LATHE MACHINE

Specifications
 Swing- the largest work diameter that can be swung for the lathe bed.
 The distance between the headstock and tailstock center.
 Length of the bed in a meter.
 The pitch of the lead screw.
 Horsepower of the machine.
 Speed range and the number of speeds of HS spindle.
 The weight of the machine in a tonne.

Different Parts

Headstock
The headstock is usually located on the left side of the lathe and is equipped with gears, spindles,
chucks, gear speed control levers, and feed controllers.

Tailstock
Usually located on the right side of the lathe, the workpiece is supported at the end.

Bed
The main parts of the lathe, all parts are bolted to the bed. It includes the headstock, tailstock,
carriage rails and other parts.

Carriage
The carriage is located between the headstock and the tailstock and contains apron, saddle,
compound rest, cross slide and tool post.
Lead Screw
The lead screw is used to move the carriage automatically during threading.

Feed Rod
It is used to move the carriage from left to right and vice versa.

Chip Pan
It is present at the bottom of the lathe. Chip pan is used to collect the chips that are produced during
the lathe operation.

Hand Wheel
It is the wheel that is operated by hand to move a cross slide, carriage, tailstock and other parts that
have handwheel.

Modifications
Taper turning attachment
Taper cylindrical surface, which is a very common feature of several engineering components, is
generally produced in lathes in a number of methods, depending upon length and angle of the
tapered position of the job, such as offsetting tailstock, swivelling the compound slide using form
tool and combined feed motions. But jobs with wide ranges of length and angle of taper, are easily
machined by using a simple attachment, called taper turning attachment. Thus, the cutting tool,
which is fitted on the cross slide through the tool post and the compound slide, also moves along
with the guide black in the same direction resulting the desired taper turning.

Milling attachment
This is a milling head, comprising a motor, a small gear box and a spindle to hold the milling cutter,
mounted on the saddle after removing the cross slide etc. Milling attachments are generally used for
making flat surfaces, straight and helical grooves, splines, long and deep screw threads, worms etc.
in centre lathes by using suitable milling cutters.

Grinding attachment
Grinding attachment is very similar to milling attachment. But in the former, there is no gear box
and the spindle speed is much higher as needed for grinding operation. Such attachments are
employed for external and internal cylindrical grinding, finishing grooves, splines etc. and also for
finish grinding of screw threads in centre lathe. But unlike dedicated machines, attachments cannot
provide high accuracy and finish.

Spherical turning attachments

These simple attachments are used in centre lathes for machining spherical; both convex and
concave surfaces and similar surfaces. The desired path of the tool tip is controlled by the profile of
the template which is premade as per the radius of curvature required. The saddle is disconnected
from the feed rod and the leadscrew. So when the cross slide is moved manually in transverse
direction, the tool moves axially freely being guided by the template only.

Uses
Lathes are used in woodturning, metalworking, metal spinning, and in glass working. Lathes can be
used to shape pottery as well. Most suitably metalworking lathes can be used to produce most solids
of revolution, plane surfaces and screw threads or helices. Ornamental lathes can produce three-
dimensional solids of incredible complexity.
 SHAPING MACHINE

Specifications
1. Length of Stroke.
2. Maximum Horizontal Travel of Table.
3. Maximum Vertical Travel of Table.
4. Maximum distance from Table to Ram.
5. Maximum Vertical Travel of Tool Slide.
6. Length &Width of Table Top.
7. Length &Depth of Table Side.
8. Power of Motor.

Different Parts
Base
The base of the machine is the main body of the machine and serves as the backbone for the other
parts. The base of the machine is designed to carry the weight of the machine and is bolted. It is
made of cast iron and can withstand the vibration and load of the machine.

Column
The Column of shaper machine is a cast-like casting that is cast from iron and mounted on a
pedestal. It is equipped with precision guide rails on which the ram moves back and forth.

Cross-rail
The beam is mounted on the column, allowing the movement of the table to move laterally. The
table can be raised or lowered by rotating the lifting screws to suit different sizes of work.

