Chapter 2 METAL CUTTING LATHE

1. INTRODUCTION
A lathe is a machine tool which spins a block of material to
perform various operations (such as cutting, knurling,
drilling, or deformation) with tools that are applied to the
work piece to create an object which has symmetry about
an axis of rotation.
As per Encyclopedia Britannica, A lathe is machine tool that
performs various operations in which unwanted material is
removed from a work piece, rotated against a cutting tool.
Lathe is a machine which removes the metal from the
piece of work to the required shape and size.

2. HISTORY

2. HISTORY

2. HISTORY & revolution

During the industrial revolution, mechanized power was
applied to the lathe via steam engines and line shafting,
allowing faster and easier work.
Between the late 19th and mid 20th centuries, individual
electric motors at each lathe replaced line shafting as the
power source.
Beginning in the 1950s, servomechanisms were applied to the
control of lathes and other machine tools via numerical
control (NC).
Today manually controlled and CNC lathes coexist in the
manufacturing industries.

3. Lathe machine

3.Schmetic diagram

List of major parts

1. Head Stock
2. Tail Stock
3. Carriage
4. Bed
5. Feed Mechanism
6. Screw Cutting Mechanism

1. Headstock Assembly

Headstock Spindle
(on which work
mounted)

holding

device

Driver
Mechanism
(Belt Drive / Gear
Box Mechanism)

is

 Headstock

Located at the far most left of the lathe on the inner ways of bed.

Provides arrangement of rotating the work at different speeds.

Sub parts of Headstock:

Hollow spindle

Arrangement for altering the speed

Different mechanism for obtaining speed

Headstock Spindle

The headstock spindle is made from carbon or nickel-chrome

steel.

The headstock spindle is mounted on the machine tool grade

anti friction bearings so that the run out (or eccentricity) of the
spindle as it rotates is held to be minimum.

The spindle is hollow to hold the long bar through the bore.

Front end of the hole made for holding centers.

There are two types of spindles :

Threaded design (Carries Chuck, Driving Plate, Face Plate)
Flanged nose (Direct Attachment)

The inside of the

spindle nose has
taper surface.

A taper sleeve fits

into the taper hole
and a live center
which
supports
the work and act
as bushing for the
work piece.

Speed Changing

Why to change the speed of lathe??

To suit to different machining conditions which are

Type of Material to be cut

Type Cutting tools Material

Diameter of work piece

Type of operation to be performed

Type of surface finish requirement

Type Cutting fluid used

The rigidity and Condition of the machine

Speed Changing

How to change the speed

Belt driven

1. Direct Speed (Back gear out)

2. Indirect Speed (Back gear in)

Gear drive (Sliding gear/ Clutches)

Variable Speed Motor

Belt driven
1. Direct Speed (Back gear out)

All belt drives are provided with counter shaft.

The countershaft receives power from the main shaft.
Main shaft rotates at constant speed while based on
step cone pulley on the counter shaft, different speed is achieved.
The spindle speed increases when the belt is shifted from
a larger to a smaller step of the cone
pulley
Speed is maximum at the smallest diameter of cone
pulley.
When the position of driving belt on the step pulley is
changed a number of speeds can be obtained

2. Indirect Speed (Back gear in)

Additional feature for belt driven lathe

Permits to attain wider range of speed
When only cone pulley is used, the variation in speed restricted
as per the steps available on it.

When back gear is engaged, spindle speed reduces, for

conditions such as,

In turning jobs of large diameter work piece,

Tough or hard material,
Operations such as Thread cutting, reaming etc.,
High depth of cut required as in rough turning.

DIRECT SPEED

INDIRECT SPEED

Gear driven

Generally sliding gear mechanism or sliding clutch

mechanism is used.

Spindle speed increases in geometric progression.

For example, suppose L is the first speed, and r is the

constant for increasing the speed, then second speed will
be L x r, Third speed will be L x r x r and so on.

If H is the Highest speed, L is the lowest speed and n is the

number of speed required, then constant r, can be find out
by,
r=

 Multiple speed obtained by

1. Sliding Gear Mechanism
2. Clutch Mechanism
Modern Lathes are often equipped with both the arrangement.
9-speed all geared headstock employing sliding gear mechanism is
shown in figure.
There are three main shafts:
One is connected with spindle shaft , other second one is
intermediate shaft and final one is directly connected to work piece.
Spindle shaft gears and final shaft gears can be changed by lever
provided on each shaft for changing the gear.

DisadvantagesCostlier
Power lost due to friction
In case of overloading it may damage parts as no arrangement of belt
.

Advantages of all gear drive

Enclosed compact unit
Power input is constant at all speed,in cone
pulley it varies.
No belt shifting is necessary.
Change in spindle speed made by simple
movement of one or more levers, which is
simple and safe.
No overhead shafting is needed.
Isolated from headstock, so vibration of
spindle reduced.

2. Tailstock Assembly

 Tailstock

Located at the far most right of the lathe.

Tail stock can be adjusted on the

accommodate different lengths of work.

Functions:-

bed

by

sliding,

to

1. Support the other end of the work when it is being

machined between two centers.

2. Holds tool for performing operations such as

drilling, reaming, tapping etc.

The tail stock is made hollow called barrel, to carry the tailstock
spindle.

Tailstock spindle moves in and out in the barrel by means of

tail stock hand wheel.

Front end of the tailstock spindle can carry either dead center
or tool for different operations, such as drilling, reaming, etc.

3. Carriage

The carriage consists of the

Saddle
Cross slide
Compound rest
Tool Post

Apron mechanism* is also mounted on the carriage.

(As it is part of feed mechanism, it will be covered in feed
mechanism portion)

Saddle
The saddle is an H shaped
casting.
It slides on the top of the
lathe bed.
It carries tool post and
cross slide.
Lathe bed guides the
longitudinal motion of the
saddle.

