Lathe - 131903 - MANUFACTURING PROCESS 1

PowerPoint to accompany
Technology of Machine Tools

6th Edition
Krar Gill Smid
The Lathe
Section 11
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
History
Lathe forerunner of all machine tools
First application was potter's wheel
Rotated clay and enabled it to be formed into
cylindrical shape
Very versatile (many attachments)

Used for turning, tapering, form turning, screw
cutting, facing, drilling, boring, spinning,
grinding and polishing operations
Cutting tool fed either parallel or right angles
Special Types of Lathes

Engine lathe
Not production lathe, found in school shops,
toolrooms, and jobbing shops
Basic to all lathes
Turret lathe
Used when many duplicate parts required
Equipped with multisided toolpost (turret) to
which several different cutting tools mounted
Employed in given sequence

6th Edition
Krar Gill Smid
Engine Lathe Parts

Unit 45
Engine Lathe
Accurate and versatile machine
Operations
Turning, tapering, form turning, threading,
facing, drilling, boring, grinding, and polishing
Three common
Toolroom
Heavy-duty
Gap-bed
Lathe Size and Capacity

Designated by largest work diameter that
can be swung over lathe ways and generally
the maximum distance between centers
Manufactured in wide range of sizes
Most common: 9- to 30- in. swing with
capacity of 16 in. to 12 feet between centers
Typical lathe: 13 in. swing, 6 ft long bed, 36 in.
Average metric lathe: 230-330 mm swing and
bed length of 500 3000 mm
Lathe Size
Indicated by the swing

and the length of the bed
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Parts of the Lathe

Headstock
Tailstock
Bed
Quick
Change
Gearbox
Carriage


Setting Speeds on a Lathe

Speeds measured in revolutions per minute
Changed by stepped pulleys or gear levers
Safety
Belt-driven
lathe
Note!!
NEVER change speeds
Various speeds obtained by changing flat belt
when
lathe
is
running.
and back gear drive
Geared-head lathe
Speeds changed by moving speed levers into
proper positions according to r/min chart
fastened to headstock
Shear Pins and Slip Clutches

Prevents damage to feed mechanism from
overload or sudden torque
Shear pins
Made of brass
Found on feed rod, lead screw, and end gear train
Spring-loaded slip clutches

Found only on feed rods
When feed mechanism overloaded, shear pin will
break or slip clutch will slip causing feed to stop
Shear pin in end gear

train prevents damage
to the gears in case
of an overload
Spring-ball clutch
will slip when too
much strain is
applied to feed rod


6th Edition
Krar Gill Smid
Lathe Accessories
Unit 46

46-15
Lathe Accessories
Divided into two categories
Work-holding, -supporting, and driving devices
Lathe centers, chucks, faceplates
Mandrels, steady and follower rests
Lathe dogs, drive plates
Cutting-tool-holding devices
Straight and offset toolholders
Threading toolholders, boring bars
Turret-type toolposts
46-16
Lathe Centers
Work to be turned between centers must
have center hole drilled in each end
Provides bearing surface
Support during cutting

Most common have
solid Morse taper shank
60 centers, steel with carbide tips
Care to adjust and lubricate occasionally
46-17
Chucks
Used extensively for holding work for
machining operations
Work large or unusual shape
Most commonly used lathe chucks

Three-jaw universal
Four-jaw independent
Collet chuck
46-18
Three-jaw Universal Chuck

Holds round and hexagonal work
Grasps work quickly and accurate within
few thousandths/inch
Three jaws move
simultaneously when
adjusted by chuck wrench
Caused by scroll plate into
which all three jaws fit
Two sets of jaw: outside chucking and

inside chucking
46-19
Four-Jaw Independent Chuck

Used to hold round, square, hexagonal, and
irregularly shaped workpieces
Has four jaws
Each can be adjusted independently by chuck
wrench
Jaws can be reversed to hold work by inside

diameter
46-20
Headstock Spindles
Universal and independent chuck fitted to
three types of headstock spindles
1. Threaded spindle nose
Screws on in a
clockwise direction
2. Tapered spindle nose
Held by lock nut

that tightens on chuck
46-21
Headstock Spindles
3. Cam-lock spindle nose
Held by tightening cam-locks using T-wrench

Chuck aligned by taper
on spindle nose
Registration lines on spindle nose

Registration lines on cam-lock
Cam-locks
Cam-lock mating stud on
chuck or faceplate
46-22
Collet Chuck
Most accurate chuck
Used for high-precision work
Spring collets available to hold round,
square, or hexagon-shaped workpieces
Each collet has range of only few
thousandths of an inch over or under size
stamped on collet
46-23
Collet Chuck
Special adapter fitted into taper of headstock spindle,

and hollow draw bar having internal thread inserted
in opposite end of headstock spindle. It draws collet
into tapered adapter causing collet to tighten on workpiece.
46-24
Types of Lathe Dogs

