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Unite-II

LATHE

Unit II Lathe: Introduction, type, construction of simple lathe, mechanism and attachments for various operations, machine specifications, basis for selection of cutting speed, feed and depth of cut, time estimation for turning operations such as facing, step turning, taper turning, threading, knurling. [8 Hrs.] Two Question (i.e. 26 Marks) Numerical of 7 to 8 Theory of 17 to 26

Introduction
A lathe is a machine tool which spins a block of material to perform various operations

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Introduction
Lathe is a machine, which removes the metal from a piece of work to the required shape & size operations such as cutting, sanding, knurling, drilling, or deformation with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation.

Turning Parameters
Forces in turning Cutting force: acts downward on the tool tip Thrust force: acts in the longitudinal direction Radial force: acts in the radial direction Roughing and Finishing Cuts Rough cut: high speed cut with little regard for dimensional tolerance Finishing cut: lower feed rate and depth of cut Tool Materials, Feeds, and Cutting Speeds See table 22.4 Cutting Fluids See table 22.5

History
The origin of turning dates to around 1300BC when the Egyptians first developed a two-person lathe. One person would turn the wood work piece with a rope while the other used a sharp tool to cut shapes in the wood The Romans improved the Egyptian design with the addition of a turning bow. Early bow lathes were also developed and used in Germany, France and Britain.
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History
In the Middle Ages a pedal replaced hand-operated turning, freeing both the craftsman's hands to hold the woodturning tools. The pedal was usually connected to a pole, often a straight-grained sapling. The system today is called the "spring pole" lathe ( Pole-lathe).

History
During the industrial revolution, mechanized power was applied to the lathe via steam engines and line shafting, allowing faster and easier work. Between the late 19th and mid 20th centuries, individual electric motors at each lathe replaced line shafting as the power source. Beginning in the 1950s, servomechanisms were applied to the control of lathes and

Machine Classification
Size designation
Swing - maximum diameter that can be rotated on the lathe
2xs distance from spindle center line to ways

Maximum distance between centers

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Size of Lathe
Workpiece Length

Swing

Size of Lathe ..
Example: 300 - 1500 Lathe Maximum Diameter of Workpiece that can be machined = SWING (= 300 mm) Maximum Length of Workpiece that can be held between Centers (=1500 mm)

Types of Lathes
Speed
Simple construction of a head stock and tail stock with a tool post. Used for wood turning, metal polishing, or metal spinning.12003600rpm

Engine
Most frequently used lathe Heavy duty power drive for most tool movements Size range 12x24 to 24x48 - can be larger

Bench Lathe
A bench top model usually of low power used to make precision machine small work pieces 13

Types of Lathes
Tool room
Greater accuracy More versatility Wider range of speeds and feeds

Turret
Hex turret replaces tailstock Multiple tools set to machine part High production rates Still may require some operator skill
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Turret Lathes
Capable of performing multiple cutting operations on the same workpiece Turning Boring Drilling Thread cutting Facing Turret lathes are very versatile Types of turret lathes Ram-type: ram slides in a separate base on the saddle Saddle type: more heavily constructed Used to machine large workpeiceces
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Types of Lathes
Automatic
Similar to turret A lathe in which the work piece is automatically fed and removed without use of an operator. Cutting operations are automatically controlled by sequencer of some form Capable of simultaneous cuts Can be a cam controlled mechanism Can be single spindle or multiple spindle
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Types of Lathes
Tracer Hydraulic attachment used to copy the shape of a part from a master. lathe that has the ability to follow a template to copy a shape or contour. Machine tools with attachments Capable of turning parts with various contours A tracer finger follows the template and guides the cutting tool

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Types of Lathes
CNC
Computer controlled Wide variety of process capability multiple axis Indexing and contouring head On- line and off- line programming available Computer Numerical Controls (CNC) Equipped with one or more turrets Each turret is equipped with a variety of tools

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Computer Numerically Controlled Lathes

Fig : A computer numerical control lathe. Note the two turrets on this machine. 19