Cross Slide
It is connected to the
saddle on inner side
and on the upper side it
is connected to the tool
post or compound rest.
To move the cross-slide,
the feed screw is turned
by rotating the hand
wheel.
It also provides support
for the Taper turning
attachment.

 Compound Rest
Mounted on to the cross slide
Base has graduation to rotate
w.r.t. lathe axis
Turn through 360
Compound rest is Hand
operated.
Function: Provide mechanism for angular
cut.
Also, micrometer dial is
attached on compound rest
handle in order to measure the
depth of cut and get accurate
dimension.

Tool post
Located on the top of the
compound rest to hold the
tool and to enable it to
adjusted to a convenient
working position.
Types of tool post:
1. Single screw tool post
2. Four bolt tool post
3. Open side tool post
4. Four way tool post

Apron
Located at the lower vertical
position of the carriage
Contains gears and clutches
for transmitting motion from
the feed rod to the carriage.

4. Lathe Bed

Contains Inner ways and Outer Guide

ways
Supports Headstock, Tail stock,

5. Feed Mechanism
Relative motion of tool with the work piece is termed
as Feed.
Feed is transmitted from headstock spindle to
carriage.
Three types of feed: Longitudinal
Cross
Angular

Longitudinal feed: Tool moves parallel to the lathe axis

Cross feed: Tool moves perpendicular to the lathe axis
Angular Feed:Compound slide is swiveled at an angle

 Feed mechanism has different units

End of bed gearing
Feed gear box
Feed rod and lead screw
Apron Mechanism

 End of bed gearing

Serves the purpose for transmitting
the drive to the lead screw and feed
shaft
Two mechanisms are used for
transmission: 1. Tumbler gear Mechanism
2. Bevel gear feed reversing Mechanism

 Tumbler Gear Mechanism

Pulley Stack 1: This stack drives the spindle

Pulley Stack 2: This stack is on the motor
Pulley Stack 3: These are the "Low Gears"
Change Gears: For cutting threads

 Tumbler gear are used to give the

desired direction of movement to the
lathe carriage, via lead screw or the feed
shaft.
This mechanism contains two pinions.
This pinions are mounted on brackets.
These brackets are pivoted about 1 st
stud shaft.
Brackets can achieve three position
Forward
Neutral
Reverse

 During FORWARD motion (i.e.

carriage moves towards the
headstock), only one gear is in
contact between the lathe spindle
and the main gear train, and the
lathe carriage is moved towards the
headstock.

 During REVERSE motion (i.e.

carriage moves away from the
headstock), two gears are in
contact between the lathe spindle
and the main gear train, and the
lathe carriage is moved away from
the headstock.

 During NEUTRAL motion, spindle is

disengaged from the lead screw or
feed shaft gear box .

FEED GEAR BOX

Known as quick change gear box is
fitted directly below the headstock.
Power from lathe spindle transmitted
through gears to quick change gear
box which contains no of gears of
different sizes which provides a
change the rate of feed.
FEED ROD-long shaft has key way
extending from the feed box across and in
front of the bed.

 Power is transmitted from lathe spindle to

apron gears through feed rods via large no of
gears, it is used except for thread cutting.
LEAD SCREW- long threaded shaft used as a
master screw and used in thread cutting, all
other time disengaged from gear box and
stationary.
APRON MECHANISM- different designs used to
transforming rotary motion of feed rod and lead
screw into feed motion of carriage via no of
gears.

LATHE ACCESSORIES

& ATTACHMENTS

Accessories Supplementary items (Equivalent to necessary)

Attachments Equipment used for specific purpose
1. Lathe Centers

5.

Angle Plates

2. Catch Plates and carriers

3. Chucks

4. Face Plate

7.

6.

Rests

Mandrels

Centers
. Why centers are required?
Holding the work in between live centre and dead center
These two (live and dead) centers take the thrust due to metal
cutting and also bear the load of the work piece. So they are
made of very hard material to resist deflection and wear.

. Generally dead center has to bear the friction load.

. For routine purpose the contact angle of work piece and
center is 600 ,while for heavy work contact angle is 750.
. Following are the different types of centers: --

Centers
1.
2.
3.
4.

Ordinary Center
Ball Center
Frictionless Center
Half Center

5. Tipped center
6. Insert type
7. Pipe center

Centers
1. Ordinary Center:
2. Ball Center:

Used for most general work.

Used to minimize wear and strain

on the ordinary center.

3. Friction less center:

Used at tailstock to support the
heavy work revolving at high
speed.
4. Half center:

Used for facing operation.

Centers
5. Insert type Center:
In ordinary center type tool,
whole tool is to replaced when it
goes blunt. In this, insert type of
center, only
inserted tip has to be
changed. So, it is
economical.
6. Tipped Center:
An ordinary tool center contains,
hard alloy tip brazed is called
tipped center.
7. Pipe Center :
Used for open end pipes, shell
etc. for thread cutting or Turning
operation on the lathe.

Catch plates & carriers

. Why catch plates and carriers are required?
To drive a work piece when it is held between two
centers.
Catch plates are either screwed or bolted to the nose of
the headstock spindle.
Carriers are attached at the end of the work piece by a
set screw.

Catch plates & carriers

carrier

CHUCKS
. Function of chuck: - For holding and rotating a piece of
work.
. Jobs of short length, and large diameter or irregular
shapes, which can not be held conveniently mounted
between centers are held quickly and rigidly in a chuck.
.
1.
2.
3.
4.

Types of chucks:
4-Jaw Chuck
5. Collet Chuck
3-Jaw Chuck
6. Air or hydraulic Chuck
Combination chuck 7. Drill Chuck
Magnetic Chuck

4- Jaw CHUCK

4- Jaws can slide in the

slots of the body for
gripping the different size
of work piece.
Each jaw has three steps
which can be used for
holding the work piece of
irregular shapes.
Also, each jaw can move
independently.
For small pieces, they can
be moved inside and vice
versa.
By this kind of chuck,
centering can be done
easily.

