It is said that a machine can perform the work of a hundred men. This is true with the lathe machine that is regarded as the mother of all machines. It is versatile and very useful in manufacturing, production and maintenance workshops.

Bearings on the other hand are widely used in automobile, motors, pneumatic and hydraulic machines, engines, wheel hubs, gear boxes, industrial transmission lines, aircraft and ship. They are virtually applied in nearly all equipments that have rotating parts and therefore represent a large local and international market.

The main types of bearings are ball, roller and the journal bearings. All these require the lathe machines during their manufacture.

Manufacture ball bearing

These have an outer and inner race, the ball and cage to mount and hold the balls. Specially designed lathes are used to turn cylindrical work pieces in large quantities to form the inner and outer race. The turning operation ensures that the inner and outer rings of bearing have very accurate and precise diameters that meet the tolerance limits.

The device is also used to lap or smooth the inner and outer race to minimize friction. The lapping operation gives the bearing a very smooth surface where shaft and balls can roll on. The outside faces are also cut to the required flatness.

It is also used to face and lap the inner surfaces where the ball rolls. The type used depends on the size of the bearing with heavy duty all geared type being suitable for large diameter sizes.

For very precise applications such as those in aviation, medical equipments and sensitive instruments; the CNC type achieves the required precision and dimensional accuracy.

Application in manufacture of roller type

These have rollers instead of balls. They are used in heavy loading applications such as gears, transmission shafts and areas with high axial thrust. Again turning and facing operations are performed using this machine tools. The precision, size, accuracy and tolerances determine the type of equipment to use with CNC be favored for high precision work.

Use of lathe to manufacture journal bearing

They are applied in all internal combustion engines and forms the rotating parts of crank shaft. They are also used in large turbines, motors and heavy machinery where roller and ball types cannot be used. Essentially, this device is made of two rotating parts that slide along each other.

Specially designed turret and capstan lathes are used in mass manufacture of these journals. These reduce the diameter (turning) to suitable inner and outer diameter. This is followed by parting-off or cutting the concentric cylinder to accurate length.

For journal to function effectively, they must be smoothened. This is achieved using lapping operation. The cylindrical work piece is rotated against smooth abrasive material to remove a very small layer of materials and achieve high quality and extra smooth surface.

The rate of advancement in the beverage industry is just phenomenal especially when we consider technological advancements. Globally, this is due to increasing population and the need to achieve efficiency in manufacturing. Certain equipments have become vital in this industry such as high-speed picking and packing machines, palletizing equipment, automatic inspection systems, filling equipments, capping machines, conveyors, shrink sleeving machines and movers.

Advantages of Packing Equipments

The machines help the manufacturer to lower operating costs, reduce dependence on human labor, economical utilization of material, maintenance of high and consistent quality, higher efficiency and productivity, flexibility in manufacturing and better implementation of health and safety procedures.

Importance of workshops in Manufacturing

A processing factory or plant with such machines is bound to experience down times due to servicing, breakages and machinery failures. A workshop is therefore crucial in such a setting to avoid extreme down times when unexpected failure occurs. One of the most important equipment that such as workshop must have is a lathe. This is because the equipment can handle numerous activities related to the installed equipments. These activities include;

Motor shafts machining

Damaged shafts are very common in motors and pumping equipments used in industry. Bearings attached to shafts are made of harder material than the shafts therefore, during continued use; the shaft may wear off leading to wobbling motion, which could be disastrous. The sunken areas are filled up with material and the machine is used to reduce the shaft back to the required dimensions.

Repairs for punching machine die forms

The punching mechanism is commonly used in erection of packaging boxes, and some containers. Regular wear and tear is therefore common on the punching die and hence constant recalibration may be required. In this case, accuracy is of utmost importance and this is possible with the lathe in the workshop.

Conveyor Belt Roller knurling Process

This is the process of creating tiny grooves on conveyor rollers to maximize friction and enhance the grip between the roller and the conveyor. The knurling tool is held firmly against the roller shaft on the lathe and it imprints the grooves. With the gradual usage, the grooves wear off and repair is required.

