Lath

e
By S K
Mondal
 Lathe
A lathe is a large machine that rotates the work,
and cutting is done with a non-rotating cutting tool.
The shapes cut are generally round, or helical. The
tool is typically moved parallel to the axis of
rotation during cutting.
head stock - this end of the lathe contains the
driving motor and gears. Power to rotate the part is
delivered from here. This typically has levers that
let the speeds and feeds be set.
ways - these are hardened rails that the carriage
rides on.
tail stock - this can be used to hold the other end
of the part.
 Lathe
Bed - this is a bottom pan on the lathe that catches
chips, cutting fluids, etc.
carriage - this part of the lathe carries the cutting tool
and moves based on the rotation of the lead screw or
rod.
Lead screw - A large screw with a few threads per inch
used for cutting threads. It has ACME threads with
included angle of 29o for easy engagement and
disengagement of half nut.
Lead rod - a rod with a shaft down the side used for
driving normal cutting feeds.
The critical parameters on the lathe are speed of rotation
(speed in RPM) and how far the tool moves across the
work for each rotation (feed in IPR)
General classifications used when describing
lathes
Swing - the largest diameter of work that can
be rotated.
Distance Between Centres - the longest
length of workpiece
Length of Bed - Related to the Distance
Between Centres
Power - The range of speeds and feeds, and
the horsepower available
 Number of Spindle Speed
Number of spindle speed is in a geometric
progression.
If n number of spindle speed is required with N1
is the minimum
N , N r , speed
N r 2 , N then
r 3 ,.............N r n 1
1 1 1 1 1
n 1
N1 N min and N1r N max
1
N max n 1
Therefore, Step Ratio r
N min
The values of step ratios are 1.06, 1.12, 1.26,
1.41, 1.58 and 2
 IES - 2001
The spindle speed range in a general
purpose lathe is divided into steps which
approximately follow
(a) Arithmetic progression
(b) Geometric progression
(c) Harmonic progression
(d) Logarithmic progression
 IES - 1992
Feed gear box for a screw cutting lathe is
designed on the basis of
(a) Geometric progression
(b) Arithmetic progression
(c) Harmonic progression
(d) None.
 Turning
Turning - produces a smooth and straight
outside radius on a part.
Video
 Threading
Threading - The cutting tool is moved quickly
cutting threads.
Video
 Threading
In one revolution of the spindle, carriage
must travel the pitch of the screw thread to
be cut. N s Pzs N L Lz L
P Pitch of the screw thread to be cut
L Pitch of the lead screw
z s Number of start of the screw thread to be cut
z L Number of start of the lead screw
icg gear ratio of spindle N s to carriage N L gear train
 IES - 1998
A single start thread of pitch 2 mm is to be
produced on a lathe having a lead screw
with a double start thread of pitch 4 mm.
The ratio of speeds between the spindle
and lead screw for this operation is
(a) 1 : 2 (b) 2: 1
(c) 1: 4 (d) 4: 1
 IES 1993, ISRO-2009
It is required to cut screw threads of 2 mm
pitch on a lathe. The lead screw has a
pitch of 6 mm. If the spindle speed is 60
rpm, then the speed of the lead screw will
be
(a) 10 rpm (b) 20 rpm
(c) 120 rpm (d) 180 rpm
 Facing
Facing - The end of the part is turned to be
square.
Video
 Tapering
Tapering - the tool is moves so as to cut a taper
(cone shape).
 Parting/Slotting/Grooving
A tool is moved in/out of the work. shallow cut
will leave a formed cut, a deep cut will cut off
the unsupported part.
Video
 Drilling/Boring
Drilling/Boring - a cutter or drill bit is pushed
into the end to create an internal feature.
Video
 Knurling
Knurling is a manufacturing process
whereby a visually-attractive diamond-
shaped (criss-cross) pattern is cut or
rolled into metal.
This pattern allows human hands or
fingers to get a better grip on the knurled
object than would be provided by the
originally-smooth metal surface.
 Spinning
Metal Spinning is a process by which circles of
metal are shaped over mandrels (also called
forms) while mounted on a spinning lathe by the
application of levered force with various tools.
 Reaming
A reamer enters the workpiece axially through
the end and enlarges an existing hole to the
diameter of the tool. Reaming removes a
minimal amount of material and is often
performed after drilling to obtain both a more
accurate diameter and a smoother internal
finish.
 Tapping
A tap enters the workpiece axially through the
end and cuts internal threads into an existing
hole. The existing hole is typically drilled by
the required tap drill size that will
accommodate the desired tap.
Work holding Devices for Lathes
Held between centers
3 jaw self centering chuck (Disc type jobs
being held in chucks )
4 jaw independently adjusted chuck
Held in a collet (Slender rod like jobs being
held in collets )
Mounted on a face plate (Odd shape jobs,
being held in face plate)
Mounted on the carriage
Mandrels
Magnetic chuck for thin job
 Lathe chucks
Lathe chucks are used to support a wider variety of
workpiece shapes and to permit more operations to
be performed than can be accomplished when the
work is held between centers.
Three-jaw, self-centering chucks are used for work
that has a round or hexagonal cross section.
Each jaw in a four-jaw independent chuck can be
moved inward and outward independent of the
others by means of a chuck wrench. Thus they can
be used to support a wide variety of work shapes.
Combination four-jaw chucks are available in which
each jaw can be moved independently or can be
moved simultaneously by means of a spiral cam.
3 Jaw Chuck 4 Jaw Chuck
Collets Magnetic
Chuck

