Clamping Force Optimization for Four-Jaw Lathe Chuck Operators

Abstract

The manufacturing industry faces critical challenges related to shortages of skilled technicians and declining skill levels, compounded by a lack of instructors and limited training time. Effective skill transfer and the development of new skilled operators are essential. In lathe operations, proper clamping of workpieces is crucial for safety and machining accuracy. However, in the absence of clear standards for clamping force, reliance on instructors’ experience is common. This study addressed this issue by developing a clamping force monitoring device for a four-jaw lathe chuck, incorporating theoretical calculations and experimental verification of the required clamping force. Additionally, it investigated the clamping force applied by instructors and quantified the operator’s clamping force using a safety factor. For rough cutting, the safety factor was 1.7 times the reference instructor’s force, and for finish cutting, it was 2.1 times. The optimal clamping force was determined by adjusting the required force with a safety factor and half the observed variation width, resulting in 15.1 kN for rough cutting and 4.7 kN for finish cutting. The study concluded that the clamping force monitoring device optimizes clamping for safe and accurate machining, establishing a clear standard for beginners.