Machining Processes Used to

Produce Round Shapes: Turning and

Hole Making
The Turning process
Lathes and lathe operations
Boring
Drilling
Reaming
Produce Round Shapes

Fig 23.1 Miscellaneous cutting operations that can be performed on a lathe. Note that
all parts are axisymmetric.
Produce Round Shapes

(h) Boring and

(g) Cutting with a form tool internal grooving
Fig 23.1 Miscellaneous cutting operations that can be performed on a lathe. Note that
all parts are axisymmetric.
Produce Round Shapes

(i) Drilling
(j) Cutting off

(k) Threading
(l) Knurling
Fig 23.1 Miscellaneous cutting operations that can be performed on a lathe. Note that
all parts are axisymmetric.
 Produce Round Shapes - Turning

(a)

(b)

Fig 23.3 (a) Photograph of a turning operation, showing insert and discontinuous chips. The
cutting tool is traveling from right to left in this photograph. (b) Schematic illustration of the
basic turning operation, showing depth of cut, d; feed, f; and spindle rotational speed, N, in
rev/min. The cutting speed is the surface speed of the workpiece at the tool tip.
Produce Round Shapes - Turning

Fig 21.2 Schematic illustration of the turning operation, showing various features.
 Produce Round Shapes - Turning
(a)

(b)

Fig 21.10 (a) Schematic illustration of a right-hand cutting tool. The various angles on these
tools and their effects on machining are described in Section 23.2. Although these tools
traditionally have been produced from solid-tool steel bars, they have been replaced largely
with. (b) inserts, typically made of carbides and other materials; they are available in a wide
variety of shapes and sizes.
 Produce Round Top view
Shapes - Turning
Fig 23.4 Designations for a right-
hand tool. Right-hand means that
the tool travels from right to left, as
shown in Fig. 23.3b.
re
u

Side view

End
view
 Produce Round Shapes - Turning
Rake angle control (i) direction of chip flow; (ii) strength of the tool
tip. Positive rake angles (i) reduce cutting forces and temperatures;
(ii) can lead to premature tool chipping and failure (ie small
included angle of the tool tip).
Cutting-edge angle affects chip formation, tool strength, and
cutting forces to various degrees.
Relief angle controls interference and rubbing at the tool-workpiece
interface. Too large , The tool tip may chip off (if too large); flank
wear may be excessive (if too small).
Nose radius affects surface finish and tool-tip strength. Too small:
poor surface roughness, weak tool; too large: tool chatter.
 Produce Round Shapes - Turning

Table 23.2 General Recommendations for Tool Angles in Turning.

Produce Round Shapes - Turning

Table 23.3 Summary of Turning

Parameters and Formulas.
Note: The units given are those
that are commonly used;
however, appropriate units must
be used and checked in the
formulas.
 Produce Round Shapes - Turning

Fig 23.5 Forces acting on a cutting tool in

turning. Fc is the cutting force, Ft is the
thrust or feed force (in the direction of
feed), and Fr is the radial force that tends
to deflect the tool away from the Fig 23.6 The range of applicable cutting speeds
workpiece being machined. and feeds for a variety of tool materials.
 Produce Round Shapes - Turning
Example Material-removal rate and cutting fore in turning
Given: A 150-mm-long, 10-mm-diameter, 304 stainless-steel rod is
being reduced in diameter to 8 mm by turning on a lathe. The spindle
N = 400 rpm, and the tool is traveling at an axial speed of 200
mm/min.
Calculate: the cutting speed, material-removal rate, cutting time,
power dissipated, and cutting force.
Soln:
Max cutting speed 𝑉𝑉 = 𝜋𝜋𝐷𝐷o 𝑁𝑁 = 𝜋𝜋 0.01 400 = 12.57 m/min
At machined surface 𝑉𝑉 = 𝜋𝜋 0.008 400 = 10.05 m/min
Depth of cut 𝑑𝑑 = 10 − 8 ⁄2 = 1 mm
Feed 𝑓𝑓 = 200⁄400 = 0.5 mm/rev
MMR = 𝜋𝜋 9 1 0.5 400 = 5655 mm3 /min
Actual time to cut 𝑡𝑡 = 150⁄ 0.5 400 = 0.75 min
 Produce Round Shapes - Turning
Soln:
Using Table 21.2 and taking ave for stainless steel as 4 W � s/mm3
Power = 4.1 5655 ⁄60 = 386 W
Power (W) m rev min 2𝜋𝜋 rad
Torque (Nm) = ; = � �
rotational speed m/s s min 60 s rev
386
= = 9.2 Nm
400 2𝜋𝜋⁄60
Torque 9.2
Cutting force = = = 2.0 kN
ave radius 0.009⁄2
Produce Round Shapes - Lathe

Fig 23.2 General view of a typical lathe, showing various components. Source: Courtesy
of South Bend Lathe Co.
Produce Round Shapes - Lathe

Carriage

Tailstock
 Produce Round Shapes - Lathe
workholding
(a) (b)

Chucks with (a) 3 jaws; and (b) 4 jaws.

