece too deep
because it will damage the cutter, so if you want to make a deep cut, you
must do the process several times in small depth.
- Backlash in turning process will affect the zero position. To overcome this
problem, we must locate the cutter again after turning the work piece.
About 1 to 2 times rotation.
Irma Sofiani (13406049)

 We did 5 processes in this experiment, there are: Facing, center boring,

reduction diameter, grooving and threading. Each process needs different
types of cutting tools. A wrong placement of cutting tool may defect the
product and damaged the cutter also. In each process, we also need to
determine the zero position of cutting tool in addition to produced a good
quality product.
 In facing process, a fault in determining zero position will result a scrap on
the surface of work piece therefore will affected the center boring process.
The centre boring process means to give the nipper place, so that the work
piece would not bent and rebound. We set the work piece and flanked it.
So that the work piece would have no vibration and moment force caused
by threading process which can make the bad result. A long process of
threading process will turn to a cutting process.
 The work piece should place not to far from the nipper, in order to
decrease the moment force so that it will stable
 Higher spindle rate will produced a better (smooth) surface result and
longer cutter’s life. Because the low spindle rate will make a bigger impact
to the cutter and it will damage the cutter
 Higher feed rate would make the surface of work piece worse; it will be
rough and have scrap on it. Because if work piece move faster it probably
will skip the cut, so that the surface will not smooth
 In this experiment, the threading process appeared to be failed. There are
two reasons two explained it. First, the age of cutting tool is too old, so that
it already dull. This condition result a bad effect on the work piece, such us
rough and scraped. The second one is the human error. A zero positioning
was un-located in the same order, so there are two different thread piled
up.
 In reducing diameter process, deeper depth cut will damaged the cutting
tool. If we want to create a deep cut, we have to repeat the process
several times
Nadia Fadhilah Riza (1306069)

In this turning experiment, we did 5 processes, which are facing, centre boring,
diameter reduction, grooving, and threading.

Each turning process needed different types of cutting tools. For facing, centre
boring, and diameter reduction process used the same cutting tool. For grooving
and threading process were both using different types of cutting tool. If a wrong
cutting tool used in the wrong process, it would damaged the cutting tool.

First, we have to decided the zero position of the cutting tool, which would effect
the surface of the workpiece. A false zero position would effect the result of
facing process, even more, the centre boring process.
The centre boring process mean to give the holder place, so that the work piece
would not bent and rebound. If the workpiece not been holded, workpiece would
have endurance limit cause of the dynamic force from the cutting tool. The
workpiece might not holded to far in the holder, which means the work piece
located far from the spindle that would increase moment force to the workpiece.
In threading process, if we did the process at a long time, the process would turn
out to be a cut-off process.

The chips were formed in several ways. In centre boring, facing and diameter
reduction process the chips were continuous and short. This was caused by
relatively small feeds and depths. In threading process, the chips were
segmented (caused by the cuting tool’s damaged edge) and long (caused by
small feed and small depth).

Higher spindle rate would produce a smoother surface workpiece and longer
cutting tool’s life. A low spindle rate would make a greater impact for the cutting
tool which would make a greater damage to the cutting tool. Higher feed rate
would make the surface of workpiece rougher.

There is a small box attached to the lead screw that contains a few gears that can
be used to control the lead screw for threading process. Each gear is compatible
for a few number of feeds. The adjustments on the used gear should match with
what we adjusted previously on the feed. If it is different, it could cause defects
on the thread.

A bad result in threading process happened in this experiment. It happened

because when the operator located the zero position for threading process
there’s an error occurred, so depth of cut become too deep, the threading
process result become unarranged, and the surface of workpiece was covered of
chips.
A broken cutting tools would make the chips covered the surface of the
workpiece.

The used turning macine did not use a backlash compensator. Backlash in
turning process will effect in deciding the zero position. To overcome this
problem, we must always located the cutting tool after the turning process work
on the workpiece. But there is a way to compromise the backlash without any
additional component attched to the turning. That is by turning the handwheel to
the opposite direction two times in order to reduce the gap between gears.

