Unit 5 - Turning

 CA1 (35 %)
◦ Assignments -15% (review, sketching,
case study)
◦ 2 BB Quizzes -10% (turning and milling)
◦ General Performance -10% (attitude,
attendance..)

 CA2 (40%)
◦ Practical (machining tape holder -
individual)

 CA3 (25%)
◦ Mini Project (machining car chassis and
Learning Objectives:

 List the components of a centre lathe

 Discuss the safety rules
 Discuss the use of tool holding devices
 Discuss the characteristics of cutting tool
materials and inserts
 Watch and discuss video VC2495/8
 What is the primary function of a centre
lathe?
 Can you name the components of a lathe?
 What 2 movements are necessary before
turning process can take place?
a) Saddle
b) cross slide
c) compound slide
d) tool post
e) apron
 Boring
tool

Facing tool
Undercutting
tool
Radius forming
Parting Chamfering Knife tool
Knurling tool tool turning tool
tool
Facing and
turning tool
 Can you give other examples of
turning besides facing and parallel
turning?
 Compare and contrast the differences of a
4-way tool-post (above) and quick change
tool-post?
  On Centre –
good finish

 Above Centre -
not cutting

 Below Centre –
poor finish
α = Front Clearance
β = Wedge Angle
 Locking screw
Insert
Chip
Breaker
Insert holder

 The carbide insert is locked by a locking

screw or cam. Shape may be triangular
(as above) or diamond, square or round.
2. Define “Turning Operation”.
3. State the effects of improper tool setting.
4. List 10 safety precautions in the machine shop
and how would you categorised them?
5. State the 3 purposes of facing operation.
6. What is the main advantage of quick change
tool post?
Learning Objectives:

 Compare and contrast 3-jaw and 4-jaw

chucks
 Explain the use of work holding support used
in between centres
 Discuss the use of other work holding
devices like faceplate, mandrels and
steadies.
 Normally used for holding round or
hexagonal stock.
 Suitable for round, square, octagonal and
odd-shaped workpieces.
 Long Workpiece

 Normally used for turning a long

workpiece supported between
between centres. It requires 2
centres, a drive plate and a lathe dog.
Drive Plates
 Plain

Morse standard taper

Sleeve

Live

 Compare and contrast live and plain

centres.
  ✂ Plain solid mandrel – one
size of bore

✂ Gang mandrel – many

workpieces with same
Internal diameter

✂ Expansion mandrel –
slight difference (up to
2mm variation) in
diameter

 
✂ Cone mandrel – large
variation in diameter
allowed.
Workpiece
Fixed
Steady

Travelling
Steady
1. How would you hold a hollow thin wall round
pipe for turning?
2. When is a faceplate used?
3. Explain the reason why the 3-jaw chuck is
self-centred.
4. State the advantages of a 4-jaw chuck.
Learning Objectives:

 Distinguish between Orthogonal and oblique

cutting.
 Discuss the tool geometry of a single-pointed
tool.
 Discuss the factors that influence metal cutting
operations.
 Discuss the types of chips
 Cutting edge is set at 90° to the direction of movement.
 Chips in the form of a clock spring or a flat spiral
 Chips disposal problem & damage to workpiece surface.
 Cutting edge is set at any angle other than 90º to
the direction of tool movement.
 Chips able to move freely away from workpiece
 Taking deeper cuts is possible
 surface finish is better with a nose radius
  Side Rake angle :
provides a cutting edge
 to allow chips to escape

during cutting.
 Back Rake angle :
promotes smooth chip

flow and good finishing
  Front Relief angle :
prevents tool end from
rubbing
 Side Relief angle: allows
the tool to feed into the
work
 Nose Radius 
Minor cutting edge
 angle

Major cutting
edge
Minor cutting edge Major cutting edge
angle 

 Side (Major) cutting edge angle - Mainly responsible for the chip
removal
 End (Minor) Cutting edge angle - Mainly responsible for producing
the finished workpiece surface
 Nose radius - Influences the surface finish of the workpiece
Continuous ------------ Discontinuous Chips
1. Compressive stress cause movement of
metal.
2. Then, compression increases until plastic
flow or rupture (or fracture) occurs.