4- Jaw CHUCK
Advantages:

a. Any type of work piece can be held easily.

b. High grip is possible as four jaws are employed.

Disadvantages:
a. Centering is a little difficult process.
b. Semi skilled labor are required.

3- Jaw CHUCK
Three jaw chuck or selfcentering chuck is the chuck,
which has three jaws for
holding the work piece.
If one jaw is moved (in any

direction, Backward or forward)

then all the other jaws also

move by same distance.

This mechanism is obtained

by engaging pinions which
meshes with the teeth cut on
the under surface of the
chuck. This chuck is also
called
universal chuck.

3- Jaw CHUCK
Advantages:
a. Centering process is not necessary as all the jaws moves at
a time.
b. Consumes less time for mounting and un mounting the
work piece.
Disadvantages:
a. Grip is not so high as only three jows are employed.
b. All type of jobs cannot be mounted on these chucks, as
they are useful in machining only axis symmetrical objects.

Combination CHUCK
As the name indicates it is a
combination of both threejaw chuck and four-jaw
chuck.
It acts as both self-centering
and independent chuck.
This is obtained by engaging
a scroll disc at the backside
of jaws.

Magnetic CHUCK
Used for very thin work piece
made of magnetic material
which can not be held in
other chucks.
Also, used where distortion
occurs when it is held in
other chucks tightly.
Holding power is obtained by
magnetic flux radiating either
from electro-magnets or from
the permanent magnets
inserted in the chuck.

Magnetic CHUCK
In ON position, the flux passes through the work piece and grips it.
In OFF position, magnets are set aside bringing them in contact with high
permeable keepers which short circuit the flux and prevent them from passing
through work piece.
Advantages:
Work pieces in which damage due to the jaws of chucks is not tolerated can
be effectively machined by using this chuck.
If the work to be held is of very small size and cannot be hold by the above
three chucks then this chuck can be used.
Disadvantages:
a. All type of jobs cannot be held.
b. Size of the job affects the efficiency of the holding.
c. All type of materials cannot be held as it works on magnetic property only
magnetic materials can be held.

Collet CHUCK
Collet chucks are used for
holding bar stock in
production work where quick
setting and accurate
centering is needed.
The chuck attached to the
spindle by a nut consists of a
thin cylindrical busing known
as collet having a slot cut on
the periphery of chuck.
So, it is a holding device,
that forms a collar around
the object and provides high
clamping force, when it is
tighten by outer tapered
collar.

Collet CHUCK

Advantages:
Speed of chucking is high(Easy reclamping)

Self-centering

Strong clamping force

Resistance against being jarred loose (untightened)

Centering at a high level of precision (runout <.005" TIR)

Disadvantages:
Each collet chuck has limited range, so for different range
of work piece size, different collets are required leads to
high capital cost.

Air or hydraulic operated CHUCK

This type of chuck is used for mass production work for its
fast and effective gripping capacity.

The mechanism is operated by hydraulically or

pneumatically, mounted at the back end of the headstock
spindle and rotates with it .

Fluid pressure may be communicated to the cylinder by

operating a valve with a lever and the piston will slide within
the cylinder.

DRILL CHUCK

Drill chuck is mounted for

holding straight shank drill,
reamer or tap for drilling,
reaming or tapping
operations.

The chuck may be held

either in headstock or
tailstock spindle.

It has self-centering jaws

which may be operated by
rotating a key.

Face plate
Faceplates are used for holding
those work pieces, which cannot
be held both by centers and by
chucks.
It consists of a center bore and
plain and radial slots through the
plate for facilitating the holding
of the work piece.
The central bore has a radius
equal to that of the radius of the
spindle of the lathe. And the
plain and radial slots provide a
healthy platform for holding the
jobs by using T-bolts and clamps.

Angle plate

These are used along with

faceplates for maintaining
the given work piece
horizontal i.e.
perpendicular to the tool
used.

Angle plates consist of two

faces, which are highly
machined, and these also
have the provision of holes
for the easy clamping of
the work piece to it.

Example: Machining of a
pipe elbow

mandrels
. Function of Mandrel: - A device used for holding and rotating a hollow or
pre-drilled piece of work between two centers.
. The ends of the mandrels are made slightly smaller than the original diameter
for effective gripping of the mandrel in the chuck or any other holding device.
. In general the material used for the manufacturing of the mandrels is plain
carbon steel.
. Types of Mandrels:
1. Plain mandrels

5. Cone mandrels

2. Step mandrels

6. Gang mandrels

3. Collar mandrels 7. Expansion mandrels

4. Screwed mandrels

Plain mandrel
This type of mandrels finds
a numerous number of
applications in shops
where identical pieces are
to be generated.
The body of these
mandrels has generally a
tapered shape. The
difference in the tapped
diameter is of 1 to 2 mm
and the length varies
between 55mm to 430mm.

The tapper is provided for

facilitating high end
gripping for holding the
work piece.

For different sizes of holes

in work pieces different
mandrels are used.

step mandrel

A special type of mandrel,

which facilitates faster
processings by holding
various sized jobs with out
replacing the mandrel.

This type of mandrels finds

applications in repair shops
and generally used for
turning collars, washers
and odd sized jobs.

collar mandrel

A collar mandrel having

solid collar is used for
turning workpieces having
holes of larger diameters
usually above 100mm.

This type of construction is

a type of optimizing the
material being used
compared to solid
mandrel.

Screwed mandrel

These mandrels have a

thread cut engraved on one
side along with a collar. Such
type of mandrels is called as
screwed mandrels.