Face Plate
Turning
 Formula for Turning
D1 D2
d DOC
Depth of cut, mm
2
Average diameter of workpiece D1 D2
Davg mm
2

Cutting Time, LA O
CT
fN

Metal Removal Rate D2

D22
1
MRR Davg dfN
4 / fN
Cutting Speed, VD
=1N ,m / min
1000
 Example
How much machining time will be required to
reduce the diameter of a cast iron rod from 120
mm to 116 mm over a length of 100 mm by
turning using a carbide insert. Cutting velocity is
100 m/min and feed rate = 0.2 mm/rev.
 IES 2010
In turning a solid round bar, if
the travel of the cutting tool in
the direction of feed motion is
1000 mm, rotational speed of the
workpiece is 500 rpm, and rate
of feed is 0.2 mm/revolution,
then the machining time will be
(a) 10 seconds (b) 100 seconds
(c) 5 minutes (d) 10 minutes
 IES - 2003
The time taken to face a workpiece of 72
mm diameter, if the spindle speed is 80
r.p.m. and cross-feed is 0.3 mm/rev, is
(a) 1.5 minutes (b) 3.0 minutes
(c) 5.4 minutes (d) 8.5 minutes
GATE-2013 (PI) Common Data
A disc of 200 mm outer and 80 mm inner
diameter is faced of 0.1 mm/rev with a
depth of cut of 1 mm. The facing operation
is undertaken at a constant cutting speed
of 90 m/min in a CNC lathe. The main
(tangential) cutting force is 200 N.
Assuming approach and over-travel of the
cutting tool to be zero, the machining time
in min is
(a) 2.93 (b) 5.86 (c) 6.66 (d)
13.33
 IES - 2004
A medium carbon steel workpiece is
turned on a lathe at 50 m/min. cutting
speed 0.8 mm/rev feed and 1.5 mm depth
of cut. What is the rate of metal removal?
(a) 1000 mm3/min
(b) 60,000 mm3/min
(c) 20,000 mm3/min
(d) Can not be calculated with the given data
 Turning Tapers on Lathes
Using a compound slide,

Using form tools,

Offsetting the tailstock, and

Using taper turning attachment.

 Using a Compound Slide
Limited movement of the compound slide
Feeding is by hand and is non-uniform. This is
responsible for low-productivity and poor
surface finish.
Can be employed for turning short internal and
external tapers with a large angle of (steep)
taper.
Using a Compound Slide contd..

