MACHINING PROCESS –I

Lecture 5
Lathe Machine Operations
And Calculation
Engr. Muhammad Mahboob
 Operations Related To Turning
A variety of other machining operations can be performed on a lathe in
addition to turning; these include the following,
 Facing
 Taper turning
 Contour turning
Form turning
Chamfering
 Operations Related To Turning
Cutoff
Threading
Boring
Drilling
 knurling
 Facing
The tool is fed radially into the rotating work on one end to
create a flat surface on the end.
 Taper Turning
Instead of feeding the tool parallel to the axis of rotation of
the work, the tool is fed at an angle, thus creating a tapered
cylinder or conical shape.
 Contour Turning
Instead of feeding the tool along a straight line parallel to the
axis of rotation as in turning, the tool follows a contour that is
other than straight, thus creating a contoured form in the
turned part.
 Form Turning
In this operation, some times called forming, the tool has a
shape that is imparted to the work by plunging the tool
radially into the work.
 Chamfering
The cutting edge of the tool is used to cut an angle on the corner of the
cylinder, forming what is called a ‘‘chamfer.’’
 Cutoff
The tool is fed radially into the rotating work at some location along its
length to cut off the end of the part. This operation is sometimes
referred to as parting.
 Threading
A pointed tool is fed linearly across the outside surface of the rotating
work part in a direction parallel to the axis of rotation at a large
effective feed rate, thus creating threads in the cylinder.
 Boring
A single-point tool is fed linearly, parallel to the axis of rotation, on the
inside diameter of an existing hole in the part.
 Drilling
Drilling can be performed on a lathe by feeding the drill into the
rotating work along its axis. Reaming can be performed in a similar way.
 Knurling
This is not a machining operation because it does not involve cutting of
material. Instead, it is a metal forming operation used to produce a
regular crosshatched pattern in the work surface.
 Cutting Conditions In Turning
The rotational speed in turning is related to the desired cutting speed
at the surface of the cylindrical work piece by the equation.

where
N =Rotational speed, rev/min;
v = cutting speed, m/min (ft/min);
Do =original diameter of the part, m (ft).
 Cutting Conditions In Turning
The turning operation reduces the diameter of the work from its
original diameter Do to a final diameter Df, as determined by the
depth of cut d:

Df =Do -2d

The feed in turning is generally expressed in mm/rev (in/rev). This

feed can be converted to a linear travel rate in mm/min (in/min) by
the formula.
f r = Nf
 Cutting Conditions In Turning
where
fr =feed rate, mm/min (in/min);
f = feed, mm/rev (in/rev).
The time to machine from one end of a cylindrical work part to the other is given
by
Tm =L fr

Where
Tm =machining time, min;
L= length of the cylindrical work part, mm (in).
 Cutting Conditions In Turning
A more direct computation of the machining time is provided by the
following equation

where
Do = work diameter, mm (in);
L= work part length, mm (in);
f =feed, mm/rev (in/rev);
V=cutting speed, mm/min (in/min).
 Cutting Conditions In Turning
As a practical matter, a small distance is usually added to the work
part length at the beginning and end of the piece to allow for
approach and over travel of the tool. Thus, the duration of the feed
motion past the work will be longer than Tm.
The volumetric rate of material removal can be most conveniently
determined by the following equation:

RMR = vfd

where RMR = material removal rate, mm3/min (in3/min).

 Problem 1
A cylindrical work part 200 mm in diameter and700
mm long is to be turned in an engine lathe. Cutting
speed = 2.30 m/s, feed =0.32 mm/rev, and depth of cut
=1.80 mm. Determine (a) cutting time, and (b) metal
removal rate?
 SOLUTION
Solution:
(A) N = v/(πD) = (2.30 m/s)/0.200π = 3.66 rev/s
fr = Nf = 6.366(.3) = 1.17 mm/s
Tm= L/fr = 700/1.17 = 598 s = 9.96 min
Alternative calculation using Eq.
• Tm = 200(700)π/(2,300 x 0.32) = 597.6 sec = 9.96 min

• (B) RMR = vfd = (2.30 m/s)(103)(0.32 mm)(1.80 mm) = 1320

mm3/s
 Problem 2
In a production turning operation, the foreman has decreed
that a single pass must be completed on the cylindrical work
piece in 5.0 min. The piece is 400 mm long and 150 mm in
diameter. Using a feed = 0.30 mm/rev and a depth of cut = 4.0
mm, what cutting speed must be used to meet this machining
time requirement?
 Problem 3
A facing operation is performed on an engine lathe. The diameter of
the cylindrical part is 6 in and the length is 15 in. The spindle rotates at
a speed of 180 rev/min. Depth of cut = 0.110 in, and feed= 0.008 in/rev.
Assume the cutting tool moves from the outer diameter of the work
piece to exactly the center at a constant velocity.
Determine (a) the velocity of the tool as it moves from the outer
diameter towards the center and (b) the cutting time?
Power And Energy Relationships In Machining

A machining operation requires power. The cutting force in a

production machining operation might exceed 1000 N
(several hundred pounds). Typical cutting speeds are several
hundred m/min.
The product of cutting force and speed gives the power
(energy per unit time) required to perform a machining
operation.
Pc = Fc.v
 Power And Energy Relationships In Machining
where
Pc =cutting power, N-m/s or W (ft-lb/min)
Fc= cutting force, N (lb)
v=cutting speed, m/s (ft/min).
In U.S. customary units, power is traditionally expressed as
horsepower by dividing ft-lb/min by 33,000. Hence,