Workbench Table
The table is fixed to the saddle by bolts and receives lateral or vertical movement from the saddle
rail. The table can be rotated at any angle to meet the working requirements. The main work of the
table is to fix the workpiece.

Ram
The tool moves back and forth on the guide rail and carries the tool head with a single-point cutting
tool. The working punch performs the cutting motion in the forward direction, while the reverse
direction drives the tool head to quickly slide back and repeats the round trip to perform the same
work again.

Tool Head
The tool head is equipped with a cutting tool that can feed the screw handle downwards to allow the
cutting tool to perform a cutting motion.

Modifications
Attachment for double cut
This simple attachment is rigidly mounted on the vertical face of the ram replacing the clapper box.
It is comprised of a fixed body with two working flat surfaces and a swing type tool holder having
two tools on either faces as can be seen in Fig. 4.6.9. The tool holder is tilted by a spring loaded
lever which is moved by a trip dog at the end of its strokes. Such attachment simply enhances the
productivity by utilising both the strokes in shaping machines.

Thread rolling attachment

The thread of fasteners is done by mass production methods. Thread rolling is hardly done
nowadays in shaping machines. However the configuration, mounting and the working principle of
the thread rolling (in shaping machine) attachment are visualised in Fig. 4.6.10. In between the flat
dies, one fixed and one reciprocating, the blanks are pushed and thread – rolled one by one.

Matterson’s attachment
Various machines and processes have been developed for producing gear teeth with high
productivity and job quality. Gear teeth are hardly produced nowadays in shaping machines. But, if
required, it may be occasionally done by shaping machine in some small tool room or small
workshop specially for repair and maintenance work. One or two, even all the teeth of a gear may
be cut by forming tool in shaper using an indexing head. But such forming, specially in shaper is
not only very slow process but also not at all accurate. But the Matterson’s attachment can produce
gear (spur) teeth even in shaping machine by generation process. The working principle of the
attachment is shown in Fig. 4.6.11. For generation of the tooth by rolling the blank is rotated and
the bed is travelled simultaneously at same linear speed by the synchronised kinematics as indicated
in the diagram. After completing one tooth gap both the tool and blank are returned to their initial
positions and then after indexing the blank for one tooth, the tool – work motions are repeated.

Uses
A shaping machine is used to machine flat surface. It can cut grooves, angles and many other
shapes. The Main Function of shaper is to generate a flat surface by combination of linear
movement of cutting tool and work piece. Shaping is where the work piece is fed at right angles to
the cutting motion between successive strokes of the tool.
DIAGRAM

Milling Machine Definition

The milling machine is defined as perhaps most widely used in manufacturing
industries after the lathe machine. 
However, In the case of lathe machine tool, the tools used there single point
cutting tools but In the case of this machine, the tool used is multi-point cutting
tools.
The milling is a process of metal-removing by feeding the workpiece passes
through the rotating multipoint cutter.
This machine can hold one or more number of cutters at a time and rotates at
high speed to remove the metal at a faster rate.
The metal removal rate is faster as compared to a lathe machine.
This machine is used to make gears like Spur gears, and also drill the workpiece
bore, and produce slots.

Milling Machine Parts

A milling machine consists of the following parts:
 Base
 Column
 Knee
 Saddle
 Table
 Overhanging Arm
 Spindle
 Arbor
 Arbor Supports
 Milling Head
 Ram

Milling Machine Types

The types of milling machines are the following:
 Column and Knee Type Milling
 Vertical Milling
 Horizontal Milling
 Universal milling
 Fixed Bed Milling
 Simplex Milling
 Duplex Milling
 Triple Milling
 Planer Milling
 CNC Milling
 Tracer Milling

Operations that can be performed in a Milling Machine:

There are several types of operation that can be performed in a milling machine,
and those are:
 Plain Milling Operation
 Face Milling Operation
 End Milling Operation
 For Milling Operation
 T-slot Milling Operation
 Side Milling Operation
 Gear Milling Operation
 Straddle Milling Operation
 Grooves Milling Operation
 Gang Milling Operation

Plain Milling Operation:

It is the operation on producing plain, flat, horizontal surface, parallel to the axis
of rotation.

