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Abstract
This project work “reactivation and maintenance of centre lathe machine in mechanical workshop” seeks to identify the likely causes of the equipment breakdown and the extent to which the breakdown has affected the machine, to conduct routine repairs and maintenance on the equipment as to bring the equipment to its working order. Under trouble shooting and inspection, the equipment was observed to have certain fault: there was stiffness of operating the cross slide, stiffness in movement of 3 jaw chuck of the head stock, stiffness in movement of tail stock for centering noisy operation in the head-stock, unacceptable quality of lubricant, stiffness in the reversed gear, general corrosion of metal parts, leakage of current causing electrical shock and faully fuse. Key components requiring replacement and servicing were undertaken and the final work was lubricated and painted, the equipment was now observed to give noiseless operation generate less heat and vibration, easy movement and operation. Also maintenance cost and operating guidelines are prescribed as a basis for further work. It is the opinion of this work that while the equipment can be restored to its working order at affordable cost and effort, there is need for urgent equipment replacement and account of all this activities is the basis of this project report.
TABLE OF CONTENTS
COVER PAGE i
TITLE PAGE ii
DEDICATION iii
ACKNOWLEGEMENT iv
DECLARATION v
CERTIFICATION v
Abstract vii
TABLE OF CONTENTS viii
CHAPTER ONE 1
1.1 INTRODUCTION 1
1.2 STATEMENT OF PROBLEM 2
1.3 AIM/OBECTIVES OF PROJECT 4
1.4 SIGNIFICANCE OF PROJECT 4
1.5 SCOPE/LIMITATIONS OF PROJECT 5
CHAPTER TWO 7
LITERATURE REVIEW 7
2.1 HISTORICAL DEVELOPMENT OF THE LATHE 8
2.2 EVOLUTIONARY TREND IN MAINTENANCE PRACTICES 9
2.3 KNOWLEDGE GAP 11
CHAPTER THREE 13
3.1 MATERIAL SELECTION FOR PARTS 13
3.2 BILL OF ENGINEERING MEASUREMENT AND 14
3.3 ENGINEERING DRAWING 15
CHAPTER FOUR 20
4.1 MAINTENANCE PRACTICES CARRIED OUT ON THE MACHINE 20
4.1.1 ELECTRICAL CORRELATION 20
4.1.2 MECHANICAL CORRELATION 20
4.2 PRESENTATION OF MAINTENANCE RESULT 20
4.2.1 RESULT FOR ELECTRICAL CORRELATION 20
4.2.2 RESULT FOR MECHANICAL CORRELATION 21
4.3 MAINTENANCE PROCEDURE 21
CHAPTER FIVE 24
5.1 CONCLUSION 24
5.2 RECOMMENDATION 24
REFERENCES 25
CHAPTER ONE
1.1 INTRODUCTION
Generally, maintenance is reviewed as all actions taken to retain materials, equipments or plants in a serviceable condition or to restore it to good working condition.
Maintenance involves functional checks, servicing repairing or replacing of necessary devices, equipment, machinery, building infrastructure and supporting utilities in industrial, business, governmental and residential installation.
Overtime, this has come to often include both scheduled and preventive maintenance as cost effective practices to keep equipment ready for operation at the utilization stage of a system lifecycle.
The lathe machine is a conventional machine that rotates the work piece about an axis of rotation and gives shape to metal by filing away excess unwanted parts. Operation carried out on lathe machine include facing, taper turning, parting off, knurling, grooving, drilling, boring, chamfering etc.
However, every equipment deteriorates either due to conditions of storage or ways by incompetence of the operator. If this condition is not checked, the equipment degenerates with a drastic decline in performance and actual equipment output compared to installed capacity until it eventually breakdown. The unexpected equipment breakdown has accompanying consequences; very high cost of repairs, possible industrial accident, increased downtime, manpower loses production disruptions etc.
Centre lathe machine has lived up to many years of operation, serving powerful purpose in students practical, group projects and in some consultancy services. Over the years, defined routine maintenance has not being scheduled and this resulted in the breakdown of this center lathe.
1.2 STATEMENT OF PROBLEM
The lathe machine is a conventional machine that rotates the work piece about an axis and gives shape to metal by filling away excess unwanted parts. Basic operation carried out on lathe machines are facing turning, knurling, grooving, tapping, under cut, parting off drilling, boring, screw cutting. When the lathe machine is set into operation, it causes rotation of the headstock while the tail stock is stationary.
Therefore, work held in the head stock rotates as the machine is switched on-during machining operation, it generates chips which sometimes can be washed away by the use of water based coolant.
After certain periods of usage, incompetence of the operator and conditions of the machine causes the lathe to exhibit characteristics different from intended design. In this condition, work produced on the machine must contain error requiring further grinding. The dimensional accuracy and surface finish of the work begins to fall outside the tolerance limit. In this condition, maintenance practices are required.
Maintenance practices are intended to restore the equipment to good working condition.
The machine has the following inherent problems:
- The headstock of the machine gives noisy operation; this could be caused by absent of lubrication or broken gear teeth in the gear rail.
- Works produced on the machine have unacceptable surface finish and falls outside the tolerance limit.
- There is stiffness of the cross slide giving difficulty in the adjustment of the tool post.
- The general condition of the equipment requires some corrosion control due to rust and further cleaning.
This project therefore, seeks to overcome the above mentioned problems and restore the equipment to its condition of optimal performance. This can be achieved by replacement of worn out parts, lubrication of members in relative motion, painting of corroded parts and re-installation of the machine to allow for balanced loading.
1.3 AIM/OBJECTIVES OF PROJECT
The aim of the project work is to maintain Centre Lathe Machine in the mechanical work shop as to restore it to its condition of optimal performance.
The key objectives are as follows:
To reduce the amount of wastages of components on the machine.
Reduce the power consumption on the machine by reducing surface friction through lubrication.
To ensure a noiseless, vibration free operation of the machine.
To ensure that the equipment is ergonomically safe without adverse effect on its operator.
To increase the productivity of the machine.
1.4 SIGNIFICANCE OF PROJECT
The result or outcome of this project shall be beneficial to its immediate environment and the society in the following ways:
It will reduce the amount of noise it generates to the environment thereby making the environment to be free from noise pollution.
The amount of vibration it generates shall be minimized thereby protecting other machines and structure form the negative effect of machine vibrations.
The machine shall produce components that meets intended standard of tolerance.
Lead time to delivery, customer requirement of products and overall price of the product shall be minimized.
User friendliness or operator friendliness shall be enhanced thus machine productivity is raised.
There shall be increased return on investment.
Maintaining the equipment shall cause the equipment to attain its life span, increase its useful life at minimal operating cost.
1.5 SCOPE/LIMITATIONS OF PROJECT
Scope: “This project work is intended to cover routine and periodic maintenances whose cost falls within available resources as to increase the performance of the machine or productivity of the machine.
Limitation: This project therefore has the following limitations.
This current maintenance activity is limited to corrective and predictive maintenance only.
The current maintenance is limited to the initial earthing problem that has to do with partial current leakage.
The coolant mechanism has been faulty for years. Beyond repair/maintenance thereby excess the scope of our maintenance.
The lightening system has been faulty beyond repair for years thereby exceeds the scope of our maintenance.