Standard bent-tail lathe dog
Most commonly used for round
workpieces
Available with square-head
setscrews of headless setscrews
Straight-tail lathe dog

Driven by stud in driveplate
Used in precision turning
46-25
Types of Lathe Dogs

Safety clamp lathe dog
Used to hold variety of work
Wide range of adjustment
Clamp lathe dog

Wider range
than others
Used on all shapes
46-26
Left-Hand Offset Toolholder

Offset to the right
Designed for machining work close to
chuck or faceplate and cutting right to left
Designated by letter L
46-27
Right-Hand Offset Toolholder

Offset to the left
Designed for machining work close to the
tailstock and cutting left to right
Also for facing operations
Designated by letter R
46-28
Straight Toolholder
General-purpose type
Used for taking cuts in either direction and
for general machining operations
Designated by letter S
46-29
Toolholders for Indexable

Carbide Inserts
Held in holder by cam action or clamps
Types available
Conventional
Turret-type
Heavy-duty toolposts
46-30
Cutting-Off (Parting) Tools

Used when work must be grooved or
parted off
Long, thin cutting-off blade locked
securely in toolholder by either cam lock or
locking nut
Three types of parting toolholders
Left-hand
Right-hand
Straight
46-31
Threading Toolholder
Designed to hold special form-relieved
thread-cutting tool
Has accurately ground 60 angle
Maintained throughout life of tool
Only top of cutting surface sharpened when
becomes dull
46-32
Super Quick-Change Toolpost

6th Edition
Krar Gill Smid
Cutting Speed,
Feed, and Depth
of Cut
Unit 47

47-34
Cutting Speed
Rate at which point on work circumference
travels past cutting tool
Always expressed in feet per minute (ft/min)
or meters per minute (m/min)
Important to use correct speed for material
Too high: cutting-tool breaks down rapidly
Too low: time lost, low production rates
47-35
Lathe Cutting Speeds in Feet and Meters per

Minute Using High-Speed Steel Toolbit
Turning and Boring
Rough Cut Finish Cut Threading
Material
ft/min
m/min
ft/min
m/min
11
Machine steel
90
27
100
30
35
Tool steel
70
21
90
27
30
Cast iron
60
18
80
24
25
Bronze
90
27
100
30
25
Aluminum 200
61
300
93
60
18
47-36
Calculating Lathe 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 (in/min) by circumference of work (in)
CS x 12 CS x 4
r/min
D
D
47-37
Example:
Calculate r/min required to rough-turn 2 in. diameter
piece of machine steel (CS 90):
CS x 4
r/min
D
90 x 4
r/min
180
2
CS x 320
r/min
Metric Formula
D
47-38
Lathe Feed
Distance cutting tool advances along length
of work for every revolution of the spindle
Feed of engine lathe dependent on speed of
lead screw for feed rod
Speed controlled by change gears in
quick-change gearbox
47-39
Two Cuts Used to Bring

Diameter to Size
Roughing cut
Purpose to remove excess material quickly
Coarse feed: surface finish not too important
.010- to .015-in. (0.25- to 0.4-mm)
Finishing cut
Used to bring diameter to size
Fine feed: Produce good finish
.003- to .005-in (0.07- to 0.012-mm)
47-40
Feeds for Various Materials

(using high-speed steel cutting tool)
Rough Cuts
Material
in.
Machine steel
Finish Cuts
mm
in.
.010.020 0.250.5
.003.010 0
Tool steel
.010.020 0.250.5
.003.010 0.070
Cast iron
.015.025 0.40.65
.005.012 0.130
Bronze
.015.025 0.40.65
Aluminum .015.030 0.40.75
.003.010 0
.005.010 0.130
47-41
Depth of Cut
Depth of chip taken by cutting tool and onehalf total amount removed from workpiece
in one cut
Onlyoneroughingandonefinishingcut
Roughingcutshouldbedeepaspossibleto
reducediametertowithin.030to.040in.(0.76
to1mm)ofsizerequired
Finishingcutshouldnotbelessthan.005in.
47-42
Example: Depth of cut on a lathe

47-43
Factors Determining Depth of

Rough-Turning Cut
Condition of machine
Type and shape of cutting tool used
Rigidity of workpiece, machine, and cutting
tool
Rate of feed
47-44
Inch System
Circumference of crossfeed and compound
rest screw collars divided into 100-125
equal divisions
Each has value of .001 in.
Turn crossfeed screw clockwise 10 graduations,
cutting tool moved .010 in. toward work
Lathe revolves, so .010 depth of cut taken from
entire work circumference reducing diameter .020 in.
Check machine for its' graduations
47-45
On machines where the workpiece revolves,

the cutting tool should be set in for only half
the amount to be removed from the diameter.

47-46
On machines where the workpiece does not

revolve, the cutting tool should be set in for
the amount of material to be removed.