The angle is determined by

Dd
tan
2l
Half taper angle
D Diameter of stock
d smaller diameter
l length of the taper
 IES - 2006
For taper turning on centre lathes, the
method of swiveling the compound rest is
preferred for:
(a) Long jobs with small taper angles
(b) Long jobs with steep taper angles
(c) Short jobs with small taper angles
(d) Short jobs with steep taper angles
 Example
Find the angle at which the compound rest
should be set up to turn taper on the
workpiece having a length of 200 mm,
larger diameter 45 mm and the smaller 30
mm.
 Offsetting the tailstock
It is necessary to measure the tailstock offset
when using this method.
This method is limited to small tapers (Not
exceeding 8o ) over long lengths.
By offsetting the tailstock, the axis of rotation of
the job is inclined by the half angle of taper.
 Offsetting the tailstock Contd..

Tailstock offset (h) can be determined by

L D d
h or h L tan
2l
 IES - 1992
Tail stock set over method of taper turning
is preferred for
(a) Internal tapers
(b) Small tapers
(c) Long slender tapers
(d) Steep tapers
 IAS - 2002
The amount of offset of tail stock for
turning taper on full length of a job 300
mm long which is to have its two
diameters at 50 mm and 38 mm
respectively is
(a) 6 mm (b) 12 mm
(c) 25 mm (d) 44 mm
 IES - 1998
A 400 mm long shaft has a 100 mm
tapered step at the middle with 4
included angle. The tailstock offset
required to produce this taper on a lathe
would be
(a) 400 sin 4 (b) 400 sin 2
(c) 100 sin 4 (d) 100 sin 2
 Form tool
Special form tool for generating the tapers is
used. The feed is given by plunging the tool
directly into the work. This method is useful for
short external tapers, where the steepness is of
no consequence, such as for chamfering.
 Taper Turning Attachment
Additional equipment is attached at the rear of
the lathe.
The cross slide is disconnected from the cross
feed nut.
The cross slide is then connected to the
attachment.
As the carriage is engaged, and travels along
the bed, the attachment will cause the cutter to
move in/out to cut the taper.
For turning tapers over a comprehensive range
is the use of taper turning attachment.
 Errors in tool settings

Setting the tool below the centre decrease actual

rake angle, while clearance angle increases by the
same amount. Thus cutting force increased.
Setting the tool above the centre causes the rake
angle to increase, while clearance angle reduces.
More rubbing with flank.
 IES 2010
The effect of centering
error when the tool is set
above the center line as
shown in the figure results
effectively in
1. Increase in rake angle.
2. Reduction in rake angle.
3. Increase in clearance angle.
4. Reduction in clearance angle.
Which of these statements
is/are correct?
(a) 1 only (b) 1 and 4 only
(c) 2 and 4 only (d) 1, 2, 3 and
4
 Turret Lathe
A turret lathe, a number of tools can be set up
on the machine and then quickly be brought
successively into working position so that a
complete part can be machined without the
necessity for further adjusting, changing tools,
or making measurements.
Turret Lathe
Capstan Lathe
Video
Capstan lathe
Short slide, since the saddle
is clamped on the bed in
position.
Light duty machine, generally
for components whose
diameter is less than 50 mm.
Too much overhang of the
turret when it is nearing cut.
Ram-type turret lathe, the
ram and the turret are moved
up to the cutting position by
means of the capstan Wheel.
As the ram is moved toward
the headstock, the turret is
automatically locked into
Turret lathe
Saddle moves along the
bed, thus allowing the
turret to be of large size.
Heavy duty machine,
generally for components
with large diameters, such
as 200 mm.
Since the turret slides on
the bed, there is no such
difference.
Saddle-type lathes, the
main turret is mounted
directly on the saddle, and
the entire saddle and turret
assembly reciprocates.
 IES - 2012
Lathe machine with turret can turn a work piece
of limited length only because,
(a) Cross slide motion is obstructed by turret
(b) Turret cannot work on a long job
(c) Chuck cannot be replaced by a face plate
(d) Turret replaces the loose centre
 Turret indexing mechanism
The hexagonal turret is rotated (for indexing) by a
Geneva mechanism where a Geneva disc having
six radial slots is driven by a revolving pin. Before
starting rotation, the locking pin is withdrawn by a
cam lever mechanism. The single rotation of the
disc holding the indexing pin is derived from the
auxiliary shaft with the help of another single
revolution clutch as indicated.
For automatic lathe: Ratchet and Pawl mechanism
 Automatic Lathe
The term automatic is somewhat loosely applied, but
is normally restricted to those machine tools capable
of producing identical pieces without the attention of
an operator, after each piece is completed. Thus,
after setting up and providing an initial supply of
material, further attention beyond replenishing the
material supply is not required until the dimensions
of the work pieces change owing to tool wear.
A number of types of automatic lathes are
developed that can be used for large volume
manufacture application, such as single spindle
automatics, Swiss type automatics, and multi-spindle
automatics.
Video
 Swiss type Automatic Lathe Or Sliding
Headstock Automatics
Headstock travels enabling axial feed of the bar
stock against the cutting tools.
There is no tailstock or turret
High spindle speed (2000 10,000 rpm) for
small job diameter
The cutting tools (upto five in number including
two on the rocker arm) are fed radially
Used for lot or mass production of thin slender
rod or tubular jobs, like components of small
clocks and wrist watches, by precision
machining.
 Multi Spindle Automatic Lathe
For increase in rate of production of jobs usually