Screwed mandrels are used

when work pieces having
internal threads are to be
machined. The size of the
threads to be engraved on
the screwed mandrels
depends on the type of work
piece, which is going to fit
over it.

cone mandrel

Cone mandrels have a cone

shaped piece attached at one of
the mandrel.

This type of arrangement allows

the mandrel to handle a variety
of work pieces having a varying
internal c/s diameter.

The work piece is held tightly

by fixing a nut at the other end
of fixing the work piece to the
mandrel.

Too tight fitting of the work

piece over the cone may
damage the internal surface
finish of the work piece along
with the damage to the cone
shape of the mandrel.

gang mandrel

Gang mandrel is generated

by some of the optimizers so
as to reduce the material.
This type of mandrel can
facilitate machining for work
pieces of various diameters.
The gang mandrels consist
of a fixed collar at one end
and removable mandrels at
the other end which is fixed
by the help of the threads
engraved both on the
mandrel and also on the
internal surface of a ho
llow mandrel.

This mandrel can be used for

machining various diameter
pieces by just removing and
fixing various collars over the
thread. The friction between
the walls of collar and sides
of work piece is enough to
hold the work piece tightly
and hence facilitating is a
high end machining.

expansion mandrel

This is a special type of

mandrel, which has a
central tapered pin.

Over this tapered pin a

sleeve is arranged when
this sleeve is moved over it
form one corner to other
the size increases or
decreases.

This type of mandrels is

best used when a varying
diameter pieces are to be
hold without much
difficulty.

rests
. Function of Rest: - A device which supports a long
slender work piece, which is turned between center, at
any intermediate point to prevent bending of the work
piece due to its own weight and vibrations due to
machining.
. Rest are used when the length of the work piece is 10 to 12
times the diameter of the work piece.
. By using rest, we can achieve highest accuracy and heavy
depth of cut.
. Types of Rests:

1. Steady Rest 2. Follower Rest

Steady rest

A steady rest consist of

cast iron base, which may
be made to slide on the
lathe
bed
ways
and
clamped at any desired
position where a support is
required.
One jaw on the upper side,
and other two jaws are on
the lower side.
Upper jaw can be moved
to accommodate larger
size diameter, by providing
rotation of screw.

Steady rest

Jaws work as clamping the

work piece and provides
resistance to any deflection
due to machining force.

Sometimes, if the job is

very lengthy, then one or
more steady rest can be
used.

It is used to support the free

end of a long work piece for
operations, such as drilling,
boring, reaming etc.

Follower rest

Two adjustable jaws,

accompanied by c block.

The rest is bolted to the

back end of the carriage
and moves with it.

Before setting the follower

rest, the end of the work
piece is machined slightly
wider than the jaws to
provide the true bearing
surface.

Follower rest

The tool is set slightly in

advanced position than the
jaws, and as the tool is fed
longitudinally by the
carriage, the jaws always
follow the tool giving
continuous support to the
work piece.
The follower rest prevents
the job from springing
away when the cut is made
and is used in finish
turning operations.

LATHE OPERATIONS

Classification is based on two parameters :

Either on the bases of supports and driven by method

or

Based on the holding the work piece.

Based on supports and driven by (Method 1) :

1. Held between centers and driven by carrier and catch plates.

2. Held in mandrel and driven by carriers and catch plates.

3. Held and driven by chuck with end supported on the tailstock.
4. Held and driven by chuck or a faceplate or an angle plate.

Based on the holding the work piece(Method 2) :

1. Work piece held between centers
2. Work piece held by a chuck or any other fixtures.

Operations which are performed either by holding the work piece

between centers or by a chuck are :

1.

Centering

7.

Filing

2.

Turning

8.

Polishing

3.

4.

Thread cutting

5.

Facing

11. Spring winding

6.

Knurling

12. Forming.

Chamfering

9.

Grooving

10. Spinning

Operations which are performed either by holding the work piece

between by a chuck or an angle plate are :

1.

Drilling

5.

Tapping

2.

Reaming

6.

Under cutting

3.

Boring

7.

Parting off

4.

Internal thread cutting

centering

When the work is required to be turned between centers or

between a chuck and a center, conical shaped holes must be
provided at the ends of the job to provide bearing surface
for the lathe centers.

Centering is the operation of producing conical holes in work

pieces.

To prepare a cylindrical work piece for centering, it is first

necessary to locate the center hole by marking.

There are many methods of marking the center. (Practically)

like using calliper,divider & surface plate,bell center punch
etc.

centering

After the center has been located, a center punch and a

hammer are used to make a deep indentation to produce the
hole to hold and to revolve the work on the lathe centers.

Center holes are produced by using combined drill and

counter shank tool.

This is held on a drill chuck and may be mounted on the

headstock or on the tailstock spindle to produce a conical
hole on the ends of the work piece.

The included angle should be 600 to fit with lathe centres so

that rubbing of dead centre with the w/p can be avoided.

turning
What do you mean by turning?

Removal of excess material from the workpiece to produce

desired cylindrical surface or cone shaped surface.

Types of turning :
1.Straight Turning
2.Shoulder Turning

Further straight turning can be divided as :

1.Rough Turning
2.Finish Turning

Straight turning

The work is turned straight when it is made to rotate about

the lathe axis and the tool is fed parallel to the lathe axis.

This leads to production of cylindrical surface by removing

excess metal.

After centering, the job is carefully mounted between

centers using a lathe dog attached to the work piece.

If the work piece is mounted on a chuck or a face plate, care

should be taken to center it accurately with the lathe axis.

Straight turning

Right hand tool is fitted in the tool center with proper

position.

Then correct speed and proper feed is determined.

The automatic feed is engaged to move the carriage to the

desired length, then the feed is disengaged and the carriage
is brought back to the starting position.

The process is repeated until the job is finally finished after

two or three similar cuts.

rough turning

The rough turning is the

process of removal of excess
material from the work piece in
a minimum time by applying
high rate of feed and heavy
depth of cut.

