Turning Workpiece (Basic)

Worksheet 4.1.2 : Workholding Devices

Learning outcomes:

1 Turn workpiece

Learning Activity:

1.1 Objectives
1. Identify the lathe workholding devices and its uses and parts.

• 3-jaw Self-centering Chuck
• 4-jaw Independent Chuck
• Types of Drive Plates
• Lathe dogs
• Center
• Steady rest

Direction: Choose the best answer.

1. It is used to hold round, triangular, and hexagonal workpieces.
a) 3-jaw chuck
b) 4-jaw chuck
c) Steady rest
d) Drive plate

2. It is used to hold round, square, octagonal, offset, eccentric, irregular- shaped and ‘scaled’
workpieces.

a) 3-jaw chuck
b) 4-jaw chuck
c) Steady rest
d) Drive plate

3. They are used to drive the work held in a lathe
dog for turning between centres.

a) 3-jaw chuck
b) 4-jaw chuck
c) Steady rest
d) Drive plate

4. They are used to hold and drive the work for turning between centres.

a) 3-jaw chuck

b) Lathe dogs

c) Steady rest

d) Drive plate

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 1

Worksheet 4.1.2 : Workholding Devices

5. It is used to support the end of a long cylindrical bar for facing, drilling or boring.
a) 3-jaw chuck
b) 4-jaw chuck
c) Steady rest
d) Drive plate

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 2

Worksheet 4.1.2 : Workholding Devices

Answer Key:

1. A
2. B
3. D
4. B
5. C

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 3

Worksheet 4.2.2: Surface gauge and Dial indicator
Learning outcomes:
1 Turn workpiece
Learning Activity:
1.1 Objectives

1. Identify the parts of Tools and Instrument Used in Setting up Workpiece
2. Identify the uses of Tools and Instrument Used in Setting up Workpiece

Test 1. Name the Parts of a Surface Gauge

15

2 6
7
3 8

4

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 1

Worksheet 4.2.2: Surface gauge and Dial indicator

Test 2. Name the Parts of a Dial Indicator

1

4

2
3

5

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 2

Worksheet 4.2.2: Surface gauge and Dial indicator

Test 1. Name the Parts of a Surface Gauge

Column 1 5 Scriber

Sleeve Clamping 6 Scriber Clamp
screw 2 7 Fine Adjusting Screw
8 Locating Pin
Sleeve 3
Rocking Bar 4

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 3

Worksheet 4.2.2: Surface gauge and Dial indicator

Test 2. Name the Parts of a Dial Indicator

Bezel Locking
Screw 1

4 Bezel Dial

Revolution
counter 2

Spindle 3

5 Stylus

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 4

Information Sheet 1.1.1 :

Learning outcomes:
1 Turn workpiece
Learning Activity:
1.1
6.0 Cutting Tools Set-up

6.1 Types of Cutting Tool Holders

The cutting tool holder is used to hold the tool bits which are small as it would be costly
to have a tool which is completely made from tool steel.

Tool Holder Purpose

Straight Tool Holder General purpose machining and for thread
Right Hand Tool Holder cutting.
Left Hand Tool Holder
For facing operations and for machining work
close to the tailstock.

For facing operations and for machining work
close to the headstock.

Holder for Carbide Used for holding carbide inserts, the inserts are
Inserts held by clamping.

Parting Tool Holder For parting-off operations.

The direction of the tool holder is checked by holding the head and observe where the
shank points. If it points to the right, it is then a right hand tool holder.

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 1

Information Sheet 1.1.1 :

Left Hand Tool Holder
Right Hand Tool Holder

Straight Tool Holder Parting Tool Holder

Figures 6.1 Types of Tool Holders

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 2

Information Sheet 1.1.1 :

Holder for Ceramic Inserts Holder for Carbide Inserts

Figure 6.1 – Types of Cutting Tool Holders

6.2 Setting-Up the Lathe Tool to Centre Height

It is important that the lathe tool be set up properly so that it can cut the work properly and
effectively. The tool held in the toolpost must be set to the correct centre height.

