Chapter 2 - Metal Cutting Lathe
Chapter 2 - Metal Cutting Lathe
Chapter 2 - Metal Cutting Lathe
1. INTRODUCTION
A lathe is a machine tool which spins a block of material to
perform various operations (such as cutting, knurling,
drilling, or deformation) with tools that are applied to the
work piece to create an object which has symmetry about
an axis of rotation.
As per Encyclopedia Britannica, A lathe is machine tool that
performs various operations in which unwanted material is
removed from a work piece, rotated against a cutting tool.
Lathe is a machine which removes the metal from the
piece of work to the required shape and size.
2. HISTORY
2. HISTORY
3. Lathe machine
3.Schmetic diagram
1. Headstock Assembly
Headstock Spindle
(on which work
mounted)
holding
device
Driver
Mechanism
(Belt Drive / Gear
Box Mechanism)
is
Headstock
Located at the far most left of the lathe on the inner ways of bed.
Hollow spindle
Headstock Spindle
The spindle is hollow to hold the long bar through the bore.
Speed Changing
Speed Changing
Belt driven
Belt driven
1. Direct Speed (Back gear out)
DIRECT SPEED
INDIRECT SPEED
Gear driven
DisadvantagesCostlier
Power lost due to friction
In case of overloading it may damage parts as no arrangement of belt
.
2. Tailstock Assembly
Tailstock
Functions:-
bed
by
sliding,
to
The tail stock is made hollow called barrel, to carry the tailstock
spindle.
Front end of the tailstock spindle can carry either dead center
or tool for different operations, such as drilling, reaming, etc.
3. Carriage
Saddle
The saddle is an H shaped
casting.
It slides on the top of the
lathe bed.
It carries tool post and
cross slide.
Lathe bed guides the
longitudinal motion of the
saddle.
Cross Slide
It is connected to the
saddle on inner side
and on the upper side it
is connected to the tool
post or compound rest.
To move the cross-slide,
the feed screw is turned
by rotating the hand
wheel.
It also provides support
for the Taper turning
attachment.
Compound Rest
Mounted on to the cross slide
Base has graduation to rotate
w.r.t. lathe axis
Turn through 360
Compound rest is Hand
operated.
Function: Provide mechanism for angular
cut.
Also, micrometer dial is
attached on compound rest
handle in order to measure the
depth of cut and get accurate
dimension.
Tool post
Located on the top of the
compound rest to hold the
tool and to enable it to
adjusted to a convenient
working position.
Types of tool post:
1. Single screw tool post
2. Four bolt tool post
3. Open side tool post
4. Four way tool post
Apron
Located at the lower vertical
position of the carriage
Contains gears and clutches
for transmitting motion from
the feed rod to the carriage.
4. Lathe Bed
5. Feed Mechanism
Relative motion of tool with the work piece is termed
as Feed.
Feed is transmitted from headstock spindle to
carriage.
Three types of feed: Longitudinal
Cross
Angular
LATHE ACCESSORIES
& ATTACHMENTS
5.
Angle Plates
3. Chucks
4. Face Plate
7.
6.
Rests
Mandrels
Centers
. Why centers are required?
Holding the work in between live centre and dead center
These two (live and dead) centers take the thrust due to metal
cutting and also bear the load of the work piece. So they are
made of very hard material to resist deflection and wear.
Centers
1.
2.
3.
4.
Ordinary Center
Ball Center
Frictionless Center
Half Center
5. Tipped center
6. Insert type
7. Pipe center
Centers
1. Ordinary Center:
2. Ball Center:
Centers
5. Insert type Center:
In ordinary center type tool,
whole tool is to replaced when it
goes blunt. In this, insert type of
center, only
inserted tip has to be
changed. So, it is
economical.
6. Tipped Center:
An ordinary tool center contains,
hard alloy tip brazed is called
tipped center.
7. Pipe Center :
Used for open end pipes, shell
etc. for thread cutting or Turning
operation on the lathe.
carrier
CHUCKS
. Function of chuck: - For holding and rotating a piece of
work.
. Jobs of short length, and large diameter or irregular
shapes, which can not be held conveniently mounted
between centers are held quickly and rigidly in a chuck.
.
1.
2.
3.
4.
Types of chucks:
4-Jaw Chuck
5. Collet Chuck
3-Jaw Chuck
6. Air or hydraulic Chuck
Combination chuck 7. Drill Chuck
Magnetic Chuck
4- Jaw CHUCK
4- Jaw CHUCK
Advantages:
Disadvantages:
a. Centering is a little difficult process.
b. Semi skilled labor are required.
