Lesson Title: Lathe Operations Lesson Duration: 4 hours Industry Competencies: Participants will: research and discuss theoretical

l and background information about engine lathes and turning operations select cutting speeds and feeds, and calculate the RPM appropriate to a specific material/cutting tool combination link the basic theory of turning to tool geometry (chip formation) describe the relative motions of the lathe and describe the interactions of various subsystems, including the machine tool, machine controls, drive mechanisms, cutting tools, tool holder, work piece, and work holder demonstrate safe operating procedures for each machine tool used (Comp. 2) develop a list of lathe and turning operations, and identify the sequence of operations needed to make a specific product (Comp. 4) use hand tools to support the setup and operation of lathe machinery (Comp. 5) operate lathes at an introductory level (Comp. 6) select cutting speeds and feeds, and calculate the RPM appropriate to a specific material/cutting tool combination (Comp. 7) apply basic precision measurement instruments before, during, and after turning operations to ensure that product specifications and tolerances are met (Comp. 9). Specific Objectives: Participants will: read schematics and engineering sketches accurately measure accurately using SI and US systems and tools employ all personal and environmental safety requirements collaborate successfully to solve machining problems set up and use the lathe properly. Assessment(s): Rubric for Evaluating the Transfer Activity Participant:
Participant Deliverable Safe Operation of machinery Participant Task with Competency Operate machine tools in a safe and proper manner. Use hand tools to support setup of machinery. (Comp. 1, 3, 4, 5) Develop a list of machining Highly Competent

Date:
Competent Machinery and tools are operated safely and in accordance with manufacturer's instructions. Needs Improvement Safe and proper operating procedures are not followed.

Process Planning Sheet: Making

Sketch of part is detailed and

Sheet includes a sketch of the part

Sheet is inaccurate or incomplete.

Parts for the Robotic Gripper

Inspection Sheet: Making Parts for the Robotic Gripper

Part

operations and identify the sequence of operations needed to make the part. (Comp. 2, 10) Record part measurements before, during, and after machining and ensure that specifications have been met. (Comp. 6, 9) Make a part within tolerances. (Comp. 4, 5, 7, 8)

professionally presented. List of operations shows an indepth understanding of the process. Examination of part tolerances on inspection sheet shows variation from tolerances specified on engineering drawing. Part is within tolerances specified on engineering drawing. Part moves well with parts made by other teams. Highly Competent

and complete list of operations, in a correct sequence required to produce the part. Measurements of part to determine conformance to engineering drawing are accurately done and recorded on inspection sheet. Part achieves the correct basic geometry of part as specified on the engineering drawing. Sheet is inaccurate or incomplete.

Part is not attempted, or is not completed, or basic geometry of part is incorrect.

Overall Assessment Competency or Task Measurements are accurate using both US and SI devices. Conversions within the US system are accurate.

Competent

Needs Improvement Needs Improvement One or more measurements are incorrect and ability to use appropriate tools is not consistent. One or more of the conversions is inaccurate and units are not displayed correctly. One or more of the conversions is inaccurate and units are not displayed correctly. One or more of the conversions is inaccurate and units are not displayed correctly.

Conversions with the SI system are accurate.

Conversions between the US and SI systems are accurate.

Highly Competent All measurements are made accurately with full understanding and ability to use measurement tools. All conversions are accurate with full understanding and appropriate units indicated. All conversions are accurate with full understanding and appropriate units indicated. All conversions are accurate with full understanding and appropriate units indicated.

Competent All measurements are made with appropriate tool and are accurate. All conversions are accurate with appropriate units indicated. All conversions are accurate with appropriate units indicated. All conversions are accurate with appropriate units indicated.

Competency or Task Write clearly and effectively on a specific topic.

Speak clearly and present information about a specific topic.

Highly Competent Topic is fully addressed with highly effective supporting information with no errors in grammar, punctuation, or spelling. Topic is fully addressed with highly effective supporting information with a clear voice, excellent syntax, excellent grammar, and superb volume.

Competent Topic is fully addressed with adequate supporting information and no errors in grammar, punctuation, or spelling. Topic is fully addressed with adequate supporting information in a clear voice with effective grammar and pronunciation.

Needs Improvement Topic is not addressed or poorly supported with one or more errors in grammar, spelling, and punctuation. Topic is not addressed or poorly attempted with inadequate supporting information, low voice, and one or more errors in grammar.

