Author(s): Lucas M Ferreira, Andreia C Moretti and Jonas K Schneider

Abstract: Dimensional accuracy is a critical quality attribute in machined components, particularly in conventional lathe operations where manual control and machine-condition variability play significant roles. This research investigates dimensional variations observed in cylindrical components produced using conventional engine lathes under controlled workshop conditions. The research focuses on identifying the influence of cutting parameters, tool geometry, machine rigidity, operator skill, and material properties on dimensional deviations. A series of turning operations were performed on mild steel specimens using standardized cutting tools and predefined machining parameters. Measurements of diameter, length, and roundness were recorded using precision metrological instruments after each machining cycle. Statistical analysis was applied to evaluate the consistency of the produced dimensions and to quantify the extent of variation from nominal values. The results indicate that feed rate and depth of cut significantly affect dimensional stability, while spindle speed shows a moderate influence within the selected operating range. Tool wear progression was observed to contribute to gradual dimensional drift, particularly in extended machining runs. Machine tool alignment and vibration were also identified as secondary contributors to dimensional inaccuracies. The findings highlight the importance of systematic process control, periodic tool inspection, and adherence to optimal cutting conditions in reducing dimensional variability. This research provides practical insights for workshop-based manufacturing environments and educational laboratories, where conventional lathes remain widely used. The outcomes support the development of improved machining guidelines aimed at enhancing dimensional consistency without requiring advanced CNC systems. The conclusions drawn from this work can assist manufacturers, instructors, and students in understanding the sources of dimensional variation and in implementing cost-effective measures for quality improvement in conventional turning operations.

DOI: 10.22271/27078043.2026.v7.i1a.108

Pages: 20-25 | Views: 45 | Downloads: 18

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