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Machine tool

 A machine tool is a non‐portable power operated and


reasonably valued device or system of device in which
energy is expended to produce jobs of desired size, shape
and surface finish by removing excess material from the
preformed blanks in the form of chips with the help of
cutting tools moved past the work surface.
Lathe
Lathe
 A lathe is a large machine that rotates the work, and
cutting is done with a non-rotating cutting tool. The
shapes cut are generally round, or helical. The tool is
typically moved parallel to the axis of rotation during
cutting.
 head stock - this end of the lathe contains the driving
motor and gears. Power to rotate the part is delivered
from here. This typically has levers that let the speeds
and feeds be set.
 ways - these are hardened rails that the carriage rides
on.
 tail stock - this can be used to hold the other end of the
part.
Lathe
 Bed - this is a bottom pan on the lathe that catches chips,
cutting fluids, etc.
 carriage - this part of the lathe carries the cutting tool and
moves based on the rotation of the lead screw or rod.
 Lead screw - A large screw with a few threads per inch used
for cutting threads. It has ACME threads with included angle
of 29o for easy engagement and disengagement of half nut.
 Lead rod - a rod with a shaft down the side used for driving
normal cutting feeds.
 The critical parameters on the lathe are speed of rotation
(speed in RPM) and how far the tool moves across the work
for each rotation (feed in IPR)
General classifications used when describing lathes
 Swing - the largest diameter of work that can be rotated.
 Distance Between Centres - the longest length of
workpiece
 Length of Bed - Related to the Distance Between
Centres
 Power - The range of speeds and feeds, and the
horsepower available
Number of Spindle Speed
 Number of spindle speed is in a geometric progression.
 If n number of spindle speed is required with N1 is the
minimum speed then
N1 , N1r , N1r 2 , N1r 3 ,.............N1r n 1
n 1
N1  N min and N1r  N max
1
 N max  n 1
Therefore, Step Ratio  r    
 N min 
 The values of step ratios are 1.06, 1.12, 1.26, 1.41, 1.58 and 2
Turning
 Turning - produces a smooth and straight outside radius
on a part.
Threading
 Threading - The cutting tool is moved quickly cutting
threads.
Threading
 In one revolution of the spindle, carriage must travel
the pitch of the screw thread to be cut.
N s Pzs  N L Lz L
P  Pitch of the screw thread to be cut
L  Pitch of the lead screw
z s  Number of start of the screw thread to be cut
z L  Number of start of the lead screw
icg  gear ratio of spindle N s  to carriage N L  gear train
Facing
 Facing - The end of the part is turned to be square.
Tapering
 Tapering - the tool is moves so as to cut a taper (cone
shape).
Parting/Slotting/Grooving
 A tool is moved in/out of the work. shallow cut will leave
a formed cut, a deep cut will cut off the unsupported
part.
Drilling/Boring
 Drilling/Boring - a cutter or drill bit is pushed into the
end to create an internal feature.
Knurling
 Knurling is a manufacturing process whereby a
visually-attractive diamond-shaped (criss-cross)
pattern is cut or rolled into metal.
 This pattern allows human hands or fingers to get a
better grip on the knurled object than would be
provided by the originally-smooth metal surface.
Spinning
 Metal Spinning is a process by which circles of metal are
shaped over mandrels (also called forms) while mounted
on a spinning lathe by the application of levered force
with various tools.
Reaming
 A reamer enters the workpiece axially through the end
and enlarges an existing hole to the diameter of the
tool. Reaming removes a minimal amount of material
and is often performed after drilling to obtain both a
more accurate diameter and a smoother internal
finish.
Tapping
 A tap enters the workpiece axially through the end and
cuts internal threads into an existing hole. The
existing hole is typically drilled by the required tap
drill size that will accommodate the desired tap.
Work holding Devices for Lathes
 Held between centers
 3 jaw self centering chuck (Disc type jobs being held
in chucks )
 4 jaw independently adjusted chuck
 Held in a collet (Slender rod like jobs being held in
collets )
 Mounted on a face plate (Odd shape jobs, being held
in face plate)
 Mounted on the carriage
 Mandrels
 Magnetic chuck – for thin job
Lathe chucks
 Lathe chucks are used to support a wider variety of
workpiece shapes and to permit more operations to be
performed than can be accomplished when the work is
held between centers.
 Three-jaw, self-centering chucks are used for work that
has a round or hexagonal cross section.
 Each jaw in a four-jaw independent chuck can be moved
inward and outward independent of the others by means
of a chuck wrench. Thus they can be used to support a
wide variety of work shapes.
 Combination four-jaw chucks are available in which each
jaw can be moved independently or can be moved
simultaneously by means of a spiral cam.
3 Jaw Chuck 4 Jaw Chuck
Collets Magnetic Chuck

