Lec2 Lathe Machine
Lec2 Lathe Machine
Lec2 Lathe Machine
Machining
Lecture 2: Lathes
D r James Wakir u
M e ch anical Engineer in g
Machine Tools:
Machines tools are the kind of machines on which the metal cutting or metal
forming processes are carried out. They employ cutting tools to remove excess
material from the given job.
The functions of a machine tool are :
(i) To hold the tool ;
(ii) To move the tool or the workpiece or both relative to each other ;
(iii) To supply energy required to cause the metal cutting
Machine Tools:
Classification of machine tools
The machine tools are classified as follows :
1. General purpose :
(i) Lathe (ii) Drilling machine (iii) Shaping machine (iv) Planing machine (v)
Milling machine (vi) Sawing machine.
2. Special purpose :
(i) Special lathes like capstan, turret and copying lathes (ii) Boring machine (iii)
Broaching machine
(iv) Production milling machine (v) Production drilling machine.
Machine Tools:
Classification of machine tools
3. Automatic machine tools :
These machine tools, also called Automatic screw cutting machines (or simply auto-
mats),
are used for mass production of essentially small parts using a set of pre-designed
and job-specific
cams.
4. Computer numerical control (CNC) machine tools :
Under CNC machine tools, we have CNC turning centre, which does all the work of a
lathe
and CNC machining centre which does milling, drilling etc., with provision for
automatic tool
changing and tool wear correction built into it.
Machine Tools:
Characteristics of ‘General purpose’ machine tools are :
(i) Less set-up and debugging time.
(ii) Less maintenance cost.
(iii) Usually less initial investment in equipment.
(iv) Less danger of obsolescence.
(v) Fewer machines may be required.
(vi) Greater machine flexibility.
Characteristics of ‘Special purpose’ machine tools are :
(i) Higher output.
(ii) Higher product quality.
(iii) Reduced skill requirements.
(iv) Reduced inspection cost.
Machine Tools:
Characteristics of ‘General purpose’ machine tools are :
(v) Uniform product flow.
(vi) Reduced manpower requirements.
(vii) Reduced factory floor space.
(viii) Reduced in-process inventory.
Elements of machine tools
Various elements of machine tools are :
1. Structure—formed by bed, column and frame.
2. Slides and tool structure.
3. Spindles and spindle bearing.
4. Kinematics of machine tool drives.
5. Work holding, and tool holding elements
Lathe Machine:
A lathe is a machine tool which spins a block of material to perform
various operations such as cutting, Turning, Facing, Threading, sanding,
knurling, drilling, or deformation such as metal spinning with tools that
are applied to the work piece to create an object which has symmetry
about an axis of rotation
The term Centre Lathe is derived from the fact that in its operation the
lathe holds a piece of material between two rigid supports called
centres, or by some other device such as a chuck or faceplate which
revolves about the centre line of the lathe.
Lathe Machine
Center lathe
LATHE
Major categories of lathes
Woodworking lathes
Metalworking lathes or universal Engine Lathes
Glassworking lathes
Metal spinning lathes
Ornamental turning lathes
Rotary lathes
Turret Lathe
Lathe Operation
TURNING FACING
Lathe Operation
Carriage with legend, numbers and text within the description refer to those in the
image
Carriage
▪ The carriage controls and supports the cutting tool.
▪ The carriage has the following five major parts :
(i) Saddle. It is a H-shaped casting fitted over the bed. It moves along
the guideways.
(ii) Cross-slide. It carries the compound slide and tool post ; can be
moved by power or by hand.
(iii) Compound rest. It is marked in degrees ; used during taper turning
to set the tool for angular cuts.
(iv) Tool post. The tool is clamped on the tool post.
(v) Apron. It is attached to the saddle and hangs in front of the bed. It
has gears, levers and clutches for moving the carriage with the lead
screw for thread cutting.
Cross-slide
The cross-slide stands atop the carriage and has a leadscrew that travels
perpendicular to the main spindle axis, this permit facing operations to
be performed.
This leadscrew can be engaged with the feedscrew (mentioned
previously) to provide automated movement to the cross-slide; only
one direction can be engaged at a time as an interlock mechanism will
shut out the second gear train.
Compound rest
The compound rest (or top slide) is the part of the machine where the
tool post is mounted. It provides a smaller amount of movement along
its axis via another leadscrew. The compound rest axis can be adjusted
independently of the carriage or cross-slide. It is utilized when turning
tapers, when screwcutting or to obtain finer feeds than the leadscrew
normally permits.
Tailstock
▪ The tailstock is a toolholder
directly mounted on the spindle
axis, opposite the headstock
▪ It is situated at the right hand
end of the bed.
▪ It is used for supporting the
right end of the work.
▪ It is also used for holding and
feeding the tools such as drills,
reamers, taps etc.
Tailstock with legend, numbers and text within the description refer to those in the
image
Tailstock
▪ It is situated at the right hand end of the bed.
▪ It is used for supporting the right end of the
work.
▪ It is also used for holding and feeding the
tools such as drills, reamers, taps etc
▪ The spindle (T5) does not rotate but does Tailstock with legend, numbers and text within the description
travel longitudinally under the action of a refer to those in the image
Lathe Operations
Taper turning methods.
