04-02 Turning and Related Operations - Problems

04-02
Turning and Relate Operations

d
azharhussain@uettaxila.edu. 3
pk
Material Removal Processes
• The starting material is solid metal
• Excess material is removed from the starting metal so

that the resulting part has the desired geometry
• Most common in this category are machining operations

such as turning, drilling and milling, accomplished using
cutting tools that are harder and stronger than the work
metal
• In grinding abrasive grinding wheel is used to remove
material
pk
What is a Machine Tool?
• A machine tool is a non-portable, power operated

device or system of devices in which energy is
expended to produce jobs of desired size, shape and
surface finish by removing excess material from the
preformed blanks in the form of chips with the help of
cutting tools moved past the work surface(s).
pk
Lathe Cutting
Operations
Miscellaneous cutting operations

that can be performed on a lathe.
Note that all parts are circular – a
property known as axisymmetry.
pk
What is Common in Machine Tools?
• Electric Motor • Different Levers,

• Transmission Mechanism Handwheels & Gauges
• Spindle • Workpiece holding
• device
Base or Bed
• Slides or Ways • Accessories
• • Cutting Speed
Cutting Tool
• • Feed Rate
Mechanisms for different
movements
pk
The Lathe
• The forerunner or mother of all machine tools
• The work is held and rotated on its axis while the

cutting tool is advanced along the lines of a desired cut
main purpose of a lathe is to machine round

work
• The engine lathe is the most common lathe found in a

machine shop
pk
Parts of the Lathe
• The main parts of the lathe are

– The bed (and ways)
– Headstock
– Quick-change gear box
– Carriage
– Tailstock
Bed:
• The bed is a heavy casting made to support the
working parts of the lathe
• On its top section are machined ways that guide and

align the major parts of the lathe
pk
Parts of the Lathe…
Headstock:
• The headstock is clamped on the left-hand side of the
bed
• The headstock spindle, a hollow cylindrical shaft provides
a drive through gears from motor to work-holding
devices
• A live center, a faceplate, or a chuck can be fitted to the
spindle nose to hold and drive the work
• The live center has a 60° point that provides a bearing for
the work to turn between centers
pk
Quick-change Gearbox:
• The quick-change gearbox, containing a number of
different-size gears, provides the feed rod and lead
screw with various speeds for turning and thread
cutting operations
• The feed rod advances the carriage for turning

operations when the automatic feed lever is engaged
• The lead screw advances the carriage for thread
cutting when the split-nut lever is engaged
pk
Carriage:
• Used to move the cutting tool along the lathe bed
• The saddle, an H-shaped casting mounted on the top

of the lathe ways, provides a means of mounting the
cross-slide and the apron
• The cross-slide, mounted on the top of the saddle,

provides a manual or an automatic cross movement
for the cutting tool
pk
• The compound rest, fitted on top of the cross-slide, is

used to support the cutting tool
• It can be swiveled to any angle for taper-turning

operations
• The cross-slide and compound rest both have graduated

collars
• The apron, fastened to the saddle, houses the gears and

the mechanism required to move the carriage or cross-
slide automatically
pk
• The apron handwheel can be turned manually to

move the carriage along the bed
• This handwheel is connected to a gear that meshes

in a rack fastened to the lathe bed
• The automatic feed lever engages a clutch that

provides automatic feed to the carriage
pk
• The feed-change lever can be set for longitudinal feed or for

crossfeed
• When in neutral position , the feed-change lever permits the

split-nut lever to be engaged for thread cutting
• For thread cutting, the carriage is moved automatically
when the split-nut lever is engaged
• This causes the threads of the split-nut to engage into the

threads of the revolving lead screw and move the carriage at
a predetermined rate.
pk
Tailstock:
• The tailstock can be adjusted for taper or parallel turning
by two screws set in the base
• The tailstock spindle has an internal taper to receive the

dead center, which provides support for the right-hand
• end of the work
Other standard tapered-shank tools, such as reamers and
drills, can be held in the tailstock spindle
•
A spindle clamp is used to hold the tailstock spindle in a
• fixed position
The tailstock handwheel moves the tailstock spindle in
or out of the tailstock casting
pk
Schematic view of a center lathe
pk
General view of a typical lathe, showing various components
pk
Movement of different parts of Lathe in different axes
The Carriage
azharhussain@uettaxila.edu 20
.pk
Turret Lathe
Schematic illustration of the components of a turret lathe. Note the two

