Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
2
Basic functional principles of machine
tool operations
We need Machine Tools to produce desired
geometrical surfaces on solid bodies (conventionally
called work piece).
To achieve these purposes, they are basically
comprised of:
4
Basic traditional metal forming process based on chip
formation are classified as shown in the chart below :
Metal Forming
Chip-forming
Process Chipless Processes
(Metal Cutting)
Continuous-
Intermittent
Contact Continues Impact of Intermittent Contact
Cutting
Cutting (Forging, Drop-stamping)
Double edged
Single-edge Cutting cutting Ground Chips
Sizeable Swarf
(Turning, Shaping, (Drilling) (Honing, Grinding etc.)
Boring) (Milling, Hobbing)
5
Lathes
Milling machines
Drilling machines
Boring machines
Grinding machines
Shaping machines
Planning machines
Slotting machines
Hobbing machines
Gear shaping machines
Broaching machines 6
Machine - Tool Drives
Motion of Cutting
Operation Motion of Job
Tool
Milling Translation Rotation
7
Machine - Tool Drives
Machine tools essentially need a wide range
of cutting speed and feed rate to enable
Machining of different materials and job sizes
Use of cutting tools of different material,
geometry and size
Different machining operations ranging from high
speed turning to low speed thread cutting in
lathes
To achieve the desired surface finish of the job.
8
Machine - Tool Drives
Machine tool drives may be
Stepped drive
Stepless drive
Stepped drives, most common in conventional
machine tools, provide a discrete number of
speeds and feeds that are available preferably in
GP series.
10
Basic Machine Tools -
Configuration and their use
11
(a) According to configuration
Horizontal - Most common for ergonomic conveniences
Vertical - Occupies less floor space, only some large
lathes are of this type.
12
Horizontal and vertical lathe
13
(b) According to purpose of use
General purpose - Very versatile and almost all
possible types of operations are carried out on a range
of sizes, shapes 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 - 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.
14
(c)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 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
15
(d) 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
the processing operations) are done automatically;
example single spindle automat (automatic lathe),
swiss type automatic lathe, etc.
16
(f) 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
FIGURE 22-1 Schematic of a standard engine lathe performing a turning operation, with the cutting tool shown in inset.
Center Lathe
19
Lathe Parts
Carriage assembly
21
Center Lathe
22
Gear System
23
Tailstock
24
Long Job is supported by tailstock
25
Drilling in lathe machine
26
Lathe Design and Terminology
Lathe Engine essential
components:
Bed
Gray cast for vibration
dampening
Headstock assembly
Spindle
Transmission
Drive motor
Tailstock assembly
Longitudinal way clamp
Transverse way clamp
Quill for cutting tools, FIGURE 22-8 Schematic diagram of an engine lathe, showing basic components.
live centers, or dead
centers
Lathe Design and Terminology
Lathe Engine essential
components:
Quick-change gearbox
Powers Carriage
Assembly movement
with lead screw
Carriage Assembly
Fixed to cross slide
Holds tool post at
variable orientations
Provides longitudinal
and transverse
movement of tooling
Ways
Provides precise
guidance to carriage
assembly and tailstock FIGURE 22-8 Schematic diagram of an engine lathe, showing basic components.
Centre lathe
Centre lathes configuration Fig. 2.9 shows the general
configuration of center lathe. Its major parts are:
Head stock - It holds the blank / job and through a jaw.
The power and rotation to the job are transmitted at
different speeds from this part.
tailstock: supports longer blanks and often
accommodates tools like drills, reamers, etc.
carriage: holds the moving tools
bed: headstock is fixed and tailstock is clamped on it at
different locations carriage travels on the bed
columns: on which the bed is fixed
work-tool holding devices
29
Amongst the various types of lathes, centre lathes are the most versatile and commonly
used.
30
While cutting screw threads the half nuts are engaged with the rotating
lead screw to positively cause travel of the carriage and hence the tool
parallel to the lathe bed i.e., job axis.
As and when required, the tailstock is shifted along the lathe bed by
operating the clamping bolt and the tailstock quil is moved forward or
backward or is kept locked in the desired location.
32
Some of those common operations are shown in Fig.
2.10. Several other operations can also be done on
center lathes using suitable attachments.
33
Basic Turning Operations
FIGURE 22-2 Basic turning machines can rotate the work and feed the tool longitudinally for turning and can
perform other operations by feeding transversely. Depending on what direction the tool is fed and on what portion
of the rotating workpiece is being machined, the operations have different names. The dashed arrows indicate the
tool feed motion relative to the workpiece.
Knurling
The machining operations generally carried out
by centre lathes are :
Facing
Centering
Rough and finish turning
Chamfering, shouldering, grooving, recessing etc
Axial drilling and reaming by holding the cutting tool
in the tailstock barrel
Taper turning
37
Boring (internal turning); straight and taper
Forming; external and internal
Cutting helical threads; external and internal
Parting
Knurling
38
In addition to the aforesaid regular machining
operations, some more operations are also
occasionally done on centre lathes by mounting
suitable attachments available in the market,
such as,
Grinding, both external and internal by mounting a
grinding attachment on the saddle
Copying (profiles) by using hydraulic copying
attachment
Machining long and large threads for leadscrews,
power-screws, worms etc. by using thread milling
attachment.
39
Specification of Lathe Machine
1. Swing over bed
2. Swing over carriage
3. Distance between centers
4. Hole through spindle
5. Travel of cross-slide
6. Taper of tailstock spindle
7. Length overall
8. Width overall
9. Height overall
10.Shipping weight
11.Motor/Speed Control
12.Spindle speed range
40
Turret and Capstan Lathe
41
Introduction
Turret lathes were developed to extend center
lathe work.
Designed for multiple tooling (TURRET), which
is commonly hexagonal in shape and mounted
on a vertical axis in place of the tailstock of
standard lathe machine.
An entire sequence of operations can be
performed by indexing the turret
42
Elements of the turret lathe
43
44
Top View of turret lathe
45
Type of Turret lathe
Ram type turret lathe
Saddle type turret lathe
46
Ram type turret lathe
Revolving turret is
mounted on a ram or a
slide carried in a base
which can be clamped
in any position along
the bed of the machine.
47
Ram type turret lathe
Lighter in construction
Quickly and easily
operated
Also called CAPSTAN
Lathe
48
Ram type turret lathe
49
Saddle type turret lathe
Revolving turret is
mounted on the saddle
which moves back and
forward directly on the
machine.
50
Saddle type turret lathe
More heavier and rigid
Also called TURRET
lathe
51
Saddle type turret lathe
52
Application of Capstan Lathe
Ram or slide is lighter and can be moved more
quickly than a saddle.
Lacks rigidity
Ideally suited for the production of parts
relatively short in length.
53
Size range of capstan lathe
Bar diameter : 12-60 mm
Swing over bed : 200-300 mm
Swing over cross slide: 100-200 mm
Max turret movement: 75-350 mm
54
Application of Turret lathe
Due to heavier construction----- More rigid
Provides good support for tool
Suitable for longer and heavier cuts
55
Size range of turret lathe
Bar diameter : 50-100 mm
Swing over bed : 350-900 mm
Swing over cross slide: 250-650 mm
Max turret movement: 750-2000 mm
56
Boring via Vertical Turret Lathe