Component Description

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Lathe Basics
Spindle Nose HEADSTOCK Tool Post Compound Rest Saddle Tailstock Spindle Clamp TAILSTOCK Feed Change Lever Lead Screw APRON Carriage Hand Wheel Motor Drive Frictionclutch Control Cross Slide Half Nut Lever Bed

Feed Reverse Lever Gear Box

BED WAYS

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Lathe Drive Mechanism

Belts are moved from pulley to pulley to change speeds (rpm). Pulley System without back gear: 4 High range speeds Pulley System with back gear: 4 Low range speeds
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Carriage Feed

A. Longitudinal Feed or Turning - The tool is fed along the work. C. Cross Feed or Facing The tool is fed across the work.

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Carriage Feed
Power Feed for: Turning Facing Used for greater control and accuracy. Speed controlled by the Quick Change Gear Box

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Carriage and Apron

The controls on the carriage and apron control all the tool and carriage movement.

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Lathe Carriage and ApronPost Tool

Apron Hand Wheel Cross Feed Knob Compound Rest Cross Slide Carriage Lock Screw Apron Feed Change Lever Half Nut Lever

Power Feed Clutch

Compound Rest Knob

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Carriage and Apron

Apron Hand-wheel: Turning Cross-feed knob: Facing Apron Feed-change lever: Selects power feed between turning and facing Power Feed Clutch: Engages the power feed
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Apron Hand Wheel

Used to move tool along the work - for Turning (Longitudinal Feed)
Apron Hand Wheel

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Cross Feed Knob

Used to move cutting tool across the end of the stock - Facing (Cross Feed)
Cross Feed Knob

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Power Feed Clutch

Engages the power feed for turning or facing operations

Power Feed Clutch

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Switches power feed between turning and facing directions

Apron Feed Change Lever

Apron Feed Change Lever

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Chuck
Three Jaw Chuck - For holding cylindrical stock centered. - For facing/center drilling the end of your aluminum stock

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Chucks
Used extensively for holding work for lathe machining operations
Work large or unusual shape

Most commonly used lathe chucks

Three-jaw universal Four-jaw independent Collet chuck

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Work Holding Devices

Fig : (a) and (b) Schematic illustrations of a draw-in-type collets. 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. (c) A push-out type collet. (d) Workholding of a part on a face plate.
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Three jaw chuck - For holding cylindrical stock centered. - For facing/center drilling the end of your aluminum stock Four-Jaw Chuck - This is independent chuck generally has four jaws , which are adjusted individually on the chuck face by means of adjusting screws
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Collet Chuck Collet chuck is used to hold small workpieces

Thin jobs can be held by means of magnetic chucks.

Magnetic Chuck

Thin jobs can be held by means of magnetic chucks.

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Three-jaw Universal Chuck

Holds round and hexagonal work Grasps work quickly and accurate within few thousandths/inch Three jaws move simultaneously when adjusted by chuck wrench
Caused by scroll plate into which all three jaws fit

Two sets of jaw: outside chucking and inside chucking

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Three-jaw Universal Chuck

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Four-Jaw Independent Chuck

Used to hold round, square, hexagonal, and irregularly shaped workpieces Has four jaws
Each can be adjusted independently by chuck wrench

Jaws can be reversed to hold work by inside diameter

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Four-Jaw Independent Chucks

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Headstock Spindle Types

1. Threaded spindle nose
Screws on in a clockwise direction

1. Tapered spindle nose

Held by lock nut that tightens on chuck

3. Cam-lock spindle nose

Held by tightening cam-locks using Twrench Chuck aligned by taper on spindle nose
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Threaded Spindle Nose

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Tapered Spindle Nose

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Cam Lock Spindle Nose

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Collet Chucks
Most accurate chuck Used for high-precision work Spring collets available to hold round, square, or hexagon-shaped workpieces Each collet has range of only few thousandths of an inch over or under size stamped on collet
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Spring Collet Chucks

Spring-collet chuck
One form: Handwheel draws collet into tapered adapter Another form: Uses chuck wrench to tighten collet on workpiece
Can hold larger work than draw-in type