3- Jaw CHUCK
Three jaw chuck or selfcentering chuck is the chuck,
which has three jaws for
holding the work piece.
If one jaw is moved (in any
3- Jaw CHUCK
Advantages:
a. Centering process is not necessary as all the jaws moves at
a time.
b. Consumes less time for mounting and un mounting the
work piece.
Disadvantages:
a. Grip is not so high as only three jows are employed.
b. All type of jobs cannot be mounted on these chucks, as
they are useful in machining only axis symmetrical objects.
Combination CHUCK
As the name indicates it is a
combination of both threejaw chuck and four-jaw
chuck.
It acts as both self-centering
and independent chuck.
This is obtained by engaging
a scroll disc at the backside
of jaws.
Magnetic CHUCK
Used for very thin work piece
made of magnetic material
which can not be held in
other chucks.
Also, used where distortion
occurs when it is held in
other chucks tightly.
Holding power is obtained by
magnetic flux radiating either
from electro-magnets or from
the permanent magnets
inserted in the chuck.
Magnetic CHUCK
In ON position, the flux passes through the work piece and grips it.
In OFF position, magnets are set aside bringing them in contact with high
permeable keepers which short circuit the flux and prevent them from passing
through work piece.
Advantages:
Work pieces in which damage due to the jaws of chucks is not tolerated can
be effectively machined by using this chuck.
If the work to be held is of very small size and cannot be hold by the above
three chucks then this chuck can be used.
Disadvantages:
a. All type of jobs cannot be held.
b. Size of the job affects the efficiency of the holding.
c. All type of materials cannot be held as it works on magnetic property only
magnetic materials can be held.
Collet CHUCK
Collet chucks are used for
holding bar stock in
production work where quick
setting and accurate
centering is needed.
The chuck attached to the
spindle by a nut consists of a
thin cylindrical busing known
as collet having a slot cut on
the periphery of chuck.
So, it is a holding device,
that forms a collar around
the object and provides high
clamping force, when it is
tighten by outer tapered
collar.
Collet CHUCK
Advantages:
Speed of chucking is high(Easy reclamping)
Self-centering
Disadvantages:
Each collet chuck has limited range, so for different range
of work piece size, different collets are required leads to
high capital cost.
This type of chuck is used for mass production work for its
fast and effective gripping capacity.
DRILL CHUCK
Face plate
Faceplates are used for holding
those work pieces, which cannot
be held both by centers and by
chucks.
It consists of a center bore and
plain and radial slots through the
plate for facilitating the holding
of the work piece.
The central bore has a radius
equal to that of the radius of the
spindle of the lathe. And the
plain and radial slots provide a
healthy platform for holding the
jobs by using T-bolts and clamps.
Angle plate
Example: Machining of a
pipe elbow
mandrels
. Function of Mandrel: - A device used for holding and rotating a hollow or
pre-drilled piece of work between two centers.
. The ends of the mandrels are made slightly smaller than the original diameter
for effective gripping of the mandrel in the chuck or any other holding device.
. In general the material used for the manufacturing of the mandrels is plain
carbon steel.
. Types of Mandrels:
1. Plain mandrels
5. Cone mandrels
2. Step mandrels
6. Gang mandrels
Plain mandrel
This type of mandrels finds
a numerous number of
applications in shops
where identical pieces are
to be generated.
The body of these
mandrels has generally a
tapered shape. The
difference in the tapped
diameter is of 1 to 2 mm
and the length varies
between 55mm to 430mm.
step mandrel
collar mandrel
Screwed mandrel
cone mandrel
gang mandrel
expansion mandrel
rests
. Function of Rest: - A device which supports a long
slender work piece, which is turned between center, at
any intermediate point to prevent bending of the work
piece due to its own weight and vibrations due to
machining.
. Rest are used when the length of the work piece is 10 to 12
times the diameter of the work piece.
. By using rest, we can achieve highest accuracy and heavy
depth of cut.
. Types of Rests:
Steady rest
Steady rest
Follower rest
Follower rest
LATHE OPERATIONS
1.
Centering
7.
Filing
2.
Turning
8.
Polishing
3.
4.
Thread cutting
5.
Facing
6.
Knurling
12. Forming.
Chamfering
9.
Grooving
10. Spinning
1.
Drilling
5.
Tapping
2.
Reaming
6.
Under cutting
3.
Boring
7.