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 3

Information Sheet 1.1.1 :
Figure 6.2 – Mounting of Lathe Tool

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 4

Information Sheet 1.1.1 :
Packing pieces are used to raise the tool to centre height. The tool must be supported correctly
so that the cutter cuts properly.

Figure 6.2 – Proper Support of the Tool Holder
6.3 Minimum Tool Overhang
When setting-up the tool holder, it is essential that the overhang be kept to a minimum. A tool
with too much overhang will cause chattering which can cause a poor finished workpiece. Too
much overhang will also cause the tool to break.

Figure 6.3 – Tool Overhang

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 5

Information Sheet 1.1.1 :

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 6

Information Sheet 1.1.1 :

6.4 Setting the Lathe Tool to Centre Height

There are four methods used to set the lathe tool to the machine centre height:

 Use markings on the tailstock spindle
 Using the tailstock centre
 Using a steel rule (Height from centre to cross slide must be known)
 Using a scribing block

Figure 6.4 – Methods to Set Tool to Centre Height

6.5 Effects of Tool Centre Height

When setting the lathe tool height, there are three scenarios that could occur :

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 7

Information Sheet 1.1.1 :

6.5.1 Tool Set at Centre Height
If the tool is set to the correct centre height, the correct cutting action will take place.

 The top rake and the front clearance angles will not be affected.
 The tool cuts properly.
 A flat surface is produce at the end of the workpiece.

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 8

Information Sheet 1.1.1 :

Figure 6.5.1 – Tool Set at Centre Height

6.5.2 Tool Set Above Centre Height

When the tool bit is set above centre height, it would rub on the work surface and wear
away the cutting edge of the tool.

 The top rake angle increases.
 The front clearance angle decreases.
 The flank of the tool rubs against the work and makes cutting difficult.
 A sharp point is left at the centre.

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 9

Information Sheet 1.1.1 :
Figure 6.5.2 – Tool Set Above Centre Height

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 10

Information Sheet 1.1.1 :

6.5.3 Tool Set Below Centre Height

When the tool is set below centre height it is weakened due to its increased front
clearance angle and the tool tends to dig into the workpiece.

 The top rake angle decreases.
 The front clearance angle increases.
 The tool may dig into the work.
 A flat point (stub) is left at the centre.

Figure 6.5.3 Tool Set Below Centre Height

Code No. Servicing Starting System Date: Developed Date: Revised Page #
ALT723307 Aug 15, 2003
Mar 01, 2006 11

Worksheet 4.3.2 : Setting Tool
Learning outcomes:
1 Turn workpiece
Learning Activity:
1.1 Objectives

1. Identify different set up of tool to center height.
2. Identify methods of setting up tool.
Test I . Direction: Identify the method use in setting tool.
1.

2.

3.

4.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 1

Worksheet 4.3.2 : Setting Tool

Test II . Direction: Choose the best answer.

1. What causes the cutting tool to dig into the work?
(A) The tool is set at the centre height.
(B) The tool is set below centre height.
(C) The tool is set above centre height.
(D) The tool has a small front clearance angle.

2. If the turning tool is set below the centre height, the top
rake angle will
(A) decrease.
(B) Increase.
(C) Remain the same.
(D) Give a better finish

3. What will happen when a lathe tool is set below centre height?
( A )The front clearance and the top rake are reduced.
( B ) The front clearance and the top rake are increased.
( C )The front clearance is reduced and the top rake is increased..
( D ) The front clearance is increased and the top rake is reduced.

4. A lathe tool set below centre height will tend to

(A) Raise and bend the work.
(B) Produced a more accurate work.
(C) Give a good finish on the work.
(D) Have the tendency to rub on the work.