Face Plate
Turning
Formula for Turning
D1  D2
 Depth of cut, d  DOC  mm
2
 Average diameter of workpiece D1  D2
Davg  mm
2

 Cutting Time,CT  L  A  O
fN

 Metal Removal Rate


MRR 
 D 2
1  D22   D dfN
avg
4 / fN
D1N
 Cutting Speed, V = ,m / min
1000
Turning Tapers on Lathes
 Using a compound slide,

 Using form tools,

 Offsetting the tailstock, and

 Using taper turning attachment.


Using a Compound Slide
 Limited movement of the compound slide
 Feeding is by hand and is non-uniform. This is
responsible for low-productivity and poor surface
finish.
 Can be employed for turning short internal and
external tapers with a large angle of (steep) taper.
Using a Compound Slide contd..
 The angle is determined by
Dd
tan  
2l
  Half taper angle
D  Diameter of stock
d  smaller diameter
l  length of the taper
Offsetting the tailstock
 It is necessary to measure the tailstock offset when using
this method.
 This method is limited to small tapers (Not exceeding 8o
) over long lengths.
 By offsetting the tailstock, the axis of rotation of the job
is inclined by the half angle of taper.
Offsetting the tailstock Contd..
 Tailstock offset (h) can be determined by
LD  d 
h or h  L tan 
2l
Form tool
 Special form tool for generating the tapers is used. The
feed is given by plunging the tool directly into the work.
This method is useful for short external tapers, where
the steepness is of no consequence, such as for
chamfering.
Taper Turning Attachment
 Additional equipment is attached at the rear of the lathe.
 The cross slide is disconnected from the cross feed nut.
 The cross slide is then connected to the attachment.
 As the carriage is engaged, and travels along the bed, the
attachment will cause the cutter to move in/out to cut
the taper.
 For turning tapers over a comprehensive range is the use
of taper turning attachment.
Errors in tool settings