Face milling Operation:

This machining operation is done on the surfaces which are perpendicular to the
axis of the cutter.

End milling operation:

It is the process of producing flat surfaces which may be horizontal, vertical and
at an angle taking worktable as a reference.

Form milling Operation:

It is the process of machining special contour (outline) composed of curves,
straight lines, or entirely of curves, at a single cut.

T-slot milling Operation:

It is the operation of producing the T-slots on the workpiece by using the T-slots
milling cutter.

Side milling Operation:

It is the operation on producing the flat vertical surface on the sides of the
workpiece by using a side milling cutter.

Gear cutting Operation:

It is the operation on producing gear tooth on the gear blank by using a form-
relieved cutter in a milling machine.

Straddle milling Operation:

It is the operation on producing the flat vertical surface on both sides of the
workpiece by using two side milling cutter mounted on the same arbor.

Grooves milling Operation:

It is the operation on producing the groove on the surface of the workpiece by
using a saw-milling cutter or end milling cutter.
Gang milling Operation:
It is the machining process in which two or more milling cutters are used
together to perform different milling operations simultaneously.

Application of Milling machine:

In the milling machine there are following applications, those are:
Ideal for the production of individual pieces and small batches.
Capable of producing complex shapes with the use of multitooth, as well as a
single point, cutting tools.
Operation cost can be very modest given general-purpose equipment and
cutters are used.
DIAGRAM

  
                         
 

Slotter Machine Specification: 

The specifications of a Slotter Machine are depended on the several factors
some of these are: 

 Power Input 
 Type of drive 
 Maximum table drive 
 The maximum length of ram stroke 
 Number of speed 
 Number of feed 
 Table feed 
 Floor space required 
 The diameter of the Work Table in MM 
 kW of motor 
Slotter Machine Parts: 
A slotter machine consists of these following parts: 
 Base 
  Column 
 Saddle 
 Cross-slide 
 Rotating or Circular table 
 Ram and tool head 
 Ram drive 
 Feed drive 
 

Slotter Machine Operations: 

It is used for various operations like: 
 Internal and external Flat surface Machining. 
 The internal recess of circular, semi-circular, concave and convex
surfaces. 
 Internal and External Circular surfaces Machining. 
 Blind Holes Internal machining. 
 For shaping internal and external forms or profiles. 
 The machine operates vertical, Horizontal and at Some angle too (Inclined
Surfaces). 
 Irregular surface machining. 
 Machining operation of Dies and Punches. 
 The operation like slots, grooves, splines, and keyways for both internal
and external surfaces. 
 Internal and external gear teeth machining. 

Types of slotter machines:

Slotting machines are mostly of the following 4 types:
 Precision Tool Room Slotter
 Puncher Slotter
 General Production Slotter
 Keyseater Slotter
 
Slotter Machine Mechanism: 
 Hydraulic Drive (Greater speed Flexibility, Smoother operation, Stroke
length can be adjusted) 
 Variable Speed Motor Drive (In this Multi-speed arrangement) 
 
Hydraulic Drive: 
A speed motor drives a hydraulic pump that delivers oil at a constant pressure
to the line. 
A regulating valve admits oil under pressure to each end on the piston
alternately. 
At the same time allowing oil from the opposite end of the piston to return to
the reservoir. 
The piston is pushed by the oil and being connected to ram by piston rod,
pushes the ram carrying the tool. 
The admission of oil to each end of the piston, alternately, is accomplished with
the help of trip dogs and pilot valves. 
As the ram moves and complete its stroke (Forward and Return) a trip dog will
trip the pilot valve which operates the regulating valve. 
The regulating valve will admit the oil to the other side of the piston and the
motion of the ram will get reversed. 
The length of the ram stroke will depend upon the position of trip dogs. The
length of the ram stroke can be changed by unclamping and moving the trip
dogs to the desired position. 
 