Production of a Part
Competency or Task Machine Operation Analysis Machine/Tool Use Highly Competent All machine operations were followed with high level of quality and superb detail. The actual machine and related tool use was superb with no mistakes. All safety rules were followed exemplary with assistance to others. All parts were measured and fabricated accurately with exact precision beyond any tolerances. Competent All machine operations were followed with high level of quality. The actual machine and related tool use was done well with required detail. All rules were followed as directed. All parts were measured and fabricated accurately within acceptable tolerances. Needs Improvement One or more of the key procedures were not followed or poorly done. There were one or more instances of poor tool use during the process. One or more rules was not followed which established some risk. One or more parts were measured wrong or fabricated poorly outside of required tolerances.

Safety

Accuracy

Resource(s): Print Materials - Basic mathematics textbook and Machining textbook (to be identified) Audiovisual Internet sitesKey word search - lathe, lathe operations, lathe safety, lathe manufacturers, lathe parts, lathe attachments, lathe tooling. Purpose of the Lesson: To introduce participants to lathe machining operations, including safety, tooling, and applications for manufacturing.

Required Knowledge and Skills: Participants will: perform basic operations in mathematics measure accurately using SI and US tools and units convert measurements between SI and US systems read basic schematics and machine part drawings/sketches follow personal and environmental safety requirements. Tools, Materials, Equipment Needed: 1 lathe bar stock 1 pad of 3" x 5" Post-it Notes 1" x 6-1/2" bar stock For the facing and center drilling portion of this activity, per participant: setup tools 1 micrometer with collar 1 center drill reference chart in Machine Tool Practices 1 vernier caliper same work piece used above For the turning portion of this activity, per participant: 1 lathe 1 micrometer with collar same work piece used above Specific Safety Requirements: Everyone must wear safety glasses at all times during equipment demonstrations and operator evaluations. Observe proper safety and operating procedures at all times. Dispose of chips and other debris as required by your facility. Each participant must pass the Lathe Safety Test and Operator Evaluation before being allowed to operate any lathe. Participants may not proceed until all safety knowledge is addressed. You must ensure that participants can demonstrate safe and proper operating procedures before using equipment. Lesson Elements: (5-E model) Engagement: In preparation for this activity, you should have assigned participants to research topics such as: types of machine tools operations types of tooling ways of holding work speeds feed rates tolerances

surface finishes measuring and measuring instruments.

At the beginning of this session, have the group decide how the discussion should proceed (such as, work through a list or go around the room). Have them establish ground rules for the discussion; for example, the person presenting information is allowed to finish before the rest of the group can ask questions or present differing opinions. Be sure to emphasize the importance of respect for the ideas and information provided by others. Review the parts of a lathe, either in this discussion or as part of the equipment demonstration that follows. Make sure that the discussion and/or demonstration includes the information that appears on the quiz. Exploration: Before observing a lathe demonstration, participants should be required to visit one or more lathes available in the manufacturing laboratory and using a part identification worksheet as shown below, they should identify and describe each machine part that has been labeled by the instructor with sticky notes or some other simple form of labeling. Machine Part Number Machine Part Name Purpose or Description

Participants should view the following image and prepare a written description for lathe machining operations. The written descriptions will be used to guide discussions led by the instructor about what these machines can and cannot do.

Another interesting exploration activity is to challenge participants to explore a variety of Lathe manufacturers and locate product descriptions and machine specifications for comparison of machine capabilities and features. This research will help participants understand the wide range or products and machine features depending on the scope of production work needed by an organization. Participants can accomplish this as independent or small team work. Examples are provided below to guide this research.

YCL-1236/YCL-1340 Options: Taper Turning attachment Micro Carriage Stop 5-C Lever Collet Closer 2 axis Digital Readout Birmingham YCL 12"dia x 36" Geared Head Bench Lathe Manufactured in China. Floor stand included 7" diameter max swing over carriage 2 HP, 220 volt, 1 phase main motor 9 speeds from 70 - 1400 RPM Standard Equipment: 6" 3-jaw chuck 8" 4-jaw chuck 10" face plate 1-1/2" spindle bore 3 3/4" steady rest follow rest Gap 4-way tool post thread chasing dial 2 dead centers reducing sleave full splash guard chip tray Automatic longitudinal and cross feeding Hardened and ground Spindle and Bedways 12" swing x 36" center distance Precision Geared Head Gap Bench type including floor stand: $2,495.