 Produce Round Shapes - Lathe
workholding
(a)

(b)

Fig 23.8 (a) Schematic illustrations of a draw-in type of collet. The workpiece is placed in
the collet hole, and the conical surfaces of the collet are forced inward by pulling it with a
draw bar into the sleeve. (b) Schematic illustrations of a draw-in type of collet. The
workpiece is placed in the collet hole, and the conical surfaces of the collet are forced
inward by pulling it with a draw bar into the sleeve.
 Produce Round Shapes - Lathe
workholding
(c)

Face plate
(mounted on spindle)

(d)

Fig 23.8 (c) A push-out type of collet. (d) Workholding of a workpiece on a face plate.
 Produce Round Shapes - Lathe

workholding

Fig 23.9 Various types of mandrels to hold workpieces for turning; they are usually mounted
between centers on a lathe. Note that in (a) both the cylindrical and the end faces of the
workpiece can be machined, whereas in (b) and (c) only the cylindrical surfaces can be machined.
Produce Round Shapes - Lathe
type

Fig 23.10 Schematic illustration of the components of a turret lathe; note the two turrets:
square and hexagonal (main).
 Produce Round Shapes - Lathe
type
Tool for
turning or
boring

(a)
Individual
Reamer motors (b)
Fig 23.11 (a) A computer-numerical-control lathe with two turrets. (b) A typical turret
equipped with 10 tools, some of which are powered.
 Produce Round Shapes - Lathe
(a) (b)

(c)

Fig 23.12 Typical parts made on CNC lathes, (a)

housing base; (b) inner bearing race; (c) tube reducer.
 Produce Round Shapes - Lathe
(a) (b)

(c) (d)

Fig 23.13 Examples of complex shapes that can be produced on a CNC lathe.
Source: based on technical literature supplied by Okuma Corp.
 Produce
Round Shapes
- Lathe

Fig 23.14 The range of

surface roughnesses
obtained in various
processes; note the wide
range within each group,
especially in turning and
boring.
 Produce
Round Shapes
- Lathe

Fig 23.15 Range of dimensional

tolerances in various machining
processes as a function of
workpiece size. Note that there
is one order of magnitude
difference between small and
large workpieces.
 Produce Round Shapes – Lathe
Thread cutting

Fig 23.16 (a) Cutting screw threads on a lathe with a single-point cutting tool. (b) Cutting
screw threads with a single-point tool in several passes, normally utilized for large threads.
The small arrows in the figures show the direction of feed, and the broken lines show the
position of the cutting tool as time progresses. In radial cutting, the tool is fed directly into
the workpiece. In flank cutting, the tool is fed into the piece along the right face of the
thread. In incremental cutting, the tool is fed first directly into the piece at the center of
the thread, then at its sides, and finally into the root.
 Produce Round Shapes - Lathe
Thread cutting

Fig 23.16 (c) A typical coated-carbide insert in the process of cutting screw threads on a
round shaft. (d) Cutting internal screw threads with a carbide insert. Source: (c) Courtesy of
Iscar Metals, Inc.
 Produce Round Shapes - Boring

Fig 23.18 (a) Schematic illustration of a steel boring bar with a carbide insert; note the
passageway in the bar for cutting fluid application. (b) Schematic illustration of a boring bar with
tungsten-alloy inertia disks, sealed within the bar to counteract vibration and chatter while
boring. This system has been found to be effective for boring-bar length-to-diameter ratios of up
to 6.
 Produce Round Shapes - Boring

Fig 23.19 Schematic illustration of a vertical boring

mill. Such a machine can accommodate workpiece
sizes as large as 2.5 m (98 in.) in diameter.
 Produce Round Shapes - Drilling
Fig 23.20 Two common types of drills: (a)
Chisel-edge drill. The function of the pair of
margins is to provide a bearing surface for
the drill against walls of the hole as it
penetrates the workpiece. Drills with four
margins (double-margin) are available for
improved guidance and accuracy. Drills can
have chip-breaker features.

(a)

Lip
 Produce Round Shapes - Drilling
(a) cont

Fig 23.20 Two common types of drills: (b) Crankshaft drill. These drills have good centering
ability, and because the chips tend to break up easily, crankshaft drills are suitable for
producing deep holes.
Produce Round Shapes - Drilling

Fig 23.21 Various types of drills and drilling and reaming operations.
 Produce Round Shapes - Drilling
(a)

(b)
(d)

(c)

Fig 23.22 Various types of drills. (a) Spade drill; (b) straight-flute drill; (c) drill with
indexable carbide inserts; (d) drill with brazed-carbide tip.
Produce Round Shapes - Drilling

Fig 23.24 (a) Trepanning tool. (b) Trepanning with a drill-mounted single cutter.
 Produce Round Shapes - Drilling
Given: A hole is being drilled in a block of magnesium alloy with a
10-mm drill bit at a feed of 0.2 mm/rev and with the spindle
running at N=800 rpm.
Find: Calculate the material-removal rate (MRR) and the torque on
the drill.
Soln: 𝜋𝜋𝐷𝐷 2
cross-sectional area of hole
𝜋𝜋𝐷𝐷 2 4
MRR = 𝑓𝑓𝑓𝑓 f feed (penetration/rev)
4
𝜋𝜋 102 N rotational speed (rev/min)
= 0.2 800
4
= 12,570 mm3 ⁄min or 210 mm3 ⁄s
Using Table 21.2, an ave unit power of 0.5 W � s/mm3 is used.
Power = unit power × MMR = 210 × 0.5 = 105 W
Rotational speed= 800 rev⁄min 2𝜋𝜋 rad⁄rev min⁄60sec =
83.8 rad⁄s
Torque = Power⁄rotational speed = 105⁄83.5 = 1.25 Nm
 Produce Round Shapes - Drilling
(a) (b)

Fig 23.25 (a) Schematic illustration of the components of a vertical drill press.
(b) A radial drilling machine.
 Produce Round Shapes - Reaming

(a)

(b)

Fig 23.27 (a) Terminology for a helical reamer. (b) Inserted-blade adjustable reamer.