Variable Speed Motor Drive: 
In this type of slotter, speed is obtained by different gears present in the gearbox
and the shaft rotates with the help of an electrical motor. 
Basically it is used in modern large slotting machines. 
 

Slotter Machine Application: 

These are the applications of a Slotter Machine: 
 It is used for cutting Slots, Spline and Keyways, both internal and
external. 
 It is also used for the Machining of internal and external gears. 
 Internal machining of blind holes. 
 It is used for light cuts. 
CNC

The term CNC stands for

'computer numerical control',
and the CNC machining
definition is that it is a
subtractive manufacturing
process which typically
employs computerized
controls and machine tools to remove layers of material from a stock piece—known as the blank or
workpiece—and produces a custom-designed part. This process is suitable for a wide range of
materials, including metals, plastics, wood, glass, foam, and composites, and finds application in a
variety of industries, such as large CNC machining and CNC machining aerospace parts. When
speaking in terms of the machine itself, the CNC machine definition is that it represents the actual
programmable machine that is capable of autonomously performing the operations of CNC
machining. Note the contrast between the process (CNC machining definition) versus the machine
(CNC machine definition).

Subtractive manufacturing processes, such as CNC machining, are often presented in contrast to
additive manufacturing processes, such as 3D printing, or formative manufacturing processes, such
as liquid injection molding. While subtractive processes remove layers of material from the
workpiece to produce custom shapes and designs, additive processes assemble layers of material to
produce the desired form and formative processes deform and displace stock material into the
desired shape. The automated nature of CNC machining enables the production of high precision
and high accuracy, simple parts and the cost-effectiveness when fulfilling one-off and medium-
volume production runs. However, while CNC machining demonstrates certain advantages over
other manufacturing processes, the degree of complexity and intricacy attainable for part design and
the cost-effectiveness of producing complex parts is limited.

Specifications-
Specification of a CNC machine can be categorized into these following points:

Machine specifications:

Centers height.
Distance between centers.
Swing diameter over the bed.
Swing diameter over the cross slide.
Transverse movement of the cross slide.

Headstock specifications:
Hole in the headstock spindle.
Spindle end-use taper.
Tailstock specifications:

Spindle diameter.
Spindle end taper.
Sleeve travel.
Feed rate:
Rapid transverse.
Programmable feed rate.
Main Spindle specifications:

Speed range.
Output power.

Parts of a CNC Machine-

Parts of CNC Machine:
A CNC machine is consists of the following parts:

Bed
Headstock
Tailstock
Tailstock quill
Footswitch or pedal
Chuck
Control panel
Tool turret
Let’s go into details.

Bed:
The bed is kind of hardened parts of a machine because The tool turret travels over the CNC lathe
bed, kind of machining can’t affect them.

Headstock:
The headstock is the main part of the machine, here the workpiece is fixed to perform an operation
and also Headstock of a CNC lathe machine has the main motor which drives the main spindle.

Tailstock:
The tailstock is for providing extra grip to the workpiece. When the operation like knurling,
threading has performed these parts used to hold the workpiece.

Tailstock quill:
This is kind of setting the workpiece between the centers.

Footswitch or pedal:
Through these pedals, CNC machinist’s open and close the chuck to grip the component, the same
way tailstock quill is taken to forward position or reversed.

Chuck:
Chuck is mounted on the main spindle. Here we fixed the workpiece.

Control panel:
The control panel is another main part of the CNC machine in which we use to set or feed the
program for the operation we perform on the workpiece.

This is also called the brain of a CNC machine.

Tool turret:
The tool is mounted on the tool turret which is used for component machining.
Tool turrets vary in shapes and the number of tools that can be mounted on them.

These are the Parts of CNC machine, now I will talk about the CNC system.

