Lecture Notes

Class: FS BEIII Mechanical Subject: Production Technology II

SEMI-AUTOMATIC LATHES
 Lecture Notes
Class: FS BEIII Mechanical Subject: Production Technology II
1. Difference Between Engine/Center Lathe & Capstan & Turret Lathe

S.No Centre lathe Capstan/turret lathe

1 It is a manually operated lathe
2 It has only one tool post
3 It has tail stock
Only one tool can be fitted in the tail
4
stock
5 Number of speeds is less
6 Tool changing time is more
The machine should be stopped for
7
changing tool
8 It is not suitable for mass production
9 No feed stops to control the tool
The tool is centered manually after
10
changing the tool
11 Only one operation is done at a time
It is a semi automatic lathe
Front and rear tool posts are available.
It has turret head instead of tail stock
Six different tools can be fitted in the turret
head.
Number of speeds is more
Tool changing time is less
Tool can be changed without stopping the
machine
It is suitable for mass production
The tools are controlled by feed stops
The tool is centered automatically
More than one operation can be done at a
time

2. DIFFERENCE BETWEEN CAPSTAN LATHE & TURRET LATHE

3. FEATURES & APPLICATIONS OF CAPSTAN & TURRET LATHES

4. PRINCIPAL PARTS OF CAPSTAN & TURRET LATHES

 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

Turret & capstan

tan lathes have parts similar to engine lathe except the turret &
mechanism to index it & a bar feeding setup to make the lathe suitable for mass production
work. The principal parts of these lathes are indicated in the figure above. The principal parts
include
1) Headstock 2) Cross slide tool post 3) Hexagonal turret 4) Turret saddle 5) Feed Rod 6)
Saddle for cross-slide

4.1 HEADSTOCK
 Step cone pulley driven headstock – 3 or 4 steps of pulley; for small lathes with almost
constant diameter work;
 Lecture Notes
Class: FS BEIII Mechanical Subject: Production Technology II
 Direct electric motor driven headstock – armature shaft of motor & machine spindle are
integrated; speed variation by speed control of motor;
 All geared headstock – different mechanisms for speed changing by levers
 Preoptive or preselective headstock – all geared with provisions for rapid stopping,
starting & speed changing; for next operation the speed is preselected & put into action
as soon as current operation is over by a push button or selection lever.

4.2 CROSS SLIDE & SADDLE

The cross slide may be fed longitudinally or crosswise by hand or power. Longitudinal
feed of each tool can be controlled by stop bars set against the stop fitted on the bed &
carriage. Stop bars are indexed by hand to synchronize with the indexing of the tool.
 Hand operated cross slide for smaller lathes clamped on bed where required
 Conventional type carriage placed on front & rear guideways with two four station type
tool posts – one at the front & other at the rear.
 Side hung type carriage for heavy duty turret lathes for handling swing of larger
diameter workpieces.

4.3 TURRET SADDLE & AUXILIARY SLIDE

In capstan lathe the turret saddle is placed on the bed guideways with top face
machined accurately to hold the auxiliary slide. The saddle is clamped at desired position. The
hex turret is mounted on auxiliary slide.
In turret lathe the turret is directly mounted on the saddle and movement is affected by
movement of saddle itself by hand or power.
The hex turret is a hex tool holder with six faces capable of holding tools. Each face is
accurately machined. There are accurately bored holes at center of each face for shanks of tool
holders. Centerline of each hole coincides with the spindle axis when facing the headstock.
Four additional tapped holes on each face for tool holding attachments. At center of turret, on
the top, there is a clamping lever to lock the turret on the saddle. Six stop bars mounted on the
saddle to control the longitudinal feed of each of the tool on the faces of the turret.

5. MECHANISMS OF TURRET LATHE

5.1 TURRET INDEXING MECHANISM
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

A simple line sketch of the mechanchanism is shown in the Fig. The fig is ann inverted plan
p of the
turret assembly. The turret 1 is mou
mounted on the spindle 5, whish rests on a bearing on the turret
saddle (not shown in the sketch). ). The index plate 2, the bevel gear 3 and an indexing ratchet
ra 4
are keyed to the spindle 5. The plu
plunger 14 fitted within the housing and mounted ed on the saddle
locks the index plate by spring 15 pressure and prevents any rotary movement of the turret as
the tool feeds into
nto the work. A pin 13 fitted on the plunger projects out off the housing. An
actuating cam 10 and the indexing pawl 7 are attached to the lathe bed 9 at the desired position.
Both the cam and the pawl are spring loaded. As the turret reaches the backward position,
actuating cam 10 lifts the plunge
plunger 14 out of the groove in the indexplate, due to the riding of
the pin 13 on the beveled surface
rface of the cam 10 and thus unlocks the indexplate 2. The spring
loaded pawl 7 which by this time engages with th a groove of the ratchet plate 4, causes the
ratchet to rotate as the turret head moves backward. When the indexplate or the turret .rotates
.rota
through one sixth of revolution, the pin 13 and the plunger 14 drops out of the cam 10 and the
plunger locks the indexplate
xplate at the next groove.
gr The turret is thus indexed by one sixth of
revolution and again, locked into the new position automatically. The turret holding
ho the next
tool is now fed forward and the pawl is released
re from
m the ratchet plate by the spring pressure.
The synchronized movement of stop rods with the indexing of the turret can also be
understood from the above fig. The bevel pinion 6 meshes with the bevel gear 3 mounted on
the turret spindle. The extension of the pinion shaft carries the plate holding
ding 6 adjustable stop
rods 8. As the turret rotates through one sixth of revolution, the bevel gear 3 causes the plate to
rotate. The teeth ratio between pinion & gear is so chosen that when tool mounted on a turret
face is brought into position for cutting,
cutting, the corresponding stop rod for controlling the
longitudinal travel of the tool is aligned with stop 12. The setting of the stop rods for limiting
feed of each operation can be done by removing the lock nuts & rotating the stop rods on the
plate. Thus sixix stop rods can be adjusted to control the feed of the tools mounted on six faces
of the turret.
 Lecture Notes
Class: FS BEIII Mechanical Subject: Production Technology II

