MKSSS’s

Cummins College of Engineering for Women, Pune

Department of Mechanical Engineering

Second Year of Engineering

Subject Name: Manufacturing Processes – I

Subject Code : ME 2103

Subject Teacher : Prof. Vishwanath Mali

Contact : vishwanath.mali@cumminscollege.in
 A
Presentation
On

UNIT III

Metal Cutting Lathes

by

Prof. V. A. Mali
Department of Mechanical Engineering
Syllabus
• Introduction to Lathes, type of lathes, construction, all arrangement
and principal units of engine lathes, specifications of lathes,
operations carried on lathe, attachment extending the processing
capacities of engine lathes, capstan and turret lathe, taper turning
lathe, thread cutting on lathe using gear train and chasing dial.
Introduction to Lathes
• Lathe is one of the most important machine tools in the metal
working industry.

• A lathe operates on the principle of a rotating work piece and a fixed

cutting tool.

• Lathe machine is also known as “the mother/father of the entire tool

family”.

• As early as 1569, wood lathes were in use in France.

Tree Lathe
Lath
Henry Maudslay (1797)
Working Principle Of Lathe Machine
• The lathe is a machine tool which holds the work piece between two
rigid & strong supports called centers or in a chuck or in face plate
which revolves.

• The cutting tool is held and fed against the revolving work. Cutting
tool fed either parallel or at right angles to the axis of w/p. Or may
also at an angle .
Function of Lathe
• To remove metal from a piece of work to give it the required shape
and size.

• To support lathe accessories and the workpiece.

• To hold and move cutting tools.

Types of Lathe
• Speed Lathe
• Engine Lathe
• Bench Lathe
• Tool room Lathe
• Capstan & Turret Lathe
• Special purpose Lathe
• Automatic Lathe
Speed Lathe
• It is the simplest type lathe.
• Due to high speed of spindle it is called “Speed Lathe”.
• Speed of Spindle : 1200 to 3600 rpm.
• It is mainly used for wood working, metal spinning, polishing etc.
Engine or Center Lathe
• In starting it was driven by steam engine, So it is called as Engine
lathe.
• Not production lathe, found in school shops, tool rooms, and job
shops.
• Primarily for single piece or short runs.
• Manually operated.
• Types :-
a) Belt driven lathe
b) Individual motor driven lathe
c) Gear head drive lathe
Bench Lathe
• It is small sized engine lathe mounted on bench.
• A bench top model usually of low power
used to make precision machine small
& light weight work pieces.
Tool room Lathe
• Same as engine lathe.
• It is used for production of small & precision works like tools, gauges,
fixtures and accurate parts in tool room.
• Different speeds can achieved.
• Costly as compared to a same size engine lathe.
Capstan & Turret Lathe
• Modified Engine lathe.

• Capstan and Turret lathes are used in mass production used.

• No tailstock.

• Instead of tailstock hexagonal turret is there.

• No time waste for re-setting of tools.

Special purpose Lathe
• They are used for special purposes and can not be accommodated on
a standard lathe.
• Wheel Lathe
• Gap bed lathe
• Duplicating Lathe
Automatic Lathe
• High speed, heavy duty, mass production lathes with automatic
control.

• Performs automatically all the operations o finish the job.

• Changing of tools, speed and feeds are also done automatically.

Construction of Lathe
Bed
• It forms a base for all other parts.
• On top section are machined ways Guide and
align major parts of lathe

➢Functions of Bed

• It faces the static load of all other parts

• It absorb all vibrations

• Made from cast iron or nickel cast iron alloy.

Headstock
• Clamped on left-hand end of bed
• Rotates the workpiece at multiple speed
• It compromises a hollow spindle and mechanism for driving
Chuck
• Function
1. Rigidly hold the workpiece
2. Rotates the workpiece

• Types
1. Three jaw chuck
2. Four jaw chuck
Tailstock
• Placed at right side of lathe.
• To support long work piece.
• Operations like drilling, tapping, reaming can done using sleeve of tailstock.
Carriage
➢ Used to support, move and control the cutting tool along lathe bed
Consists of four main parts
• Saddle
• Cross-slide
• Apron
• Compound rest
• Tool post
Specifications of Lathe
Operations carried out on lathe
• Centering
It is the operation of producing conical hole in workpiece.
Facing operation
• To produce a flat surface at the end of the work- piece

• Motion of tool is perpendicular to the work piece surface.

• It reduces the length of workpiece

Turning Operation
• To remove material from the outside diameter of a workpiece to obtain a finished
surface.

• Work piece become cylindrical.

• Motion of tool is parallel to the work piece surface.

Taper Turning
• Diameter of cylindrical work piece decreasing or increasing gradually is called as taper turning.
Threading Operation
• To produce external or internal threads on the workpiece.
• Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotation at a
large feed rate, thus creating threads.
Grooving
• It is a process of reducing the diameter of a workpiece over a very
narrow surface.

• It is often done at the of thread.

Chamfering
• Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer"
Knurling Operation
• To produce a regularly shaped roughness on the work piece.
Drilling
• It is the operation of producing a cylindrical hole in a workpiece
Reaming
• It is the process of finishing and sizing a hole which has been
previously drilled.
Boring
• It is the process of enlarging the hole.
Parting off
• It is the process of removing finished part from workpiece.
Filing
• Filing is the finishing operation performed after turning.
• This is done to remove burrs, sharp corners, feed marks on a
workpiece.
Polishing
• Polishing is performed after filing to improve the surface quality of
the workpiece.
Eccentric Turning
• If cylindrical workpiece has more than one axis of rotation the
workpiece is termed as eccentric and turning of different surfaces of
workpiece is known as eccentric turning.
Spinning
• Spinning is the process of forming a thin sheet of metal by revolving
the job at high speed and pressing it against a die or mandrel
attached to headstock spindle
Lathe attachment
• Attachment are additional equipment used for specific purposes.