Prilla Sista LJ (13406080)

1. With a high cutting speed, we could get smooth turning result. If the cutting
speed is lower than the feed, thread could be formed on the workpiece
surface.
2. In the turning process, there is a plane particularly designed for the flow of
the chips so they will flow out themselves. Because if the chips stay, the
friction that occurs could resist the feed and wear out the cutting tool.
3. In threading process, the depth of cut could not be too deep in a turning
process because it could wear out and even break the cutting tool.
Therefore, to make a deep cut thread, the process should be done in many
times.
4. Each turning process has different types of cutting tools needed.
Therefore, the cutting tool should be replaced with the proper one for
every turning process.
 5. From the observation we could see the backlash that occurs on the
worktable whereas we rotate the spindle that moves the worktable once
and twice, the table has not moved yet. To overcome this problem, we
should rotate the spindle two more than the rotation needed.
6. The result of the turning process might not be appropriate to our required
dimension. It could be caused by the setting of 0 position before the
process was not very precise.

Ira Wulandari (13406094)

We do the observations of turning process in three base process which are

facing, diameter reduction and threading.
First, we do the facing process to create a flat surface on the end. Then we do the
reduction of the diameter. In this case the diameter that we reduced is the inside
diameter. Finally, we observe the making of threading.

The threading processes have several steps. We cannot do the threading directly
into the depth we want because it can damage the cutting tools. We also have to
be careful with exchange every cutting tools when we do the different process, it
is also can be the cause of damaging cutting tools. (It happened on the previous
observations.)

The chips were formed in many ways. In centre boring, facing and diameter
reduction process the chips were continuous and short. This was caused by
relatively small feeds and depths. In threading process, the chips were
segmented (caused by the cuting tool’s damaged edge) and long (caused by
small feed and small depth)

Higher spindle rate will produced a better surface finish and longer cutter’s life,
because low spindle rate will make greater impact for the cutting tools which will
damage the form of the work piece. Higher feed rate will make the turning result
worse. It can happen because the work piece will move fast and maybe skip the
cut, so the surface result will not flat.
Backlash in turning process will affect the zero position. To overcome this
problem, we must locate the cutter again after turning the work piece. About 1 to
2 times rotation. A bad result in threading process happened in this experiment. It
happened because when the operator located the zero position for threading
process there’s an error occurred, so depth of cut become too deep, the
threading process result become unarranged, and the surface of work piece was
covered of chips.

The used lathe didn’t use a backlash compensator. But there is a way to
compromise the backlash without any additional component attched to the lathe.
That is by turning the handwheel to the opposite direction two times in order to
reduce the gap between gears.

There is a small box attached to the lead screw that contains a few gears that can
be used to control the lead screw for threading process. Each gear is compatible
for a few number of feeds. The adjustments on the used gear should match with
what we adjusted previously on the feed. If it is different, it could cause defects
on the thread
Prilla Sista Lily Jane
Conclusion

1. Principal components of an engine lathe is:

 Headstock contains the drive unit to rotate the spindle, which rotates
the work
 Tailstock, opposite the headstock in which a center is mounted to
support the other end of the workpiece
 Tool post is where the cutting tool is held
 Cross-slide is where the tool post is fastened, designed to feed in a
direction perpendicular to the carriage movement
 Carriage is designed to slide along the ways of the lathe in order to
feed the tool parallel to the axis of rotation
 Ways are like tracks along which the carriage rides, and they are made
with great precision to achieve a high degree of parallelism relative to
the spindle axis
 The Bed of the lathe provides a rigid frame for the machine tool
 Leadscrew drives the carriage rotating at the proper speed to obtain
the desired feed rate

2. Turning is a machining process in which a single point tool removes

material from the surface of a rotating cylindrical work piece

3. Processes of turning:
a. Facing process
b. Diameter reduction process
c. Threading process
d. Taper turning
e. Contour turning
f. Form turning
g. Cut-off
h. Drilling
 i. Boring
j. Knurling
k. Chamfering

