CHAPTER 2.

METAL CUTTING LATHE

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Introduction
Lathe is a machine, which removes the metal from a piece of work to the required shape &size

INTRODUCTION
A lathe is a machine tool which spins the workpiece to perform various operations such as cutting, turning, knurling, drilling, or deformation with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation. Lathes are used in woodturning, metalworking, metal spinning, and glassworking. Lathes can be used to shape pottery, the best-known design being the potter's wheel. Most suitably equipped metalworking lathes can also be used to produce most solids of revolution, plane surfaces and screw threads or helices. Ornamental lathes can produce three-dimensional solids of incredible complexity. The material can be held in place by either one or two centers, at least one of which can be moved horizontally to accommodate varying material lengths. Other workholding methods include clamping the work about the axis of rotation using a chuck or collet, or to a faceplate, using clamps or dogs.

Live center (top) Dead center (bottom)

Tail stock
Handwheel (T1), reduction gear box (T2), tailstock (T4), spindle (T5), clamped (T6)

Types of Lathe
Engine Lathe The most common form of lathe, motor driven and comes in large variety of sizes and shapes. Bench Lathe A bench top model usually of low power used to make precision machine small work pieces. Tracer Lathe a lathe that has the ability to follow a template to copy a shape or contour.

Automatic Lathe A lathe in which the work piece is automatically fed and removed without use of an operator. Cutting operations are automatically controlled by a sequencer of some form Turret Lathe :link to video lathe which have multiple tools mounted on turret either attached to the tailstock or the cross-slide, which allows for quick changes in tooling and cutting operations. Computer Controlled Lathe A highly automated lathe, where both cutting, loading, tool changing, and part unloading are automatically controlled by computer coding.

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

Lathe Operations

Cutting Tools
Single point cutting tool

Dimensions Tool Signatur e 8 Back Rake Angle

Abbreviation

BR

14
6 12 6 12 20 15 3/4

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

SR
ER . SRF ECEA SCEA NR

Fig : (a) Designations and symbols for a right-hand cutting tool; solid high-speed-steel tools have a similar designation. Right-hand means that the tool travels from right to left.

- For holding cylindrical stock centered. - For facing/center drilling the end of your aluminum stock

Four-Jaw Chuck

- This is independent chuck generally has four jaws , which are adjusted individually on the chuck face by means of adjusting screws

Collet Chuck Collet chuck is used to hold small workpieces

Thin jobs can be held by means of magnetic chucks.

Magnetic Chuck

Thin jobs can be held by means of magnetic chucks.

Drives work machined between centers Has opening to receive work and setscrew to fasten the dog to work Tail of dog fits into slot on driveplate and provides drive to workpiece Made in variety of sizes and types to suit various workpieces

13

Most commonly used for round workpieces Available with square-head setscrews of headless setscrews

14

 Driven by stud in driveplate Used in precision turning

15

Workholding Devices ..

Workpiece (job) with a hole

Workpiece

Mandrel

TYPES OF MANDREL

MANDREL:- workpiece which cannot be held between centers because its axis has been drilled or bored, and which is not suitable for holding in a chuck or against a faceplate, is usually machined on a mandrel. A mandrel is a tapered axle pressed into the bore of the workpiece to support it between centers.

SINGAL POINT CUTTING TOOL FOR LATHE

DIFFERENT LATHE OPERATIONS

Provides fast, accurate, and reliable method of quickly changing and setting various toolholders for different operations Locking system has two sliding gibs forced out against toolholder
Handle pulled into lock position Provides rigid, positive lock with zero backlash

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Steady Rest

Follower Rest

Jaws Work Hinge

Work

Jaws

Carriage Lathe bed guideways

24

25

Jaws Work Hinge

Work

Jaws

Carriage Lathe bed guideways

- Turret and Capstan, both, are production machines and are usually of semiautomatic, type. Both turret and capstan lathes are provide with tool head, usually hexagon, to carry a set of tools and to supplement this by an additional slide carrying tools for cutting off and forming operations. A Capstan lathe is usually a small or medium size machine with the tool head carried upon a slide mounted in a saddle bolted to the bed of the lathe, while a turret lathe has the (hexagon) tool head mounted on a saddle sliding directly on the bed.

- Whereas turret lathe is adapted to quantity production work, engine lathe is primarily used for miscellaneous jobbing, tool room or single operation work. Another difference between an engine lathe and turret is that the tailstock is replaced by a (usually) hexagon turret upon which are bolted various toolholders for knee turning, roller box turning, drilling, boring and recessing. Unlike engine lathe, a turret lathe can hold a number of cutting tools at a time. In engine lathe one tool cuts at a time whereas in turret, a number of tools can operate on the job simultaneously. Tools may be permanently set up in the turret in the sequence in which they need be used. Extreme rigidity in the holding of work and tools is built into the turret lathe to permit multiple land combined cuts. Using a turret lathe instead of an engine lathe can often cut machining time by 25 to 75% The original cost of a turret lathe is considerably higher than that of the engine lathe.

A leadscrew (or lead screw), also known as a power screw[1] or translation screw,[2] is a screw designed to translate radial motion into linear motion. Common applications are machine slides (such as in machine tools), vises, presses, and jacks.[3]

A split nut is a nut that consists of two pieces which can be clamped together to engage the thread of the nut with the bolt, or released, to allow the nut to move along the bolt without turning the bolt. A split nut assembly is often used in positioning systems, for example in the lead screw of a lathe.

