Study Material From Various Sourse

ACROPOLIS TECHNICAL CAMPUS, INDORE MECHANICAL ENGINEERING DEPARTMENT "Study material for students, collected from various sources"
Metal Cutting & CNC

GENERAL SAFETY GUIDELINES 1. Do not attempt to remove foreign objects from the eye or body. Report to the student health service for medical treatment. If chemicals get in the eye(s), wash eye(s) for 15 minutes in an open flow of water before proceeding for medical treatment. 2. Avoid excessive use of compressed air to blow dirt or chips from machinery to avoid scattering chips. Never use compressed air guns to clean clothing, hair, or aim the gun at another person. 3. Machines must be shut off when cleaning, repairing, or oiling. 4. Do not wear ties, loose clothing, jewelry, gloves, etc. around moving or rotating machinery. Long hair must be tied back or covered to keep it away from moving machinery. Hand protection in the form of suitable gloves should be used for handling hot objects, glass or sharp-edged items. 5. Wear appropriate clothing for the job (i.e. do not wear short sleeve shirts or short pants when welding). 6. Do not work in the shop if you are tired or in a hurry this almost always ruins the work, and often results in injury. 7. Never indulge in horseplay in the shop areas. 8. All machines must be operated with all required guards and shields in place. 9. A brush, hook, or special tool is preferred for removal of chips, shavings, etc. from the work area. Never use your hands to clean cuttings they are sharp! 10. Keep your fingers clear of the point of operation of machines by using special tools or devices, such as, push sticks, hooks, pliers, etc. Never use a rag near moving machinery. 11. A hard hammer should not be used to strike a hardened tool or any machine part. Use a soft faced hammer. 12. Keep the floor around machines clean, dry and free from trip hazards. Do not allow chips to accumulate. 13. Think through the entire job before starting. Ask for help if you have questions. 14. Before starting a machine, always check it for correct setup and always check to see if machine is clear by operating it manually, if possible. 15. Do not drink alcoholic beverages before or during work in the machine shop area. Do not bring food or snacks into the shop.
Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)
Vijchoudhary16@gmail.com
ACROPOLIS TECHNICAL CAMPUS, INDORE MECHANICAL ENGINEERING DEPARTMENT "Study material for students, collected from various sources" Metal Cutting & CNC
16. If you have not worked with a particular material before, check the hazardous materials data sheets book for any specific precautions to be taken while working with the material. Also, ask the shop personnel before cutting any unusual material. 17. Heavy sanding and grinding should only be done in well-ventilated areas, preferably on the patio. Painting on the patio only make sure that the doors to the shop are closed. 18. Follow all appropriate precautions when working with solvents, paints, adhesives or other chemicals. Use appropriate protective equipment. 19. Safe procedures for most shop operations are described in the Health and Safety Procedures Notebook located by the safety cabinet. 20. Check the power cords and plugs on portable tools for before using them. 21. Always store oily rags in an approved metal container. INTRODUCTION A Lathe is an important and oldest known machine tool in any workshop. The job to be machined is held and rotated in a chuck, face plate, catch plate, between centers etc. A suitable cutting tool is advanced against rotating job. Since the cutting tool material is harder than the workpiece, the metal is easily removed from the job in the form of chip. Cutting tool used is a single point cutting tool. The principal parts of Lathe machine are shown in Fig.
