Synopsis

Presentation
On

“REPAIR & MAINTENANCE LATHE M/C”

By

ABHAY TIWARI
E. No – E18330834500033

Under Supervision of

Mr. VIRENDRA SINGH

Mr. MAYANK KANAUJIA
Lecturer

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC GHATAMPUR, KANPUR NAGAR
Affiliated by Uttar Pradesh Board of Technical Education,Lucknow
 A
PROJECT
ON
REPAIR & MAINTENANCE LATHE M/C

Guided By:-
Mr. MAYANK KANAUJIA
(Department of Mechanical Engineering)

PresentedBy:-
ABHAY TIWARI, HIMANSHOO, SATYENDRA SINGH, SACHENDRA KUMAR, AKHILESH
KUMAR, ADITYA, RAGHVENDRA SINGH, PANKAJ KUSHWAHA
 CONTENT

* INTRODUCTION
* COMPONENT
* TYPES OF LATHE MACHINE
* CONSTRUCTION
* WORKING
* LATHE OPERATIONS
* MAINTENANCE OF LATHE MACHINE
*TIMELINE
* SAFETY PRECAUTIONS BEFORE USE
* CONCLUSION
 Introduction-

Lathe Machine The lathe machine is a tool used principally for shaping articles of
materials especially metals by causing the work piece to be held and rotated by the
lathe while a tool bit is advanced into the work causing the cutting action. The basic
lathe that was designed to cut cylindrical metal stock has been developed further
to produce screw threads, tapered work, drilled holes, knurled surfaces, and
crankshafts. The typical lathe provides a variety of rotating speeds and a means to
manually and automatically move the cutting tool into the work piece. Machinists
and maintenance shop personnel must be thoroughly familiar with the lathe and
its operations to accomplish the repair and fabrication of needed parts. Figure 1
shows the engine lathe which is usually used for metal lathing.
 COMPONENTS
• Bed
• Headstock
• Tailstock
• Carriage
• Toolpost
• Spindle
• Apron
• Gearbox
• Saddle
• Leadscrew & Feedrod
• Slidebox
• Paddle Break
 TYPES OF LATHE MACHINE

• Center Lathe OR Engine Lathe Machine

• Capstan Lathe Machine
• Turret Lathe Machine
• Bench Lathe Machine
• Tool Room Lathe Machine
• Special Lathe Machine
• CNC Lathe Machine
• Speed Lathe Machine
• Automatic Lathe Machine
 CONSTRUCTION OF LATHE MACHINE

A simple lathe comprises of a bed made of grey cast iron on which head stock, tail
stock, carriage and other components of lathe are mounted. Fig. shows the
different parts of engine lathe or central lathe. The major parts of lathe machine
are given as under:

1.Bed
2.Headstock
3.Tailstock
4.Carriage
5.Feedmechanism
6. Thread cutting mechanism
1. Bed

The bed of a lathe machine is the base on which all other parts of lathe are
mounted. It is massive and rigid single piece casting made to support other active
parts of lathe. On
left end of the bed, head stock of lathe machine is located while on right side tail
stock is located. The carriage of the machine rests over the bed and slides on it. On
the top of the bed there are two sets of guide ways-inner ways and outer ways. The
inner ways provide sliding surfaces for the tail stock and the outer ways for the
carriage. The guide ways of the lathe bed may be flat and inverted V shape.
Generally cast iron alloyed with nickel and chromium material is used for
manufacturing of the lathe bed.

2. Head Stock

The main function of head stock is to transmit power to the different parts of a
lathe. It comprises of the head stock casting to accommodate all the parts within it
including gear train arrangement. The main spindle is adjusted in it, which
possesses live centre to which the work can be attached. It supports the work and
revolves with the work, fitted into the main spindle of the head stock. The cone
pulley is also attached with this arrangement, which is used to get various spindle
speed through electric motor. The back gear arrangement is used for obtaining a
wide range of slower speeds. Some gears called change wheels are used to produce
different velocity ratio required for thread cutting.
3. Tail Stock

Fig. shows the tail stock of central lathe, which is commonly used for the
objective of primarily giving an outer bearing and support the circular job being
turned on centers. Tail stock can be easily set or adjusted for alignment or non-
alignment with respect to the spindle centre and carries a centre called dead centre
for supporting one end of the work. Both live and dead centers have 60° conical
points to fit centre holes in the circular job, the other end tapering to allow for good
fitting into the spindles. The dead centre can be mounted in ball bearing so that it
rotates with the job avoiding friction of the job with dead centre as it important to
hold heavy jobs.

4. Carriage

Carriage is mounted on the outer guide ways of lathe bed and it can move in a
direction parallel to the spindle axis. It comprises of important parts such as apron,
cross-slide, saddle, compound rest, and tool post. The lower part of the carriage is
termed the apron in which there are gears to constitute apron mechanism for
adjusting the direction of the feed using clutch mechanism and the split half nut for
automatic feed. The cross-slide is basically mounted on the carriage, which
generally travels at right angles to the spindle axis. On the cross-slide, a saddle is
mounted in which the compound rest is adjusted which can rotate and fix to any
desired angle. The compound rest slide is actuated by a screw, which rotates in
a nut fixed to the saddle.
The tool post is an important part of carriage, which fits in a tee-slot in the
compound rest and holds the tool holder in place by the tool post screw. Fig. shows
the tool post of centre lathe.