Operating Conditions..

D Diameter (mm) N Revolutions per Minute (rpm) DN v m/min 1000

The Peripheral Speed of Workpiece past the Cutting Tool

=Cutting Speed

Operating Conditions..

f the distance the tool advances for every

rotation of workpiece (mm/rev)

D1

D2

f Feed

Operating Conditions..

perpendicular distance between machined surface and uncut surface of the Workpiece d = (D1 D2)/2 (mm)

D1

D2 d Depth of Cut

Cutting speed Workpiece

N

Depth of cut (d) Machined surface Chip Depth of cut Tool

Chuck Feed (f )

Operations on Lathe ..

Turning
Facing knurling Parting

Chamfering Taper

Grooving

turning Drilling Threading

Operations on Lathe ..

Cylindrical job

Cutting speed

Workpiece
N

Depth of cut (d) Machined surface Feed Tool Chip Depth of cut

Chuck

Operations on Lathe ..

Excess Material is removed to reduce Diameter Cutting Tool: Turning Tool

a

reduce diameter by 2 mm

depth of cut of 1 mm will

Operations on Lathe ..

Flat Surface/Reduce length

Chuck

Workpiece d Machined Face

Cutting speed Tool Feed

Depth of cut

Operations on Lathe ..

machine

end of job Flat surface or to Reduce Length of Job Turning Tool Feed: in direction perpendicular to workpiece axis Length of Tool Travel = radius of workpiece Depth of Cut: in direction parallel to workpiece axis

Operations on Lathe ..

4-jaw chuck

Axis of job

Ax Cutting speed Eccentric peg (to be turned)

Operations on Lathe ..

Produce rough textured surface

Knurling Tool

For Decorative and/or Functional Purpose

A Forming Process MRR~0

Operations on Lathe ..

Knurled surface Cutting speed Feed Knurling tool Tool post Movement for depth

Operations on Lathe ..

Produces

a Groove on workpiece Shape of tool shape of groove Carried out using Grooving Tool A form tool Also called Form Turning

Operations on Lathe ..

Shape produced by form tool

Groove

Form tool

Feed or depth of cut

Grooving tool

Operations on Lathe ..

Cutting workpiece into Two Similar to grooving

Parting Tool

Tool rides over at slow feed Coolant use

Operations on Lathe ..

Parting tool Feed

Operations on Lathe ..

Chamfer

Feed Chamfering tool

Operations on Lathe ..

Beveling sharp machined edges Similar to form turning Chamfering tool 45 To

Avoid Sharp Edges Make Assembly Easier Improve Aesthetics

Operations on Lathe ..

Drill cutting tool held in TS feed from TS

Quill clamp moving Drill quill Tail stock Feed Tail stock clamp

Operations on Lathe ..

D1 D2 tan 2L

D1

90

D2

B A

Operations on Lathe ..

Methods

Form Tool Swiveling Compound Rest Taper Turning Attachment Simultaneous Longitudinal and Cross Feeds

Operations on Lathe ..

Workpiece Taper

Form Straight tool cutting edge

Direction of feed

Operations on Lathe ..

Dog

Mandrel Tail stock quill Tail stock

Face plate Tool post & Tool holder Cross slide

Direction of feed Compound rest Slide Compound rest Hand crank

Taper attachment
A plain taper attachment for the lathe is illustrated in Figure A bed bracket attaches to the lathe bed and keeps the angle plate from moving to the left or the right. The carriage bracket moves along the underside of the angle plate in a dovetail and keeps the angle plate from moving in or out on the bed bracket. The taper to be cut is set by placing the guide bar, which clamps to the angle plate, at an angle to the ways of the lathe bed. Graduations on one or both ends of the guide bar are used to make this adjustment. A sliding block which rides on a dovetail on the upper surface of the guide bar is secured during the machining operation to the cross slide bar of the carriage, with the cross feed screw of the carriage being disconnected. Therefore, as the carriage is traversed during the feeding operation, the cross slide bar follows the guide bar, moving at the predetermined angle from the ways of the bed to cut the taper. It is not necessary to remove the taper attachment when straight turning is desired. The guide bar can be set parallel to the ways, or the clamp handle can be released permitting the sliding block to move without affecting the cross slide bar, and the cross feed screw can be reengaged to permit power cross feed and control of the cross slide from the apron of the carriage.

Tailstock set lover = Taper length x sine of half of taper angle (D d)/2 = L x sin (a/2) Where D = diameter of the large end of job d = diameter of the small end of job L = length of the taper of cylindrical job.

Operations on Lathe ..

Turning Time Job length Lj mm Feed f mm/rev Job speed N rpm f N mm/min

Lj fN

min

TUMBLER REVERSE MECHANISM

vT C
n
where v = cutting speed;

T = tool life; and

n and C are parameters that depend on feed,

depth of cut, work material, and tooling material, but mostly on material (work and tool).

n is the
C is the life on the speed axis at one minute tool

A tool run at 160m/min lasts for 5 min. If the tool is run at 100m/min it lasts for an average of 41 min. What is C and n?

Single-Point Tool Geometry

(a) Seven elements of single-point tool geometry; and (b) the tool signature convention that defines the seven elements.

 APRON MECHANISM

References
Book work shop Technolgy by Hajra choudry Advances in Manufacturing Technology C.J Thomas Website www.tkckt.weebly.com