BY

MECHANICAL ENGINEERING DEPARTMENT

ARAAVINRAJ A/L S.MANIRAJ

ANUSHA RAJ A/P RAJANDREN
YEH JIA REN
NURUL IZZATI BINTI MOHAMAD SALBRI
NAFIZATUL AINI BINTI ZAIDON

TOPIC 3 MUHAMMAD SALIHIN BIN ABDUL RAHMAN

LATHE MACHINE
 3.1. CONSTRUCTION AND OPERATION OF A LATHE MACHINE

3.1.1 Function Of Lathe Machine

A lathe is a machine tool which turns cylindrical material, touches a cutting tool to it and cuts the
material. The lathe is one of the machine tools most well used by machining. Other operations that can
be performed with a lathe machine are :

Turning
Facing
Boring
Chamfering
Drilling
Treading
Knurling
3.1.2 Types Of Lathe Machine

1. Speed Lathes
- It is the simplest type lathe. It is mainly used for metal spinning, polishing and more.

2. Engine Lathes
- The most common form of lathe, motor driven and comes in large variety of sizes and shapes.

3. Tool room Lathes

- It is used for production of small tools, gauges, fixtures and accurate parts in tool room.

4. Turret Lathes
- Turret lathe which have multiple tools mounted on turret either attach to tailstock or the cross-slide,
which allows for quick changes in tooling and cutting operations.

5. Special Types of Lathe Machines

- Bench lathes
- Automatic lathes
- Multispindle lathes
- Crankshaft lathes
- Duplicating lathes
3.1.3 Parts Of Lathe Machine
Five Main Parts Of Lathe Machine

HEADSTOCK
- Mounted in a fixed position on the inner ways, usually at the left end. Using a chuck, it rotates the work.

CARRIAGE
- Moves on the outer ways. Used for mounting and moving most the cutting tools.

TAILSTOCK
- Fits on the inner ways of the bed and can slide towards any position of the headstock to fit the length of the
work piece. An optional taper turning attachment would be mounted to it.

BED
- Usually made up of cast iron. Provides a heavy rigid frames which all the main components are mounted.

QUICK CHANGE GEARBOX

- Controls the movement of the carriage using levers.
Lathes Size And Capacity

Designated by largest work diameter that can be swung over lathe ways and generally the maximum
distance between centres.

Manufactured in wide range of sizes

- Most common : 9 in to 30 in swing with capacity of 16 in to 12 ft between centres.
- Typical lathe : 13 in swing, 6 ft long bed, 36 in.
- Average metric lathe : 230 330mm swing and bed length of 500 3000mm.
3.2 WORK HOLDING DEVICES

3.2.1. Types Of Work Holding Devices

THREE JAWS CHUCK

- For holding cylindrical stock centred.

- For facing / centre drilling the end of the aluminium
stock

FOUR JAWS CHUCK

- This is independent chuck generally has four jaws, which

are adjusted individually on the chuck face by means of
adjusting the screw.
 LATHE CENTRES

- Work to be turned between centres must have centre hole drilled in each end
- Provides bearing surface
- Support during cutting
- Most common have solid Morse tapper shank 60 centres, steel with carbide
tips
- Care to adjust and lubricate occasionally

COLLET CHUCK

- Is used to hold small workpiece

 FACE PLATES

- Is a flat round plate that threads to the headstock spindle to the lathe
- Is used for irregular shaped workpiece that cannot successfully held
by chuck

MANDRELS

- Used to held the hollow or drilled the workpiece

9.3 CUTTING TOOLS AND TOOLS HOLDER

9.3.1 Materials for Cutting Tools

- A cutting tool is a pointed tool mounted in a machine tool and used for
cutting materials.
- Lathes and milling machines use different types of cutting tools.
- Diamonds are sometimes used in cutting tools because its hardness
allows it to cut other hard materials.
 9.3.2 Types Of Material For Cutting Tool

Carbon Steels

Carbon steel tools containing about 0.9% - 1.2% carbon and about 1% manganese. Carbon steels start to
soften at a temperature of about 180 C. It is unstable, very inexpensive and extremely sensitive to heat. It is
malleable, can be used for turning soft materials and possible for shape cutting edges.
High Speed Steel (HSS)

High speed steel containing about 18% tungsten, 4% chromium, 1% vanadium and 0.6% - 0.8% carbon. It can
withstand higher temperatures and does not easily crack compared to other tool materials. Cutting speed is
almost three times higher than carbon steel. It is unstable, inexpensive and possible for shape cutting edges. It
is malleable and can be used for turning soft materials.
Cast Cobalt Alloys

Cast cobalt alloys containing about 25% - 35% chromium, 25% tungsten and 2% carbon. Stellite,
Tantung and Rex alloys are proprietary trademark of Alloy Cast Products. Cutting speed is almost
three times higher than high speed steel. Cast cobalt alloy is brittle and not as strong as high speed
steel. It is hard to resist tool wear at high temperatures.
Carbides

Carbides is containing about 82% tungsten carbide, 10% titanium and tantalum. This type of tool is too fragile
because it must be used as a surrogate tool. It is welded or glued on carbon steel rods, have high hardness over a
wide range of temperatures and high thermal conductivity. Cutting speed is almost three times or four times
higher than carbon steel.
Ceramics

Ceramics is a mixture of aluminium oxide and titanium. It is used for machining harder materials because
other types of cutting quickly worn during machining. Cutting speed is almost two times higher than
carbides. It is last longer and can get a good finishing.
Diamond

The hardest known substance is diamond and can machining materials too hard. Diamond can be used at high
speeds. There are 2 types of diamond genuine diamonds and synthetic diamonds. Most of the diamond used in
the workshop is artificial diamonds. Diamond used with care because of its cost and easy fragile if it receives
strong buffeting. Cutting speed is almost 2 to 10 times higher than other materials. Can be cut until refine
0.005mm - 0.002mm
9.3.3 Angles Of Single Point Cutting Tool
1. Side Cutting Edge Angle
-The angle between side cutting edge and the side of the tool shank is called side cutting edge angle. It is
often referred to as the lead angle.