5. Feed Mechanism

Feed mechanism is the combination of different units through which motion of

headstock spindle is transmitted to the carriage of lathe machine. Following units
play role in feed mechanism of a lathe machine-

The gearing at the end of bed transmits the rotary motion of head stock spindle to
the feed gear box. Through the feed gear box the motion is further transmitted
either to the feed shaft or lead screw, depending on whether the lathe machine is
being used for plain turning or screw cutting.

The apron is fitted to the saddle. It contains gears and clutches to transmit motion
from the feed rod to the carriage, and the half nut which engages with the lead
screw during cutting threads.

6. Thread Cutting Mechanism

The half nut or split nut is used for thread cutting in a lathe. It engages or
disengages the carriage with the lead screw so that the rotation of the lead screw
is used to traverse the tool along the work piece to cut screw threads. The direction
in which the carriage moves depends upon the position of the feed reverse lever
on the head stock.
 Working Principle

The lathe is a machine tool which holds the workpiece between two rigid and
strong supports called centers or in a chuck or face plate which revolves. The
cutting tool is rigidly held and supported in a tool post which is fed against
the revolving work. The normal cutting operations are performed with the
cutting tool fed either parallel or at right angles to the axis of the work.

LATHE OPERATIONS

The engine lathe is an accurate and versatile machine on which many

operations can be performed. These operations are:

1. Plain Turning and Step Turning

2. Facing
3. Parting
4. Drilling
5. Reaming
6. Boring
7. Knurling
8. Grooving
9. Threading
10. Forming
11. Chamfering
12. Filling and Polishing
13. Taper Turning

MAINTENANCE OF LATHE MACHINE

1.- Routine Maintenance

A lathe doesn't require a great deal of maintenance and even thrives in an
environment of downright neglect. There are some habits operator can form
and some things operator can do that will greatly add to the life of the
 machine and to operator's enjoyment of using it. The first habit is to unplug
the machine when you perform most maintenance. Other habits follow
different schedules. Routine maintenance will keep the lathe machine
running smoothly for years. Table 1 shows the routine maintenance of a
lathe machine.

2.- Bearing Replacement

With plane bearings, the lathe can run smoothly by oiling the bearings on a
daily basis. Most lathes today, even those found on the used market, are
equipped with ball bearings that are lubricated and sealed for life. These
bearings don't require any regular maintenance, but they do need to be
replaced every few years. The sides of ball bearings are generally sealed with
plastic, which retains the grease packed into the bearing during assembly.
Age and use take their toll on any grease, even in a sealed-f or-life bearing.
Eventually, the grease fails and the bearing fails shortly thereafter.

3.- Lubrication Application

If the operator is ever in doubt, always know that there is never a time where
the operator can use too much lubrication. Amongst the gears and the
pulleys, there is always can be added a bit of grease. This will simply help
keep the gears and pulleys running smoothly while also ensuring that the
gears don't break down to fast by being exposed to the air and feel the
effects of oxygenation. Eventually your gears and pulleys are going to have
to be replaced, because at some point they are going wear away due to rust.

4.- Drive Belts Inspection The drive belts supply power from the motor to the
spindle. Access to the drive belts is gained by removing the end guard on the
headstock. Make sure that all power is locked out before removing any guards.
Drive belts come in matched sets and should only be replaced with a matched set
of belts. Visually inspect the drive belts for excessive wear and cracking. If notice
that one or more of the drive belts appear to be excessively worn or cracked, bring
this to the attention of the instructor. Check the belt tension by applying finger
pressure to each belt at a point midway between the two pulleys. For correct
tension a deflection of about 3/8 of an inch should be evident in each belt. If the
amount of deflection is more than 3/8 of an inch in any one or more of the belts,
bring this to the attention of the instructor.

5.- Gib Adjustment All lathes employ precision slide ways. The saddle, cross
slide, and the compound slide all ride along a box slide way or dovetail slide way.
After time the parts that ride along the slide ways begin to wear. To compensate
for this wear, machine tools are equipped with adjustable parts called gibs that
allow operator to eliminate the space that has been created by the wear between
the slide ways. There are two types of gibs, which are straight gibs and tapered gibs.
Straight gibs are adjusted by screws spaced out along the length of the gib. The
screws push the gib in to create more contact with the sliding mechanisms. Tapered
gibs use two screws. The screws are located in each end of the tapered gib. One
screw acts as an adjustment while the other screw acts as a locking mechanism.
Because tapered gibs are wider on one end than the other, they slide in or out
creating more or less contact between the sliding mechanisms.

6.- Cross Slide Gib Adjustment Wear in the cross slide ways must be adjusted
by using the screw on the front face of the cross slide. The procedure is to first
loosen the similar gib screw on the rear face of the cross slide, then re-tighten the
front screw to lock or adjust the gib in its new position. After the adjustment,
traverse the cross slide over its entire travel to be sure of smooth, even operation.