Parting off
4.
centering
centering
turning
What do you mean by turning?
Types of turning :
1.Straight Turning
2.Shoulder Turning
Straight turning
Straight turning
rough turning
finish turning
This operation requires high
cutting speed, small feed, and
a very small depth of cut to
generate a smooth surface.
A finish turning tool having
sharp cutting edge is held
securely on the tool post for
this purpose.
In finish turning operation, the
depth of cut ranges from 0.5
to 1 mm and feed from 0.1 to
0.3 mm per revolution of the
work piece.
finish turning
Shoulder turning
When work piece having
different
diameter
is
turned, the surface forming
the step from one diameter
to the other is called
shoulder and machining
this part of w/p is called
shoulder turning.
Four types
turning:
1.
2.
3.
4.
of
shoulder
Square shoulder
Angular shoulder
Radius shoulder
Under cut shoulder
chamfering
Thread cutting
A single-point threading
tool, typically with a 60
degree
pointed
nose,
moves axially, along the
side of the work piece,
cutting threads into the
outer surface.
The threads can be cut to
a specified length and
pitch and may require
multiple passes to be
formed.
Thread cutting
Lathe Operations
Thread Cutting
Threads are helical ridge and of uniform section formed on
inside or outside of cylinder or cone.
Cutting threads is another important task carried out on the
lathe.
Thread cutting on lathe is also called as thread chasing.
Thread cutting can be considered as turning operation.
Lathe Operations
Thread Cutting - Thread Terminology
Major Diameter
Commonly known as the outside diameter . On a screw thread, the
major diameter is the largest diameter of the thread on the screw or
nut.
Minor Diameter
Called the root diameter, the minor diameter is the smallest
diameter of the thread on the screw or nut.
Lathe Operations
Thread Cutting - Thread Terminology
Pitch Diameter
Diameter of imaginary cylinder that passes through thread at
point where groove and thread widths are equal.
Equal to major diameter minus single depth of thread
Lathe Operations
Thread Cutting - Thread Terminology
Pitch
The distance from a given point on one thread to a corresponding
point on the very next thread.
Lathe Operations
Thread
Lead
Lathe Operations
Thread
Root
Lathe Operations
Thread
Crest
Lathe Operations
Thread
Depth of Thread
Lathe Operations
Thread
Thread Angle
Lathe Operations
Thread
Number of Threads
Lathe Operations
Thread Cutting - Thread Terminology
Right Hand Threads
Helical ridge of uniform cross section onto which nut is threaded in
clockwise direction.
When cut on lathe, tool advanced from right to left.
Lathe Operations
Thread Cutting - Thread Terminology
Left Hand Threads
Helical ridge of uniform cross section onto which nut is threaded in anticlockwise direction.
When cut on lathe, tool advanced from left to right.
Lathe Operations
Thread Cutting - Thread Terminology
Lathe Operations
Thread Cutting
Engine Lathes are designed with features that are provided
primarily for cutting screw threads.
The gear ratios in quick change gear box are selected to enable
lathe to cut a sequence of precise screw thread leads.
Lathe Operations
Thread Cutting
The lead screw, the split nut or
half-nut and the thread chasing
dial are build on the lathe for the
exclusive purpose of
cutting
screw thread.
Thread cutting
facing
knurling
It embosses the diamond
pattern on the steel work
piece
with
purpose
of
gripping.
This diagram shows the
knurling tool pressed against
a piece of round section
steel.
The lathe is set so that the
chuck revolves at a low
speed.
The knurling tool is then
pressed against the rotating
steel and pressure is slowly
increased until the tool
produces a pattern on the
steel.
knurling
The
automatic
control
lever is engaged which
starts
the
automatic
traverse of the saddle. As
the saddle moves along
the bed of the lathe the
knurled pattern is pressed
into the steel along its
length.
If single roller is used then
it
generates
parallel
grooves, but when two
rollers are used, then
diamond
shape
is
generated.
filing
Flat single cut file is passed over the work piece at very
high speed.
grooving
It is the process of
reducing the diameter of a
work piece over a very
narrow surface.
It is often done at the end
of a thread to leave a
small margin.
Speed of operation is half
of
the
turning
and
grooving tool of required
shape is fed straight into
the work.
Spring winding
forming
drilling
It is the operation of
producing a cylindrical hole
in a work piece by a
rotating cutting edge of a
cutter known as drill.
drilling
The work piece is held in a
chuck and the drill is held
in the tail stock by drill
holder.