Elements of the CNC Machine system:

A CNC machining system is consists of the following elements:

Program
Tape Reader
Mini-computer
Servo system
CNC machine tool
Program:
This is entered into the computer through a keyboard. These are the codes used to control the
machine.

The various CNC codes are N Code, G Code, XYZ Code, F code, etc.

Below is the table where I write all the common codes used in CNC.

Tape Reader:
This is used as a storage device where we can store the program for a particular machining
operation.

Any modification of a program can easily be done by editing the existing program as per your
requirement.

Mini-computer:
It is also called the machine control unit. It is to read interprets and converts perceived input, that is
part program into the desired movement and controls the following functions:

To start and stop the machine spindle.

Vary the spindle speed accordingly and also it can control the direction of rotation of the spindle.
To start and stop the coolant supply.
To change the required tools as per requirements.
To change the workpiece.
To control the feed rate.
Also, the mini-computer equipped with diagnostic software which can detect any problem and
restore the machine accordingly.

Servo system:
The function of the servo system is to receive the control signal from the feedback devices and the
set output accordingly (To shaft, tools and other components of CNC machine)

Servo system mainly consists of:

Servo Motors
Feed-back devices
Ball screws
CNC Machine:
This is the actual machine where the finished product made. I already mentioned the parts of the
CNC machine above this heading.

This is the housing of headstock, tailstock, foot switch, chuck, and tool turret.

Accessories-
Depth controller / Engraving stopper.
Collet set for Kress router spindle motor.
Kress collet 2.35 mm.
Minimum quantity lubrication system.

Modification of a CNC Machine-

CNC laser cutting machine
As the name itself indicates “Laser cutting” it means the cutting operation is carried by laser and the
operation code is fed into machine runs automatically, it is called CNC laser cutting machine.

CNC Lathe Machine

This is widely used as a lathe in the present time because of its fast and accurate working. It is one
of the most advanced types.
It uses computer programs to control the machine tool. Once the program is fed into the computer
as per the program it starts operation with very high speed and accuracy.

CNC Milling Machine

Milling Machine is a process of metal-removing by feeding the workpiece passes through the
rotating multipoint cutter.
This machine is used to make gears like Spur gears, and also drill the workpiece bore, and produce
slots.
The same work is performed in CNC Milling by inserting the part program into the system.

CNC router Machine

It works similarly as other CNC machines like lathe or Milling do.
The main difference is, it does all the carpenter work manually like such as door carvings, interior
and exterior decorations, wood panels, signboards, wooden frames, moldings, musical instruments,
furniture, and so on.

CNC Plasma Cutting Machine

The Plasma cutting machine is defined as It is a process that cuts through electrically conductive
materials using an accelerated jet of hot plasma.

5- axis machine
5 The Axis machine is used for making sculptures.

3-D Printer
3D Printer is a CNC machine in which the metals are printed layer by layer. The 3D printer works
for the printing of buildings and complexes.
The design and drawing are made by the CAD and CAM process and then 3D Printer works for
visualizing that design.
Advantages-
The main application of the CNC machine is to remove metal at a faster rate as compared to a
traditional machine-like lathe, milling machine.
This is also used in fabrication industries.
This machine is used for automatic removal of metal from the workpiece
wherein another machine like lathe, Milling the metal remove is done manually.
Automatic Lathe-

Small- to medium-sized cam-operated automatic lathes are usually called screw machines or
automatic screw machines. These machines work on parts that (as a rough guide only) are up to 80
millimetres (3.1 in) in diameter and 300 millimetres (12 in) in length. Screw machines almost
invariably do bar work, meaning a length of bar stock passes through the spindle and is gripped by
the chuck (usually a collet chuck). As the part is being machined, the entire length of bar stock is
rotated with the spindle. When the part is done, it is 'parted' from the bar, the chuck in released, the
bar fed forward, and the chuck closed again, ready for the next cycle. The bar-feeding can happen
by various means, including pulling-finger tools that grab the bar and pull or roller bar feed that
pushes the bar from behind.