5. What will happen when turning with a tool set with too much overhang?
(A) Tool chatters.
(B) Damage to the chuck.
(C) Damaged to the tool holder.
(D) Excessive machine vibration.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 2

Worksheet 4.3.2 : Setting Tool

Answer Key:

Test I

1. By using a Scribing Block
2. By using a Steel Rule
3. By using the Tailstock Centre
4. By using the mark on the Tailstock Spindle

Test II

1. What causes the cutting tool to dig into the work?
(A) The tool is set at the centre height.
(B)The tool is set below centre height.
(C)The tool is set above centre height.
(D) The tool has a small front clearance angle.

Answer : (B)The tool is set below centre height

2. If the turning tool is set below the centre height, the top rake angle will
(A) Decrease.
(B) Increase.
(C) Remain the same.
(D) Give a better finish

Answer: (A) Decrease

3. What will happen when a lathe tool is set below centre height?
(A)The front clearance and the top rake are reduced.
(B) The front clearance and the top rake are increased.
(C)The front clearance is reduced and the top rake is increased..
(D) The front clearance is increased and the top rake is reduced.

Answer : (D)The front clearance is increased and the top rake is reduced.

4. A lathe tool set below centre height will tend to

(A) Raise and bend the work.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 3

Worksheet 4.3.2 : Setting Tool

(B) Produced a more accurate work.
(C) Give a good finish on the work.
(D) Have the tendency to rub on the work.

Answer: (A) Raise and bend the work.

5. What will happen when turning with a tool set with too much overhang?
(A) Tool chatters.
(B) Damage to the chuck.
(C) Damaged to the tool holder.
(D) Excessive machine vibration.
Answer : (A)Tool chatters

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 4

Information Sheet 1.1.1 :

Learning outcomes:
1 Turn workpiece
Learning Activity:
1.1

Vernier Caliper

• It is a precision measuring instrument which can be read to the nearest 0.02 mm or 0.05
mm.

• The common sizes are 150 mm and 300 mm.

Vernier Caliper
Inside Measuring Face
Set Screw

Main Beam

Main Scale Depth Bar
Thumb Knob
Fixed Jaw Sliding Jaw
Vernier Scale

Outside Measuring Face

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 1

Information Sheet 1.1.1 :
Uses of a Vernier Caliper

The vernier caliper is used

to obtain the following

measurements:
• Outside Measurement
• Inside Measurement
• Depth Measurement
• Step Measurement

Outside Measurement

Inside Measurement

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 2

Information Sheet 1.1.1 :
Depth Measurement

Step Measurement

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 3

Information Sheet 1.1.1 :

Preventing Errors in Measurement
Outside Measurement

Sliding Jaw
Fix Jaw

Inside Measurement

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 4

Information Sheet 1.1.1 :
Depth Measurement

Step Measurement

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 5

Information Sheet 1.1.1 :

Reading the Vernier Caliper Scale
1 Note the number of whole centimetres to
the left of the zero on the vernier scale.
Multiply the number by 10.

2 Note the number of whole millimetres
Between the figure noted in (1) and the
zero on the vernier scale.
3 Find the line on the vernier scale that
coincides with the line on the main scale.
Multiply the number by 0.02.

1 Note the number of whole centimetres
to the left of the zero on the vernier scale.
Multiply the number by 10.
2 Note the number of whole millimetres
between the figure noted in (1) and the
zero on the vernier scale.
3MuFltiipnldy tthhee lninuemobnerthbeyv1e0r.nier scale that
coincides with the line on the main scale.
Multiply the number by 0.05.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 6

Information Sheet 1.1.1 :

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 7

Information Sheet 1.1.1 :

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 8

Worksheet : 6.1.2 - Vernier Caliper
Learning outcomes:
1 Turn Workpiece
Learning Activity:

1.1 Objectives
1. Identify readings/measurements of caliper (English and metric)
Test Your Self

Test I. Direction: Read the following Measurement of the caliper
1.

2.

3.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 1

Worksheet : 6.1.2 - Vernier Caliper
4.

