Cylindrical Turning and Face Turning - Course: Techniques for Machining of Material. Instruction Examples for Practical Vocational Training: Instruction example 2.2.: Flange

Cylindrical Turning and Face Turning - Course: Techniques for Machining of Material. Instruction Examples for Practical Vocational Training

		(introduction...)
		Preface
		Instruction example 2.1.: Pressure disk
		Instruction example 2.2.: Flange
		Instruction example 2.3.: Bearing shaft
		Instruction example 2.4.: Connection piece

Instruction example 2.2.: Flange

This example serves to practise turning of shouldered cylindrical parts.

Figure

Material

GGL - 25 (GG = cast iron, L = flakes, GGL = grey cast iron, 25 = 250 MPa)

Dimensions

(blank)
dia. 85 × 70

Cutting and operating tools

Right-bent roughing tool, right-offset side-cutting tool, internal side-cutting tool, key

Measuring and testing tools

Vernier caliper, depth gauge, outside micrometer

Auxiliaries

Supporting plates, stepped chuck jaws which can be turned out, length blocks 20 and 25 mm

Required previous knowledge

Reading of drawings, types and application of clamping tools, measuring and testing

Explanations to the working drawing

ø 36^0.1 dimension with tolerance,	upper deviation 36.00
	lower deviation 35.90

Sequence of operations	Remarks
1. Measuring of blank
2. Clamping of workpiece	Type of clamping: "chucking" in stepped chuck jaws which can be turned out.
3. Clamping of tool	Central position to axis of rotation is essential.
4. Setting of cutting values
5. Turning of dia. 64	Set bed stop. Turning tool to take first cut on ø 64. Re-turn to initial position, set depth of cut, finish turning (at least 25 mm length). Grey cast iron is short-chip material - use safety goggles!
6. Facing	Turning tool to take first cut on end face. Lock tool slide in longitudinal direction. Set depth of cut and do facing. Ensure clean facing, final size will be reached when facing second face.
7. Deburring	Chamfer ø 64.
8. Re-chucking	Re-chuck part by 180° around its longitudinal axis. Locate on ø 80. Pay attention to any radial or axial run-out. If necessary, turn out the chuck jaws. Use a dial gauge. Ensure fixed location face (cross).
9. Facing - length 65 mm	Set bed stop. Take first cut on end face. Lock tool slide. Set depth of cut and do facing until final size is reached.
10. Clamping of tool	Setting angle 90°.
11. Turning ø 36^-0.1	Set bed stop. Apply 25 and 20 mm length blocks. Take first cut on end face. Remove length blocks. Take first cut on surface. Set depth of cut and finish turning ø 36^-0.1. Ensure clean cutting of shoulder face.
12. Turning ø 20	Apply 25 mm length block. Take first cut on surface. Set depth of cut. Ensure clean cutting of shoulder face.
13. Deburring	Break edges.
14. Final inspection	Dimensional and visual inspection.

For batches of workpieces and individual clamping of turning tools repeat sequence of operations until operation 06 and then continue with operation 13 at the end of the batch.

Figure