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Spring Collet Chucks

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Spring Collet Chucks

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Jacobs Collet Chuck

Jacobs collet chuck
Utilizes impact-tightening handwheel to close collets Wider range than spring-collet chuck

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Jacobs Collet Chuck

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Magnetic Chucks
Used to hold iron or steel parts that are too thin or may be damaged if held in conventional chuck Fitted to an adapter mounted on headstock spindle Used only for light cuts and for special grinding applications

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Magnetic Chucks

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Faceplates
Used to hold work too large or shaped so it cannot be held in chuck or between centers Usually equipped with several slots to permit use of bolts to secure work
Angle plate used so axis of workpiece may be aligned with lathe centers

Counterbalance fastened to faceplate when work mounted off center

Prevent imbalance and resultant vibrations
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Faceplates

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Faceplates

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Cutting Speed
D Diameter (mm) N Revolutions per Minute (rpm)
DN v= 1000
m/min

The Peripheral Speed of Workpiece past the Cutting Tool

=Cutting Speed

Feed
f the distance the tool advances for every rotation of workpiece (mm/rev)

Depth of Cut
perpendicular distance between machined surface and uncut surface of the Workpiece d = (D1 D2)/2 (mm)

Operating Conditions

Cutting Tool

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Turning Between Centers

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Some Typical Lathe Jobs

Turning/Drilling/Grooving/ Threading/Knurling/Facing...

Lathe Operations
Turning: produce straight, conical, curved, or grooved workpieces Facing: to produce a flat surface at the end of the part or for making face grooves. Boring: to enlarge a hole or cylindrical cavity made by a previous process or to produce circular internal grooves. Drilling: to produce a hole by fixing a drill in the tailstock Threading: to produce external or internal threads Knurling: to produce a regularly shaped roughness on cylindrical surfaces

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Lathe Operations

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Turning

Turning ..
Cylindrical job

Turning .. Excess Material is removed to reduce Diameter Cutting Tool: Turning Tool

a depth of cut of 1 mm will reduce diameter by 2 mm

Facing
Flat Surface/Reduce length

Facing ..
machine end of job Flat surface or to Reduce Length of Job Turning Tool Feed: in direction perpendicular to workpiece axis Length of Tool Travel = radius of workpiece Depth of Cut: in direction parallel to workpiece axis

Facing ..

Eccentric Turning

Knurling
Produce rough textured surface Knurling Tool
For Decorative and/or Functional Purpose

A Forming Process MRR~0

Knurling

Grooving Produces a Groove on workpiece Shape of tool shape of groove Carried out using Grooving Tool A form tool Also called Form Turning

Grooving ..

Parting
Cutting workpiece into Two Similar to grooving Parting Tool Hogging tool rides over at slow feed Coolant use

Parting ..

Chamfering

Chamfering
Beveling sharp machined edges Similar to form turning Chamfering tool 45 To
Avoid Sharp Edges Make Assembly Easier Improve Aesthetics

Taper Turning
D1 D2 Taper: tan = 2L

Taper Turning..
Conicity
D1 D2 K= L

Methods

Form Tool Swiveling Compound Rest Taper Turning Attachment Simultaneous Longitudinal and Cross Feeds

Taper Turning ..
By Form Tool

Taper Turning ,,
By Compound Rest

Cutting Screw Threads

Fig : (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. (c) A typical carbide insert and toolholder for cutting screw threads. (d) Cutting internal screw threads

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Types of Screw threads

Fig : Various types of screw threads

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Drilling
Drill cutting tool held in TS feed from TS

Drilling

Drilling And Drills Drills

Have high lenth to diameter ratio Capable of producing deep holes Some what fexable Flutes: two spiral grooves that run the length of the drill and allow the chips to escape Small changes in drill geometry can have a significant effect on the drills performance

Lathe Accessories
Divided into two categories
Work-holding, -supporting, and driving devices
Lathe centers, chucks, faceplates Mandrels, steady and follower rests Lathe dogs, drive plates