4. The shape of the cutting tool used and the direction of the feed vary
between processes

5. Parameters of turning process:

a. Cutting Speed, it’s connected with rotational speed and the average
diameter of work piece.
b. Depth of cut can be defined by adjusting the position of cutting tool
using the spindle. Depth of cut affects the final dimension of the
work piece. In reducing diameter process, depth of cut affects the
final dimension of work piece. However, in facing process depth of
cut affects the thickness of material removal.
c. Feed, can be define by the selector lever. The direction of Feed
affects the final dimension of work piece. If the purpose of turning is
fed the circumference of work piece’s surface, then the direction
would be axial. In the other hand, if the purpose of turning process
is fed the edge of the work piece, then the direction would be radial.
d. Length of cut is the size of the work piece that has been done by
turning process. It is affected by feed rate and time of cutting.
Those parameters, determine the result of turning process.
Post Observation Task

1. Describe and sketch the procedure of turning processes that has been done
during the observation:
a. Facing process
 Set the cutting tool in a right position. Set it in the toolspot. In
order to put the cutting tool on the centre of workpiece.
 Adjust the position of the cutting tools in one line with longitude of
the engine lathe. Then, rotate the cutting tools to 45 degrees.
 Set the depth of cut by setting the distance of cutting tool and
workpiece. This can be done by setting the toolpost.
 Set the direction of feed and the feed rate.
 Turning process.

facing process

b. Diameter reduction process

 At first, one edge of the work piece is drilled with a center drill
attached on the tailstock
 The cutting tool is positioned at 90 cutting angle
 Adjust the direction and the feed rate (vf) by adjusting the feed
rate selector lever as required.
 Adjusting the depth of cut (a): by adjusting the position of cutting
tool with the spindle.
 Turning process
 Diameter reduction process

Diameter reduction result

c. Threading process
 At first, does the grooving process, which is making a clear final,
mark for the threading process. The grooving process uses the
grooving tool. The depth of grooving is equal to the depth of
thread that is going to be done.
 Setting the required pitch: the size of pitch is set by the gear box
according to the specifications needed.
 Setting of threading dial: by checking the lead screw nipper, the
gear inside should match the specification stated on the
threading process table.
 Turning process
 grooving threading process

2. Write the name and function of the engine lathe components that were used
during the observation!
 Headstock contains the drive unit to rotate the spindle, which rotates the
work
 Tailstock, opposite the headstock in which a center is mounted to support
the other end of the workpiece
 Tool post is where the cutting tool is held
 Cross-slide is where the tool post is fastened, designed to feed in a
direction perpendicular to the carriage movement
 Carriage is designed to slide along the ways of the lathe in order to feed
the tool parallel to the axis of rotation
 Ways are like tracks along which the carriage rides, and they are made
with great precision to achieve a high degree of parallelism relative to the
spindle axis
 The Bed of the lathe provides a rigid frame for the machine tool
 Leadscrew drives the carriage rotating at the proper speed to obtain the
desired feed rate

3. Draw the shape of cutting tools and show the varieties of their angles and
planes!
 AL and AR type for boring, chamfering and turning processes that allow 90
angle.
 BL and BR type for turning, boring dan chamfering, suitable for roughing.
Have the lead angle of 15.

 Type C has a square end, commonly used for turning, boring and
chamfering.

 Type D has 800 angle and an angle tool for undercutting O.D/I.D
chamfering

 Type E is a standard cutting tool with 60 that is usually used for V-
grooving, chamfering, boring, turning, and facing

 EL and ER type have 600 angle to offset a part that is difficult to reach. Also
suitable for V-grooving.

