Manufacturing, Engineering and Technology Manufacturing and Assembly

Turning Operations for Component Production Training

SAQA US 258717 | NQF 3 | Credits 20 | Duration 17 Days
From $2,905 per delegate

Description

This course equips learners with the skills to safely and efficiently produce components using turning operations on a lathe. Learners will gain practical competence in setting up, operating, and maintaining turning equipment to achieve specified tolerances and surface finishes. The course emphasizes adherence to quality standards and occupational health and safety regulations.

Learning Outcomes

  • Apply safety procedures and use personal protective equipment when performing turning operations.
  • Set up and prepare the lathe, workholding devices, and cutting tools for turning operations.
  • Demonstrate the ability to turn components to specified dimensions, tolerances, and surface finishes.
  • Perform in-process inspection and adjust machining parameters to maintain quality.
  • Implement basic maintenance procedures on the lathe and cutting tools.
  • Analyze and troubleshoot common turning defects and process deviations.

Target Audience

This course is designed for machine tool operators, artisans, and technicians in manufacturing environments who need to perform turning operations as part of component production. It is also suitable for apprentices and individuals seeking formal recognition of their machining skills.

Prerequisites

None — open enrollment

Course Outline

Day 1: Introduction to Turning Operations

Objectives:
• Understand the scope and importance of turning operations in manufacturing
• Identify safety requirements and personal protective equipment (PPE)
• Describe the basic components of a centre lathe
• Explain the role of turning in component production

Topics:
• Overview of machining processes
• Safety in the turning workshop
• Introduction to the centre lathe: bed, headstock, tailstock, carriage
• Cutting tool materials and geometry
• Workholding methods: chucks, collets, faceplates
• Basic lathe accessories
• Introduction to cutting parameters: speed, feed, depth of cut
• Workshop rules and housekeeping

Day 2: Lathe Components and Maintenance

Objectives:
• Identify and explain the function of each lathe component
• Perform basic daily maintenance checks
• Demonstrate correct lubrication procedures
• Understand the importance of machine care

Topics:
• Detailed study of the headstock: spindle, gears, speed selection
• Tailstock: quill, taper, alignment
• Carriage: saddle, cross-slide, compound rest, toolpost
• Lead screw and feed rod
• Coolant systems
• Daily maintenance checklist
• Lubrication points and lubricants
• Cleaning and storage of tooling

Day 3: Workholding and Toolholding

Objectives:
• Select appropriate workholding devices for different workpieces
• Mount and align workpieces correctly
• Install cutting tools securely and set tool heights
• Understand the effects of improper workholding

Topics:
• Three-jaw and four-jaw chucks: mounting and centering
• Collet chucks and their applications
• Faceplates and angle plates
• Steady rests and follower rests
• Toolholders: turning, facing, boring, threading
• Insert tooling and tool clamping
• Setting tool tip at centre height
• Workpiece runout and how to minimise it

Day 4: Cutting Parameters and Tool Wear

Objectives:
• Calculate cutting speed, feed rate, and depth of cut
• Understand the relationship between parameters and surface finish
• Identify common tool wear patterns
• Adjust parameters to optimise tool life

Topics:
• Cutting speed calculation: revolutions per minute (RPM)
• Feed rate: mm per revolution
• Depth of cut and material removal rate
• Effect of cutting parameters on chip formation
• Tool wear mechanisms: flank wear, crater wear, notching
• Tool life and Taylor's tool life equation
• Coolants and their effect on cutting
• Adjusting parameters for different materials

Day 5: Facing, Turning, and Chamfering

Objectives:
• Perform facing operations to produce flat surfaces
• Execute straight turning to reduce diameter
• Create chamfers and deburr edges
• Measure workpiece dimensions accurately

Topics:
• Facing: tool setup, feed direction, surface finish
• Straight turning: roughing and finishing passes
• Chamfering: angle calculation and tool movement
• Deburring techniques
• Using micrometers and vernier callipers
• In-process measurement and inspection
• Common errors and troubleshooting
• Safety during manual turning

Day 6: Taper Turning

Objectives:
• Calculate taper angles and dimensions
• Set up compound rest for taper turning
• Use taper attachment if available
• Produce accurate external and internal tapers

Topics:
• Taper definitions: included angle, half-angle, taper per foot
• Methods: compound rest, offset tailstock, taper attachment
• Setting compound rest to angle
• Calculating tailstock offset
• Using a taper attachment
• Cutting external tapers
• Cutting internal tapers
• Inspecting tapers with gauges

Day 7: Knurling and Forming

Objectives:
• Explain the purpose of knurling
• Set up knurling tools correctly
• Perform straight and diamond knurling
• Understand forming tools and their applications

Topics:
• Knurling tools: types and selection
• Knurling tool setup: alignment and pressure
• Straight knurling technique
• Diamond knurling technique
• Common knurling defects
• Form tools: design and use
• Cutting with form tools
• Safety precautions for knurling

Day 8: Drilling and Boring on the Lathe

Objectives:
• Mount drills and boring bars correctly
• Perform centre drilling, drilling, and boring operations
• Achieve accurate hole sizes and concentricity
• Inspect holes using gauges

Topics:
• Centre drilling: purpose and technique
• Drilling: drill chucks, tailstock alignment, speeds
• Boring: boring bar setup, boring head
• Rough boring and finish boring
• Achieving concentricity
• Boring to tolerance
• Using plug gauges and telescoping gauges
• Troubleshooting: bellmouth, taper, chatter