47-47
Hints on Graduated Collar Use

1. Make sure collar is secure before setting a
depth of cut
2. All depths of cut must be made by feeding
cutting tool toward workpiece
3. If graduated collar turned past desired
setting, must be turned backward half-turn
and fed into proper setting to remove
backlash
4. Never hold graduated collar when setting
depth of cut
47-48
5. Graduated collar on compound rest can be

used for accurately setting depth of cut
Shoulder turning
Facing
Compound rest set at 90 to cross-slide

Lock carriage in place
Spacing of shoulders to within .001 in. accuracy
Compound rest swung to 30, amount removed from
length of work = amount of feed on collar
Machining accurate diameters
Set compound rest to 8416' to the cross-slide

.001 in movement = .0001-in. infeed movement
47-49
The compound rest is set at 8416' for

making fine settings.


6th Edition
Krar Gill Smid
Lathe Safety
Unit 48

48-51
Safety
Be aware of safety requirements in any area
of shop
Always attempt to observe safety rules
Failure results in:
Serious injury
Resultant loss of time and pay
Loss of production to company
48-52
Safety Precautions
Lathe hazardous if not operated properly
Important to keep machine and surrounding
area clean and tidy
Accidents usually caused by carelessness
48-53
Safety Precautions
Always wear approved safety glasses
Rollup sleeves, remove tie and tuck in loose
clothing
Never wear ring or watch
48-54
Safety Precautions
Do not operate lathe until understand controls
Never operate machine if safety guards
removed
Stop lathe before measure work or clean, oil
or adjust machine
Do not use rag to clean work or machine
when in operation
Rag can get caught and drag in hand
48-55
Safety Precautions
Never attempt to stop a lathe chuck or
driveplate by hand
Be sure chuck or faceplate mounted securely
before starting
If loose, becomes dangerous missile
Always remove chuck wrench after use

Fly out and injure someone
Become jammed, damaging wrench or lathe
48-56
Safety Precautions
Move carriage to farthest position of cut and
revolve lathe spindle one turn by hand
Ensure all parts clear without jamming
Prevent accident and damage to lathe
Keep floor around machine free from grease,

oil, metal cuttings, tools and workpieces
Oil and grease can cause falls
Objects on floor become tripping hazards
48-57
Safety Precautions
Avoid horseplay at all times
Always remove chips with brush
Chips can cause cuts if use hands
Chips become embedded if use cloths
Always remove sharp toolbit from

toolholder when polishing, filing, cleaning,
or making adjustments

6th Edition
Krar Gill Smid
Mounting,
Removing, and
Aligning Lathe
Centers
Unit 49
49-59
Objectives
Mount and/or remove lathe
centers properly
Align lathe centers by visual, trialcut, and dial-indicator methods
49-60
Lathe Centers
Work machined between centers turned for
some portion of length, then reversed, and
other end finished
Critical when machining work between
centers that live center be absolutely true
Concentric work
49-61
To Mount Lathe Centers

Remove any burrs from lathe spindle,
centers, or spindle sleeves
Clean tapers on lathe centers and in
headstock and tailstock spindles
Partially insert cleaned center in lathe spindle
Force center into spindle
Follow same procedure when mounting
tailstock center
Check trueness of center
49-62
To Remove Lathe Centers

Live center
Use knockout bar pushed through headstock
spindle (slight tap)
Use cloth over center and hold to prevent damage
Dead center
Turn tailstock handwheel to draw spindle back
into tailstock
End of screw contacts end of dead center, forcing it out
of spindle
49-63
Alignment of Lathe Centers
Parallel diameter produced when lathe

center aligned
Three common methods
used to align
1. Aligning centerlines
on back of tailstock
with each other
Only a visual check

and not too accurate
49-64
Alignment of Lathe Centers

2. Using the trial-cut
method where small
cut taken from each
end of work and
diameters measured with a micrometer
3. Using parallel test bar and dial indicator
Fastest and most accurate method
49-65
To Align Centers by Adjusting

the Tailstock
1. Loosen tailstock clamp nut or level
2. Loosen on of the adjusting screws,
depending on direction tailstock must be
moved and tighten other until line on top
aligns with line on bottom half
3. Tighten screw to lock both halves in place
4. Make sure tailstock lines still aligned
5. Lock tailstock clamp nut or lever
49-66
To Align Centers by
Trial-Cut Method
1. Take a light cut (~.005 in.) to true
diameter from section A at tailstock end
for .250 in. long
2. Stop feed and note reading on graduated
collar of crossfeed handle
3. Move cutting tool away from work with
crossfeed handle
4. Bring cutting tool close to headstock end
49-67
To Align Centers by
Trial-Cut Method
5. Return cutting tool to same graduated
collar setting as at section A
6. Cut a .500-in (13 mm) length at section B
and stop lathe
7. Measure both diameters with micrometer
49-68
To Align Centers by
Trial-Cut Method
8. If both diameters not same size, adjust
tailstock either toward or away from
cutting tool difference of two readings
9. Take another light cut at A and B at same
crossfeed graduated collar setting.
Measure diameters and adjust tailstock.
49-69
To Align Centers Using Dial