of smaller size and simpler geometry.

Having four to eight parallel spindles are
preferably used.
Multiple spindle automats also may be parallel

action or progressively working type.

Video
Norton type Tumbler-gear quick-change
Gear box
 Norton type Tumbler-gear quick-change
Gear box
It comprises a cone of gears 1 to 8 mounted on shaft S2.

The tumbler gear can slide on shaft S1. It can mesh with

any gear on shaft S2 through an intermediate gear which

is located on a swinging and sliding lever so that it can
engage gears 1 to 8 of different diameters, on shaft S2.
The lever can be fixed in any desired ratio position with

the help of a stop pin.

The drive is usually from the driving shaft S1 to the

driven shaft S2.

 GATE 2008
The figure shows an incomplete schematic of
a conventional lathe to be used for cutting
threads with different pitches. The speed
gear box Uv, is shown and the feed gear box
Us, is to be placed. P, Q. R and S denote
locations and have no other significance.
Changes in Uv, should NOT affect the pitch of
the thread being cut and changes in Us,
should NOT affect the cutting speed.

Contd..
 GATE -2008 Contd.

The correct connections and the correct placement of Us are

given by
(a) Q and E are connected. Us, is placed between P and Q.
(b) S and E are connected. Us is placed between R and S.
(c) Q and E are connected. Us, is placed between Q and E.
(d) S and E are connected. Us, is placed between S and E.
 IES - 2009
Which one of the following methods
should be used for turning internal taper
only?
(a) Tailstock offset
(b) Taper attachment
(c) Form tool
(d) Compound rest
 IES - 1997
Consider the following operations:
1. Under cutting 2. Plain turning
3. Taper turning 4. Thread cutting
The correct sequence of these operations in
machining a product is
(a) 2, 3, 4, 1 (b) 3, 2, 4, 1
(c) 2, 3, 1, 4 (d) 3, 2, 1, 4
 IAS - 2001
Consider the following operations and time
required on a multi spindle automatic
machine to produce a particular job
1. Turning 1.2 minutes
2. Drilling 1.6 minutes
3. Forming 0.2 minute
4. Parting 0.6 minute
The time required to make one piece (cycle
time) will be
(a) 0.6 minutes (b) 1.6 minutes
(c) 3.6 minutes (d) 0.9 minute
 IES 2011
In Norton type feed gearbox for cutting Whitworth
standard threads with a standard TPI Leadscrew,
power flows from:
(a) Spindle to Tumbler gear to Norton cone to
Meander drive to Leadscrew
(b) Spindle to Norton cone to Tumbler geat to
Meander drive to Leadscrew
(c) Spindle t o Tumbler gear to Meander drive to
Norton cone to Leadscrew
(d) Spindle to Norton cone to Meander drive to
Tumbler gear to Leadscrew
 Ch 2:
Lathe
Q. No Option Q. No Option

1 C 6 A

2 A 7 B

3 D 8 B

4 B 9 D

5 B 10 C