Turret indexing mechanism of capstan and single spindle turret lathe is typically shown
schematically in Fig. 4.7.10.
The turret (generally hexagonal) holding the axially moving cutting tools have the following
motions to be controlled mechanically and manually ;
ο forward axial traverse comprising;
Δ quick approach – manually done by rotating the pinion as shown
Δ slow working feed – automatically by engaging the clutch
Δ stop at preset position depending upon the desired length of travel of
the individual tools
o quick return – manually done by disengaging the clutch and moving the
turret back
o
o indexing of the turret by 60 (or multiple of it) – done manually by further
moving the turret slide back.
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II
Just before indexing at the end of the return stroke, the locking pin is withdrawn by the
lever which is lifted at its other end by gradually riding against the hinged wedge as
indicated in Fig. 4.7.10 (a). Further backward travel of the turret slide causes rotation of
the free head by the indexing pin and lever as indicated in Fig. 4.7.10 (b). Rotation of the
turret head by exact angle is accomplished by insertion of the locking pin in the next hole
of the six equispaced holes.
les. After indexing and locking, the turret head is moved forward
with the next cutting tool at its front face when the roller of the lever returns through the
wider slot of the wedge without disturbing the locking pin as indicated in the figure. The
forwardrd motion of the turret head is automatically stopped when the set-screw set
corresponding to the working tool is arrested by the mechanical stop. The end position
and hence length of travel of the tool is governed by presetting the screw. There are six
such screws,
crews, each one corresponds with particular face or tool of the turret. The drum
holding those equispaced six screw with different projection length is rotated along with
the indexing (rotation) of the turret head by a pair of bevel gears (1:1) as indicated
indicate in Fig.
4.7.10 (a). The bottom most screw, which corresponds with the tool on the front face of
the turret, when hits or touches the stop, the turret movement is stopped either manually
by feeling or automatically by disengaging the clutch between the feedfeed rod and the turret
slide.

5.2 BAR FEEDING MECHANISM

a) Dead Weight Type
 Lecture Notes
Class: FS BEIII Mechanical Subject: Production Technology II
The capstan and turret lathe are used extensively for bar type work & hence need a mechanism
for bar feeding. The long bars which protrude out of the headstock spindle require to be fed
through the spindle upto the bar stop once the first piece is completed & the collet chuck is
opened. The bar may be pushed by hand but this process unnecessarily increases the total
production time, because the spindle and & the bar must come to a dead stop before any
adjustment can be made. Various bar feeding mechanisms are designed & used which feed the
bar as soon as the collet releases the bar without stopping the machine. Fig. shows one such
mechanism.
Bar 6 is passed through bar chuck 3, spindle & then through the collet chuck. Bar chuck
3 rotates in the sliding bracket body 2 mounted on a long slide bar. Bar chuck grips the bar
centrally by two screws 5 & rotates the bar in the sliding bracket body. One end of chain 8 is
connected to the pin 9 fitted on sliding bracket 10 & other end supports weight 4, the chain
running over the sprockets 7 & 11 mounted on the slide bar. Weight 4 constantly exerts end
thrust on the bar chuck while it revolves on the sliding bracket & forces the bar through the
spindle as soon as the collet chuck releases the bar.

b) Lever Type

The figure typically shows the kinematic arrangement of feeding and clamping of bar stock
in capstan lathes. The bar stock is held and tightly clamped in the push type spring collet which
is pushed by a push tube with the help of a pair of bell-crank levers actuated by a taper ring as
shown in figure. Bar feeding is accomplished by four elementary operations;

 unclamping of the job – by opening the collet

 bar feed by pushing it forward
 clamping of the bar by closing the collet
 free return of the bar-pushing element.