Birmingham CT-1440G Precision Lathe $3595. Manufactured in Taiwan. ** Uses 110 volt electrics ** Swing over bed 14" [355mm] Between Centers 40" [1016mm] D1-4 with 1-1/2" Spindle Bore [38mm] Width of Bed 7-5/32" Lathe bed is made of high tensile cast iron in rigid construction structure, the bed way is hardened and ground. The main spindle is equipped with 2 precision taper roller bearings. Provides 12 spindle speeds from 70 to 1350 RPM, quick speed change by lever. All gears head stock with oil immersed lubrication design, provides vibration free Vbelt replacement 2HP motor has power suitable for heavy duty cutting. Includes heavy duty floor stand along with full length splash guard as standard equipment. In addition to complete lathe turning centers, participants can locate and review information about various components and lathe parts such as the examples shown below-

Birmingham Extended Range Precision Gap Bed Lathes

Swing diameter over bed - chose from 26" / 32" / 40" Between centers: 40" / 60" / 80" / 120" / 160" / 200" Width of bed 21 21/32" 20 HP main motor (15 HP ON DL-26 series only) 67 kinds of inch threads 18 speeds from 7.5 to 1000 RPM D1-11 camlock with 5-1/8" spindle bore on most lathe sizes Main spindle hardened and precision ground Bed made of fine grain high tensible cast iron 4-way rapid travers to carriage and cross slide Bed ways induction hardened and precision ground All gears and shafts hardened and precision ground Spindle supported at 3-point by precision bearings Automatic lubrication system in headstock and feed box

 Hydra-control multi-disc clutch for spindle turning and brake Manufactured in China After discussing the lathe, participants are ready to observe a brief demonstration of the machines capabilities. This demonstration should include a review of the parts of the machine, proper nomenclature, and any specific safety procedures. One interesting approach to the actual machine lathe demonstration and related setups is to have participants complete the setups and then prepare photos of those key configurations which could be used in participant tutorials or remedial instructional episodes needed throughout the course.

A detailed machine parts drawing should be provided by instructor for participants to review. This example provided below is very detailed and may not be needed for a foundations course, but it is good for participants to review such documents to see the scope of detail in a basic turret lathe, including the motor and drive assemblies as well as the lathe bed and various controls and attachments. Participants should be able to review a lathe parts drawing or photo with parts labeled as shown below. It is suggested that participants prepare their own documents by photographing and then drawing detailed drawings to be kept in their class notebooks or journals. These must be kept for future reference and exam studies.

Explain and demonstrate the following turning operations and concepts, which the participants will perform in the Lathe Exercise: operating speeds and feeds facing and center drilling turning to tight tolerance Explanation: Identify and describe the various types of machine tools: engine lathes gap beds chuckers turret lathes (old technology) CNC lathes automatic screw machines Discuss (written and oral) the following operations: turn face bore thread knurl drill ream taper grove trepan internal vs. external operations Discuss these types of tooling: tool geometry of turning tool tool geometry of facing tool tool geometry of threading tool tool geometry of boring bars tool material type (HSS/carbides/ceramics) Describe these ways of holding work: chucks (3-jaw universal vs. 4-jaw independent) face plate (collets) between centers Discuss how to determine proper RPM for lathe work: (RPM = (cutting speed x 4) diameter)

Extension: Lead participants in a discussion of the activity by asking questions such as: Is the lathe the most efficient way to produce this part? What other operations can be performed on the lathe? Is it easy to turn a part to a tight tolerance? When turning to a tight tolerance, what went wrong or was unexpected? How did you correct the problems you encountered? What are the economies of tight tolerances ( .001")? How can you match your machining speeds and techniques, as well as your measuring instruments, to the tolerances specified on the print? 1. Perform the following practice operations on the lathe: Using pre-made Post-it Notes, label the parts of the lathe. Remove the Post-it Notes. Practice changing speeds on the lathe. Practice operating automatic cross and longitudinal feeds. 2. Perform the following facing and center drilling operations on the lathe: Load a tool and set it to center. Select the proper center drill using the reference chart in Machine Tool Practices. Face and center drill both ends of the work piece. Use a caliper to measure the length of the work piece: ___________________________ Explain how the choice of measuring tools corresponds to blueprint tolerances and whether a caliper is accurately calibrated. 3. Perform the following operations pertaining to turning to tight tolerance: Set up the work piece between chuck and center. Determine whether the lathe is equipped with a single- or double-depth micrometer. Using Engineering Drawing: Lathe Exercise for reference, practice turning diameters to size. Discuss how to turn a diameter to a tolerance of .001". Discuss how surface finish affects tight tolerance. Use a micrometer to measure the diameters of the work piece. Consider the micrometers tolerances, measuring range, usage, and calibration to discuss why a part may be within tolerances though the micrometer may indicate otherwise: The following planning sheet can be used to guide the practice exercises identified above.