The roughing cut should be so

made that the machine, the
tool, and the work piece can
bear the load and it does not
make too rough a surface and
spoil the centers.

The depth of cut for roughing

operations in average machine
shop work is from 2 to 5 mm
and the rate of feed is from 0.3
to 1.5 mm per revolution of the
work.

finish turning
This operation requires high
cutting speed, small feed, and
a very small depth of cut to
generate a smooth surface.
A finish turning tool having
sharp cutting edge is held
securely on the tool post for
this purpose.
In finish turning operation, the
depth of cut ranges from 0.5
to 1 mm and feed from 0.1 to
0.3 mm per revolution of the
work piece.

finish turning

The depth of cut to be given is

determined by subtracting the
finished diameter from the
measured value.

The tool is then made to

advance by half the above value
by rotating the cross slide handwheel through required number
of divisions on the dial.

Once the correct setting is

made, the rest is finished by
automatic feed.
Depth of cut ranges from0.5to
1mm and feed from 0.1 to 0.3
mm.

Shoulder turning
When work piece having
different
diameter
is
turned, the surface forming
the step from one diameter
to the other is called
shoulder and machining
this part of w/p is called
shoulder turning.
Four types
turning:

1.
2.
3.
4.

of

shoulder

Square shoulder
Angular shoulder
Radius shoulder
Under cut shoulder

chamfering

The operation of beveling

the extreme end of work
piece is chamfering

It removes burrs to protect

the end of the work piece
from being damaged.
It also gives better look.
It is done after knurling,
rough
turning,
boring,
drilling.
Essential
after
thread
cutting to pass the nut.

Thread cutting

A single-point threading
tool, typically with a 60
degree
pointed
nose,
moves axially, along the
side of the work piece,
cutting threads into the
outer surface.
The threads can be cut to
a specified length and
pitch and may require
multiple passes to be
formed.

Thread cutting

In thread cutting, helical groove on a cylindrical surface is

produced by feeding the tool longitudinally when the job is
revolved between centers.
This longitudinal feed should be equal to the pitch of the
thread to be cut per revolution of the work piece.
The lead screw of the lathe, through which the saddle
receives its traversing motion, has a definite pitch.
This definite ratio is obtained by change gears.
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 lead screw.
So, Change gears = Driver teeth / Driven Teeth
= Pitch of the Work / Pitch of the Lead screw

Lathe Operations
Thread Cutting
Threads are helical ridge and of uniform section formed on
inside or outside of cylinder or cone.
Cutting threads is another important task carried out on the
lathe.
Thread cutting on lathe is also called as thread chasing.
Thread cutting can be considered as turning operation.

Lathe Operations
Thread Cutting - Thread Terminology
Major Diameter
Commonly known as the outside diameter . On a screw thread, the
major diameter is the largest diameter of the thread on the screw or
nut.

Minor Diameter
Called the root diameter, the minor diameter is the smallest
diameter of the thread on the screw or nut.

Lathe Operations
Thread Cutting - Thread Terminology
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

Lathe Operations
Thread Cutting - Thread Terminology
Pitch
The distance from a given point on one thread to a corresponding
point on the very next thread.

Lathe Operations
Thread

Cutting - Thread Terminology

Lead

The distance a screw thread advances in one revolution.

The lead and the pitch of a single lead thread are the same.
On double lead threads, the lead is twice the pitch.
A double lead thread has two start points.

Lathe Operations
Thread

Cutting - Thread Terminology

Root

Bottom surface joining sides of two adjacent threads.

External thread on minor diameter.
Internal thread on major diameter.

Lathe Operations
Thread

Cutting - Thread Terminology

Crest

Top surface joining two sides of thread.

External thread on minor diameter.
Internal thread on major diameter.

Lathe Operations
Thread

Cutting - Thread Terminology

Depth of Thread

Distance between crest and root measured perpendicular to axis.

Lathe Operations
Thread

Cutting - Thread Terminology

Thread Angle

Included angle between sides of thread measured in axial plane.

Lathe Operations
Thread

Cutting - Thread Terminology

Number of Threads

The number of threads per inch.

Lathe Operations
Thread Cutting - Thread Terminology
Right Hand Threads
Helical ridge of uniform cross section onto which nut is threaded in
clockwise direction.
When cut on lathe, tool advanced from right to left.

Lathe Operations
Thread Cutting - Thread Terminology
Left Hand Threads
Helical ridge of uniform cross section onto which nut is threaded in anticlockwise direction.
When cut on lathe, tool advanced from left to right.

Lathe Operations
Thread Cutting - Thread Terminology

Upper Left - American

Standard Thread Acme
Thread Cutting Tool Profile
Upper Right Square
thread Cutting Profile
Lower Left British
Standard
Withworth
Thread Cutting Tool Profile
Lower Right 29 Degree
Worm Thread Cutting Tool
Profile

Lathe Operations
Thread Cutting
Engine Lathes are designed with features that are provided
primarily for cutting screw threads.
The gear ratios in quick change gear box are selected to enable
lathe to cut a sequence of precise screw thread leads.

Lathe Operations
Thread Cutting
The lead screw, the split nut or
half-nut and the thread chasing
dial are build on the lathe for the
exclusive purpose of
cutting
screw thread.

Thread cutting

facing

Facing is the operation of

machining the ends of a
piece of work to produce a
flat surface square with
the axis.
This is also used to cut the
work
to
the
required
length.
In this operation, the tool
is fed perpendicularly to
the axis of rotation of the
job.

knurling
It embosses the diamond
pattern on the steel work
piece
with
purpose
of
gripping.
This diagram shows the
knurling tool pressed against
a piece of round section
steel.
The lathe is set so that the
chuck revolves at a low
speed.
The knurling tool is then
pressed against the rotating
steel and pressure is slowly
increased until the tool
produces a pattern on the
steel.

knurling

The
automatic
control
lever is engaged which
starts
the
automatic
traverse of the saddle. As
the saddle moves along
the bed of the lathe the
knurled pattern is pressed
into the steel along its
length.
If single roller is used then
it
generates
parallel
grooves, but when two
rollers are used, then
diamond
shape
is
generated.

filing

It is finishing operation performed after turning.