Indicator and Test Bar
1. Clean lathe and work center, mount test
bar
2. Adjust test bar snugly between centers and
tighten tailstock spindle clamp
3. Mount dial indicator on toolpost or lathe
carriage
Indicator plunger should be parallel to lathe

bed and contact point set on center
49-70

4. Adjust cross-slide
Indicator registers approximately .025 in at

tailstock, indicator bezel to 0
5. Move carriage by hand so indicator

registers on diameter at headstock end and
not indicator reading
6. If both indicator readings not same, adjust
tailstock with adjusting screws until
indicator registers same at both ends
49-71

7. Tighten adjusting screw that was loosened
8. Tighten tailstock clamp nut
9. Adjust tailstock spindle until test bar snug
between lathe centers
10. Recheck indicator readings at both ends
and adjust tailstock, if necessary

6th Edition
Krar Gill Smid
Grinding Lathe
Cutting Tools
Unit 50
50-73
Grinding Lathe Cutting Tool

Wide variety of cutting tools for lathe
All have certain angles and clearances regardless
of shape
Shape and Dimensions of General-purpose Lathe Toolbit
50-74
To Grind a
General-Purpose Toolbit
1. Dress face of grinding wheel
2. Grip toolbit firmly, supporting hands on grinder
toolrest
3. Hold toolbit at proper
angel to grind cutting
edge angle
Tilt bottom of toolbit

toward wheel and
grind 10 side relief
or clearance angle
50-75
Cutting edge ~ In long and extend

over width of toolbit
10 side relief or
clearance angle
50-76
4. While grinding, move toolbit back and

forth across face of wheel
Prevents grooving wheel
5. Toolbit must be cooled frequently during

grinding
Never overheat toolbit!

Never quench stellite or cemented-carbide
tools
Never grind carbides with aluminum oxide
wheel
50-77
6. Grind end cutting edge so it forms angle of

a little less than 90 with side cutting edge
Hold tool so that end cutting edge angle and

end relief angle of 15 ground at same time
70 to 80 Point Angle
50-78
7. Using toolbit grinding gage, check amount

of end relief when toolbit is in toolholder
50-79
8. Hold top of toolbit approximately 45 to

axis of wheel and grind side rake to
approximately 14
Do not grind below top of toolbit
Creates a chip trap
Side rake ground the length

of the cutting edge
50-80
9. Grind slight radius on point of cutting

tool, being sure to maintain same front
and side clearance angle
10. With oilstone, hone cutting edge of toolbit
slightly
Lengthen life of toolbit

Enable it to produce better surface finish on
workpiece

6th Edition
Krar Gill Smid
Machining
Between Centers
Unit 52
52-82
Machining Between Centers

Training programs (schools)
Remove and replace work in lathe many times
before completed
Need assurance that machined diameter will run
true with other diameters
Machining between centers saves time in setting up
Common operations
Facing, rough and finish-turning, shoulder
turning, filing and polishing
52-83
Setting Up a Cutting Tool

1. Move toolpost to the left-hand side of the T-slot
in the
compound
rest
2. Mount toolholder in
toolpost so
setscrew in
toolholder 1 in.
beyond toolpost
52-84
Heavy Cuts: Set toolholder at right

angles to work

52-85
Setting Up a Cutting Tool: cont.

3. Insert proper cutting tool into toolholder,
having tool extend .500 in. beyond
toolholder and never more than twice its
thickness
4. Set cutting-tool point to center height
Check it against lathe center point
5. Tighten toolpost securely to prevent it

from moving during a cut
52-86
Purposes of a Trial Cut
Produce accurate turned diameter
Measured with micrometer
Set cutting-tool point to the diameter
Set crossfeed micrometer collar to the

diameter
52-87
Procedure to Take a Trial Cut

1. Set up workpiece and cutting tool as for
turning
2. Set proper speeds and feed to suit material
3. Start lathe and position toolbit over work
approximately .125 in. from end
4. Turn compound rest handle clockwise
of a turn to remove any backlash
52-88
5. feed toolbit into work by turning crossfeed

handle clockwise until light ring appears
around entire circumference of work
6. Do NOT move crossfeed handle setting
7. Turn carriage handwheel until toolbit
clears end of workpiece by about .060 in.
8. Turn crossfeed handle clockwise about .
010 in. and take trial cut .250 in. along
length of work
9. Disengage automatic feed and clear toolbit
past end of work with carriage handwheel
52-89
10. Stop the lathe