Process Planning Sheet: Lathe Exercise Participant: Sketch of Part Date:

Operations

Materials & Equipment

Approved By:

The following is a part drawing for a thread cutting exercise that can be presented to participants as part of basic lathe skill development and refinement. The instructor can offer other similar examples for participants to complete based on their class ability level.

The following images are provided for the instructor to help guide participants in their understanding of thread cutting operationsThree Wire Method of measuring threads:

Thread Nomenclature

Screw Thread Lead and Pitch

Enrichment: Have participants investigate the history of lathe machines and prepare a timeline that begins with crude devices such as the one shown below. Key machine features and innovations should be highlighted in their timelines. This activity can be accomplished as independent or collaborative work.

Evaluation: 1. List two ways to face off a piece to a given dimension. Turn the compound 30 and feed in twice the amount that you want to cut. Turn the compound 90 and feed in the same amount that you want to cut. 2. What is backlash and what adjustments do you have to make for backlash? Backlash is play in the longitudinal or cross feed screw. In the backlash area, the micrometer dial will change but the corresponding machine slide will not move. As long as you have removed the backlash and are moving the screw in the same direction, you do not need to worry about backlash. To get rid of backlash when you change directions, go two full turns past your position and then come back to your position. 3. Calculate the correct spindle speed for turning 2-1/2" diameter cold-rolled steel. Use the formula: cutting speed x 4 diameter of work piece 100 x 4 (2.5in.) 160 RPM 4. What happens if you drill too deeply with a center drill? If you drill too deeply, the bearing surface for the center will be a sharp edge instead of a 60 angle. This will give a poor bearing surface. 5. You need to turn a work piece to a 0.547 0.002 diameter and you're turned down to 0.557. What are the last five steps you will take to hit the final size correctly? a. Turn the micrometer collar to the desired cut. b. Start the cut for 1/8-1/4 inch. c. Quickly move the cutter to the right of the work piece without changing the micrometer collar. d. Measure whether you are cutting the desired diameter. e. If so, continue the cut. If not, readjust the micrometer collar. 6. What is the difference between single-depth and double-depth cross feed micrometer collars? A single-depth micrometer collar cuts twice as deep as the reading on the micrometer collar. A double-depth micrometer collar cuts the same amount as the reading on the micrometer collar. 7. Why do you need to center drill a work piece? To provide a bearing surface for a center or to provide a starting point for a drill since a drill tends to walk when it starts the cut. 8. You have a 0.002 tolerance on your blueprint, but when you made the final cut, the surface finish was very rough. Is this a problem? Why or why not? Yes. If the surface finish is rough, the high points of the surface irregularities will wear off quickly, changing the size of the work piece.

9. What precaution should you take when turning between a chuck and a center? Explain. The work piece can slip into the chuck jaws and move away from the tailstock center, leaving it unsupported at the tailstock end. This unsupported end can whip around, causing a hazard for the lathe operator. Also, the chuck jaws may not align the work piece with the tailstock center. 10. 11. What is a good feed rate for a roughing cut on the lathe? Explain. The feed rate for roughing should be 1/5 to 1/10 of the depth of cut. What is a good feed rate for a finishing cut on the lathe? Explain. Finishing feeds should be .003 to .005 for steel.

The following inspection sheet can be used to evaluate all Lathe exercises. Inspection Sheet: Lathe Exercise Participant: Date: Acceptable Within Tolerance Yes No

Description

Required Sizes

Machined Sizes

Enrichment: 1. Look up recommended feed rates from technical manuals for tool suppliers. 2. Discuss the quick-change gear box. 3. Use two or three different feed rates to explain how feed rate affects surface finish. 4. Discuss the typical tolerances for various lathe operations and tooling. 5. Describe the typical finishes generated on lathes. 6. Discuss the use of graduated dials, compound rest stops, digital readouts, and gauges.