Machining

Machining is the process of removing the excess

material from the work piece in the form of
chips, by forcing a cutting tool with one or more
cutting edges.
Machine tool is a power driven machine to
perform machining. A machine tool performs
three major functions;
(i) It rigidly supports the work piece and the
cutting tool.
(ii) It provides relative motion between the work
piece and the cutting tool
(iii) It provides a range of speeds & feeds.
P R Venkatesh, Mech Dept, RVCE, B'lore
 Machining
Generally, machine tools produce either
cylindrical or flat surfaces.

The most commonly used machine tools are;

(i) Lathe
(ii) Drilling Machine
(iii) Shaping Machine
(iv) Planing Machine
(v) Milling Machine
(vi) Grinding machine

P R Venkatesh, Mech Dept, RVCE, B'lore

 Lathe
It is a machine tool which holds the work in a
holding device and rotating it against a suitable
cutting tool to remove the excess metal from the
work.
If the tool is moved parallel to the axis of
rotation of the work, a cylindrical surface is
produced.
If the tool is moved perpendicular to the axis of
rotation of the work, a flat surface is produced.
Lathes are classified as;
(i) Bench Lathe (ii) Speed lathe (iii) Engine Lathe
(iv) Tool room lathe (v) Capstan & Turret lathe
(vi) Automatic lathe (vii) Special purpose lathe
P R Venkatesh, Mech Dept, RVCE, B'lore
Bench Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

Speed Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

Engine Lathe (or) Center Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

Tool Room Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

Capstan & Turret Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

Automatic Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

Special Purpose Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

 Lathe Specifications
Overall length of bed

Distance between centers

Swing diameter
over gap in the bed
Swing diameter
Lathe Bed
over lathe bed

Specifications of a Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

 Lathe Specifications
The size of a lathe is specified by the following:
1. Maximum diameter of the work piece that can
be revolved over the lathe bed.
It is also called as height of centers above the
lathe bed Or Swing diameter over lathe bed.
2. Maximum diameter and width of the work
piece that can swing when the lathe has a gap
bed.
3. Maximum length of work piece that can be
mounted between centers
4. Overall length of bed: It is the total length of
the lathe itself.
5. Maximum number of speeds & feeds
available. P R Venkatesh, Mech Dept, RVCE, B'lore
 Gear box controls
Chuck Tailstock
Cross slide
HeadStock Tool post

Rack

Feed box Lead screw

Carriage Feed Feed rod

engage Bed
Tray
Screw cutting
engage lever

Parts of a Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
The major parts of a lathe are:
1. Bed
2. Headstock
3. Tailstock
4. Carriage
5. Feed rod
6. Lead screw

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
1. Bed:
The lathe bed forms the support for all other
parts.
At the top of the bed, precision machined
guide ways (inner & outer) are present.
The headstock & tailstock are mounted on the
inner ways which keep them perfectly aligned
with each other.
The outer ways guide the movement of
carriage assembly.
Bed is usually made of grey cast iron because
of its good damping property and low
frictional resistance.
P R Venkatesh, Mech Dept, RVCE, B'lore
 Lathe Bed

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
2. Headstock
Headstock is a box like casting mounted at
the left end of the machine.
It consists of a spindle and gear box to
rotates the spindle at different speeds.
The spindle has external threads to
receive a work holding device such as a
chuck or face plate.
The gear box distributes power to the feed
rod and lead screw for turning or thread
cutting operation.
P R Venkatesh, Mech Dept, RVCE, B'lore
Headstock

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
3. Tailstock
Tailstock is mounted at the right end of the
machine.
It may be slided on the guide ways to support
different lengths of work pieces between
centers and clamped to bed at any desired
location.
It carries a dead center or revolving center.
Tailstock can be offset for taper turning. It can
also carry tools like drill bit, reamer, tap, etc.
P R Venkatesh, Mech Dept, RVCE, B'lore
 Tailstock

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
4. Carriage Assembly
It supports and feeds the cutting tool against
the work during operation of the lathe.
The carriage slides along the outer guide ways
and consists of the following parts;
(i) Saddle
(ii) Cross slide
(iii) Compound slide
(iv) Tool post
(v) Apron P R Venkatesh, Mech Dept, RVCE, B'lore
Carriage Assembly