This is done in a lathe to remove burrs, sharp corners, and

feed marks on work piece and also to bring it to the size
by removing very small amount of metal.

Flat single cut file is passed over the work piece at very
high speed.

grooving

It is the process of
reducing the diameter of a
work piece over a very
narrow surface.
It is often done at the end
of a thread to leave a
small margin.
Speed of operation is half
of
the
turning
and
grooving tool of required
shape is fed straight into
the work.

Spring winding

It is the process of making a coiled spring by passing a

wire around a mandrel which is revolved on a chuck or
between centers.

A small hole is provided on a steel bar which is supported

on the tool post and the wire is allowed to pass through it.

The diameter of the mandrel should be less than the

desired spring diameter as all springs expand in diameter
after they are taken out of the mandrel.

forming

Forming is the process of turning a convex, concave or

any irregular shape.

Form- turning may be accomplished by the following

methods: 1. Using a forming tool
2. Combining cross land longitudinal feed
3. Tracing or copying a template

drilling

It is the operation of
producing a cylindrical hole
in a work piece by a
rotating cutting edge of a
cutter known as drill.

This can be done by two

methods:-

drilling
The work piece is held in a
chuck and the drill is held
in the tail stock by drill
holder.
The drill is held and driven
by a drill chuck attached to
the headstock spindle. And
the work is held against
tailstock.
This second method is
adopted in case of irregular
shapes of work piece.

drilling

boring

It is the process of
enlarging and truing a hole
produced
by
drilling,
punching,
casting
or
forging.
Boring can not generate
the hole.
It can also be done in two
ways:-

boring

The work is revolved in a

chuck and the tool is fitted
the tool post is fed into the
work to produce small
sized work.

The work is clamped on

the carriage and boring bar
holding
the
tool
is
supported between the
centers and made to
revolve.

Counter boring

It is the operation of
enlarging a hole through a
certain distance from one
end instead of enlarging
the whole drilled surface.

It is similar to shoulder
work in external turning.

reaming
It is the operation of
finishing and sizing a hole
which has been previously
drilled or bored.
The tool used is called
reamer, which has multiple
cutting edges.
Reamer
is
held
on
tailstock, which is held
stationary and the work
piece is revolved at very
slow speed.
Feed varies from 0.5 to 2
mm per revolution

Internal thread cutting

Principle is similar to the

external thread, but the
tool used is different.
The tool is similar to the
boring tool with cutting
edge ground to the shape
as per thread to be cut.
For cutting metric thread,
the compound slide is
swiveled 300 towards the
headstock.

Internal thread cutting

It is the operation of
cutting internal threads of
small diameter using a
multipoint
cutting
tool
called the tap.
In the lathe, the work is
mounted on a chuck and
revolved at a very slow
speed.
A tap of required size held
on a special fixture is
mounted on tailstock.

undercutting

It is similar to grooving operation when performed inside a

hole.

It is the process of boring a groove or a large hole at a fixed

distance from the end of a hole this is similar to boring
operation except that a square nose parting tool is used.

Undercutting is done at the end of an internal thread or a

counter bore to provide clearance for the tool or any mating
part.

Parting-off

It is the operation of
cutting a work piece after
it has been machined to
the desired size and shape.
The
process
involves
rotating the work piece on
a chuck at half the speed
of the turning and feeding
by a narrow parting-off
tool perpendicular to the
lathe axis by rotating the
cross slide screw by hand.

Parting-off

Before the operation is started, the carriage is locked in

position on the lathe bed and the cutting tool is held rigidly
on the tool post with the compound slide set parallel to the
lathe axis.

The tool should be fed very slowly to prevent chatter.

The feed varies from 0.07 to 0.15 mm per revolution and

the depth of cut which is equal to the width of the tool
ranges from 3 to 10 mm.

milling

It is the operation of
removing metal by feeding
the work against a rotating
cutter
having
multiple
cutting edges.

milling

For cutting keyways, the work supported on the cross slide

by a special attachment and fed against a rotating milling
cutter held by a chuck. The depth of cut is given by vertical
adjustment of the work provided by the attachment.

The work may be supported between centers and held

stationary. The attachment mounted on the carriage drive
the cutter from an individual motor.

grinding

It is the operation of
removing metal of minute
chips by feeding the work
against
the
rotating
abrasive wheel.
External grinding is shown
in the figure.
For internal grinding, a
special attachment is used.

Taper and taper turning

A taper may be defined as a uniform increase or decrease

in diameter of a piece of work measured along the length

Taper turning means to produce a conical surface by

gradual reduction in diameter from a cylindrical work piece.

Application of tapering :
Construction of machines
taper shanks of tool
work holding devices

Taper turning methods

A taper may be turned in a lathe by any one of the
following methods

Taper
Taper
Taper
Taper
Taper

turning
turning
turning
turning
turning

by
by
by
by
by

a form tool
setting over the tailstock
swiveling the compound rest
a taper attachment
combining feeds

Taper turning by a form tool

It is shown in the figure.
A broad nose tool having
straight cutting edge is set
on to the work at half taper
angle(angle formed by path
of tool with axis of work
piece), and is fed straight
into the work to generate a
tapered surface.
The half angle of taper will
correspond to the 90 minus
side cutting angle of the
tool.