Day 9: Thread Cutting – External

Objectives:
• Calculate thread dimensions and change gear ratios
• Set up lathe for thread cutting
• Cut external V-threads using the half-nut lever
• Inspect threads using thread gauges

Topics:
• Thread terminology: pitch, major/minor diameter, thread angle
• Change gear setup for metric and imperial threads
• Thread chasing dial and half-nut engagement
• Tool grinding for thread cutting
• Setting tool perpendicular to workpiece
• Cutting external threads: roughing and finishing
• Using thread micrometers and thread rings
• Common thread defects and corrections

Day 10: Thread Cutting – Internal

Objectives:
• Set up internal threading tools
• Cut internal threads accurately
• Coordinate internal and external thread fits
• Inspect internal threads

Topics:
• Internal threading tool selection and grinding
• Boring to minor diameter
• Setting tool height and alignment
• Cutting internal threads: technique and feeds
• Using thread plug gauges
• Fit classes: clearance, transition, interference
• Troubleshooting: torn threads, poor fit
• Safety during thread cutting

Day 11: Parting Off and Grooving

Objectives:
• Select appropriate parting-off tools
• Perform parting-off operations safely
• Cut external and internal grooves
• Understand tool geometry for grooving

Topics:
• Parting-off tools: blade types, holders
• Parting-off technique: speed, feed, coolant
• Safety: avoiding tool breakage and workpiece ejection
• Grooving: external and internal
• Groove width and depth control
• Using grooving tools
• Deburring after parting
• Common parting problems and solutions

Day 12: Eccentric and Off-Centre Turning

Objectives:
• Calculate eccentricity and set up workpieces
• Turn eccentric features using four-jaw chuck
• Use faceplates and angle plates for off-centre work
• Inspect eccentric dimensions

Topics:
• Eccentric turning: applications
• Setting up four-jaw chuck for eccentric turning
• Using dial indicator to set eccentricity
• Turning eccentric diameters
• Off-centre turning using faceplate
• Balancing workpieces
• Inspection: measuring eccentric throw
• Safety considerations

Day 13: Advanced Workholding and Fixtures

Objectives:
• Design and use soft jaws for repeatability
• Apply steady rests and follower rests for long workpieces
• Understand fixture principles for complex parts
• Improve productivity through workholding

Topics:
• Soft jaws: machining and application
• Pie jaws and collet blocks
• Steady rest setup for slender shafts
• Follower rest for threading long parts
• Fixture design basics: locating and clamping
• Quick-change tooling systems
• Workholding for fragile parts
• Reducing setup time

Day 14: Machining Difficult Materials

Objectives:
• Identify characteristics of stainless steel, aluminium, and plastics
• Adjust cutting parameters for different materials
• Select appropriate tooling and coolants
• Manage chip control and surface finish

Topics:
• Machining stainless steel: work hardening, tool selection
• Machining aluminium: speed, chip evacuation
• Machining plastics: heat management, tool sharpness
• Machining brass and bronze
• Coolant selection for material groups
• Chip breakers and chip control
• Surface finish optimisation
• Safety when machining exotic materials

Day 15: Quality Control and Inspection

Objectives:
• Use inspection instruments correctly
• Interpret engineering drawings and tolerances
• Apply statistical process control (SPC) basics
• Document inspection results

Topics:
• Engineering drawing symbols: GD&T, surface finish
• Using micrometers, callipers, bore gauges
• Thread gauges and taper gauges
• Surface roughness measurement
• Introduction to SPC: control charts
• Process capability and Cp/Cpk
• Inspection reports and traceability
• Corrective actions for non-conformance

Day 16: Production Planning and Optimisation

Objectives:
• Plan turning operations sequence for efficiency
• Calculate machining time and cost
• Optimise cutting parameters for productivity
• Apply lean principles to turning operations

Topics:
• Operation sequence planning
• Machining time calculation: turning, facing, threading
• Tool life optimisation for cost reduction
• Cutting parameter optimisation using charts
• Lean manufacturing: 5S, setup reduction
• Total productive maintenance (TPM)
• Batch production vs. single part
• Continuous improvement in turning

Day 17: Final Assessment and Integration

Objectives:
• Demonstrate competence in all turning operations
• Complete a complex component from drawing to finished part
• Apply quality inspection and documentation
• Reflect on learning and identify areas for growth

Topics:
• Review of key concepts
• Practical assessment: turning a multi-feature component
• Inspection and quality report
• Troubleshooting during assessment
• Feedback session
• Career pathways in machining
• Course evaluation
• Certification criteria

Practicals

68 hours of practicals To be conducted online or on-campus or in-house
Overview

Hands-on practical sessions are integral to this course, allowing learners to apply theoretical knowledge to real turning operations. Under supervision, learners will set up lathes, select tooling, and produce components to specified tolerances, developing the psychomotor skills required for competent operation.

Practical Activities
  • Basic Turning and Facing — Learners perform facing, straight turning, and chamfering on mild steel workpieces, focusing on setup, measurement, and safety. (12h)
  • Taper Turning and Knurling — Learners cut external tapers using the compound rest and produce knurled surfaces on aluminium and steel. (12h)
  • Drilling, Boring, and Thread Cutting — Learners drill, bore, and cut internal and external threads on a single workpiece, achieving specified tolerances. (16h)
  • Parting, Grooving, and Eccentric Turning — Learners part off workpieces, cut grooves, and produce an eccentric component using a four-jaw chuck. (14h)
  • Final Practical Assessment — Learners produce a complex component from an engineering drawing, incorporating multiple operations, and complete a quality inspection report. (14h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
Online training — attend live sessions from anywhere via our virtual classroom.
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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