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
(i) Saddle :
It is a H-shaped casting that slides over the
outer guide ways and serves as a base for
the cross slide.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
(ii) Cross slide:
It is mounted on the saddle and enables the
movement of the cutting tool laterally across
the lathe bed by means of a cross feed hand
wheel.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
(iii) Compound rest:
It is mounted on the top of the cross slide
and supports the tool post. It can be
swiveled to any angle to facilitate taper
turning & threading operations.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
(iv) Tool Post
It is mounted on the top of the
compound rest and carries the cutting
tool.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
(v) Apron:
The portion of the carriage that extends in front
of the lathe is called an apron. It houses feed
mechanisms. It contains pinion which engages
with the rack for longitudinal feed.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
6. Feed Rod:
The feed rod is a long shaft used to drive the
apron mechanism for cross & longitudinal
power feed during turning, boring & facing
operations. The feed rod is powered by a set of
gears from the headstock.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
5. Lead Screw:
It is a long threaded shaft geared to the
headstock. Closing a split nut around the
lead screw engages it with the carriage. It
used only for thread cutting operations.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Lathe Operations
The most common operations performed on
a lathe are:
1. Turning
2. Facing
3. Parting
4. Grooving
5. Knurling
6. Drilling
7. Boring
8. Taper turning
9. Thread cutting
P R Venkatesh, Mech Dept, RVCE, B'lore
 Turning or Plain Turning:
Chuck
Work piece
Spindle Depth of cut

Dead center

Feed Cutting Tool

Plain Turning
P R Venkatesh, Mech Dept, RVCE, B'lore
 Turning or Plain Turning:
Plain turning is a lathe operation to remove
excess material from the workpiece & to
produce cylindrical surface.
Using the cross slide the cutting tool is first
adjusted for desired depth of cut.
As the workpiece revolves, the tool is fed against
the workpiece in a direction parallel to the axis
of the spindle.

P R Venkatesh, Mech Dept, RVCE, B'lore

Plain turning animation

P R Venkatesh, Mech Dept, RVCE, B'lore

 Facing Operation
Chuck
Work piece
Spindle

Machined
flat surface

Feed

Facing Tool

P R Venkatesh, Mech Dept, RVCE, B'lore

 Facing:
Facing is a lathe operation to produce a flat
surface normal to the axis of rotation of the
spindle.
During facing, the carriage is locked to the lathe
bed to prevent its movement.
Using cross slide the cutting tool is fed at right
angles to the axis of the work piece.

P R Venkatesh, Mech Dept, RVCE, B'lore

Parting off & Grooving
Chuck
Work piece
Spindle
Groove

Feed

Parting tool

Parting & Grooving

P R Venkatesh, Mech Dept, RVCE, B'lore
 Parting & Grooving:
Parting or cutting off is the operation of
separating a piece of finished work from the bar
stock. It is done with a narrow cutting tool called
Parting tool.
Grooving or necking is the operation of reducing
the diameter of the workpiece over a narrow
surface. It is done by feeding a form tool or
parting tool into the work using cross slide.

P R Venkatesh, Mech Dept, RVCE, B'lore

Parting off & Grooving

P R Venkatesh, Mech Dept, RVCE, B'lore

 Knurling
Chuck
Knurled
Spindle surface

Knurling
tool

Feed Movement
for depth

Tool
Post

P R Venkatesh, Mech Dept, RVCE, B'lore

 Knurling
Knurling is the process of embossing a diamond
shaped pattern on the surface of the workpiece
by the use of revolving hardened steel wheels
pressed against the work.
Knurling is done to provide grip on handles,
screw heads and other cylindrical parts to be
gripped by hand.

P R Venkatesh, Mech Dept, RVCE, B'lore

Knurling Tool
Knurled surface

P R Venkatesh, Mech Dept, RVCE, B'lore

 Drilling
Chuck

Work piece Tailstock

Spindle Drill bit

Sleeve
Feed

P R Venkatesh, Mech Dept, RVCE, B'lore

 Drilling
Drilling is an operation of producing cylindrical
hole by means of a cutting tool called drill.
A drill it is placed in the tapered hole of a
tailstock sleeve and is fed into the work by
rotating the hand wheel of the tailstock.

Twist Drill
P R Venkatesh, Mech Dept, RVCE, B'lore
 Boring
Chuck
Work piece
previously drilled
Spindle Depth of cut

Feed

Boring Tool
Feed

P R Venkatesh, Mech Dept, RVCE, B'lore

Boring in Lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

 Boring
Boring is an operation of enlarging a hole
previously drilled with the help of a boring tool.
As in turning, the depth of cut is adjusted by the
cross slide and the feed is obtained by carriage
movement.

Boring Bar
P R Venkatesh, Mech Dept, RVCE, B'lore
 Taper Turning
Taper turning is an operation on a lathe to produce
conical surface on work pieces.
Taper on a lathe is the difference between the diameters
over a length.
If D is the larger diameter & d the smaller diameter, l is
the length between the two diameters, then
Taper (or) Conicity = (D-d)/ l

D - d
(D-d)/2
Half angle of taper = tan
-1

D 2l
d

l
P R Venkatesh, Mech Dept, RVCE, B'lore
 Taper Turning Methods
A taper may be turned by any one of the following
methods.
1. By form tool
2. By swiveling the compound rest
3. By Tailstock off set method
4. By using Taper turning attachment