HPc =Fcv/33000
Power And Energy Relationships In Machining
The gross power required to operate the machine tool is greater than
the power delivered to the cutting process because of mechanical
losses in the motor and drive train in the machine.
 These losses can be accounted for by the mechanical efficiency of the
machine tool
where
Pg =gross power of the machine tool motor, W;
HPg= gross horsepower
E=mechanical efficiency of the machine tool.
Typical values of E for machine tools are around 90%.
 Power And Energy Relationships In Machining
It is often useful to convert power into power per unit volume rate of
metal cut.
This is called the unit power, Pu (or unit horsepower, HPu), defined:

where
RMR =material removal rate, mm3/s (in3/min).
The material removal rate can be calculated as the product of v.to.w.
 Power And Energy Relationships In Machining
Unit power is also known as the specific energy U.

energy are typically The units for specific N-m/mm3 (in-lb/in3).

 Problem 4
In a turning operation on stainless steel with hardness =
200 HB, the cutting speed = 200 m/min, feed = 0.25
mm/rev, and depth of cut = 7.5 mm. How much power
will the lathe draw in performing this operation if its
mechanical efficiency = 90%. Use Table 21.2 to obtain
the appropriate specific energy value.
 Solution
From Table 21.2, U = 2.8 N-m/mm3 = 2.8 J/mm3

RMR = vfd = (200 m/min)(103 mm/m)(0.25 mm)(7.5 mm)

= 375,000 mm3/min = 6250 mm3/s

Pc = (6250 mm3/s)(2.8 J/mm3) = 17,500 J/s = 17,500 W = 17.5 kW

Accounting for mechanical efficiency, Pg = 17.5/0.90 = 19.44 kW
 Problem 5
In a turning operation on aluminum, cutting speed =
900 ft/min, feed = 0.020 in/rev, and depth of cut =
0.250 in. What horsepower is required of the drive
motor, if the lathe has a mechanical efficiency = 87%?
Use Table 21.2 to obtain the appropriate unit
horsepower value.
 Problem 6
A turning operation is to be performed on a 20 hp lathe
that has an 87% efficiency rating. The roughing cut is
made on alloy steel whose hardness is in the range 325
to 335 HB. The cutting speed is 375 ft/min, feed is
0.030 in/rev, and depth of cut is 0.150 in. Based on
these values, can the job be performed on the 20 hp
lathe? Use Table 21.2 to obtain the appropriate unit
horsepower value.
 Cutting Temperature
Of the total energy consumed in machining, nearly all of it (98%) is
converted into heat.
This heat can cause temperatures to be very high at the tool–chip
interface—over 600 C (1100 F)is not unusual.
The Remaining energy (2%) is retained as elastic energy in the chip
 Cutting Temperature
Cutting temperatures are important because high
temperatures
1. reduce tool life
2. produce hot chips that pose safety hazards to the machine
operator
3. can cause inaccuracies in work part dimensions due to
thermal expansion of the work material.
 Cutting Temperature Calculation
In this section, we discuss the methods of calculating and measuring
temperatures in machining operations.
Known as Cook Equation.

where
T=mean temperature rise at the tool–chip interface, C (F)
U= specific energy in the operation, N-m/mm3 or J/mm3 (in-lb/in3)
Cutting Temperature Calculation
v=cutting speed, m/s (in/sec)

to=chip thickness before the cut, m (in)

pC =volumetric specific heat of the work material, J/mm3- C (in-

lb/in3-F)

K=thermal diffusivity of the work material, m2/s (in2/sec).

 Problem 7
Orthogonal cutting is performed on a metal whose mass
specific heat = 1.0 J/g-C, density = 2.9 g/cm3, and thermal
diffusivity = 0.8 cm2/s. The cutting speed is 4.5 m/s, uncut
chip thickness is 0.25 mm, and width of cut is 2.2 mm. The
cutting force is measured at 1170 N. Using Cook's equation,
determine the cutting temperature if the ambient
temperature = 22°C.
 Solution
ρC = (2.9 g/cm3)(1.0 J/g-°C) = 2.90 J/cm3-°C = (2.90x10-3) J/mm3-°C
K = 0.8 cm2/s = 80 mm2/s
U = Fcv/RMR = 1170 N x 4.5 m/s/(4500 mm/s x 0.25 mm x 2.2 mm)
= 2.127 N-m/mm3
T = 0.4U/(ρC) x (vto/K)0.333
T = 22 + (0.4 x 2.127 N-m/mm3/(2.90x10-3) J/mm3-C) [4500 mm/s x
0.25 mm/80 mm2/s]0.333
T = 22 + (0.2934 x 103 C)(14.06).333
= 22 + 293.4(2.41) = 22° + 707° = 729°C
 Problem 8
An orthogonal cutting operation is performed on a certain
metal whose volumetric specific heat = 110 in-lb/in3-F, and
thermal diffusivity = 0.140 in2/sec. The cutting speed = 350
ft/min, chip thickness before the cut = 0.008 in, and width of
cut = 0.100 in. The cutting force is measured at 200 lb. Using
Cook's equation, determine the cutting temperature if the
ambient temperature =70°F.
 Problem 9
A turning operation uses a cutting speed = 200 m/min, feed =
0.25 mm/rev, and depth of cut = 4.00 mm. The thermal
diffusivity of the work material = 20 mm2/s and the
volumetric specific heat = 3.5 (10-3) J/mm3-C. If the
temperature increase above ambient temperature (20°F) is
measured by a tool-chip thermocouple to be 700°C,
determine the specific energy for the work material in this
operation.