7.- Compound Slide Gib Adjustment The compound slide ways must be
adjusted by using the screw on the front face of the compound slide. The procedure
is to first loosen the similar gib screw in the rear face of the tool slide, then re-
tighten the front screw to lock or adjust the gib in its new position. After making
the adjustment, traverse the compound slide over its entire travel to be sure of
smooth, even operation.

8.- Wipers Pads Cleaning Most lathes are equipped with wiper pads. Wiper
pads are typically made of felt that will hold oil. Wipers are designed to keep out
small chips and dirt between the slides and the ways. Wipers are saturated with oil
to catch the fine particles of dirt or debris before they get between the two sliding
surfaces. The wipers should be removed, cleaned, and re-saturated with oil
regularly. You should never use compressed air for cleaning a lathe. Compressed
air will push the fine particles trapped in the wiper between the mating surfaces of
the slides, causing premature wear on these precision surfaces.

9.- Tailstock Clamp Adjustment The lock position of the bed clamp lever on
the tailstock is adjustable and should be located before top dead center. The lever
is adjusted by a self-locking bolt located on the underside of the tailstock front
clamp plate and between the bed way. Turn the bolt clockwise to increase the
clamping action. Lathes may also be equipped with an auxiliary bolt on the tailstock.
This bolt is used to give additional clamping action when required. It does not
require any adjustment.

10.- End Gearing and Backlash Inspection The end gearing on the lathe
connects the spindle rotation with the feed and threading rods. The gears supplied
with a lathe allow the operator to obtain an extensive range of feeds, metric
threads, threads per inch, module and diametral pitch threads. To cut threads over
a broad range, the lathe operator will need to make changes to the end gear train.
Basic lathe setup and operation includes being able to properly change the gears in
the train. Most lathes are equipped with charts that explain the gear positioning
for certain types and ranges of threads. When the proper gears have been selected
and set in the gear train, the mounting or clamping bolts should be lightly snugged
in place with a strip of paper or feeler stock placed between the gears. The gears
should then be pushed together against the paper shim. The clamping bolts should
then be tightened. Remove the shim. The space left between the gears, where the
shim was placed, is known as backlash. On most lathes the backlash amount should
be between 0.007 and 0.011 inches. If the gears are noisy, more backlash space
should be made between the gears. Finish the backlash adjustment by placing a
small amount of lubricant on the gear train.
 Timeline-

APRIL 2021
GOT THE PROJECT AND DISCUSSION STARTED
PROJECT SECLTION
PROJECT ANALYSIS WITH GROUP GATHERING

MAY 2021
RESEARCH WORK CONTINUED DIFFERENT METHODOLOGIES FOUND

JUNE 2021
SYNOPSIS FILE SUBMITTED
INTERNAL SYNOPSIS PRESENTATION
EXTERNAL PRESENTATION

JULY 2021
FINAL PROJECT SUBMITTED ALONG WITH FINAL REPORT
 SAFETY PRECAUTION

• Wear appropriate safety glasses. It may be necessary for others in the area
to wear safety glasses too as objects will fly off the work.
• Make sure entanglement hazards are removed (e.g. loose clothing, loose
gloves, jewelry, etc.). Tie back and confine long hair.
• Keep the floor free from obstructions, or slip hazards.
• Follow job specifications for the speed, feed, and depth of cut for materials
being turned. Make sure all work runs true and centered.
• Centre-drill works deeply enough to provide support for the piece while it is
turning.
• Secure and clamp the piece being worked.
• Adjust tool and tool rest so that they are slightly above the center of the
work.
• Use a lifting device to handle heavy chucks or work.
• Inspect chucks for wear or damage. Flying pieces can be very dangerous.
• Remove chuck wrench immediately after adjusting chuck.
• Use a barrier guard when operating the lathe in semi-automatic or automatic
mode.
• Guard all power transmission parts.
• Remove all tools, measuring instruments, and other objects from the saddle
or lathe bed before starting the machine.
• Keep all lathe cutting tools sharp.
• Shut off the power supply to the motor before mounting or removing
accessories.
• Stop lathe before taking measurements of any kind.
• Use a vacuum, brush, or rake to remove cuttings only after the lathe has
stopped moving.
• Keep working surface clean of scraps, tools, and materials.
• Keep the floor around the lathe clean and free of oil and grease.
 CONCLUSION

Lathe machine is an extremely useful piece of equipment that can be used

in workshop. For those who do extensive lathing work, owning a working
lathe is very important. However, having said that, it is also important to note
that this piece of equipment is as dangerous as it is useful. It may increase
the range of jobs that you can do, but it can also cause accidents. Thus, users
should follow the safety guidelines when using lathe machine. Besides that,
there are many different lathe problems that can occur while you are using
this tool. Fortunately, most of these problems can be avoided by following
troubleshooting guidelines. A part of that, a lathe machine can perform more
efficient and longer by having suitable maintenance.