turrets: square and hexagonal (main).
pk
Turret Lathe in Action Video
pk
Numerical Control Lathe and Turret
(a) A computer numerical-control lathe. Note the two turrets on this machine. These
machines have higher power and spindle speed than other lathes in order to take
advantage of new cutting tools with enhanced properties. (b) A typical turret equipped
with ten tools, some of which are powered.
azharhussain@uettaxila.e 24
du.pk
Boring and Boring Mill
(a) Schematic illustration of a steel
boring bar with a carbide insert.
Note the passageway in the bar for
cutting fluid application. (b)
Schematic illustration of a boring
bar with tungsten-alloy “inertia
disks” sealed in the bar to
counteract vibration and chatter
during boring. This system is
effective for boring bar length-to-
diameter ratios of up to 6.
Schematic illustration of a vertical boring mill. Such a

machine can accommodate workpiece sizes as large as
2.5m (98 in.) in diameter.
pk
Lathe Workholding Devices
Lathe Centers:
• Most turning operations can be performed between centers
on a lathe
• Work to be turned between centers must have a center
hole
• drilled
A latheindog,
each end into
fitted to provide a bearing
a driving surface a drive for
plate, provides the
work
• The lathe dog has an opening to receive the work and a
setscrew to fasten the dog to the work
• The tail of the dog fits into a slot on the driveplate and
provides a drive to the workpiece
pk
Lathe centers and lathe dogs
azharhussain@uettaxila.edu.pk 27
Lathe centers and lathe dogs
Chucks:
The most common are three-jaw universal, four-
jaw independent, and collet chuck
The three-jaw universal chuck:
• Holds round and hexagonal work
• Three jaws move simultaneously when adjusted
by
• the chuck wrench
Usually provided with two sets of jaws, one for
outside chucking and the other for inside chucking
pk
Three-jaw universal chuck
azharhussain@uettaxila. 30
edu.pk
Four-jaw Independent Chucks:

• 4-jaw chucks are usually non-self-centering
• Each jaw can be moved independently
• Ideal for gripping round, square, hexagonal and
irregularly shaped workpieces
• The jaws can be reversed to hold work by inside
diameter
• Multi-jaw chucks (6 or 8 jaws) for special purpose
and high standards of accuracy
pk
Four-jaw and six-jaw chucks
azharhussain@uettaxila.ed 32
u.pk
Magnetic Chuck:
• It has the advantage of holding iron or steel parts
• The parts that are too thin or that may be if
damaged
• held in a conventional chuck
• Suitable
A magnetic onlychuck
for light operations
consists of an accurately centered
permanent magnet face
pk
Magnetic chuck
azharhussain@uettaxila. 34
edu.pk
Faceplates:
• Circular metal plate fixed to the end of spindle
• Used to hold work that is too large or of such a shape
that it cannot be held in a chuck or between centers
• It has slots or threaded holes
• W.piece is clamped using T-bolts in the slots or
threaded holes
pk
Faceplate and T-bolts
Collet Chucks:
• Used for small parts that cannot be held in a jaw-
chuck
pk
Collet Chucks:
Workpiece held in collet chuck

Mandrels:
• Mandrels are shafts specially made to hold work to be
machined concentrically around a previously bored or
drilled hole
• There are two general types, plain and expanding
• Plain mandrels have a 0.006-in. taper per foot
• There must be a mandrel for each hole size
pk
Plain Mandrels:
pk
Sleeve-type Expanding Mandrels:
pk
Steadyrest:
• Used to support long or slender work held in a chuck or

between lathe centers
•
It is located on, and aligned by, the ways of the lathe
•
It may be positioned at any point along the lathe bed,
provided it clears the carriage travel
• Its three jaws my be adjusted to support any work
diameter within the steadyrest capacity
• It also supports the center of long work to prevent

springing when the work is machined between centers
pk
Steadyrest
pk
Follower Rest:
• Often used to support a long, slender workpiece
during machining
• Mounted on the saddle, travels with the carriage to

prevent work from springing up and away from the
cutting tool
• The cutting tool is generally positioned just ahead of
the follower rest to provide a smooth bearing surface
for the two jaws of the follower rest
pk
Follower Rest
pk
Lathe Machine Types
Multispindle Lathe Machine

https://www.youtube.com/watch?
v=y2dd_G_vjGE
CNC Lathe, Conventional Lathe, Lathe
Accessories
pk
Cutting Speed, Feed and Depth of Cut
• Lathe work cutting speed (CS) : the rate at which a point

on the work circumference travels past the cutting tool
• Expressed as ft / min or m / min
• r / min = CS x 12 / π D ≈ CS x 4 / D
• Example: Calculate the r/min required to turn a 2-in.
diameter piece of machine steel (CS 90).
• For metric calculations: r/min =
CS (m) x 1000/π x D (mm) ≈ CS (m) x 320/D (mm)
pk
Cutting Speed, Feed and Depth of Cut
• The feed of a lathe may be defined as the distance the

cutting tool advances along the length of the work for
every revolution of the spindle
• For example, if the lathe is set for a 0.015-in. feed, the