Larger cam-operated automatic lathes are usually called automatic chucking lathes, automatic
lathes, automatic chuckers, automatics, or chuckers. The 'chucker' part of the name comes from the
workpieces being discrete blanks, held in a bin called a "magazine", and each one takes a turn at
being chucked and machined. (This is analogous to the way that each round of ammunition in the
magazine of a semi-automatic pistol gets its turn at being chambered.)

Specifications-
An automatic lathe may have a single spindle or multiple spindles. Each spindle contains a bar or
blank of material that is being machined simultaneously. A common configuration is six spindles.
The cage that holds these six bars of material indexes after each machining operation is complete.
The indexing is reminiscent of a Gatling gun.

Each station may have multiple tools that cut the material in sequence. The tools are usually
arranged in several axes, such as turret (rotary indexing), horizontal slide (linear indexing), and
vertical slide (linear indexing). The linear groups are called "gangs". The operation of all these tools
is similar to that on a turret lathe.

By way of example: a bar of material is fed forward through the spindle. The face of the bar is
machined (facing operation). The outside of the bar is machined to shape (turning operation). The
bar is drilled or bored, and finally, the part is cut off (parting operation).

In a single-spindle machine, these four operations would most likely be performed sequentially,
with four cross-slides each coming into position in turn to perform their operation. In a multi-
spindle machine, each station corresponds to a stage in the production sequence through which each
piece is then cycled, all operations occurring simultaneously, but on different pieces of work, in the
manner of an assembly line.

Parts of a Lathe Machine-

Headstock:
The headstock is usually located on the left side of the lathe and is equipped with gears, spindles,
chucks, gear speed control levers, and feed controllers.
Tailstock:
Usually located on the right side of the lathe, the workpiece is supported at the end.
Bed:
The main parts of the lathe, all parts are bolted to the bed. It includes the headstock, tailstock,
carriage rails and other parts.
Carriage:
The carriage is located between the headstock and the tailstock and contains apron, saddle,
compound rest, cross slide and tool post.
Lead Screw
The lead screw is used to move the carriage automatically during threading.
Feed Rod
It is used to move the carriage from left to right and vice versa.
Chip Pan
It is present at the bottom of the lathe. Chip pan is used to collect the chips that are produced during
the lathe operation.
Hand Wheel
It is the wheel that is operated by hand to move a cross slide, carriage, tailstock and other parts that
have handwheel.

Modifications-

ROTARY MAGIC GUIDE BUSH (RMGB)

Previously, operators had difficulty managing variations in bar diameters. The revolutionary system
is pneumatically controlled to grip both ground or drawn bar stock within a 30 micron tolerance.

Slanted dovetail slideway structure

The Y-axis slidewav of the tool post incorporates a slanted dovetail structure. Because of this, the
X- and Y-axis slideways can be arranged in a pattern close to the cutting point, increasing machine
rigidity. In addition a straight line passing through the ball screw center,in parallel with the Y-axis
slideway and the cutting point are close to each other (al), reducing the moment load caused by
cutting resistance and thereby improving rigidity.

Balance cut turning

The Y-axis slidewav of the tool post incorporates a slanted dovetail structure. Because of this, the
X- and Y-axis slideways can be arranged in a pattern close to the cutting point, increasing machine
rigidity. In addition a straight line passing through the ball screw center,in parallel with the Y-axis
slideway and the cutting point are close to each other (al), reducing the moment load caused by
cutting resistance and thereby improving rigidity.

XYZ axes control turret

XYZ axes control turret
Mounting multiple tools onto one turret station reduces the number of indexing times and tool
change time by XYZ axes control.
Applications-
Make round or partially round parts.
Cut male and female threads.
Cut off material.
Bore and drill holes.
Knurl a knob.
Polish a surface of a round part.
Taper a shaft.
Face or dress rough stock.