11. Test accuracy of micrometer by cleaning
and closing measuring faces and then
measure trial-cut diameter
12. Calculate how much material must still be
removed from diameter of work
13. Turn crossfeed handle clockwise
amount of material to be removed
52-90
14. Take another trial cut .250 in. long and

stop the lathe
15. Clear toolbit over end of work with
carriage handwheel
16. Measure diameter and readjust crossfeed
handle until diameter is correct
17. Machine diameter to length
52-91
Rough Turning
Removes as much metal as possible in
shortest length of time
Accuracy and surface finish are not
important in this operation
.020- to .030-in. feed recommended
Work rough-turned to
Within .030 in. of finished size when removing
up to .500 in. diameter
Within .060 in. when removing > .500 in.
52-92
Procedure for Rough Turning

1. Set lathe to correct speed for type and size
of material being cut
2. Adjust quick-change gearbox for a .010to .030-in. feed
Depends on depth of cut and condition of

machine
3. Move toolholder to left-hand side of

compound rest and set toolbit height to
center
52-93
4. Tighten toolpost securely to prevent

toolholder from moving during machining
5. Take light trial cut at right-hand end of
work for a .250 in. length
6. Measure work and adjust toolbit for
proper depth of cut
7. Cut along for .250 in., stop lathe, and
check diameter for size
1. Diameter .030 in. over finish size
8. Readjust depth of cut, if necessary
52-94
Finish Turning
Follows rough turning
Produces smooth surface finish and cuts
work to an accurate size
Factors affecting type of surface finish
Condition of cutting tool
Rigidity of machine and work
Lathe speeds and feeds
52-95
Procedure For Finish Turning

1. Make sure cutting edge of toolbit free
from nicks, burrs, etc.
2. Set toolbit on center; check it against lathe
center point
3. Set lathe to recommended speed and feed
52-96
4. Take light trial cut .250 in. long at righthand end of work
Produce true diameter

Set cutting tool to diameter
Set graduated collar to diameter
5. Stop lathe and measure diameter

6. Set depth of cut for half amount of
material to be removed
7. Cut along for .250 in., stop lathe, check
8. Readjust depth of cut and finish-turn
52-97
Filing in a Lathe
Only to remove small amount of stock,
remove burrs, or round off sharp corners
Work should be turned to within .002 to .003
in. of size
For safety, file with left hand so arms and
hands kept clear of revolving chuck
Remove toolbit from toolholder before filing
Cover lathe bed with paper before filing
52-98
Procedure to File in a Lathe

1. Set spindle speed to twice that for turning
2. Mount work between centers, lubricate,
and carefully adjust dead center in work
3. Move carriage as far to right as possible
and remove toolpost
4. Disengage lead screw and feed rod
5. Select 10- or 12-in. mill file or long-angle
lathe file
52-99
6. Start lathe
7. Grasp file handle in left hand and support
file point with fingers of right hand

52-100
8. Apply light pressure and push file forward

to its full length; release pressure on
return stroke
9. Move file about half width of file for each
stroke and continue filing until finished
Use 30-40 strokes per minute
10. Safety precautions
Roll sleeves above elbow

Remove watches and rings
Never use file without properly fitted handle
Never apply too much pressure
Clean file frequently with file brush
52-101
Procedure for
Polishing in a Lathe
1. Select correct type and grade of abrasive
cloth for finish desired
Piece about 6 8 in. long and 1 in. wide

Use aluminum oxide abrasive cloth for
ferrous metals
Use silicon carbide abrasive cloth should be
used for nonferrous metals
2. Set lathe to run at high speed

3. Disengage feed rod and lead screw
52-102
4. Remove toolpost and toolholder

5. Lubricate and adjust dead center
6. Roll sleeves up above elbows and tuck in
any loose clothing
7. Start lathe
8. Hold abrasive cloth on work
9. With right hand, press cloth firmly on
work while tightly holding other end of
abrasive cloth with left hand
10. Move cloth slowly back and forth
52-103
Shoulder
Shoulder: the change in diameters, or step,
when turning more than one diameter on a
piece of work
Three common types of shoulders
Square
Filleted
Angular or Tapered
52-104
Three Types of Shoulders


6th Edition
Krar Gill Smid
Knurling,
Grooving,
andFormTurning
Unit 53

53-106
Knurling
Process if impressing a diamond-shaped or
straight-line patter into the surface of the
workpiece
Improve its appearance
Provide better gripping surface
Increase workpiece diameter when press fit
required
53-107
Knurling
Diamond- and
straight-pattern
rolls available in
three styles
Fine
Medium
Course
53-108
Knurling Tool
Toolpost-type toolholder on which pair of
hardened-steel rolls mounted
Knurling tool with
one set of rolls in
self-centering head
Knurling tool with
three sets of rolls
in revolving head
53-109
Universal Knurling Tool System

Dovetailed shank and as many as seven
interchangeable knurling heads that can
produce wide range of knurling patterns
Combines in one tool
Versatility
Rigidity
Ease of handling
Simplicity
53-110
Procedure to Knurl in a Lathe