The drill is held and driven
by a drill chuck attached to
the headstock spindle. And
the work is held against
tailstock.
This second method is
adopted in case of irregular
shapes of work piece.
drilling
boring
It is the process of
enlarging and truing a hole
produced
by
drilling,
punching,
casting
or
forging.
Boring can not generate
the hole.
It can also be done in two
ways:-
boring
Counter boring
It is the operation of
enlarging a hole through a
certain distance from one
end instead of enlarging
the whole drilled surface.
It is similar to shoulder
work in external turning.
reaming
It is the operation of
finishing and sizing a hole
which has been previously
drilled or bored.
The tool used is called
reamer, which has multiple
cutting edges.
Reamer
is
held
on
tailstock, which is held
stationary and the work
piece is revolved at very
slow speed.
Feed varies from 0.5 to 2
mm per revolution
It is the operation of
cutting internal threads of
small diameter using a
multipoint
cutting
tool
called the tap.
In the lathe, the work is
mounted on a chuck and
revolved at a very slow
speed.
A tap of required size held
on a special fixture is
mounted on tailstock.
undercutting
Parting-off
It is the operation of
cutting a work piece after
it has been machined to
the desired size and shape.
The
process
involves
rotating the work piece on
a chuck at half the speed
of the turning and feeding
by a narrow parting-off
tool perpendicular to the
lathe axis by rotating the
cross slide screw by hand.
Parting-off
milling
It is the operation of
removing metal by feeding
the work against a rotating
cutter
having
multiple
cutting edges.
milling
grinding
It is the operation of
removing metal of minute
chips by feeding the work
against
the
rotating
abrasive wheel.
External grinding is shown
in the figure.
For internal grinding, a
special attachment is used.
Application of tapering :
Construction of machines
taper shanks of tool
work holding devices
Taper
Taper
Taper
Taper
Taper
turning
turning
turning
turning
turning
by
by
by
by
by
a form tool
setting over the tailstock
swiveling the compound rest
a taper attachment
combining feeds
Taper turning by
setting over the tailstock
Taper turning by
setting over the tailstock
Taper turning by
setting over the tailstock
Or
Where,
o
o
o
Taper turning by
swiveling the compound rest
Taper turning by
swiveling the compound rest
By a compound slide
o Taper angle calculation
o Where
o D and d are the major and minor diameter of the workpiece.
o = half included angle
o L = Length of the tapered portion
By a compound slide
o ProblemDetermine 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.
o Solution
Given data:
o D = Major diameter of the workpiece = 80 mm
o d = Minor diameter of the workpiece = 50 mm
o L = Length of the workpiece to be tapered = 80 mm
Taper turning by
taper attachment
Taper turning by
taper attachment
When the taper turning
attachment is used, the
cross slide (4) is made free
from the lead screw by
removing the binder screw
(5).
The rear end of the cross
slide is then tightened with
the guide block by means
of bolt.
When the longitudinal feed
is
engaged,
the
tool
mounted on the cross slide
will follow the angular path,
as the guide block (2) will
Taper turning by
taper attachment
The required depth of cut is
given by the . compound
slide which is placed at right
angles to the lathe axis.
The bar must be set at half
taper angle and the taper on
the
work
converted
in
degrees.
The maximum angle through
which the guide bar may be
swiveled is 100to 12on
either side of the centre line.
Taper turning by
combining feeds
As shown in fig, this is a
more specialized method
of turning taper.
TYPES OF LATHE
Bench lathe
Speed lathe
Centre or engine lathe
Tool room lathe
Capstan and turret lathe
Special purpose lathe
Automatic lathe
Types of lathe
Special purpose lathe Wheel lathe-finishing the journal and turning the threadon
car and locomotive
Gap bed lathe-swing extra large piece diameter
Duplicate lathe-duplicating the shape of flat or round
templates
T-lathe-for machining of rotor for jet engines
Turret lathe
1. The turret directly mounted on the
saddle which slides on the bed.
So it moves on entire length of
bed and can machine longer work.
2. The turret is mounted on the
saddle which slides directly on
lathe bed ways .It provides rigidity
to tool .
ASSIGNMENT-2
1. How a lathe is specified ? Discuss.
2. What is the function of lathe ? List various types of lathe .
3. What is mandrel ? Where it is used ? List different types
of mandrel.
4. What are the feed mechanisms used in lathe ?
5. What are the different types of centres used in lathe ?
ASSIGNMENT-3
1.
2.
3.
4.
5.
6.