5.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 2

Worksheet : 6.1.2 - Vernier Caliper

Answer Key:

1. 9.32 mm.
2. 2.26 mm.
3. 19.80 mm.
4. 247.66 mm.
5. Reading= 1.297

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 3

Information Sheet 1.1.1: Micrometer Outside Caliper
Learning outcomes:
1 Turn Workpiece
Learning Activity:
1.1
Metric Outside Micometer
A micrometer is a precision instrument used
to measure a job. Micrometer used to take
the outside measurements are known as
outside micrometer.

Main Parts of Outside Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 1

Information Sheet 1.1.1: Micrometer Outside Caliper

Parts of Outside Micrometer

SPINDLE: One end of the spindle is the measuring
face. The other end is threaded and passes through
a nut. The threaded mechanism allows for the forward
and backward movement of the spindle.

SPINDLE LOCK NUT: The spindle lock nut is
used to lock the spindle at a desired position.

BARREL/SLEEVE: The barrel or sleeve is fix
to the frame. The datum line and graduation are
marked on this.

THIMBLE: On the beveled surface of the thimble
also, graduation is marked. The spindle is
attached to this.

RATCHET STOP: The ratchet stop ensures a
uniform pressure between the measuring
surface.

ANVIL: The anvil is one of the measuring
faces which is fitted on the micrometer frame.
It is made of alloy steel and finished to a
perfectly flat surface.

FRAME: The frame is made of drop forge
steel or malleable cast iron. All other part
of the micrometer are attached to this.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 2

Information Sheet 1.1.1: Micrometer Outside Caliper

WOKING PRINCIPLE:
The micrometer works on the principle of
screw and nut .The longitudinal movement
of the spindle during one rotation is equal to
the pitch of the screw. The movement of the
spindle to the distance of the pitch or its
fractions can be accurately measured on
the barrel and thimble.

Graduation of Metric Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 3

Information Sheet 1.1.1: Micrometer Outside Caliper
Graduation of Inch Micrometer

Graduation of Metric Vernier Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 4

Information Sheet 1.1.1: Micrometer Outside Caliper
Graduation of Inch Vernier Micrometer

Readings of Metric Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 5

Information Sheet 1.1.1: Micrometer Outside Caliper
Readings of Inch Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 6

Information Sheet 1.1.1: Micrometer Outside Caliper
Readings of Metric Vernier Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 7

Information Sheet 1.1.1: Micrometer Outside Caliper
Readings of Inch Vernier Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 8

Information Sheet 1.1.1: Micrometer Outside Caliper

Summary
1. Identify types of micrometer caliper
2. Identify parts of outside micrometer
3. Describe graduations and readings of outside micrometer.

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 . 9

Information Sheet 1.1.1: Other Measuring Tools
Learning outcomes:
1 Turn Workpiece
Learning Activity:
1.1
Inside Micrometer (Caliper Type)

Measuring the Diameter of a hole

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 1

Information Sheet 1.1.1: Other Measuring Tools
Measuring with the Inside Micrometer

Check zero error with a ring gauge

Reading on inside micrometer

The reading is 13.88 mm

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 2

Information Sheet 1.1.1: Other Measuring Tools
Vernier Height Gauge

• It is used on a reference surface (surface table or surface plate).
• It has a vernier scale similar to that of a vernier caliper.
• It can be read up to 0.02 mm.
• The size range from 150 mm to 1000 mm (based on the maximum measuring range)

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 3

Information Sheet 1.1.1: Other Measuring Tools
Applications of Vernier Height Gauge

Measuring height of a block

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 4

Information Sheet 1.1.1: Other Measuring Tools

Scribing lines at desired height

Depth Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 5

Information Sheet 1.1.1: Other Measuring Tools
Applications of depth Micrometer
Measuring depth of Hole

Measuring Height of shoulder

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 6

Information Sheet 1.1.1: Other Measuring Tools
Measuring the depth of a groove

Interchangeable Rod

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 7

Information Sheet 1.1.1: Other Measuring Tools
Zero-setting the Depth Micrometer
0-25mm Depth Micrometer

Code No. Turn Workpiece Date: Developed Date: Revised Page #
MEE722302 8