◦ Ductile material - continuous chip is formed

◦ Brittle materials - rupture takes place with

small discontinuous fractured chip
 Brittle material, small rake angle, large
depth of cut or feedrate and no cutting fluid
 Ductile materials, large rake angle, small
depth of cut or feedrate and efficient use of
cutting fluid.
 Higher values in depth of cut & feedrate, lower
value for rake angle and wrong application of
coolant produced higher friction.
2. Compare and contrast orthogonal and oblique
cutting.
3. With simple sketches, show the tool geometry
of single-pointed cutters.
4. List the three types of chip formation.
5. State the conditions for the formation of
continuous chip.
Learning Objectives:

 Describe 3 cutting forces acting on the tool

 Discuss the relationship of cutting forces and the
following:
◦ rake angle
◦ depth of cut
◦ feedrate
◦ cutting speed, and
◦ plan approach angle
 Tangential and Axial Forces
 Besides Tangential and Axial Forces, there is
also a Radial Force.
 Tangential Force (Ft) – tangential to the
work surface, main power-consuming.

 Axial Force (Fa) – parallel to the work axis

and opposing the lengthwise feed direction.

 Radial Force (Fr) – present only in oblique

cutting and opposing the crosswise feed
direction.
 Use a Force Dynamometer - calibrate before use.
 Units - Newton
 Ft
A Test piece
Dry
With coolant

Rake angle (γ)

Uniform thickness

 Side Rake angle varies from 0 to 40º in steps of 5º

 Lower Tangential force when Rake angle is smaller.
 Ft Ft
Test piece with
stepped-wall
Fa

Depth of cut (mm)

 Depth of Cut varies from 2 to 10 mm.

 Bigger Tangential and Axial forces

encountered when Depth of cut increases.

 Ft Fa
Ft

Fa

Test piece with Feed rate (mm)

uniformed wall thickness

 Feedrate varies from 0.1 to 1.0 mm/rev

 Axial force increases exponentially when Feedrate
increases.
 Ft

Breakage point of cutter

Cutting speeds (m/min)

 Cutting Speed varies from 30º to 80º of allowable

speed value
 No change in tangential force before tool break-up.
 χ

 Plan Approach Angle varies from 45º to 90º.

 Axial force equals to Radial force at 45º.
 Radial force equals to zero at 90º and
tangential force is at maximum.
2. Describe the forces acting on the cutter
during orthogonal and oblique cutting.
3. Sketch the graph and explain test results
when the rake angle was varied.
4. Explain the effects of depth of cut and
feedrate on the following:
• Chip thickness
• Cutting force
5. Explain the effects of the cutting forces
when plan approach angle is set at 45º.
Learning Objectives:
 Discuss the differences of cutting speed, spindle
speed and feedrate.
 Calculate the machining time, cutting power,
feed power and specific metal removal rate.
 Discuss the different types of cutting tool
materials.
 Describe the effects of positive and negative
back rake angle
 Explain the functions of cutting fluid.
 WORKPIECE FEED (mm/rev) CUTTING
MATERIALS SPEED (m/min)

Aluminium 0.2 1.0 70 100

Brass (Alpha, 0.2 1.0 50 80
Ductile)
Brass (free-cutting) 0.2 1.5 70 100
Bronze (phosphor) 0.2 1.0 35 70
Cast iron (grey) 0.15 1.0 25 40
Copper 0.2 1.0 35 - 70
Steel (mild) 0.2 1.0 35 - 70
Steel (medium 0.15 0.7 30 - 35
carbon)
Steel (alloy, high- 0.08 0.3 5 10
tensile)
Thermo-setting 0.2 1.0 35 - 50
plastic
 1
min

0
sec

1 rev = π
d

 The rate at which a point in the circumference of the work

travels past the cutting tool (V=m/min).
 Depends on work material, tool material, type of operation,
machine condition, coolant type, type of cuts.
The spindle speed is the number or
revolutions turned in one min.