1. Mount work between centers and mark
required length to be knurled
If work held in chuck for knurling, right end

of work should be supported with revolving
tailstock center
2. Set lathe to run at one-quarter speed

required for turning
3. Set carriage feed to .015 to .030 in.
53-111
4. Set center of floating head of knurling tool

even with dead-center point
5. Set knurling tool at right angles to

workpiece and tighten it securely
53-112
6. Start machine and lightly touch rolls

against work to check tracking
7. Move knurling tool to end of work so
only half the roll face bears against work
8. Force knurling tool into work
approximately .025 in. and start lathe
OR
Start lathe and then force knurling tool into

work until diamond pattern come to point
53-113
9. Stop lathe and examine pattern

10. Once pattern correct, engage automatic
carriage feed and apply cutting fluid to
knurling rolls
11. Knurl to proper length and depth
Do not disengage feed until full length has

been knurled; otherwise, rings will be formed
on knurled pattern
12. If knurling pattern not to point after length

has been knurled, reverse lathe feed and
take another pass across work
53-114
Grooving
Done at end of thread to
permit full travel of nut up
to a shoulder or at edge of
Square
shoulder for proper fit
Also called recessing,
undercutting, or necking
Rounded grooves used
Round
where there is strain on
part
V-shaped
53-115
Procedure to Cut a Groove

1. Grind toolbit to desired size and shape of
groove required
2. Lay out location of groove
3. Set lathe to half the speed for turning
4. Mount workpiece in lathe
5. Set toolbit to center height
53-116
6. Locate toolbit on work at position where

groove is to be cut
7. Start lathe and feed cutting tool toward
work using crossfeed handle until toolbit
marks work lightly
8. Hold crossfeed handle in position and set
graduated collar to zero
9. Calculate how far crossfeed screw must be
turned to cut groove to proper depth
10. Feed toolbit into work slowly using
crossfeed handle
53-117
11. Apply cutting fluid to point of cutting tool
To ensure cutting tool will not bind in

groove, move carriage slightly to left and to
right while grooving
Should chatter develop, reduce spindle speed
12. Stop lathe and check depth of groove with

outside calipers or knife-edge verniers
Safety note: Always wear safety goggles when
grooving on a lathe

6th Edition
Krar Gill Smid
Threads and
Thread Cutting
Unit 55
55-119
Threads
Used for hundreds of years for holding parts
together, making adjustments, and
transmitting power and motion
Art of producing threads continually
improved
Massed-produced by taps, dies, thread
rolling, thread milling, and grinding
55-120
Threads
Thread
Helical ridge of uniform section formed on
inside or outside of cylinder or cone
Used for several purposes:

Fasten devices such as screws, bolts, studs, and
nuts
Provide accurate measurement, as in micrometer
Transmit motion
Increase force
55-121
Thread
Terminology
55-122
Thread Terminology
Screw thread
Helical ridge of uniform section formed on
inside or outside of cylinder or cone
External thread
Cut on external surface or cone
Internal thread
Produced on inside of cylinder or cone
55-123
Major diameter
Largest diameter of external or internal thread
Minor diameter
Smallest diameter of external or internal thread
Pitch diameter
Diameter of imaginary cylinder that passes
through thread at point where groove and thread
widths are equal
Equal to major diameter minus single depth of
thread
Tolerance and allowances given at pitch
diameter line
55-124
Number of threads per inch

Number of crests or roots per inch of threaded
section (Does not apply to metric threads)
Pitch
Distance from point on one thread to
corresponding point on next thread, measured
parallel to axis
Expressed in millimeters for metric threads
Lead
Distance screw thread advances axially in one
revolution (single-start thread, lead = pitch)
55-125
Root
Bottom surface joining sides of two adjacent
threads
External thread on minor diameter
Internal thread on major diameter
Crest
Top surface joining two sides of thread
External thread on major diameter
Internal thread on minor diameter
Flank
Thread surface that connects crest with root
55-126
Depth of thread
Distance between crest and root measured
perpendicular to axis
Angle of thread
Included angle between sides of thread
measured in axial plane
Helix angle
Angle that thread makes with plane
perpendicular to thread axis
55-127
Right-hand thread
Helical ridge of uniform cross section onto
which nut is threaded in clockwise direction
When cut on lathe, toolbit
advanced from right to left
Left-hand thread
Helical ridge of uniform cross section onto
which nut is threaded in counterclockwise
direction
When cut on lathe, toolbit
advanced from left to right
55-128
Thread Forms
April, 1975 ISO came to an agreement
covering standard metric thread profile
Specifies sizes and pitches for various threads
in new ISO Metric Thread Standard
Has 25 thread sizes, range in diameter from 1.6
to 100 mm
Identified by letter M, nominal diameter, and
pitch M 5 X 0.8
55-129
American National Standard Thread

Divided into four main series, all having
same shape and proportions
National Coarse (NC)

