Mapa University

Muralla St. Intramuros, Manila

Department of Mechanical and Manufacturing Engineering

SHOP PRACTICE NO. 4

Knurling

ANGELES, Marison C.
ME-2
ME137L/ A3
GRADE
2015100221
Group 04

Engr. Jose V. Hernandez

Instructor
OBJECTIVES:
1. To be able to learn the knurling process.
2. To be able to operate the lathe machine for the knurling operation.
3. To be able to knurl a workpiece between the chuck and dead centers.

METHODS AND ANALYSIS:

Knurling is the process producing raised design figure in a cylindrical surface held between
center and chuck on a lathe machine. As the pressure is done in the workpiece by the knurling
tools the metal is forced out and the shape formed depends on the knurling tools design.

MATERIALS:
2 pieces Round Bar 16mm diameter x 281 mm length

TOOLS AND EQUIPMENT TO BE USED:

- Brush
- Chalk
- Face Shield (2 pieces)
- Flat File
- Knurling Tools
- Lathe machine and its Accessories
- Oil
- Rag
- Sand paper
- Tool Post Wrench
- T-key
- T-Wrench
- Vernier Caliper
- Working bench

PROCEDURE:
1. Borrow the necessary tools and equipment to the counter. Cut the metal 16mm by 281mm.
2. With the use of a center punch, mark the center point of both ends of the metal and bore a
hole 5.62mm diameter by 6.2mm depth.
3. Check the height of the cutting tools, the dead center must be in-line with each other.
4. Set up the work piece in the lathe machine.
5. Place the tool bit on its holder and install to the compound crest.
6. Use the cutting tool for centering the workpiece by placing it close to the bar, turn the
chuck by your hand and the high part of the work will move the tool holder back.
 7. Turn the chuck to the position with the highest gap, return to the first position to move the
jaw inward half of the distance of the highest gap. Adjust the distance using only the
opposite jaws. Continue until the workpiece is centered.
8. Prepare to knurl and set the lathe to a low speed.
9. Prepare the knurling tool bit.
10. Start knurling from right to left.
11. Stop the machine when it reaches the end of the grip part.
12. Finish the handle.

QUESTIONS:
1. What is a knurling process?
- Knurling is the process of embossing a diamond shape pattern on the surface of a
work piece.

2. What is the purpose of knurling a certain workpiece?

- The purpose of knurling is to provide an effective gripping surface on a work
piece, to prevent it from slipping when operated by hand.

3. What are the three types of machine knurling tools?

- Internal knurling holders- used for a boring bar style and can knurl up to a depth in
the workpiece, which depends upon the toughness of the material to be knurled.
- Convex knurl tools- an axial feed knurling tool and is used for reducing a double
tracking problem.
- Conical knurl tools- used in decorative purposes for generating radical face
knurling or conical surfaces to the workpiece. Other knurling tools are commonly
available.

4. What are the standard pitches of rollers used in knurling tools?

- The standard pitches of rollers in knurling tools are 14 pitch (coarse), 21 pitch
(medium) and 33 pitch (Fine).

5. What kind of materials can be used for the knurling rollers?

- Knurling rollers can be rubber, industrial rubber, aluminum, urethane, diamond,
or stainless steel. As long as the knurling rollers to be used in your project must be made
out of material harder than the work piece or else the roller wont be able to imprint the
particular design.
6. What kind of knurling tools is needed for small diameter work?
- The knurling tool can be designed differently, but all accomplish the same
operation. Two common types of knurling tools are the knuckle joint and revolving head
type of knurling tools. The knuckle joint type is equipped with a single pair of rollers that
revolve with the work as it is being knurled. The revolving head type of tool is fitted with
three pairs of rollers so that the pitch can be changed to a different knurl without having to
change the setup.

7. What is the right position of the knurling tools to the workpiece?

-The Knurling tool must be perpendicular to the workpiece or must atleast be
orthogonal. In more specific words, the knurling tool must be set in the tool post with the
axis of the knurling head at center height and the face of the knurls parallel with the work
surface.

8. What are two types of knurling pattern?

-There are two knurl patterns, diamond and straight. The diamond is the most
common pattern and the medium pitch is used most often. The coarse pitch is used for
large-diameter work; the fine pitch is used for small-diameter work.

9. Knurling is done on the lathe machine, at what speed?

-Knurling is done on a lathe machine at a speed of 60 rpm to 80 rpm to avoid
damaging the workpiece and to have a good pattern outcome.

10. How do you set knurling tools in a lathe machine with the workpiece?
- The knurling operation is started by determining the location and length of the
knurl, and then setting the machine for knurling. A slow speed is needed with a medium
feed. Commonly, the speed is set to 60 to 80 RPM, while the feed is best from 0.015 to
0.030 inch per revolution of the spindle. The knurling tool must be set in the tool post with
the axis of the knurling head at center height and the face of the knurls parallel with the
work surface. Check that the rollers move freely and are in good cutting condition; then oil
the knurling tool cutting wheels where they contact the work piece. Bring the cutting
wheels (rollers) up to the surface of the work with approximately 1/2 of the face of the
roller in contact with the work.
MECHANICAL DRAWINGS:

FRONT/ RIGHT SIDE VIEW (SCALE 1mm : 2mm)

8.00

12.00

15.00
TOP VIEW (SCALE 1mm : 1mm)

ISOMETRIC VIEW (SCALE 1:2)

DISCUSSION:

Knurling is typically used to provide a uniform sure grip on an otherwise smooth surface.
Knurled finishes for handles and grips are essential characteristics for tooling and components in
a variety of industries, but especially important for surgical, dental, and other medical tooling and
devices. We produce some of the finest knurled finishes in industry. Rolled knurls are superior in
finish, form, and dimensional consistency to knurls formed by cutting or bump rolling on lathes
and screw machines. Also, knurled components are used for metal parts that are molded into plastic
or pressed into other metal components. The uniformly rough surface prevents slippage under
stress.

A knurling tool is used to press a pattern onto a round section. The pattern is normally used
as a grip for a handle. Apprentice engineers often manufacture screwdrivers. These have patterned
handles, to provide a grip and this achieved through the technique called knurling. The pattern
produced is called a knurled pattern. The setup for knurling can be made between centers or
mounted in a solid chuck. Never attempt to knurl by holding the work in a rubber or metal collet
chuck, since the great pressures of knurling could damage these devices. It is important to support
the work while knurling. If mounting the work between centers, make the center holes as large as
possible to allow for the strongest hold. If using a chuck to hold the work, use the tailstock center
to support the end of the work. If doing a long knurl, use a steady rest to support the work and
keep the piece from springing away from the tool.

CONCLUSION:

In this activity, students were able to learn the knurling process with the help of the
laboratory assistant and the professor. The activity lets students to use and operate the lathe
machine for the knurling operation. The students were also able to knurl a workpiece between the
chuck and dead centers.

RECOMMENDATION:
It is highly recommended to wear proper eye protection or face mask, if you dont have
eye protection. Also, tying is recommended for long hairs especially for the ladies. Automating
the lathe machine must be on low speed and must be properly oiled. Do not adjust or touch the
workpiece when the machine is working. It is also recommended to know the emergency stop
(which is at the bottom part) for emergency cases.
REFERENCES:
https://en.wikipedia.org/wiki/Knurling
http://www.educationportals.net/2014/09/lathe-machine-operations-facing-knurling-recessing/

http://www.globalspec.com/learnmore/manufacturing_process_equipment/cutting_tools/knurling
_tools
https://smithy.com/machining-handbook/chapter-3/page/25