CLASSIFICATION OF LATHES Lathes are very versatile of wide use and are classified according to several aspects: According to configuration Horizontal - Most common for ergonomic conveniences Vertical - Occupies less floor space, only some large lathes are of this type. According to purpose of use General purpose - Very versatile where almost all possible types of operations are carried out on wide ranges of size, shape and materials of jobs; example: centre lathes Single purpose Only one (occasionally two) type of operation is done on limited ranges of size and material of jobs; example facing lathe, roll turning lathe etc. Special purpose - Where a definite number and type of operations are done repeatedly over long time on a specific type of blank; example: gear blank machining lathe etc. According to size or capacity Small (low duty) - In such light duty lathes (upto 1.1 kW), only small and medium size jobs of generally soft and easily machinable materials are machined Medium (medium duty) - These lathes of power nearly upto 11 kW are most versatile and commonly used Large (heavy duty) Mini or micro lathe - These are tiny table-top lathes used for extremely small size jobs and precision work; example : Swiss type automatic lathe According to degree of automation Non-automatic - Almost all the handling operations are done manually; example: centre lathes
Semi-automatic - Nearly half of the handling operations, irrespective of the processing operations, are done automatically and rest manually; example: capstan lathe, turret lathe, copying lathe relieving lathe etc. Automatic - Almost all the handling operations (and obviously all the processing operations) are done automatically; example single spindle automat (automatic lathe), Swiss type automatic lathe, etc. According to type of automation Fixed automation - Conventional; example single spindle automat, Swiss type automatic lathe etc. Flexible automation - Modern; example CNC lathe, turning centre etc According to configuration of the jobs being handled Bar type - Slender rod like jobs being held in collets Chucking type - Disc type jobs being held in chucks Housing type - Odd shape jobs, being held in face plate According to precision Ordinary Precision (lathes) - These sophisticated lathes meant for high accuracy and finish and are relatively more expensive. According to number of spindles Single spindle - Common Multi spindle (2, 4, 6 or 8 spindles)
- Such uncommon lathes are suitably used for fast and mass production of small size and simple shaped jobs. TYPES OF CHIPS Depending upon the work material, cutting conditions, three basic types Relative motion between tool and workpiece compression at cutting edge plastic state. Plastic flow on rake surface Plastic flow on rake surface Shearing action of the work material Continuous Chip Continuous chip with built up edge Discontinuous chip
EFFECT OF PROCESS PARAMETERS ON CHIP FORMATION
Lathe Dimensions
Swing over bed The diameter of the largest workpiece that can be rotated on the spindle without hitting the bed. This is the first of the two numbers used to describe the size of a metal lathe. In the case of the 9x20 lathe it is 9". The longest piece of work that can be held between a center in the headstock and a center in the tailstock. (See glossary below for more information). This is the second of the two numbers used to describe the lathe size. The diameter of the largest workpiece that can rotate over the carriage without hitting it. On the 9x lathes this is about 5" The diameter of the hole that passes through the spindle. On the 9x lathes (or any lathe having a #3 Morse Taper Spindle) it is about 3/4".
Distance between centers
Swing over the carriage Diameter of Spindle
ACROPOLIS TECHNICAL CAMPUS, INDORE MECHANICAL ENGINEERING DEPARTMENT "Study material for students, collected from various sources" Metal Cutting & CNC Glossary of Lathe Terms
Apron Front part of the carriage assembly on which the carriage hand wheel is mounted . Main supporting casting running the length of the lathe 1. A dimension representing the maximum length of a work piece that can be turned between centers. A 9x20 lathe is 19" between centers; a 7x12 lathe is 12" between centers. Lathe vendors sometimes inaccurately represent this number. 2. A method of holding a work piece by mounting it between a center in the headstock spindle and a center in the tailstock spindle. Assembly that moves the tool post and cutting tool along the ways A wheel with a handle used to move the carriage by hand by means of a rack and pinion drive. A precision ground tapered cylinder with a 60 pointed tip and a Morse Taper shaft. Used in the tailstock to support the end of a long work piece. A short, stubby drill used to form a pilot hole for drilling and a shallow countersunk hole for mounting the end of a workpiece on a center. An imaginary line extending from the center of the spindle through the center of the tailstock ram, representing the central axis of the lathe around which the work rotates. A clamping device for holding work in the lathe or for holding drills in the tailstock. Movable platform on which the tool post is mounted; can be set at an angle to the workpiece. Also known as the compound slide and compound rest. Platform that moves perpendicular to the lathe axis under control of the cross-slide hand wheel. A wheel with a handle used to move the cross-slide in and out. Also