National Fine (NF)
National Special (NS)
National Pipe (NPT)
Has 60 angle with root and crest truncated

to 1/8th the pitch
Used in fabrication, machine construction
55-130
.6134
D .6134 x P or
N
.125
F .125 x P or
N

55-131
Unified Thread
Developed by U.S., Britain, and Canada for
standardized thread system
Combination of British Standard Whitworth and

55-132
.6134
D (external thread) .6134 x P or
N
.5413
D (internal thread) .5413 x P or
N
.125
F (external thread) .125 x P or
N
.250
F (internal thread) .250 x P or
N

55-133
American National Acme Thread

Replacing square thread in many cases
Used for feed screws, jacks, and vises
D=minimum.500P
=maximum.500P+0.010

F=.3707P
C=.3707P-.0052
(formaximumdepth)
55-134
Brown & Sharpe Worm Thread

Used to mesh worm gears and transmit
motion between two shafts at right angles to
each other but not in same plane
D=.6866P
F=.335P
C=.310P

55-135
Square Thread
Being replaced by Acme thread because of
difficulty in cutting it
D = .500P
Often found on vises
F = .500P
and jack screws
C = .500P + .002

55-136
International Metric thread

Standardized thread used in Europe
D = 0.7035P (maximum)
= 0.6855P (minimum)

F = 0.125P
R = 0.0633P (maximum)
= 0.054P (minimum)
55-137
Thread Fits and Classifications

Fit
Relationship between two mating parts
Determined by amount of clearance or
interference when they are assembled
Nominal size
Designation used to identify size of part
Actual size
Measured size of thread or part
Basic size: size from which tolerances are set
55-138
Allowance
Permissible difference between largest
external thread and smallest internal thread
Difference produces tightest fit acceptable
for any given classification
The allowance for a 1 in.8 UNC Class 2A and 2B fit is:
Minimum pitch diameter of the
internal thread (2B)
= .9188 in.
Maximum pitch diameter of the
external thread (2A)
= .9168 in.
Allowance = .002 in.
55-139
Tolerance
Variation permitted in part size

May be expressed as plus, minus, or both
Total tolerance is sum of plus and minus tolerances
In Unified and National systems, tolerance is plus
on external threads and minus on internal threads
The tolerance for a 1 in.8 UNC Class 2A thread is:
= .9168 in.
= .9100 in.
Tolerance = .0068 in.
55-140
Limits
Maximum and minimum dimensions of part
The limits for a 1 in.8 UNC Class 2A thread are:
= .9168 in..
= .9100 in.
55-141
Three Categories of Unified

Thread Fits
External threads classified as 1A, 2A, and 3A and
internal threads as 1B, 2B, 3B
Classes 1A and 1B
Threads for work that must be assembled
Loosest fit
Classes 2A and 2B
Used for most commercial fasteners
Medium or free fit
Classes 3A and 3B
Used where more accurate fit and lead required
No allowance provided
55-142
Thread Calculations: Example 1

To cut a correct thread on a lathe, it is necessary first to make
calculations so thread will have the proper dimensions.
Calculate pitch, depth, minor diameter, and width of flat
for a 10 UNC thread.
D=singledepthofthread Minor dia Major dia - ( D D)
P=pitch
.75 - (.061 .061)
1
1
.628 in.
P
.100 in.
tpi 10
P 1 1
Width of flat x
D .61343 x P
8 8 10
.61343 x .100 .061 in.
.0125 in.
55-143
Thread Calculations: Example 2

What are the pitch, depth, minor diameter, width of crest
and width of root for an M 6.3 X 1 thread?
P=pitch=1mm
D=0.54127x1
=0.54mm
Width of root 0.25 x P

0.25 x 1
0.25 mm
Minor dia Major dia - ( D D)

6.3 - (.54 .54)
5.22 mm
Width of crest 0.125 x P
0.125 x 1
0.125 mm
55-144
Procedure to Set the QuickChange Gearbox for Threading

1. Check drawing for thread pitch required
2. From chart on quick-change gearbox, find
whole number that represents pitch in
threads per inch or in millimeters
3. With lathe stopped, engage tumbler lever
in hole, which is in line with the pitch
4. Set top lever in proper position as
indicated on chart
55-145
5. Engage sliding gear in or out as required

6. Turn lathe spindle by hand to ensure that
lead screw revolves
7. Recheck lever settings to avoid errors
55-146
Thread-Chasing dial
Lathe spindle and
lead screw must be
in same relative
position for each cut
Thread-chasing dial
attached to carriage for
this purpose
Dial has eight divisions

Even threads use any division
Odd threads either numbered
or unnumbered: not both
55-147
Thread Cutting
Produces a helical ridge of uniform section
on workpiece
Performed by taking successive cuts with
threading toolbit of same shape as thread
form required
Work may be held between centers or in
chuck
55-148
Procedure to Set Up a Lathe for