N = 1000V (rev/min)
πd

The Spindle Speed, N depends on:

3. the cutting speed, V and

4. the diameter, d of the workpiece.
 Feedrate is the distance the tool bit advances along
the work for each revolution of the spindle
(F=mm/rev)
 Depends on work material, tool material, type of
cut, cutting speed.
 Calculate the spindle speed, to the nearest rev/min,
for turning a 50 mm diameter bar at a cutting speed
of 40 m/min.

1000 * V where, N = spindle speed

N = ---------------- V = 40 m/min
π D D = 50 mm

1000 * 40
= ------------------ = 255 (rev / min)
3.142 * 50
 Calculate the time taken to turn a brass component 65
mm diameter by 95 mm long, if the cutting speed is
45 m/min and the feed is 0.6 mm/rev. Only one cut is
to be taken.
π

π
 Work done = force * dist moved
= force * Circumference * N

=F*2π rN

= F*π dN
Power is the rate of doing work

Use Ft = work done ÷ time taken

= F*π dN Nm or watts
1000*60 sec
 π DN
WORKDONE = Ft (Newtons) x ---------- (Nm/min) or (Joules /
min)
1000

π DN 1
CUTTING POWER (watts) = Ft x ------------- x ------ (Nm / sec)
1000 60

Where, Ft = tangential force;

π = 3.142
D = diameter of workpiece (mm);
N = rotational speed in rpm
 Feed x N
WORKDONE = Fa (Newtons) x --------- (Joules / min)
1000

Fa x Feed x N
FEED POWER = ------------------------ (Joules / s or Watts)
1000 x 60

Where, Fa = Axial force;

Feed = mm / rev;
N = spindle speed in rpm
 During turning on the lathe, the workpiece has a
diameter of 75 mm & the spindle speed was set at 200
rpm. If the feed rate was 0.33 mm / rev & the
dynamometer readings for the tangential force and the
axial force were 1,600 N & 900 N respectively, find the
cutting & feed power.

3.142 x 75 mm x 200 rpm

Cutting power = 1600 N x ---------------------------------------
1000 x 60
= 1,257 watts

900 N x 0.33 mm / rev x 200 rpm

Feed power = ----------------------------------------------
1000 x 60
= 0.99 Watts
 V=25m/min

F=1.5mm/rev D=3mm

The volume of metal removed per

minute is
=V*D*F
= 25000 * 3 * 1.5
= 112500 mm3/min = 112.5 cm3/min
 = Volume removed per min
Power consumed

= (mm³/min)/watt

N.B. Power consumed is the sum of the

power at the cutting tool and including the
power to drive the mechanical systems.
 High Carbon steel
 HSS

 Cemented carbide (contains 90% carbide

powder and 10% cobalt as binder)
 Cemented ceramic (contains 95% Al2O3)
 Diamond
Ability to:
 Retain hardness at high temperature
 Resist Shock i.e. toughness
 Resist Wear
 Reasonably cheap
 Acceptable mechanical properties
 Good abrasion resistance
 Slow rate of wear
 Hot Hardness properties
 Vibration and chatter must be avoided
 Very brittle
 Unable to withstand shock and bending
loads
 Used it as a throwaway tip or insert.
  Normal force, N,
positive rake on unsupported
part

Cutting tool  Tendency to break

 Lower cutting
forces
  Normal force, N, on
N supported part
negative rake  Less likely to break

 Operate at higher

speed
 Higher compressive

forces
Functions:
 Cooling and lubrication
 Better surface finish and accuracy
 Flushing away chips
 Longer Tool life
 Preventing chip welding, corrosion
 Permits higher speed and feedrate
1. Explain the difference between cutting
speed and spindle speed.
2. What are the factors that determine
cutting speed?
3. What is SMRR used for?
4. Explain the toughness of cutting tool
material.
5. Compare and contrast positive and
negative back rake angle.
 Introduction to Milling Operations