Liquid filling Machinery components servicing

Various filling equipments are used in bottling. They include overflow filling, gravity systems, pump filling, piston type systems and many others. Maintenance of this equipment requires very high accuracy in machining, surface smoothening, and repairs. This is achieved using sensitive machine tools, which can work to very small measurements and ensure accuracy.

Bottle Washing Machinery and Maintenance

These are critical equipments in the beverage industry. This is because some plants use reusable bottles, which are always re circulated. Cleaning machines are automated and may process in stages such as pre washing, detergent cleaning stage, sanitizing and final rinse. The washers are exposed to dirt and suspended particles, which can damage the pipes and ducts and therefore regular servicing is done using the lathe for greater productivity.

The important of fully equipped maintenance workshops in industry cannot be underestimated. Soft drinks making machine are exposed to certain cyclic problems such as wearing off shafts and rollers and conducting ducts. The lathe machine is useful equipment in repairs of these faults and efficiency and productivity is maintained.

The importance of machine tools can never be underestimated industry and one of the most critical of these tools is the lathe machine. The equipment is basically used in shaping metallic pieces such as tubes, engine shafts, bolts and nuts. The effectiveness of using this machine is based on the ability to hold the work piece firmly by a vice clamping mechanism and calibrate the machining to very precise measurements.

Another major and recent innovation of the lathe is that new designs have been developed that have incorporated computer numeric controls. This allows a particular design to be prepared by the engineering software and fed to the machine for execution.

There has also been an improved level of safety in using this equipment, with the latest models operated remotely, the work piece being enclosed in a chamber.

Challenges in Oil Drilling and Production Machinery

Oil drilling and exploration is usually a complex process involving so many operations happening at the same time. This process involves using a lot of chemicals and solvents which in turn lead to very fast degradation of machines and equipments. Specialized equipments have to be on standby especially machine tools such as the lathes for quick replacements of these special parts. It is also worthy to note that most oil drilling operations are far away from industrial areas and may take long while, if there are no stand by equipments.

Special Machining Features of Oilfield Pipes

The rethreading process is one of the major challenges in oil field machining. The frequent breakdown of piping systems in oil fields has caused machine tools manufactures to work strategically to deal with this problem. Oilfield lathes have also been developed which are able to handle very large diameter pipes as those in the drilling and conveyance sections. Special features such as automatic coupling cells have been incorporated for ease of handling pipe sections during machining.

Some Of The Critical Innovation Areas Requiring Constant Maintenance Include;

• Oil couplings for enhancing efficiencies through process automation
• Down hole instrumentation systems for handling tough material
• Pumps used for the hydraulic fracturing process.
• Various components of the pump jacks such as sucker rods, and stanchions.

Special Features of Oil Field Lathes

There are very unique threading requirements in the oil exploration industry and innovations have been made to support this process. These include;

• Thread phase harmonizing. This has been done through the automatic operation of CNC lathes. Once a work piece is placed in the machine, it can automatically locate the threads and start the threading process. This allows faster machining and maintenance of the important tolerances. Accuracy and consistent quality is also maintained.
• The “variable spindle speed threading” This is an application for machining pieces with thin walled gauge, without previous threads on the work piece. This component actively controls the feed axis due to the changing speeds of the spindle. This forward feeding technology realizes very high accuracy on threading.

Conclusion

The importance of the lathe machine can never be underestimated in the oil field operations. This is due to the constant need for repairs and maintenance of piping and conveyance systems. Special machines have been constructed specifically for these processes which have increased efficiency and production.

Pitfalls in Lathe Operation

Lathe is versatile equipment that works worthwhile for several operations starting from cutting, to turning and deforming. Professional performance brings specific results in productivity because there are ample possibilities of faults to happen while staging a cutting action. The errors vary in mechanism in accordance with the type of materials such as metal or wood. Below are some of the

Rotating Speed Adjustment 

It is mandatory condition to be checked for before feeding exertion material. Though it may appear a common criterion, it is highly advised to ensure material thickness, tool and speed compatibility to achieve accuracy.