cutting tool will travel along the length of the work 0.015
in. for every complete turn of the workpiece
• The depth of cut is the depth of the chip taken by the

cutting tool and is one-half the total amount removed
from the workpiece in one cut
pk
Lathe cutting speeds in feet and meters per minute
using a high-speed steel toolbit (rough cut turning and
boring)
Material ft/min m/min
Machine steel 90 27
Tool steel 70 21
Cast iron 60 18
Bronze 90 27
Aluminum 200 61
pk
Feed for various materials using high-speed steel cutting
tool (rough cut turning and boring)
Material in. mm
Machine steel 0.010-0.020 0.25-0.50
Tool steel 0.010-0.020 0.25-0.50
Cast iron 0.015-0.025 0.4-0.65
Bronze 0.015-0.025 0.4-0.65
Aluminum 0.015-0.030 0.4-0.75
pk
Lathe Cutting Tools
pk
Taper Turning Methods
1. Offsetting the tailstock

2. Swiveling the compound slide
3. Using form tool
4. Using taper turning
5. attachment
Giving longitudinal and cross feed
simultaneously
– Very rare and risky
pk
Brief Review on Lathe
Intro to Lathe Operations Video
Lathe Workholding Video
Lathe Cutting Tools Video
Lathe Controls Video
pk
Center Lathe Specifications
• Maximum diameter and length of job that can be

accommodated
• Power of the main drive (motor)
• Range of spindle speeds
• Range of feeds
• Space occupied by the machine

pk
Questions??
pk
N = v/(πD)
Homework
Problem related to turning from 22.1-22.5
References
• Technology of Machine Tools, 6th Ed. by S. F. Krar, A. R. Gill, P.

Smid; McGraw Hill Higher Education
• Degarmo’s Materials And Processes In Manufacturing, 10th Ed.

By J.T Black, R. A. Kohser; John Wiley And Sons
• Manufacturing Engineering And Technology, 5th Ed. By S.

Kalpakjian, S. R. Schmid; Pearson Education
pk

04-02 Turning and Related Operations - Problems

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

04-02 Turning and Related Operations - Problems

Uploaded by

Copyright:

Available Formats

04-02

Turning and Relate Operations

• The starting material is solid metal

• Excess material is removed from the starting metal so

• Most common in this category are machining operations

• A machine tool is a non-portable, power operated

Miscellaneous cutting operations

• Electric Motor • Different Levers,

• The forerunner or mother of all machine tools

• The work is held and rotated on its axis while the

main purpose of a lathe is to machine round

• The engine lathe is the most common lathe found in a

• The main parts of the lathe are

• On its top section are machined ways that guide and

• The feed rod advances the carriage for turning

• The saddle, an H-shaped casting mounted on the top

• The cross-slide, mounted on the top of the saddle,

• The compound rest, fitted on top of the cross-slide, is

• It can be swiveled to any angle for taper-turning

• The cross-slide and compound rest both have graduated

• The apron, fastened to the saddle, houses the gears and

• The apron handwheel can be turned manually to

• This handwheel is connected to a gear that meshes

• The automatic feed lever engages a clutch that

• The feed-change lever can be set for longitudinal feed or for

• When in neutral position , the feed-change lever permits the

• This causes the threads of the split-nut to engage into the

• The tailstock spindle has an internal taper to receive the

Schematic illustration of the components of a turret lathe. Note the two

Schematic illustration of a vertical boring mill. Such a

Four-jaw Independent Chucks:

Workpiece held in collet chuck

• There are two general types, plain and expanding

• Plain mandrels have a 0.006-in. taper per foot

• There must be a mandrel for each hole size

• Used to support long or slender work held in a chuck or

• It also supports the center of long work to prevent

• Mounted on the saddle, travels with the carriage to

Multispindle Lathe Machine

• Lathe work cutting speed (CS) : the rate at which a point

• The feed of a lathe may be defined as the distance the

• For example, if the lathe is set for a 0.015-in. feed, the

• The depth of cut is the depth of the chip taken by the

Machine steel 0.010-0.020 0.25-0.50

Tool steel 0.010-0.020 0.25-0.50

Cast iron 0.015-0.025 0.4-0.65

Bronze 0.015-0.025 0.4-0.65

Aluminum 0.015-0.030 0.4-0.75

1. Offsetting the tailstock

Intro to Lathe Operations Video

Lathe Workholding Video

Lathe Cutting Tools Video

Lathe Controls Video

• Maximum diameter and length of job that can be

• Power of the main drive (motor)

• Range of spindle speeds

• Space occupied by the machine

• Technology of Machine Tools, 6th Ed. by S. F. Krar, A. R. Gill, P.

• Degarmo’s Materials And Processes In Manufacturing, 10th Ed.

• Manufacturing Engineering And Technology, 5th Ed. By S.

You might also like