Practical Turning Exercises

1. The raw material can be obtained by sectioning a rod using a mechanical saw. The
type of material chosen for this work can be Ck 45 and its raw dimensions should be
 40x51 mm. This material is a common application construction steel and can be
used for the manufacture of various machine organs. Fix the piece on the bushing,
taking care to leave out about 35 mm.

DIN C (Carbon) Si (Silicon) Mn (Manganese)

Ck 45 0.45% ≤0.4% 0.65%

2. Place the grinding iron in the tool holder according to the figure below. Be careful to
measure relative to the axis of the rotary point so that the tip of the tool is aligned
with that same axis.

3. Fret 0.2 mm per pass through the top of the piece until you get a smooth face. The
tool should go slightly beyond the center of the workpiece to compensate for the tool's
tip radius. All operations with Ck 45 steel must be refrigerated.
4. Perform a cylindrical turning in 32 mm length to a diameter of 34.7 mm. Although
the intended end diameter is 35 mm, we will turn para um diâmetro de 34.7 mm
since the execution of the final knurling will cause an increase in the diameter of the
piece which will approach the final diameter of 35 mm (this diameter value depends
on the knurling pitch, so the diameter to be turned should be equal to the desired final
diameter – 1/2 of the knurling spline pitch).

5. Perform a cylindrical turn in 3 mm length to a diameter of 27 mm at the top of the

spindle.

6. Perform a cylindrical turn in 3 mm length to a diameter of 26 mm at the top of the

shaft, for finishing the previous roughing.

7. Mount a quadrangular insert tool at 45 degrees to break up the edges.

8. Chamfer from 0.5 mm to 45° on the edges at the top of the workpiece.

9. Insert the point drill bit into the keyless chuck and replace the rotary point with the
bushing. Perform a dot.

10. Mount a 9.75 mm diameter drill bit to the tailstock keyless chuck.

11. Drill a through-hole in the workpiece with an HSS drill, it should use a rotational speed
of 1000 r.p.m. The reference value of the rotational speed can be obtained by
selecting the recommended cutting speed, in this case by exemplo de 25 m/min e
na tabela retira-se o valor da velocidade de rotação. Não esquecer de refrigerar.
Drilling — The drilling operation consists of making a cylindrical hole by displacing
a drill mounted on a head and with the material in rotation. These holes serve as
preparation of the material for subsequent reaming operations, drilling with common
drills, turning and internal threading.

Cutting speeds in m/min

Drill
diameter
6 8 10 12 15 20 25 40

1 1910 2546 3183 3820 4775 6366 7958 12732

1.25 1528 2037 2546 3056 3820 5093 6366 10186
1.5 1273 1698 2122 2546 3183 4244 5305 8488
2 955 1273 1592 1910 2387 3183 3979 6366
2.25 849 1132 1415 1698 2122 2829 3537 5659
2.5 764 1019 1273 1528 1910 2546 3183 5093
3 637 849 1061 1273 1592 2122 2653 4244
3.5 546 728 909 1091 1364 1819 2274 3638
4 477 637 796 955 1194 1592 1989 3183
4.5 424 566 707 849 1061 1415 1768 2829
5 382 509 637 764 955 1273 1592 2546
5.5 347 463 579 694 868 1157 1447 2315
6 318 424 531 637 796 1061 1326 2122
6.5 294 392 490 588 735 979 1224 1959
7 273 364 455 546 682 909 1137 1819
7.5 255 340 424 509 637 849 1061 1698
8.5 225 300 374 449 562 749 936 1498
9.5 201 268 335 402 503 670 838 1340
10 191 255 318 382 477 637 796 1273
11 174 231 289 347 434 579 723 1157
12 159 212 265 318 398 531 663 1061
13 147 196 245 294 367 490 612 979
14 136 182 227 273 341 455 568 909
15 127 170 212 255 318 424 531 849
16 119 159 199 239 298 398 497 796
17 112 150 187 225 281 374 468 749
18 106 141 177 212 265 354 442 707
19 101 134 168 201 251 335 419 670
20 95 127 159 191 239 318 398 637
12. Mount a countersink to the keyless chuck.