Taper turning by a form tool

This method is used for

short length of taper only.
This is due to the reason
that the metal is removed by
the entire cutting edge, and
any increase in the length of
the taper will necessitate the
use of wider cutting edge.
This will require excessive
cutting pressure, which may
distort the
work due to
vibration and spoil the work
surface.

Taper turning by
setting over the tailstock

The principle of turning

taper by this method is to
shift the axis of rotation of
the work piece, at an angle
to the lathe axis, and
feeding the tool parallel to
the lathe axis.
The angle at which the
axis of rotation of the work
piece is shifted is equal to
the half angle of the taper.

Taper turning by
setting over the tailstock

This is done when the body of

the tailstock is made to slide on
its base towards or away from
the operator by a set over
screw.
The amount of set over being
limited.
This method is suitable for
turning small taper on long jobs.
The main disadvantage of this
method is that the live and
dead centers are not equally
stressed and the wear is not
uniform.
Moreover, the lathe carrier
being set at an angle, the
angular velocity of the work is
not constant.

Taper turning by
setting over the tailstock

The amount of set over required to machine a particular taper

may be calculated as :
From the right angle triangle ABC in figure,
BC = AB sin , where BC = set over
or set over = L sin
If the angle , the angle of taper, is very small, for all practical sin
= tan .

set over = L tan

= L x D-d /2l in mm [ where, D-d / l = conicity ]
If the taper is turned on the entire length of the work piece , then L
=l,]

set over = D-d /2

in mm
Set over = 0.5 x entire length of the work x conicity

Measurement of tailstock offset

Once the amount of set over required for taper turning is

found out, the body of the tailstock is made to slide by the
same amount accurately using a scale attached to the base
of the tails stock.
Where the tailstock is not equipped with the scale a double
slided steel rule may be placed between two centers and the
amount of offset is measured.
The amount of the offset required may be more accurately
set by allowing the tool post to touch the tailstock barrel in
the normal and in the offset position.
This is done by turning the cross slide screw when the offset
is measured directly by the readings on the micrometer dial.
The dial indicator used in the conjunction with cross slide
screw gives a more accurate reading.

 By offsetting the tailstock

o

Tailstock set over or off-set :

Or

Where,
o
o
o

D and d are the major and minor diameter of the workpiece.

= half included angle.
L = Length of the tapered portion.

 By offsetting the tailstock

o ProblemFind the setting required for turning taper of 85 mm diameter to 75
mm diameter over a length of 200 mm, while the total length of
job is 300 mm between the centers. Tailstock offset is to be used
for the prescribed taper.
o Solution
Given data:
o
o
o
o

D = Major diameter of the workpiece = 85 mm

d = Minor diameter of the workpiece = 75 mm
l= Length of the workpiece to be tapered = 200 mm
L = Overall length of the workpiece = 300 mm

Put the above values in the equation

The compound rest should be swiveled at 11.25mm.

Taper turning by
swiveling the compound rest

This method employs the principle of

turning taper by rotating the work
piece on the lathe axis and feeding
the tool at an angle to the axis of
rotation of the work piece.
The tool mounted on the compound
rest is attached to a circular base,
graduated in degree, which may be
swiveled and clamped at any desired
angle.
This is illustrated in Figure.
Once the compound rest is set at the
desired half taper angle, rotation of
the compound slide screw will cause
the tool to be fed at that angle and
generate a corresponding taper.

Taper turning by
swiveling the compound rest

This method is limited to turn a

short taper owing to the limited
movement of the cross slide. But a
small taper may also be turned.
The compound rest may he swiveled
at 45on either side of the lathe axis
enabling it to turn a sleep taper.
The movement of the tool in this
method being purely controlled by
hand, this gives a low production
capacity and poorer surface finish.
The setting of the compound rest is
done by swiveling the rest at the
half - taper angle, if this is already
known. If the diameter of the small
and large end and length of taper
are known, the half taper angle can
be calculated from the equation .

 By a compound slide
o Taper angle calculation

o Where
o D and d are the major and minor diameter of the workpiece.
o = half included angle
o L = Length of the tapered portion

 By a compound slide
o ProblemDetermine the angle at which the compound rest would be
swiveled for cutting a taper on a work piece having a length of 150
mm and outside diameter 80 mm. The smallest diameter on the
tapered end of the rod should be 50 mm and the required length of
the tapered portion is 80 mm.
o Solution
Given data:
o D = Major diameter of the workpiece = 80 mm
o d = Minor diameter of the workpiece = 50 mm
o L = Length of the workpiece to be tapered = 80 mm

Put the above values in the equation

The compound rest should be swiveled at 10.62o.

Taper turning by
taper attachment

The principle of turning by a taper

attachment is to guide the tool in a
straight path set at an the axis of
rotation of the work piece, while the
work is being between centers or by
a chuck aligned to the lathe axis.
A taper attachment illustrated in
Figure.
It consists essentially of a bracket
(1) which is attached to the rear
end of the lathe bed and supports a
guide bar pivoted at the centre.
The bar having graduations in
degrees swiveled on either side of
the zero graduation and is set at
the angle with the lathe axis.

Taper turning by
taper attachment
When the taper turning
attachment is used, the
cross slide (4) is made free
from the lead screw by
removing the binder screw
(5).
The rear end of the cross
slide is then tightened with
the guide block by means
of bolt.
When the longitudinal feed
is
engaged,
the
tool
mounted on the cross slide
will follow the angular path,
as the guide block (2) will

Taper turning by
taper attachment
The required depth of cut is
given by the . compound
slide which is placed at right
angles to the lathe axis.
The bar must be set at half
taper angle and the taper on
the
work
converted
in
degrees.
The maximum angle through
which the guide bar may be
swiveled is 100to 12on
either side of the centre line.