Cutting-tool-holding devices
Straight and offset toolholders Threading toolholders, boring bars Turret-type toolposts
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Lathe Centers
Work to be turned between centers must have center hole drilled in each end
Provides bearing surface

Support during cutting Most common have solid Morse taper shank 60 centers, steel with carbide tips Care to adjust and lubricate occasionally
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Lathe Centers

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 Replaced solid dead centers for most machining operations Used to support work held in chuck or when work is being machined between centers Contains antifriction bearings which allow center to revolve with workpiece
No lubrication required between center and work

Revolving Tailstock Centers

Types: revolving dead center, long point center, and changeable point center
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Revolving Tailstock Centers

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Microset Adjustable Center

Fits into tailstock spindle Provides means of aligning lathe centers or producing slight tapers on work machined between centers Eccentric slide (dovetail) allows center to be adjusted limited amount to each side of center

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Self-Driving Live Center

Mounted in headstock spindle Used when entire length of workpiece is being machined in one operation
Chuck or lathe dog could not be used to drive work

Grooves ground around circumference of lathe center point provide drive Work usually soft material such as aluminum

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Steadyrest
Used to support long work held in chuck or between lathe centers
Prevent springing

Located on and aligned by ways of the lathe Positioned at any point along lathe bed Three jaws tipped with plastic, bronze or rollers may be adjusted to support any work diameter with steadyrest capacity
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Steadyrest

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Follower Rest
Mounted on saddle Travels with carriage to prevent work from springing up and away from cutting tool
Cutting tool generally positioned just ahead of follower rest Provide smooth bearing surface for two jaws of follower rest
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Follower Rest

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Mandrel
Holds internally machined workpiece between centers so further machining operations are concentric with bore Several types, but most common
Plain mandrel Expanding mandrel Gang mandrel Stub mandrel

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Mandrel

Fig : Various types of mandrels to hold workpieces for turning. These mandrels 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, 101 whereas in (b) and (c) only the cylindrical surfaces can be

Plain Mandrel

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Expanding Mandrel

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Gang Mandrel

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Stub Mandrel

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Lathe Dogs
Drives work machined between centers Has opening to receive work and setscrew to fasten the dog to work Tail of dog fits into slot on driveplate and provides drive to workpiece Made in variety of sizes and types to suit various workpieces
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Standard bent-tail lathe dog

Most commonly used for round workpieces Available with square-head setscrews of headless setscrews

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Standard bent-tail lathe dog

Bent tail engages in slot on drive plate

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Straight-tail lathe dog

Driven by stud in driveplate Used in precision turning

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Safety clamp lathe dog

Used to hold variety of work Wide range of adjustment

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Heavy Duty Lathe Dog

Wider range than others Used on all shapes

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Super Quick-Change Toolpost

Provides fast, accurate, and reliable method of quickly changing and setting various toolholders for different operations Locking system has two sliding gibs forced out against toolholder
Handle pulled into lock position Provides rigid, positive lock with zero backlash
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Super Quick-Change Toolpost

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Simple formula

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Simple Problems
Problem -1 A mild steel rod having 50 mm diameter and 500 mm length is to be turned on a lathe. Determine the machining time to reduce the rod to 45 mm in one pass when cutting speed is 30 m/min and a feed of 0.7 mm/rev is used.

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Solution Given data: D = 50 mm, Lj = 500 mm v = 30 m/min, f = 0.7 mm/rev Substituting the values of v and D in V = DN/1000 M/min

Required spindle speed as: N = 191 rpm

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Simple Problems
Problem -2 Determine the angle at which the compound rest would be swiveled for cutting a taper on a work piece having a length of 150 mm and outside diameter 80 mm. The smallest diameter on the tapered end of the rod should be 50 mm and the required length of the tapered portion is 80 mm. Solution Given data: D1 = 80 mm, D2 = 50 mm, Lj = 80 mm (with usual notations) tan = (80-50) / 2 80 or = 10.620 The compound rest should be swiveled at 10.62o

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