Threading (60 Thread)
1. Set lathe speed to speed used for turning
2. Set quick-change gearbox for required pitch
in threads per inch or in millimeters
3. Engage lead screw
4. Secure 60 threading toolbit and check
angle using thread center gage
5. Set compound rest at 29 to right; set to left
for left-hand thread
55-149
6. Set cutting tool to height of lathe center

point
7. Mount work between centers
Make sure lathe dog is tight on work

If work mounted in chuck, it must be held
tightly
8. Set toolbit at right angles to work, using

thread center gage
9. Arrange apron controls to allow split-nut
lever to be engaged
55-150
Thread-Cutting Operation
Procedure to cut a 60 thread
1. Check major diameter of work for size
2. Start lathe and chamfer end of workpiece
with side of threading tool to just below
minor diameter of thread
3. Mark length to be threaded by cutting
light groove at this point with threading
tool while lathe revolving
55-151
4. Move carriage until point of threading tool

near right-hand end of work
5. Turn crossfeed handle until threading tool
close to diameter, but stop when handle is at
3 o'clock position
6. Hold crossfeed handle in this position and
set graduated collar to zero
7. Turn compound rest handle until threading
tool lightly marks work
55-152
8. Move carriage to right until toolbit clears

end of work
9. Feed compound rest clockwise about .003 in.
10. Engage split-nut lever on correct line of
thread-chasing dial and take trial cut along
length to be threaded
11. At end of cut, turn crossfeed handle
counterclockwise to move toolbit away from
work and disengage split-nut lever
55-153
12. Stop lathe and check number of tpi with

thread pitch gage, rule, or center gage
13. After each cut, turn carriage handwheel to
bring toolbit to start of thread and return
crossfeed handle to zero
14. Set depth of all threading cuts with
compound rest handle
See Table 55.2 and Table 55.3
55-154
When tool is fed in at 29, most of the cutting

is done by the leading edge of toolbit.

55-155
Table 55.2Depth settings for

cutting 60 national form
threads*
Compound Rest Setting
tpi
30
29
24
.027 .031 .0308
20
.0325 .0375 .037
18
.036 .0417 .041
16
.0405 .0468 .046
14
.0465 .0537 .0525
table taken
13 Portion
.050of.0577
.057
from textbook
11
.059
.068 .0674
55-156
15. Apply cutting fluid and take successive

cuts until top (crest) and bottom (root) of
thread are same width
16. Remove burrs from top of thread with file
17. Check thread with master nut and take
further cuts
55-157
Six Ways to Check Threads
Depends on accuracy required:

1. Master nut or screw
2. Thread micrometer
3. Three wires
4. Thread roll or snap gage
5. Thread ring or plug gage
6. Optical comparator

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PowerPoint to accompany

Technology of Machine Tools

Krar Gill Smid

Very versatile (many attachments)

Special Types of Lathes

Technology of Machine Tools

Krar Gill Smid

Engine Lathe Parts

Lathe Size and Capacity

Indicated by the swing

Parts of the Lathe

Copyright The McGraw-Hill Companies, Inc.

Copyright The McGraw-Hill Companies, Inc.

Setting Speeds on a Lathe

Shear Pins and Slip Clutches

Spring-loaded slip clutches

Shear pin in end gear

Copyright The McGraw-Hill Companies, Inc.

Technology of Machine Tools

Krar Gill Smid

Copyright The McGraw-Hill Companies, Inc.

Support during cutting

Most commonly used lathe chucks

Three-jaw Universal Chuck

Two sets of jaw: outside chucking and

Four-Jaw Independent Chuck

Jaws can be reversed to hold work by inside

2. Tapered spindle nose

Held by lock nut

Held by tightening cam-locks using T-wrench

Registration lines on spindle nose

Special adapter fitted into taper of headstock spindle,

Types of Lathe Dogs

Straight-tail lathe dog

Types of Lathe Dogs

Clamp lathe dog

Left-Hand Offset Toolholder

Right-Hand Offset Toolholder

Toolholders for Indexable

Cutting-Off (Parting) Tools

Super Quick-Change Toolpost

Technology of Machine Tools

Krar Gill Smid

Copyright The McGraw-Hill Companies, Inc.

Lathe Cutting Speeds in Feet and Meters per

Calculating Lathe Spindle Speed

Two Cuts Used to Bring

Feeds for Various Materials

Aluminum .015.030 0.40.75

Example: Depth of cut on a lathe

Copyright The McGraw-Hill Companies, Inc.

Factors Determining Depth of

Check machine for its' graduations

On machines where the workpiece revolves,

Copyright The McGraw-Hill Companies, Inc.

On machines where the workpiece does not

Copyright The McGraw-Hill Companies, Inc.

Hints on Graduated Collar Use

5. Graduated collar on compound rest can be

Compound rest set at 90 to cross-slide

Machining accurate diameters

Set compound rest to 8416' to the cross-slide