Bed Distance Between Centers
Carriage Carriage Hand wheel Center both ends. Center Drill
Centerline
Chuck
Compound
Cross slide
Cross-slide
Hand wheel Headstock known as the cross feed. The main casting mounted on the left end of the bed, in which the spindle is mounted. Houses the spindle speed change gears. Precision screw that runs the length of the bed. Used to drive the carriage under power for turning and thread cutting operations. Smaller lead screws are used within the cross-slide and compound to move those parts by precise amounts. A casting, shaped like an "H" when viewed from above, which rides along the ways. Along with the apron, it is one of the two main components that make Main rotating shaft on which the chuck or other work holding device is mounted. It is mounted in precision bearings and passes through the Cast iron assembly that can slide along the ways and be locked in place. Used to hold long work in place or to mount a drill chuck for drilling into the end of the work. A cutting tool used to remove metal from a workpiece; usually made of High Speed Steel or carbide. A holding device mounted on the compound into which the cutting tool is clamped Precision ground surfaces along the top of the bed on which the saddle rides. The ways are precisely aligned with the centerline of the lathe
Lead screw
Saddle up the carriage.
Spindle headstock. Tailstock
Tool
Tool post
Ways .
LATHE OPERATIONS Turning: produce straight, conical, curved, or grooved workpieces Facing: to produce a flat surface at the end of the part or for making face grooves. Boring: to enlarge a hole or cylindrical cavity made by a previous process or to produce circular internal grooves.
Drilling: to produce a hole by fixing a drill in the tailstock. Threading: to produce external or internal threads Knurling: to produce a regularly shaped roughness on cylindrical surfaces. Step Turning: to produce flat surface with different diameter in same work piece.
TOOL GEOMETRY
To ol Sig nat ure 8 14 6 12 6 12 20 15 3/4 Dimensions Abbrev iation
Back Rake Angle Side Rake Angle End Relief Angle End Clearance Angle Side Relief Angle Side Clearance Angle End Cutting-Edge Angle Side Cutting-edge angle Nose radius
BR SR ER . SRF ECEA SCEA NR
PROCESS PARAMETER
CUTTING SPEED Depends on number of rotations (rpm) of the chuck of a lathe Always expressed in meters per minute (m/min)
Important to use correct speed for a given material to get desired surface finish Too high: cutting-tool breaks down rapidly Too low: time lost, low production rates Cutting Speeds Using High-Speed Steel Tool bit Turning Material Machine Steel Tool Steel Cast Iron Bronze Aluminum Rough Cut (m/min) 27 21 18 27 61 Finish Cut (m/min) 30 27 24 30 93
CALCULATING SPINDLE SPEED Given in revolutions per minute Cutting speed of metal and diameter of work must be known Proper spindle speed set by dividing CS (m/min) by circumference of work (mm)
FEED Distance cutting tool advances along length of workpiece for every revolution of the spindle Feed of lathe dependent on speed of lead screw or feed rod
Speed of feed rod controlled by change gears in quick-change gearbox f the distance the tool advances for every rotation of workpiece (mm/rev)
High-speed steel cutting tool feed per revolution of spindle Material Machine Steel Tool Steel Cast Iron Bronze Aluminum DEPTH OF CUT Distance tool penetrates in the workpiece It is equal to half the difference between the initial diameter and the final diameter. Generally only one roughing and one finishing cut is used Roughing cut should be as deep as possible to reduce diameter to within 0.75 to 1 mm of size required Finishing cut should be less than 0.125 mm Rough Cuts (mm/rev) 0.25-0.50 0.25-0.50 0.40-0.65 0.40-0.65 0.40-0.75 Finish Cuts (mm/rev) 0.07-0.25 0.07-0.25 0.13-0.30 0.07-0.25 0.13-0.25
Perpendicular distance between machined surface and uncut surface of the Workpiece
d = (D1 D2)/2 (mm)
MATERIAL REMOVAL RATE Volume of material removed in one revolution MRR = D d f mm3 Job makes N revolutions/min MRR = D d f N (mm3/min) In terms of v MRR is given by MRR = 1000 v d f (mm3/min) Calculating machining Time
COOLANT & ITS IMPORTANCE