P R Venkatesh, Mech Dept, RVCE, B'lore

 Taper Turning using form tool
Here a form tool which has a straight edge set at the
desired angle is used.
The angle between the cutting edge and the axis of
the spindle equals half taper angle.
This method is limited to short tapers & is mainly
used for chamfering.
Work piece
Taper

Feed
Form tool
P R Venkatesh, Mech Dept, RVCE, B'lore
 Taper Turning swiveling the compound rest
The compound rest may be swiveled & clamped at any
desired half angle of taper on a circular base graduated in
degrees.
The tool is fed by rotating the compound slide screw.
This is also limited to short tapers as the movement of
the compound slide screw is limited.
Work piece
Tool

d
Fee
Compound slide

Cross slide
P R Venkatesh, Mech Dept, RVCE, B'lore
 Taper Turning by tailstock set over (offset)
In this method, the center line of the work piece
may be offset from the axis of the lathe and the tool
is fed parallel to the axis of the lathe.
This is achieved by moving the tailstock either
towards or away from the operator by means of a
set over screw. Used for small tapers on long jobs.
L

Tailstock set over

center line of lathe
D
Offset (s)

D - d
d s= L
Headstock center 2l
where L = length of work
Center line of work
Tailstock center

P R Venkatesh, Mech Dept, RVCE, B'lore

 Taper Turning by using attachment
Guide bar Slide Block
A taper turning
Scale (deg) attachment is a fixed
casting attached to the
back of the lathe bed.
It consists of a guide
Link Bed bar which may be set
Cross slide
at any desired angle of
taper.
A sliding block moves
over the guide bar
Compound Rest thus moving the cross
slide & hence the tool
parallel to the guide
bar.
Used for long tapers
with small included
angles.
P R Venkatesh, Mech Dept, RVCE, B'lore
Taper Turning by using attachment

P R Venkatesh, Mech Dept, RVCE, B'lore

 Standard Tapers
Machine parts and tools having tapers are standardized to
ensure interchangeability of components.
The most commonly used standard tapers are Morse
Taper and Metric taper.
Morse Taper: Available in eight sizes. Taper is 5/8 inch per foot length.
Standard sizes 0,1,2,3,4,5 ,6 & 7
The number indicates the size of larger diameter in inches as
below:

#0 is 0.356
#1 is 0.475
#2 is 0.700
#3 is 0.938
#4 is 1.231,
#5 is 1.748
#6 is 2.494
#7 is 3.270
P R Venkatesh, Mech Dept, RVCE, B'lore
 Metric Taper :
Metric Taper :
Available in eight sizes. Taper is 1:20.
Standard sizes 4,6,80,100,120140,160 & 200.
The number indicates the size of larger diameter in mm.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Thread Cutting
Chuck The principle of thread
Spindle
Work piece cutting on a lathe is to
produce a helical groove
on a revolving cylindrical
surface by feeding the
tool longitudinally as
Threading tool shown in fig.
Change gears
Lead Screw Split nut The change gear
calculations are made
for the desired pitch of
the screw and the split
nut is closed.
This engages the
carriage with the lead
screw and the threading
tool is fed into the work
using both cross feed &
longitudinal feed.
P R Venkatesh, Mech Dept, RVCE, B'lore
Threading Tool

P R Venkatesh, Mech Dept, RVCE, B'lore

Milling Attachment on a lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

Grinding Attachment on a lathe

P R Venkatesh, Mech Dept, RVCE, B'lore

 Cutting Tool Materials
The following materials are commonly used in
making the cutting tools;
(i) Carbon Tool steel
(ii) High speed Steel (HSS 18-4-1)
( Means 18% Tungsten 4% Chromium & 1%
Vanadium)
(iii) Cemented carbides
(iv) Ceramics
(v) Diamonds
P R Venkatesh, Mech Dept, RVCE, B'lore
 Desirable properties of Cutting Tool materials
1. Hardness, strength to withstand cutting forces &
toughness.
2. Ability to resist high temperature
3. Low frictional coefficient
4. Resistance to wear
5. Ability to be formed into desired shape
Single Point Cutting Tools:
They have only one cutting edge.
Ex: Lathe tools, Shaper Tools, Boring tools, etc.
Multi Point Cutting Tools:
They have more than one cutting edge.
Ex: Drills, Milling cutters, Grinding wheels, etc.
P R Venkatesh, Mech Dept, RVCE, B'lore
 Single Point Cutting Tool
Shank Axis

Side rake
Face angle

End cutting Back

edge angle rake
angle

cutting edge
Nose
Side releif angle

Flank
End releif angle
P R Venkatesh, Mech Dept, RVCE, B'lore
 Flank Side rake
Back rake angle angle

Lip
angle

End releif
angle
Front view Left side view
Base
Shank Side releif
angle
Shank

End cutting
edge angle

Nose radius

side cutting
edge angle Top View
P R Venkatesh, Mech Dept, RVCE, B'lore