Lathe Operations
Lathe Operations
4. Taper turning:
(ii) By swivelling the compound rest
It is the best method as it does not affect the
Taper turning methods.
Taper turning by manipulation of both feeds is inaccurate and requires skill on the part
of the operator. It is used for sharp tapers only.
10. Knurling :
It is an operation of embossing a diamond
shaped pattern on the surface of a workpiece.
The purpose of knurling is to provide an
effective gripping surface on a workpiece to
prevent it from slipping when operated by
hand.
Lathe Operations
11. Forming:
It is an operation of turning a convex, concave or any irregular shape. Form-turning
may be accomplished by the following methods :
(i) Using a forming tool,
(ii) Combining cross and longitudinal feed,
(iii) Tracing or copying a template hand.
Lathe Accessories
1. Chucks:
The chucks provide a very efficient and true
device of holding work on the lathe during
the operation.
Some of the commonly used chucks are :
(i) Three jaw universal chucks (a)
(a)
(ii) Four jaw independent chuck (b)
(iii) Combination chuck
(iv) Magnetic chuck
(v) Air or hydraulic chucks
(vi) Collet.
(b)
Lathe Accessories
2. Face plate It is usually a circular cast iron
disc, having a threaded hole at its centre so that
it can be screwed to the threaded nose of the
spindle.
It consists of a number of holes and slots by
means of which the work can be secured to it. A
number of other things like bolts, nuts, washers,
clamping plates and metallic packing pieces, etc.,
are required for holding the work properly on a Face plate
face plate.
3. Angle plate : It is used for holding work in
conjunction with a face plate. When the size or
shape of the work is such that it is not possible
to mount the work directly on the face plate the
angle plate is secured to the face plate and the
work mounted on it
Lathe Accessories
4. Driving plate :
It is a cast circular disc having a projected boss at
its rear. The boss carries internal threads, so that
it can be secrewed on to the spindle work. It also
carries a hole to accommodate a pin which
engages with the tail of a lathe dog or carrier
when the job is held in the latter
Drive plate
5. Lathe carriers or dogs :
These are used in conjunction with the driving
plate. The two common forms are straight tail
and bent tail. The work to be held is inserted in Lathe dog or carrier
the ‘V’ shaped hole of the carrier and then finally
secured in position by means of set screw.
Lathe Accessories
6. Lathe centres :.
They act as solid bearings to support the work
during the operation. Cast steel or high grade
tool steel is the common material used for their
manufacture. They are then hardened and
ground to correct angle.
7. Lathe mandrels :
A “mandrel” can be described as a solid steel
shaft or spindle which is used for holding
bored parts for machining their outside surfaces
on lathe. They are also The common types of
mandrels are : Solid or plain (Fig. 9.29) : collar,
stepped, expanding and double cone
mandrels.known as arbors.
Lathe dog or carrier
Lathe Accessories
8. Rests :
When a very long job is to be turned between
centres on a lathe, due to its own weight it
provides a springing action and carries a lot of
bending moment. To avoid this, such jobs are
always supported on an attachment known as
‘steady rest or centre rest’ (Fig. 9.30a)
Sometimes, when the job is too flexible, it Steady rest
becomes necessary to support the job very close
to the cutting edge of the tool throughout the
operation. In such cases a ‘follower rest’ used
Follower rest
Lathe Accessories
9. Jigs and fixtures :
Jigs and fixtures are used in conjunction with the face plate on a lathe for
supporting and holding odd shaped and eccentric jobs during the operation.
This specific use is in the mass production of identical parts otherwise, if only a
single item is to be made, the cost of production of the jigs or fixtures itself will
be too high, preventing their use.
Turret lathe and capstan lathe
Limitations of Centre Lather
• Only one tool can be used in the normal course (sometimes the conventional tool
post can be replaced by a square tool post with four tools).
• Large setting time of the job (in terms of holding the job)
• The idle times involved in setting and movement of tools between the cuts is large.
• If proper care is not taken by the operator, it is difficult to achieve precise movement
of the tools to destined places. The above limitations are taken
Aspects Turret and capstan lathe differ from general purpose
◦ The headstock has more and heavier range of speeds due to which higher production
rate is possible.
◦ The tool post is indexable (four tools ; any one tool can be brought into the cutting
position).
◦ The tailstock is replaced by a tool turret with six tool positions.
◦ Feed of each tool can be regulated by means of feed stops.
◦ Two or more tools mounted on a single tool face can cut simultaneously.
◦ These lathes are used for production operations involving better repeatability.
◦ Semi-skilled operators are required.
Turret lathe
Turret lathe is a machine generally larger than a capstan lathe, but using similar
tools. The main difference between them is that the turret saddle has
longitudinal movement on the guides of the bed.
In general, the tooling equipment is arranged for either bar or clutch work, high
production being obtainable by use of multiple tooling on both the hexagon
turret and square turret : Machines fitted with two traversing saddles are
known as combination turret lathe.