Water based coolants are liable to undergo a number of changes during use with respect to their composition and properties that can impair the functional properties and increase the risks associated with abrasion, erosion and corrosion of tribomechanical system elements. The main influential factors in the coolant system are: particles; temperature; fluid composition and flow. The presence of particles has a negative influence on surface quality, machine life, tool life, coolant life and for the health aspect. The temperatures rise in coolants can be quite considerable, if the machine is of the type where the coolant sump forms an integral part of the machine framework (individual systems). The composition of a coolant changes during the use as a consequence of vaporization of water and the removal of various other materials in the filtering process. Depending on the relationship between these factors, these changes will thereby result in either a concentration or a dilution of the fluid. With respect to the significant vaporization that takes place, it is essential to monitor the quality of the water that is added to maintain the correct dilution. The salt contents in tap water cause an accumulation of salts as more water is added. The main undesirable consequence of a high salt content on the process is excessive corrosion of tribomechanical system elements. The other influential factors are free oils and microorganisms. Free oil is a combination of tramp oil from the process machines lubrication and drive systems; oil washed down from guide ways, rust inhibiting oil from work pieces and oil resulting from emulsion breakdown. The presence of free oil on the coolant surface results in a number of undesirable consequences for both the effectiveness of the process and for the health aspect. Large numbers of microorganisms (bacteria and fungi) shorten the coolants useful life to a considerable degree, as well as causing a number of technical problems. Large concentration of microorganisms causes an accumulation of metabolic organisms in the fluid, which can result in skin ailments. CUTTING TOOL MATERIALS Carbon Steels It is the oldest of tool material. The carbon content is 0.6~1.5% with small quantities of silicon, chromium, manganese, and vanadium to refine grain size. Maximum hardness is about HRC 62.
This material has low wear resistance and low hot hardness. The use of these materials now is very limited. High-speed steel (HSS) First produced in 1900s. They are highly alloyed with vanadium, cobalt, molybdenum; tungsten and chromium added to increase hot hardness and wear resistance. Can be hardened to various depths by appropriate heat treating up to cold hardness in the range of HRC 63-65. The cobalt components give the material a hot hardness value much greater than carbon steels. The high toughness and good wear resistance make HSS suitable for all type of cutting tools with complex shapes for relatively low to medium cutting speeds. The most widely used tool material today for taps, drills, reamers, gear tools, end cutters, slitting, broaches, etc.
Cemented Carbides Introduced in the 1930s. These are the most important tool materials today because of their high hot hardness and wear resistance. The main disadvantage of cemented carbides is their low toughness. These materials are produced by powder metallurgy methods, sintering grains of tungsten carbide (WC) in a cobalt (Co) matrix (it provides toughness). There may be other carbides in the mixture, such as titanium carbide (TiC) and/or tantalum carbide (TaC) in addition to WC.
In spite of more traditional tool materials, cemented carbides are available as inserts produced by powder metallurgy process. Inserts are available in various shapes, and are usually mechanically attached by means of clamps to the tool holder, or brazed to the tool holder (see the figure in the next page). The clamping is preferred because after a cutting edge gets worn, the insert is indexed (rotated in the holder) for another cutting edge. When all cutting edges are worn, the insert is thrown away. The index able carbide inserts are never reground. If the carbide insert is brazed to the tool holder, indexing is not available, and after reaching the wear criterion, the carbide insert is reground on a tool grinder.
One advance in cutting tool materials involves the application of a very thin coating (~ 10 m) to a K-grade substrate, which is the toughest of all carbide grades. Coating may consists of one or more thin layers of wear-resistant material, such as titanium carbide (TiC), titanium nitride (TiN), aluminum oxide (Al2O3), and/or other, more advanced materials. Coating allows increasing significantly the cutting speed for the same tool life.
Ceramics Ceramic materials are composed primarily of fine-grained, high-purity aluminum oxide (Al2O3), pressed and sintered with no binder. Two types are available: white, or coldpressed ceramics, which consists of only Al2O3 cold pressed into inserts and sintered at high temperature. Black, or hot-pressed ceramics, commonly known as cermets (from ceramics and metal). This material consists of 70% Al2O3 and 30% TiC. Both materials have very high wear resistance but low toughness; therefore they are suitable only for continuous operations such as finishing turning of cast iron and steel at very high speeds. There is nonoccurrence of built-up edge, and coolants are not required.
Cubic boron nitride (CBN) and synthetic diamonds Diamond is the hardest substance ever known of all materials. It is used as a coating material in its polycrystalline form, or as a single-crystal diamond tool for special applications, such as mirror finishing of non-ferrous materials. Next to diamond, CBN is the hardest tool material. CBN is used mainly as coating material because it is very brittle. In spite of diamond, CBN is suitable for cutting ferrous materials.
SPECIFICATIONS OF DIFFERENT LATHE MACHINE

Study Material From Various Sourse

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

Study Material From Various Sourse

Uploaded by

Copyright:

Available Formats

ACROPOLIS TECHNICAL CAMPUS, INDORE MECHANICAL ENGINEERING DEPARTMENT "Study material for students, collected from various sources"

Metal Cutting & CNC

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

EFFECT OF PROCESS PARAMETERS ON CHIP FORMATION

Distance between centers

Swing over the carriage Diameter of Spindle

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Bed Distance Between Centers

Carriage Carriage Hand wheel Center both ends. Center Drill

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Saddle up the carriage.

Spindle headstock. Tailstock

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

BR SR ER . SRF ECEA SCEA NR

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

d = (D1 D2)/2 (mm)

COOLANT & ITS IMPORTANCE

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

Prepared by: Vijay Kumar Choudhary Asst. Prof. MED (9827780065)

You might also like