• Ball turning
• Carriage stop
• Taper turning
• Grinding
• Milling
• Gear cutting
• Turret
Ball turning
• It is mounted on the cross slide after removing the compound rest
and is used for turning spheres.

• It has an upper half and lower half. The upper half can be rotated with
the help of a lever. The lower half is fixed to the cross slide.
Carriage Stop
• The carriage stop is attached to the bed.

• It is used for turning, facing, or boring duplicate parts, as it eliminates

taking repeated measurements of the same dimension.
Taper turning attachment
• The function of a taper attachment is to guide the tool in a direct path
set at an angle to the axis of rotation of the workpiece.
Grinding attachment
• Also known as the tool post grinder, it is mounted on the compound
rest as a substitute for the tool post.

• It consists of a base plate, grinding wheel, and a motor.

Milling attachment
• The milling cutter is held in chuck and rotated.
• The milling attachment is mounted on carriage.
• The work is supported by milling attachment.
• The feed is given by carriage.
Gear Cutting attachment
• Gear cutter is held in chuck and rotated.
• Workpiece is held cross slide.
• Feed is given with help of carriage.
Turret attachment
• No tailstock.

• Instead of tailstock hexagonal turret is there.

• No time waste for re-setting of tools.

Capstan and Turret Lathe
Limitation of Centre Lathe
• The setting time for tool is large.

• Only one tool is used in normal course.

• Due to this centre lathe can not be used for production work.
Basic difference between Capstan and Turret
and Engine lathe
• Engine Lathe – Motor 3 HP
• Capstan and Turret Lathe – Motor 12 HP

• Tool Post
• Engine Lathe Tailstock

• Turret
Introduction to Capstan and Turret Lathe
• These lathes are advanced development of centre lathe.

• Capstan and turret lathe are production lathe used for large number
of identical parts in minimum time.

• The construction and working principle of capstan and turret lathes

are same.

• The capstan lathes are used to light and small jobs and turret lathes
are used for heavy and large jobs.
Capstan Lathe
• The turret of the capstan lathe machine is mounted on a slide or ram
which can be moved longitudinally on the saddle for feeding the
tools.

• The saddle itself is mounted on the bed.

• This type of machine is lighter in construction and is suitable for

machining bars of up to 60 mm in diameter.

• More than one tool may be mounted on the same face on the turret
making it possible to machine more than one surface at the same
time.
Turret Lathe
• The tool turret is mounted directly on the saddle and the feed is given
by moving the entire unit.

• Turret lathe is heavier in construction and is particularly adapted for

larger diameter bar work.

• Turret lathes are capable of turning bars up to 200 mm diameter.

Taper Turning on Lathe
• A taper may be defined as a uniform increase or decrease in diameter
of a piece of work measured along its length.
The larger diameter (D) of workpiece is 90 mm, the smaller
diameter (d) is 80 mm and length (L) of taper is 100 mm. Find
the amount taper (K) and taper angle (α).
A shaft of 1200 mm long has a taper over a length of 600 mm.
The maximum and minimum diameter of shaft is 80 mm and 40
mm respectively. Find taper (K) and taper angle (α).
Taper turning methods
1. By a form tool

2. By setting over the tailstock

3. By Swivelling the compound rest

4. By a taper turning attachment

Taper turning by form tool
• This method is limited to turn short length of taper only.

• Tool requires excessive cutting pressure, which may distort the work
due to vibration and spoil the work surface.
Taper turning by setting over the tailstock method
• The principle of turning taper by this method is to shift the axis of
rotation of the workpiece at an angle to the lathe axis.
• Tool is feed parallel to the lathe axis.
• The amount of set over is limited.
• This method is suitable for small taper on long job.
Determine the setover required to turn a taper on the
entire length of a workpiece having diameter of the large
end 30 mm and diameter of the small end 20 mm.
Taper turning by Swivelling the compound rest
• This method employs the principle of taper turning by rotating the
feeding tool at angle to the axis of rotation of workpiece.

• The tool is mounted on the compound rest, is attached to the a

circular base graduated in degree, which may be swivelled and
clamped at any desired angle.

• This method is limited to turn short taper due to limited movement of

compound rest.
Taper turning by Swivelling the compound rest
Taper turning by a taper turning attachment
• The principle of turning taper by a taper attachment is to guide the
tool in straight path set at an angle to axis of rotation of the workpiece.

• The maximum angle through which guide bar can be swivelled is 10° to
12°.
Thread cutting on lathe
• The principle of thread cutting is to produce a helical groove on a
cylinder by feeding the tool longitudinally when the job is revolved
between centres or by chuck.
• The longitudinal feed should be equal to the pitch of the thread to be
cut per revolution of the workpiece.
Calculation for change wheels
• To calculate the wheels required for cutting screw of a certain pitch it
is necessary to know how the ratio is obtained.
Suppose the pitch of a lead screw is 12 mm and it is required to
cut a screw of 3 mm pitch, then the lathe spindle must rotate 4
times the speed of the leadscrew
The pitch of a leadscrew is 6 mm, and the pitch of
the thread to be cut is 1 mm. Find change gears.
Cutting speed (V)
A steel shaft of 25 mm diameter is turned at a cutting
speed of 50 m per min. Find the rpm of shaft.
Depth of cut (t)
Machining time
Find the time required for one complete cut on a piece of work
350 mm long and 50 mm in diameter. The cutting speed is 35
meters per minute and feed is 0.5 mm per revolution.