13. Perform a countersink of the hole by 1 mm at 45°.

14. Mount a 10 mm diameter chuck on the keyless chuck.

Boring — It is the operation that allows a surface of revolution to be obtained
with the help of a tool called a mandrel and that aims to obtain a cylindrical surface
of a high dimensional accuracy. Boring can be cylindrical, radial, conical or special
surfaced.
15. Bore the previous hole to a diameter of 10 H7 using the corresponding chuck. The
rotation speed of the chuck should be 1/4 of the rotation of the drill bit. Use cutting
oil to facilitate the pulling of the chip.

16. Assemble a knurling tool.

Knurling — Knurling is an operation that consists of defining grooves on the surface
of parts intended to be handled manually. These grooves are obtained by crushing the
material of the workpiece through the pressure exerted by the tool. The objective of
the operation is to make these surfaces rougher to increase their adhesion and
facilitate their handling.

17. Cross knurling the outer surface of the diameter of 34.7 mm over a length of 30 mm.
The rotating point must accompany the operation. This operation must be lubricated.
Due to the pressure exerted by the tool, the diameter of the workpiece will expand
and will be approximately 35 mm in the end.
18. Assemble a bleed tool.
Bleeding (Cutting) — The operation is usually called "bleeding" and consists of
separating the machined part of the workpiece from the rest of the blank material
squeezed in the bushing. Here the sharpening of the tool and the operating mode
define the success of the operation. In operation, take care to promote a lateral
movement back and forth so that the tool has only two faces, front and right or front
and left.
19. Bleed the piece by previously untouching the rotating point. The bleed tool should be
perfectly centered. In this case, the cut is facilitated by the existence of the hole. In
more critical situations, cut in a double channel. In this case, the tool advances
perpendicular to the axis of the workpiece, incrementally and alternately in two parallel
channels.
1. The raw material can be obtained by sectioning a rod using a mechanical saw. The
type of material chosen for this work can be Ck 45 and its raw dimensions must be 
50x75 mm. This material is a common application construction steel and can be used
for the manufacture of various machine organs. Fix the piece on the anchor taking
care to leave out about 57 mm.

DIN C (Carbon) Si (Silicon) Mn (Manganese)

Ck 45 0.45% ≤0.4% 0.65%

2. Place the grinding iron in the tool holder according to the figure below. Be careful to
measure relative to the axis of the rotary point so that the tip of the tool is aligned
with that same axis.
3. Fret the top of the piece until it is completely smooth. The tool should go slightly
beyond the center of the workpiece to compensate for the tool's tip radius. All
operations with Ck 45 steel must be refrigerated.

4. Perform roughing and finishing to a diameter of 48 mm over a length of 55 mm.

5. Insert a point drill bit into the keyless chuck and replace the rotary point with the chuck
in the tailstock. Execute the stitch (Refer to the stitch aperture tables to check the
depth of the stitch to be made).

6. Mount a 20 mm diameter HSS drill bit on the keyless chuck.

7. Drill a through hole in the part. Do not forget to refrigerate during operation.
8. Mount an interior chisel on the tool holder.

9. Open a case with a diameter of 22 mm to a length of 14.8 mm. Put the chisel to the
diameter of 20 mm and increment the diameter by 2 mm , then move the tool to
a depth of 14.8 mm. The body of the tool must be completely free on the side opposite
the cut to prevent chips from settling there and creating undesirable friction.
Interior roughing or boring — This operation consists of executing an internal
cylindrical surface, whether through or not, by the action of a tool moved parallel to
the axis of the lathe. With this operation we can obtain cylindrical boxes with diameters
with great precision.
10. Repeat the previous process, but now for a diameter of 24 mm in a length of 14.8
mm.

11. Finish the inner case to a diameter of 25 mm at a depth of 15 mm.

12. Mount a bleed tool in the tool holder.

13. Bleed the piece to a length of 50 mm.