 FL and FR type, commonly used for lathe turret for straddle facing, but
could also be used for conventional lathe

 GL and GR type for facing that is close to chuck jaws

  CTL and CTR used for cut-off for small diameter, also for grooving

 TSA type for boring with boring bar angle of 900

 TSC type for boring with boring bar angle of 300

 TSE type for boring with boring angle of 450

4. Determine the cutting speed, spindle rotational speed, depth of cut, and
feed rate that are needed to do the diameter reduction and the HSS type of
cutting tool and how to set the arrangement of feed lever?
Lever arrangement setting:
 Drill a hole for clamping with drill chuck-center drill
 Set the clamp so the workpiece stays rigidly in its place during turning
process.
 Set the 0 position, according to the distance of cutting edge and the
surface of workpiece.
 Determine and set the depth of cut, spindle rotational speed, and feed in
the machine to our requirement:
 In order to arrange the spindle rotational speed, the lever is turned to
letter B, and the other lever is turned to 3 to get the 370 mm/radian
spindle rotational speed.
 To set the feed direction, pull or push the lever. Pull the lever to reduce
the workpiece surface. We need to determine the feed rate required
 before setting the feed rate of the cutting tool. Then, set the lever. To
create a certain speed for feed rate, in this case 0,05 mm/rad where it is
shown AS8X in the table on the headstock. Set the first lever to letter A,
the second lever to 8, and the third lever to X.

5. Write 3 effects caused by adjusting cutting tool higher than the axis of work
piece !
a. Friction will occur between the chin part of the cutting tool and the
work piece, which could make the finished work piece very thin.
b. The surface of the work piece would be textured (not flat). The
dimension of the finished product might not appropriate to our
requirement. It is commonly found in the facing process.
c. The fracture chips of the cutting tool or the work piece could jump
out of the chuck. If the cutting tool is not placed in the right position,
it could easily wear out. It has to supply more energy because the
cutting edge is not rightly consumed when contacted to the work
piece.

6. Describe the factors initiating the cost of turning process!

a. Cutting Speed , it’s connected with rotational speed and the
average diameter of work piece.
b. Depth of cut , can be define by adjusting the position of cutting tool
using the spindle. Depth of cut affects the final dimension of the wor
piece. In reducing diameter process, depth of cut affects the final
dimension of work piece. However, in facing process depth of cut
affects the thickness of material removal.
c. Feed, can be define by the selector lever. The direction of Feed
affects the final dimension of work piece. If the purpose of turning is
fed the circumference of work piece’s surface, then the direction
would be axial. In the other hand, if the purpose of turning process
is fed the edge of the work piece, then the direction would be radial.
 d. Length of cut is the size of the work piece that has been done by
turning process. It is affected by feed rate and time of cutting
e. The machine and its maintainance
A machine with a certain type of quality will have a certain type of
perfomance. This will effect the efficency of electricity. A good
machine will not waste too much electrcity.
f. Set-up
Set-up process will effect the quality of the products. If there is a
mistake in the setting-up process, then there will be a possibilty that
the product produced will have defects

7. Explain and mention the function of knurling process, grooving, and form
turning!
a. Knurling is a turning process that will produce a cubic pattern or
stripe pattern on the surface by using knurling tool. Knurling is also
known as metal working process that is used for regular
crosshatched pattern on the workpiece surface.

b. Grooving is a process that is similar to diameter reduction process

on the edge of threading workpiece. This process is done before
 threading in order to make the end of thread. Grooving can be done
in three shapes, which are square, round, and V-shaped.

c. Form Turning is turning process that uses a cutting tool to reduce

the diameter of the workpiece and also to form the workpiece as the
contour of the cutting tool. Form turning needs special templates to
form the workpiece.
Sources

“Diktat kuliah proses manufaktur”, Operasi Pemesinan dan Mesin Perkakas.

Degarmo, E.Paul. ”Material And Processes in Manufacturing”,chapter 18.Shaping and

Planning.

Groover, Mikell P. “Fundamentals of Modern Manufacturing”. John Wiley&Sons,

2002.

Rochim,Taufiq. ”Teori dan Teknologi Proses Pemesinan”, Bab 2 Klasifikasi dan Elemen
Dasar Proses Pemesinan.

http://www.jjjtrain.com/vms/cutting_tools_lathe.html

Enclosure