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BMM3643
Manufacturing Process

Lecturer: Dr. Siti Rabiatull Aisha Idris

Email: rabiatull@ump.edu.my
Phone: 09-4246349

8.0 MATERIALS REMOVAL

PROCESSES: Machining

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Lesson Objectives:
After todays lecture, students are expected to:
Analyze the mechanism of turning operation

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Machining Processes Used to Produce

Round Shapes: Turning

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Introduction of Lathe
Lathes are considered to be the oldest
machine tools.
Although simple and versatile, an engine
lathe requires a skilled machinist because
all controls are manipulated by hand.
It is inefficient for repetitive operations and
large scale production runs.
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Lathe Components
The basic components of a common lathe are:
1. Bed
2. Carriage
3. Headstock
4. Tailstock
5. Feed Rod and Lead Screw

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Components of a Lathe

General view of a typical lathe, showing various components. Source:

Courtesy of Heidenreich & Harbeck.
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Lathe Specifications
-A lathe is usually specified based on few
criteria:
1. Swing
- The maximum diameter of the workpiece
that can be machined
2. The maximum distance between the
headstock and tailstock centre
3. The length of the bed
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Lathe Specifications (cont.)

- For example a lathe may have the following
specifications:
- 360 mm swing by 760 mm between centres
by 1830 mm length of bed.

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Lathe Devices and Accessories

- In a lathe, one end of the workpiece is clamped to
the spindle by a chuck, collet, face plate or
mandrel.
1. Chuck
- Usually equipped with three or four jaws
- Three-jaw chucks have a geared-scroll design
that makes the jaws self-centering
- Four-jaw chucks have jaws that can be moved
and adjusted independently of each other.

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Chuck

(b) three-jaw chuck

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Lathe Devices and Accessories

(cont.)
2. Collet
- The workpiece is placed inside the collet,
and the collet is pushed into the spindle
mechanically.
- Can be used for round shapes as well as
for other shapes (square, etc.)

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Collets
(a) and (b) Schematic illustrations of a draw-in type collet. The
workpiece is placed in the collet hole, and the conical surfaces of the
collet are forced inward by pulling it with a draw bar into the sleeve.
(c) A push-out type collet. (d) Workholding of a part on a face plate.

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Lathe Devices and Accessories

(cont.)
3. Face plates
- It is used for clamping irregularly shaped workpieces.
- The plates are round and have several slots and holes
through which workpiece is bolted or clamped.
4. Mandrels
- It is used to hold workpieces that require machining
on both ends or their cylinder surfaces.
- It is placed inside hollow or tubular workpieces.

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Mandrels

Various types of mandrels to hold workpieces for turning.

These mandrels are usually mounted between centers on a
lathe. Note that in (a), both the cylindrical and the end
faces of the workpiece can be machined, whereas in (b) and
(c), only the cylindrical surfaces can be machined.
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Lathe Operations
- Many operations are possible to be done on
a lathe machine.

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Lathe Cutting
Operations
Miscellaneous cutting
operations that can be
performed on a lathe. Note
that all parts are circular a
property known as
axisymmetry. The tools
used, their shape, and the
processing parameters are
described throughout this
chapter.
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Mechanics of Turning Operations

Typical turning operation is explained previously.
There are three forces acting on a cutting tool in
turning operations.
1. Cutting force, Fc:
acts downward on the tool tip
tends to deflect the tool downward

2. Thrust force, Ft:

acts in the longitudinal direction
it is called feed force because it is in the feed direction.

3. Radial force, Fr:

acts in the radial direction and tends to push the tool away from
the workpiece.
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Schematic Illustration of a Turning

Operation

(a) Schematic illustration of a turning operation showing depth

of cut, d, and feed, f. Cutting speed is the surface speed of the
workpiece at the Fc, is the cutting force, Ft is the thrust or feed
force (in the direction of feed, Fr is the radial force that tends to
push the tool away from the workpiece being machined.
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Mechanics of Turning Operations

(cont.)
There are many associated parameters in
turning operations.
These parameters can be calculated based on
the formulas.

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Summary of Turning Parameters and Formulas

TABLE 22.3
N = Rotational speed of the workpiece, rpm
f = Feed, mm/rev or in/rev
v = Feed rate, or linear speed of the tool along workpiece length, mm/min or in/min
=fN
V = Surface speed of workpiece, m/min or ft/min
= Do N (for maximum speed)
= Davg N (for average speed)
l = Length of cut, mm or in.
Do = Original diameter of workpiece, mm or in.
Df = Final diameter of workpiece, mm or in.
Davg = Average diameter of workpiece, mm or in.
= (Do + Df) /2
d = Depth of cut, mm or in.
= (Do - Df) /2
t = Cutting time, s or min
=l/f N
3
3
MRR = mm /min or in /min
= Davg d fN
Torque = Nm or lb ft
= ( Fc )( Davg /2 )
Power = kW or hp
= (Specific energy) (MRR) = (Torque) (), where =2 N radians/min
Note: The units given are those that are commonly used; however, appropriate units must be
used and checked in the formulas.
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Mechanics of Turning Operations

(cont.)
Example 1
A 15 cm long, 1.25 cm diameter 304 stainless
steel rod is being reduced in diameter to 1.2
cm by turning on a lathe. The spindle rotates at
N = 400 rpm, and the tool is travelling at axial
speed of 20 cm/min. Calculate the cutting
speed, material removal rate, cutting time,
power dissipated and cutting force. (Specific
energy of 304 stainless steel is 4 W.s/mm3)
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Solution
The cutting speed is the tangential speed of the
workpiece. The maximum cutting speed is at the outer
diameter, and is obtained from the expression
V Do N
V

12 .5 400 15 . 7 m/min
1000

The cutting speed at the machined diameter is

V

12 . 00 400 15 .1 m/ min
1000

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From the information given, note that the depth-of-cut is

d
d

and the feed is

do df
2

12.5 12.0
0.25 mm
2

200
0.5 mm/rev
400

According to Eq. (23.1a), the material-removal rate is

then
MRR 12.25 0.250.5400 1924 mm 3 /min 2 10 6 m 3 /min
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Equation (23.1b) also can be used, where we find

MRR=(0.25)(0.5)(15.7)(1000)=2106 m3/min. The actual
time to cut, according to Eq. (23.2), is
t l / fN

150

0.75 min

0.5400
The power required can be calculated by referring to
Table 21.2 and taking an average value for stainless
steel as 4 Ws/mm3. Therefore, the power dissipated is
P ( specific.energy )( MRR)
Power

41924 128 W
60

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Since 1 W = 60 N-m/min, the power dissipated is 7680

N-m/min.
The cutting force, is the tangential force exerted by the
tool. Power is the product of torque, T, and the rotational
speed in radians per unit time; hence,
T

Fc

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7680
3 .1 N - m
2 400

3 .11000 506
12 . 25 / 2

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Example 2
A cutting speed of 100 m/min has been
selected. At what rpm should a 8 cm diameter
bar be rotated?

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Example 2
V Do N
V

80 N 100 m/min

1000
N 397.88

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Mechanics of Turning Operations

(cont.)
Design considerations for Turning operations:
Parts are designed with relative ease of clamping
in workholding devices. Avoid very small
workpieces.
Wider tolerances
Avoid sharp corners, tapers etc.
Makesure the cutting tools can travel across the
workpiece without obstruction.
Design features based on commercially available
tools, inserts etc.
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Troubleshooting Guide for Turning

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Any questions??

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