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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 speed then
N1 , N1r , N1r 2 , N1r 3 ,.............N1r n 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.
Threading
Threading - The cutting tool is moved quickly cutting
threads.
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
GATE-2017
Metric thread of 0.8 mm pitch is to be cut
on a lathe; Pitch of the lead screw is 1.5 mm.
If the spindle rotates at 1500 rpm, the speed
of rotation of the lead screw (rpm) will be
_________________
GATE-2018 (PI)
A double-start thread with a pitch of 2 mm is to
be cut using a lathe machine. The pitch of the
leadscrew of the lathe is 6 mm. The job rotates at
60 revolution per minute (RPM). The RPM of the
leadscrew is ______
Facing
Facing - The end of the part is turned to be square.
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.
Drilling/Boring
Drilling/Boring - a cutter or drill bit is pushed into the
end to create an internal feature.
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.
GATE-2019
The cold forming process in which a hardened tool is
pressed against a workpiece (when there is relative
motion between the tool and the workpiece) to produce
a roughened surface with a regular pattern is
(a) Roll forming
(b) Chamfering
(c) Knurling
(d) Strip rolling
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.
ISRO-2007
Spinning operation is carried out on
(c) Lathe
Face Plate
Turning
Formula for Turning
D1 D2
Depth of cut, d DOC mm
2
Average diameter of workpiece D1 D2
Davg mm
2
Cutting Time,CT L A O
fN
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
Capstan lathe Turret lathe
Short slide, since the saddle is Saddle moves along the bed,
clamped on the bed in position. thus allowing the turret to be of
large size.
Light duty machine, generally for Heavy duty machine, generally
components whose diameter is for components with large
less than 50 mm. diameters, such as 200 mm.
Too much overhang of the turret Since the turret slides on the
when it is nearing cut. bed, there is no such difference.
Ram-type turret lathe, the ram and Saddle-type lathes, the main
the turret are moved up to the turret is mounted directly on the
cutting position by means of the saddle, and the entire saddle
capstan Wheel. As the ram is and turret assembly
moved toward the headstock, the reciprocates.
turret is automatically locked into
position.
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.
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 - 2002
A lead-screw with half nuts in a lathe, free to rotate
in both directions has
(a) V-threads
Contd…..
GATE -2008 Contd….