After a job is complete and part off, the collet is opened by moving the lever manually
rightward to withdraw the push force on the collet. Further moving of the lever in the same
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II
direction causes forward push of the bar with the help of the ratchet – paul system shown.
After the projection of the bar from the collet face to the desired length controlled by a pre
pre-set
stop – stock generally held
eld in one face of the turret or in a separate swing stop, the lever is
moved leftward resulting closing of the collet by clamping of the barstock. Just before
clamping of the collet, the leftward movement of the lever pushes the bar feeder (ratchet) back
freely against the paul.

6. WORK HOLDING DEVICES

 JAW CHUCKS
 Self centering chuck
 Independent chuck
 Combination chuck
 Air operated chuck
 COLLET CHUCKS
Used for gripping bars
ars fed through the headstock spindle. They are much more suitable
in mass production then chucks due to quick action & accurate setting. They may be
hand or power operated. Different collets with different shaped bore can be fitted in the
chuck body & gripp the work by spring action of split jaws.
 Push out type
The tapered portion of the collet is pushed into the mating taper of the chuck.
The bar tends to move slightly which make accurate length available against the
bar stop.

 Draw in type
The tapered portion of the collet is pulled back into the mating taper of the
chuck which causes the split end of the collet to close in & grip the bar.
Machining length of the bar cannot be accurately set since the bar tends to be
drawn in slightly
ightly during gripping.
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

 Dead length type

For accurate positioning of bar, stationary collet is used on the bar. A sliding
sleeve closes upon the taper collet which is prevented from end movement by
shoulder stop.

7. TOOL HOLDING DEVICES

1. Straight Cutter holder 10. Reamer holder
 Tool perpendicular to shank axis

2. Plain or Adjustable angle cutter holder 11. Knurling tool holder

 Angular slot in the body  Mounted on turret face or cross slide tool
 Front face beveled post
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II
 Accurate setting with micrometer  Knurling tool holder on cross slide can
screw knurl any diameter work.

3. Multiple cutter holder 12. Recessing tool holder

 Can accommodate double tools  Provided with adjustable slide for recessing
 Multiple operations in a bore.

4. Offset cutter holder 13. Form tool holder

lder (straight/circular)
 Holder body offset from shank  Usually on cross slide tool post.
axis
 Large diameter turning & boring

5. Combination tool holder/multiple 14. Tap holder

turning head  Clamped on turret face
 Multiple or offset cutter holder  Holds solid taps
can be mounted.
 Overhead pilot bar for rigidity
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II
passes through the topmost hole.

6. Slide tool holder 15. Die holder

 Rough & finish boring, facing,
grooving etc.

7. Knee tool holder 16. Balanced tool holder (box tool)

 Simultaneous turning & boring  Cutting tools so mounted that cutting thrust
or turning & drilling is balanced.
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

8. Drill holder 17. V-steady box tool holder

 To support workpiece during cutting.
 Both tool & V-steady steady mounted on
adjustable slide for setting diameter of
work.
 Tool set slightly in advance of V.
 Top of V parallel to shank & bottom
perpendicular to work axis to take up both
up & side thrust of tool
 Mainly used in brass work..

9. Boring bar / extension / flanged tool 18. Roller steady box tool holder
holder  Two rollers instead of V to support work.
 Flange fitted to turret face  Position of rollers & tool can be adjusted.
 For drills, reamers, boring bars  High finish due to burnishing action of
etc. rollers.
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

19. Bar Ending tool holder

 Finish end rods, pins, bars etc.
 Rollers set slightly in advance of the tools.

8. TOOLS FOR CAPSTAN & TURRET LATHES

 Turning

 Heavy duty turning tool mounted on cross slide or knee holder.

 Facing
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

 Combined facin
facing
g & turning tool mounted on cross slide or knee holder
 Parting

 Chamfering
 Bar Ending

 Grooving & Recessing

 Forming
 Drill
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II
 Boring
 Counterbore
 Reamer
 External Thread Cutting tool
 Internal Thread Cuttingg Tool
 Workstop

9. OPERATION SEQUENCE, TURRET TOOLING LAYOUT & TOOLING

SCHEDULE CHART
9.1 HEX BOLT

Operation Sequence
i) Setting of Bar Stop on first face of turret
turret– 6mm parting allowance & 4mm
clearance
earance from collet face. Therefore, 70mm

ii) Setting of roller steady box turning tool on second face of turret for turning of
16mm diameter upto a distance of 20mm from collet face.
 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

iii) Bar ending tool set on next turret face (third face) used after turning to 16mm

iv) Setting self opening die head for threads on 16mm diameter

v) Setting of chamfer tool

vi) Setting of parting off tool

 Lecture Notes
Class: FS BEIII
III Mechanical Subject: Production Technology II

Op. Description of Tool Positions Tools

No. operation
1 Hold in Collet
2 Turn to16mm dia
3 From end to the bolt
4 Screw 16 mm
5 Chamfer
6 Parting off
1st turret position Bar stop
2nd turret position Roller steady box turning tool
3rd turret position Roller Steady bar ending tool
too
4th turret position Self opening die head with chasers
for 16 mm
Front cross slide tool Chamfering tool
post
Rear tool post Parting off tool