Advantages of Taper turning by

taper attachment
The alignment of live and dead centers being not
disturbed, both straight and taper turning may be
performed on a work piece in one setting without
much loss of time.
Once the taper is set, any length of piece of work
may be turned taper within its limit.
Very steep taper on a long work piece may be
turned, which can not be done by any other
method.
Accurate taper on a large number of work pieces
may be turned.
Internal tapers can be turned with ease.

Taper turning by
combining feeds
As shown in fig, this is a
more specialized method
of turning taper.

In certain lathes both

longitudinal
and
cross
feeds may be engaged
simultaneously
causing
the tool to follow a
diagonal path which is the
resultant of the magnitude
of the two feeds.
The
direction
of
the
resultant
may
be
changed
by

TYPES OF LATHE

Bench lathe
Speed lathe
Centre or engine lathe
Tool room lathe
Capstan and turret lathe
Special purpose lathe
Automatic lathe

Types of lathe

Bench lathe-small portable size,used for small and precision

work
Speed lathe-it has no feed box, lead screw or conventional
type of carriage.used where cutting force is least like
Wood working
Spinning
Centering
Polishing
Engine lathe-contains additional mechanism for driving
Tool room lathe-similar to engine lathe and used for
precision work on tools, dies, gauges where accuracy
needed.

 Special purpose lathe Wheel lathe-finishing the journal and turning the threadon
car and locomotive
Gap bed lathe-swing extra large piece diameter
Duplicate lathe-duplicating the shape of flat or round
templates
T-lathe-for machining of rotor for jet engines

Automatic lathe-all working and job handling are done

automatically. These are high speed heavy duty mass
production lathes.

Capston and turret lathes

It is different from the engine lathe in the following respects:
They do not have a tailstock.
They carry a much larger no and variety of tools than the
engine lathe.
The tool travel can be preset for each tool, so that the tool
advances always upto the preset distance.
More than one tool may be set to operate simultaneously.
The head stock of these machines generally possesses a
much wider range of speed and heavier in construction
than engine lathe.
The tool post holds four tools .There is also a rear tool post
on which cut off parting tool is mounted.

Parts of capston and turret lathe

Capston and turret lathe

Both lathes are provided with another tool head called turret
which can accommodate six or more tools that are used in
sequence.
The tool turret is mounted directly on the saddle and feed is given
by moving the entire unit.
The tools required for machining a job are mounted in sequence
on the face of turret and the turret move to the work piece
manually or by power feed.
The length of travel of each tool is preset with help of stops or
feed trips
As one tool travelled the preset distance an automatic trip lever
stops further movement and turret returned to starting position
the next tool come for machining.
Each tool controlled by its own stops. No of machining can be
done at the same time.

Work holding devices

Jaw chucksself centering chuck
Independent chuck
combination chuck
air operated chuck.
Collet chuckspush out type
Draw in type
Dead length type

Tool holding devices

The tool holders may be mounted on turret
faces or on the cross slide tool post.In this case
tool is designed according to the tool holder.
Commonly used tools are
Box tool holder
Flanged tool Holders
Slid tool holders
Adjustable turning head
Threading Die head
Quick acting slide holder.

Tool holding devices

Box tool holderUsed for turning more than one diameters. Box type tools
are provided with rollers or V-supports to support the work.
These are also known as Balanced tool holders
Flanged tool holderUsed to hold tools like drills ,taps etc.Tools are mounted
in the socket which is fixed in the flanged tool holder with
suitable screw.
Slide tool holderIt consists of a base on which a slide is fitted Slide is
clamped to the base for boring and turning operation.The slide
supports boring bar in a hole for grooving boring etc on it and
another hole for turning.

Tool holding devices

Adjustable turning headIt is a multiple turning head which can accommodate a
no of turning tool heads, boring bars,drills.No of operations
can be done simultaneously.Head supported on the turret
face by bolts.Pilot bars provided for additional support.
Threading die headUsed for cutting external threads on bar stocks. After
the turret has covered the desired distance both the die
head and turret come back to the starting position without
unscrewing.For internal threads collapsible taps may used.
Quick acting slide tool holder- It is the slide holder
designed for quick operation and limited travel of the slide
which is controlled by lever and lever is controlled by stops.

Advantages of capston & 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

Difference between capston

and turrent lathe
Capstan lathe
1. The turret is mounted on ram
which slides on saddle
The travel of turret depend
upon the distance covered by
ram. This limits the maximum
length of work to be machined .
2. Ram feeds into the work, the
overhanging of the ram from
the stationary saddle presents a
non rigid construction subject to
bending, deflection or vibration
under heavy cutting load.
3. Suitable for bar work.

Turret lathe
1. The turret directly mounted on the
saddle which slides on the bed.
So it moves on entire length of
bed and can machine longer work.
2. The turret is mounted on the
saddle which slides directly on
lathe bed ways .It provides rigidity
to tool .

3. Larger and heavier chucking works

are usually handled.

4. The hexagonal turret

can move easily
without saddle. As it
is hand operated
light and fast cuts
can be done. The
cuts are sensitive
and less fatigue.
5. Crosswise movement
is not possible.

4. The hand feeding is a

laborious process due to the
movement of entire saddle.

5. Some turrets can be

crosswise in this case which
enables turning of large
diameters,facing,counter
turning etc.

ASSIGNMENT-2
1. How a lathe is specified ? Discuss.
2. What is the function of lathe ? List various types of lathe .
3. What is mandrel ? Where it is used ? List different types
of mandrel.
4. What are the feed mechanisms used in lathe ?
5. What are the different types of centres used in lathe ?

ASSIGNMENT-3
1.
2.
3.
4.
5.
6.

Distinguish rough and finish turning.

Define taper ? How is the amount of taper expressed ?
What is a thread chaser ? Describe.
What is spinning ? Sketch and describe.
How turning tools are classified ?
What are the differences between capstan and turret
lathes.
7. List the various tool holding devices used in Capstan and
turret lathes.