 Setting the tool below the centre decrease actual rake angle,
while clearance angle increases by the same amount. Thus
cutting force increased.
 Setting the tool above the centre causes the rake angle to
increase, while clearance angle reduces. More rubbing with
flank.
Types of Lathe
The different types of lathes are:
1. Speed lathe
(a) Wood working
(b) Spinning
(c) Centering
(d) Polishing
 2. Centre or engine lathe
(a) Be1t drive
(b) Individual motor drive
(c) Gear head lathe
Types of Lathe
3. Bench lathe
4. Tool room Lathe
5. Capstan and Turret 1athe
6. Special purpose lathe
(a) Whee1 lathe
(b) Gap bed lathe
(c) Duplicating lathe
(d) T-lathe
7. Automatic lathe
Speed Lathe
 Speed lathe is simplest of all types of lathes in construction
and operation. The important parts of speed lathe are
following-
(1) Bed
(2) Headstock
(3) Tailstock, and
(4) Tool post mounted on an adjustable slide.
 It has no feed box, 1eadscrew or conventional type of
carriage. The tool is mounted on the adjustable slide and is
fed into the work by hand control. The speed lathe finds
applications where cutting force is least such as in wood
working, spinning, centering, polishing, winding, buffing etc.
 This lathe has been so named because of the very high speed
of the headstock spindle.
Centre Lathe or Engine Lathe
 The term “engine” is associated with this lathe due to the
fact that in the very early days of its development it was
driven by steam engine.
 This lathe is the important member of the lathe family
and is the most widely used. Similar to the speed lathe,
the engine lathe has all the basic parts, e.g., bed,
headstock, and tailstock.
 But its headstock is much more robust in construction
and contains additional mechanism for driving the lathe
spindle at multiple speeds.
Bench Lathe
 This is a small lathe usually mounted on a bench. It has
practically all the parts of an engine lathe or speed lathe
and it performs almost all the operations. This is used for
small and precision work.
Tool Room Lathe
 This lathe has features similar to an engine lathe but it is
much more accurately built.
 It has a wide range of spindle speeds ranging from a very
low to a quite high speed up to 2500 rpm.
 This lathe is mainly used for precision work on tools,
dies, gauges and in machining work where accuracy is
needed.
Special Purpose Lathes
 These lathes are constructed for special purposes and for
jobs, which cannot be accommodated or conveniently
machined on a standard lathe.
 The wheel lathe is made for finishing the journals and
turning the tread on railroad car and locomotive wheels.
 The gap bed lathe, in which a section of the bed adjacent
to the headstock is removable, is used to swing extra-
large-diameter pieces.
 The T-lathe is used for machining of rotors for jet
engines. The bed of this lathe has T-shape.
 Duplicating lathe is one for duplicating the shape of a
flat or round template on to the job.
Turret Lathe
A turret lathe, a number of tools can be set up on the
machine and then quickly be brought successively into
working position so that a complete part can be
machined without the necessity for further adjusting,
changing tools, or making measurements.
Turret Lathe
Capstan Lathe
Capstan lathe Turret lathe
Short slide, since the saddle is Saddle moves along the bed,
clamped on the bed in position. thus allowing the turret to be of
large size.
Light duty machine, generally for Heavy duty machine, generally
components whose diameter is for components with large
less than 50 mm. diameters, such as 200 mm.
Too much overhang of the turret Since the turret slides on the
when it is nearing cut. bed, there is no such difference.
Ram-type turret lathe, the ram and Saddle-type lathes, the main
the turret are moved up to the turret is mounted directly on the
cutting position by means of the saddle, and the entire saddle
capstan Wheel. As the ram is and turret assembly
moved toward the headstock, the reciprocates.
turret is automatically locked into
position.
Turret indexing mechanism
 The hexagonal turret is rotated (for indexing) by a
Geneva mechanism where a Geneva disc having six
radial slots is driven by a revolving pin. Before starting
rotation, the locking pin is withdrawn by a cam lever
mechanism. The single rotation of the disc holding the
indexing pin is derived from the auxiliary shaft with the
help of another single revolution clutch as indicated.

 For automatic lathe: Ratchet and Pawl mechanism


Automatic Lathe
 The term automatic is somewhat loosely applied, but is
normally restricted to those machine tools capable of
producing identical pieces without the attention of an
operator, after each piece is completed. Thus, after
setting up and providing an initial supply of material,
further attention beyond replenishing the material
supply is not required until the dimensions of the work
pieces change owing to tool wear.
 A number of types of automatic lathes are developed
that can be used for large volume manufacture
application, such as single spindle automatics, Swiss type
automatics, and multi-spindle automatics.
Swiss type Automatic Lathe Or Sliding Headstock Automatics

 Headstock travels enabling axial feed of the bar stock


against the cutting tools.
 There is no tailstock or turret
 High spindle speed (2000 – 10,000 rpm) for small job
diameter
 The cutting tools (upto five in number including two on
the rocker arm) are fed radially
 Used for lot or mass production of thin slender rod or
tubular jobs, like components of small clocks and wrist
watches, by precision machining.
Multi Spindle Automatic Lathe
 For increase in rate of production of jobs usually of
smaller size and simpler geometry.

 Having four to eight parallel spindles are preferably used.

 Multiple spindle automats also may be parallel action or


progressively working type.
Norton type Tumbler-gear quick-change Gear box
Norton type Tumbler-gear quick-change Gear box
 It comprises a cone of gears 1 to 8 mounted on shaft S2.

 The tumbler gear can slide on shaft S1. It can mesh with any
gear on shaft S2 through an intermediate gear which is
located on a swinging and sliding lever so that it can engage
gears 1 to 8 of different diameters, on shaft S2.
 The lever can be fixed in any desired ratio position with the
help of a stop pin.
 The drive is usually from the driving shaft S1 to the driven
shaft S2.

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