Material Feed Rate

Heavy setting starts to slow down the process and diminish the quality of machining. During such conditions, the headstock gets disengaged before it meets the stop point. Professionals or skilled operators will be able to find out this error. For those who start with heavy settings, it would be better to apply small amount of hand feed and then try out with reversing the carriage and begin the next step. Checking the dial through the help of lock screw is another way to achieve precise metal working

Cutting Depth-Preventing Short Bytes

The depth of engraving goes in tune with toll selecting, pace, metal texture etc. For bigger depth requirement setting with small value of cutting and enhancing later gives better results. Therefore prefer machining with moderate velocity, lower depth and gradual increase of job portion supply.

Improper Tool Arrangement

Fixing the engraving device in an improper position with imbalanced height balance causes damage to dimension of slashing. The recommended pose is fitting at the centre of chuck as this will ensure accuracy of cuts and keep the work stuff free from damages. However, fixing can be done by running the lathe gradually so that the chuck is not fast on rotation.

Sensing Blunders through Noise

With the inception of superior ranges of lathe models like vibration free, high speed, etc the point of finding mistakes is possible if only the equipment is managed by inexperienced operator or wrong substance feed position. However, there is a smart hint for the inexperienced to tactically grasp wounding mishaps is from high sound created during processing. If there is too much rotation speed or vibration the sound differs and this could help the operator to guess processing drawbacks.

Things to confirm before Turning 

Turning is of different varieties such as facing off, tapering, facing to the length, boring, etc. The mechanism also differs wherein, the work object rotates and the instrument is fed against. Inaccuracies are identified through ensuring discoloring or ragging of job piece. Unmatched texture or surface forming on substance also indicated inappropriate operation. Such happening is likely when tempo or ingredient supply is incorrect.

Conclusion

Any workshop apparatus is designed only by means of reaching perfection and accuracy. However, errors may appear in most cases due to inexperienced trials. For successful results avoiding mistakes from operational aspects can help productivity in multiple ways.

Vehicle Manufacturing – the Major Sector that depends on Machining

Automobile companies are the major metal product users for producing different parts. Steel and aluminium are two major components. Apart from this, fibre and plastics are also considered for making varieties of transport. Major luxury motor making companies are making cars aluminium for body that gives a classic look for the transport product. Manufacturers use this ingredient because it is strong and is affordable in the market and moreover, product can be engineered in different shapes and need of crash safety. Approx 65% of vehicle parts are made up of metal products. Steel is a kind of element which has flexibility and qualities that leads to its usage in affordable way. There are machines that are used by manufacturing companies to create the required design for manufacturing.

Machines to Design Metal

Industries use various machines for forming different components required for manufacturing, one such is lathe device. Automobile industry are using this tools to get the desired shape and cut of components. Different types of lathes are used for shaping plus cutting the raw material such as, engine, turret, and special purpose lathes. Today, bigger range of workshop tools is used by makers.

Machining Equipments used in Production

There are many modern machining types of equipment for shaping and cutting materials which are eventually applied in automobile production. Some of them are:

• Lathes
• Drill
• Mill
• Hobbing apparatus
• Honing device
• Gear shapers

The user uses these devices as per the requirement and how these modern styles of tools can be used.

Varieties in Machined products Applied

• Steel: Most part of the auto product including steering and suspension are made from this. Moreover, stainless steel is also used for auto built-up because of non-rusting property.
• Aluminium: There is a big transition happening from the above material to this one in vehicle production. Though this raw ingredient cost double than the one made from the top component, but it brings a major change in the design. The reason behind this change is its light weight. Parts that are completed by using aluminium are engine and wheels.
• Iron: This is next big material used in creation after the top preferred ones. Moreover, the weight of iron makes the usage more sufficient.
• Titanium: This is strong, light weight and corrosion resistant. It is quite hard to manufacture, but is generally considered for intake and exhaust valves.

Making of Luxury Cars

Car manufacturers are now using advanced high-strength steels to make strong body. Luxury car makers are also using aluminium which is less dense material and saves 11% on making the body. For this base material, the market is very competitive for car manufacturing. Presently, advanced high potency form is largely used materials in automotive business. Metal industry has evolved greatly, and so the makers are using different forms of such products to manufacture high class design travelling product structure with the help of machining tool and lathe is one among the important requirements which is preferred for majority of creation requisites by makers.

Conclusion:

There is no doubt that metal is an important component in designing the means of transport structure. Automobile engineering is evolving dramatically and so are the machining trade introducing versatile tools for long run and getting desired shapes of the same.