2. End Cutting Edge Angle

- The angle between the end cutting edge and a line perpendicular to the shank of the tool shank is called end
cutting edge angle.

3. Side Relief Angle

- The angle between the portion of the side flank immediately below the side cutting edge and a line
perpendicular to the base of the tool.

4. End Relief Angle

- The angle between the end flank and the line perpendicular to the base of the tool is called end relief angle.

5. Back Rake Angle

- The angle between the face of the tool and line perpendicular to the base of the tool measures on
perpendicular plane through the side cutting edge. It is the angle which measures the slope of the face of the tool
from the nose, towards the rack. If the slope is downward the nose it is negative back rake.
6. Side Rake Angle
- The angle between the face of the tool and a line parallel to the base of the tool measured on plane
perpendicular to the base and the side edge. It is the angle that measure the slope of the tool face from
the cutting edge, if the slope is towards the cutting edge it is negative side rake angle and if the slope is
away from the cutting edge, it is positive side rake angle. If there is no slope the side rake angle is zero.
9.3.4 Types Of Hand Tools

1. Right-hand tool cutting edge is on the right side and cuts from right to left.

2. Left-hand tool cutting edge is on the left side and cuts from left to right.

3. Straight tool holder cutting edge in both ways.

9.3.5 Cutting Speed

Cutting speed is the rate of the circumference of a substance measured in metre when the cutting is made in 1
minute. For instance 30 metre for 1 minute is the speed of a set spindle at a certain speed with circumference
that turns out in 1 minute is 30 metre. So, cutting speed can be said in metre per minute. The speed of spindle
is called rotation per minute (RPM) which is total revolutions to be made by cutting tool within one minute.
The cutting speed varies for each material. The cutting speed also not similar with the rotation per minute.

If the cutting speed is very high, the cutting tool will worn out soon and have to be sharpen again. If the
cutting speed is very low, this will consume more time and cost. Generally, a cutting tool with a small centre
point requires high RPM than cutting tool with a bigger centre point.

Calculation For Cutting Speed :

CS = D = diameter of workpiece in mm
1000 N = R.P.M.
Factors that determine RPM

a) The material to be turned

- High RPM is used for turning soft materials such as brass, aluminium and copper.
- Low RPM is used for turning hard materials such as cast iron and high-carbon steel.

b) Type of cutting tool used

- High RPM is used for hard cutting tool such as carbide which as cutting depth 3 or 4 times than high
speed steel

c) Rate of sending in cutting

- If the rate of sending in cutting is high RPM should be reduce so that the load will be reduce on a
cutting tool and machine.

d) Type of operation handle

- , RPM which usually should be used for handling operations such as threading and knurling
Factors that determine the speed of cutting

1. The workpiece, for instance mild steel, aluminium steel and other materials. Hard workpiece needs
lower speed than mild steel.

2. Cutting tool material used such as carbon steel, high speed steel, carbide and so on. Cutting tool which is
made from carbide needs high speed.

3. Centre point required.

4. Cutting depth

5. Sturdiness of the machine

9.3.6. Speed sending ( Feed )

The sending speed of the tool also affects to the processing speed and the roughness of surface. When the
sending speed is high, the processing speed becomes quick. When the sending speed is low, the surface is
finished beautiful. There are 'manual sending' which turns and operates a handle, and 'automatic sending'
which advances a byte automatically. A beginner must use the manual sending. Because serious accidents
may be caused, such as touching the rotating chuck around the byte in automatic sending,.
Cutting Depth

The cutting depth of the tool affects to the processing speed and the roughness of surface. When the
cutting depth is big, the processing speed becomes quick, but the surface temperature becomes high,
and it has rough surface. Moreover, a life of byte also becomes short. If you do not know a suitable
cutting depth, it is better to set to small value.
9.4.1 Turning Operation

1. Facing : - To smooth the surface of the workpiece

: - To machining workpiece according to their length
: - Make sure that the surface is perpendicular to the machines axis
2. Taper Turning :- to increase or decrease the diameter of the cylindrical workpiece

Types of taper turning :- by using form tool

:- by setting over tailstock centre
:- by swiveling the compound rest
Taper turning by using form tool :

- A broad nose from tool having straight cutting edge makes half taper angle with the axis of workpiece.
- The tool is fed right angle to the workpiece axis
Taper turning by setting over tailstock centre :

- A method is suitable when the workpiece is held between the centre

- The workpiece is rotated at an angle to the lathe axis and tool fed parallel to the lathe axis.

Dd
= Tan
2p
Taper turning by swiveling the compound rest :

- The workpiece is rotated at lathe axis and tool is fat at an angle to the axis of rotation of workpiece
- Tool is mounted on compound rest
- The tool can be fed at angle of compound slide as compound rest is mounted at half taper angle
3. Chamfering :- Cutting edge cuts an angle on the corner of the workpiece
4. Cutting off :- tool is fed radially work at some location to cut off end of part, or provide a groove
9.4.2 Knurling

- Used to press a pattern onto a round section

- The pattern is normally used as a grip for a handle
THE END