The main tools for bar work are roller steady-turning tool-holders on the main
hexagon turret and cutting-off tools on the square turret, these being
supplemented by screwing drilling or forming tools to suit the work in hand. For
chuck work it is necessary to provide equipment to cover comparatively large
diameters.
Turret lathe
Turret lathe
Features of turret lathe that make it a quantity production machine :
• Rigidity in holding work and tools is built into the machine to permit multiple
and combined cuts.
• Tools may be set-up in the turret in the proper sequence for the operation.
• Each station is provided with a feed stop or feed trip so that each cut of a tool
is the same as its previous cut.
• Multiple cuts can be taken from the same station at the same time, such as
two or more turning and/or boring cuts.
• Combined cuts can be made ; that is, tools on the cross slide can be used at
the same time that tools on the turret are cutting.
• Turret lathes may be fitted with attachments for taper turning, thread chasing,
and duplicating, and can be tape controlled.
Capstan lathe
capstan lathe is a lathe designed to use a number of cutting tools mounted in a
rotating turret or capstan and arranged to perform turning operations
successively.
◦ This machine is similar both in appearance and operation to a turret lathe but is used
on smaller work.
◦ The main difference between the two types of machines is that on a capstan lathe the
turret saddle is clamped to the bed, and the turret slide has a limited amount of
movement in the saddle, whereas the saddle on a turret lathe has movement on the
slides of the bed. A longitudinal power feed is provided in both cases as well as hand
movement by a pilot wheel. In addition, a separate saddle is fitted at the front and a
cutoff rest at the back, so that further operations can be performed either separately
or simultaneously with the tools in the turret.
◦ To ensure accurate length of work being obtained, a set of six adjustable stops is fitted,
each one corresponding to a face of the turret and coming into the correct position as
the turret indexes trip the feed motion at any predetermined length.
◦ The tooling equipment varies not only on the type of work to be produced, but also
on the material to be machined.
Capstan lathe
Differences between a turret
lathe and a capstan lathe
Turret lathe and capstan lathe
The square turret on the cross slide can be rotated
manually about a vertical axis to bring each of the
four tools into operating position.
On most machines, the turret can be moved
transversely, either manually or by power, by
means of the cross slide, and longitudinally through
power or manual operation of the carriage. In most
cased, a fixed tool holder also is added to the back
end of the cross slide; this often carries a parting
tool.
Advantages of a Turret Lathe
▪ Setup time is reduced.
▪ The production time is less.
▪ The production rate increases.
▪ It is used for mass production.
▪ It does not require high skilled labour
Types of turret lathes
1. Horizontal turret lathe
(i) Ram type
(ii) Saddle type
2. Vertical turret lathes
3. Numerically-Controlled (NC) turret lathes.
Automatic turret lathes (mechanically
automated)
During the 1870s through 1890s, the automatic turret lathe
was developed and disseminated. These machines can
execute many part-cutting cycles without human
intervention.
Thus the duties of the operator (which were already greatly
reduced by the manual turret lathe) were even further
reduced, and productivity increased.
These machines use cams to automate the sliding and
indexing of the turret and the opening and closing of the
chuck.
CNC lathes and second-operation lathes
Today, most CNC lathes have turrets, and so could logically be called turret
lathes, but the terminology is usually not used that way.
Horizontal CNC lathes, with or without turrets, are generally called CNC
lathes or CNC turning centers or turning centers, and the term turret lathe
by itself is still usually understood in context to refer to horizontal, manual
turret lathes.
The changed role in the production process that such machines now play
is reflected in another name for them, which is second-operation lathe.
Vertical turret lathes
The term vertical turret lathe (VTL) is applied to machines wherein the
same essential design of the horizontal version is upended, which allows
the headstock to sit on the floor and the faceplate to become a horizontal
rotating table
This is useful for the handling of very large, heavy, short workpieces.
Vertical lathes in general are also called vertical boring mills or often
simply boring mills; therefore a vertical turret lathe is a vertical boring mill
equipped with a turret.
Today's CNC versions are called CNC VTLs.
Gang-tool lathe
A gang-tool lathe is one that has a row of tools set up on its cross-slide,
which is long and flat and is similar to a milling machine table.
The idea is essentially the same as with turret lathes to set up multiple
tools and then easily index between them for each part-cutting cycle.
Instead of being rotary like a turret, the indexable tool group is linear.
Multispindle lathe
Multispindle lathes have more than one spindle and automated control
(whether via cams or CNC).
They are production machines specializing in high-volume production.
The smaller types are usually called screw machines, while the larger
variants are usually called automatic chucking machines, automatic
chuckers, or simply chuckers.
CNC lathe / CNC turning center
CNC lathes are rapidly replacing the
older production lathes (multispindle,
etc) due to their ease of setting and
operationThe part may be designed by
the Computer-aided manufacturing
(CAM) process The machine is
controlled electronically via a computer
menu style interface
CNC Lathe
Combination lathe / 3-in-1 machine
A combination lathe, often known as a 3-in-1 machine, introduces
drilling or milling operations into the design of the lathe.
The 3-in-1 name comes from the idea of having a lathe, milling machine,
and drill press all in one affordable machine tool.
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