Professional Documents
Culture Documents
Manually operated
Capstan and Turret Lathes
Used in mass production
Semi automatic
Wide range of operations can be performed
Capstan and Turret lathe which have multiple tools mounted
on turret either attached to the tailstock or the cross-slide,
which allows for quick changes in tooling and cutting
operations.
Used when many duplicate parts
required
Equipped with multisided tool post
(turret) to which several different
cutting tools mounted
Employed in given sequence
Component Description
Main driving
Speed clamp
pulley ram
gearbox
Head stock Dead centre
Tail stock
Tool post
Lathe
Half nut Apron box bed
carriage
Feed gear
box
Lathe parts
• Bed
• Headstock
• Tailstock
• Carriage
Lathe parts contd.
Bed-
• Base of the lathe
• To remove the dead centre or any other tool from the spindle, the
hand wheel is rotated in anticlockwise direction further. The
movement of the spindle inside the hole may be locked by
operating the spindle clamp located on top of the tailstock. In
order to hold work pieces of different lengths, the tailstock can be
locked at any desired position on the lathe bed. Tailstock clamping
bolts are used for this purpose.
D1 D2
d Depth
of Cut
Feed
f – the distance the tool advances for every rotation
of work piece (mm/rev)
D1 D2
f
Feed
Feed
t= minute
Problem -1
A mild steel rod having 50 mm diameter and 500 mm length is to be turned
on a lathe. Determine the machining time to reduce the rod to 45 mm in one
pass when cutting speed is 30 m/min and a feed of 0.7 mm/rev is used.
Solution
Given data:
D = 50 mm,
Lj = 500 mm
v = 30 m/min,
f= 0.7 mm/rev
Substituting the values of v and D in
V = ΠDN/1000 m/min
Required spindle speed as: N = 191 rpm
A cylindrical stainless steel rod with length L=150 mm,
diameter D0 = 12 mm is being reduced in diameter to
Df =11 mm by turning on a lathe. The spindle rotates
at N = 400 rpm, and the tool is travelling at an axial
speed of υ=200 mm/min
Calculate:
a. The cutting speed V (maximum and minimum)
b. The depth of cut and the cutting time t
Chuck Workpiece
d
Machined
Face
Cutting
speed Depth of
cut
Tool Feed
Facing ..
• Machining at the end of job Flat surface
or to Reduce Length of Job
• Turning Tool
• Feed: in direction perpendicular to work-piece
axis
• Length of Tool Travel = radius of work-piece
• Depth of Cut: in direction parallel to work-piece
axis
• Rough facing: Cross feed-0.5-0.7mm & DOC- up
to 5mm
• Fine facing: C.F-0.1-0.3mm & DOC-0.5mm.
Knurling
• Produce rough textured surface
– For Decorative and/or Functional Purpose
• Knurling Tool
• Handles of many components, instruments and
tools, gauges and heads of small screws etc.,
are usually provided with rolled depressions on
them to provide a better grip in comparison to
a smooth surface.
• The indentation –KNURLS
• Surface – KNURLED
• The operation performing these knurls-
KNURLING
Knurling
Knurled surface
Cutting
speed
Feed Movement
for depth
Knurling tool
Tool post
Grooving
• Produces a Groove on
workpiece
• Shape of tool shape of
groove
• Carried out using Grooving Tool
A form tool
• Also called Form Turning
Grooving ..
Shape produced
by form tool Groove
Feed or Grooving
Form tool depth of cut tool
Parting off or cutting off
• It is the operation employed for cutting away
a desired length from the bar stock.
• Parting Tool – similar to square grooving tool
but have a longer point(to reach the center of
the job)
• Feed- Cross feed
Parting ..
Feed
Parting tool
Chamfering
Beveling sharp machined edges
Similar to form turning
Chamfering tool – 45°
• Avoid Sharp Edges
• Make Assembly Easier
• Improve Aesthetics
Drilling
90°
D1 D2
B C
A
D1= larger diameter of taper in mm L
D2= smaller diameter of tapered in mm
L= length of tapered part in mm
2α= full taper angle
α=angle of taper or half taper angle
The common methods of expressing the taper are.
1.Taper per foot: the difference in inches of
end diameters per foot length of the job.
2. Taper per inch: the difference in inches of
end diameter per inch length of the job
3. Taper 1 in X: For this units should be
uniform, such as a taper 1 in 20 means either
a taper of I inch on 20 inches or a taper of 1
Foot over a 20 feet length.
• From the geometry
tanα=
Methods
Form Tool
Swiveling Compound Rest
Simultaneous Longitudinal and Cross
Feeds
Taper Turning Attachment
Tailstock set over
Taper turning using a form tool
Shape of the tool is remain same as the shape of
the component to be produced.
Accuracy of taper produce depends on accuracy of
taper present on tool
Width of tool must be greater than or equal to the
length of work piece to be taper turned.
Maximum length of component which can be
taper turned is 20 mm( small lengths) only
Only external taper turning is possible.
• Limitation-
This method is limited only for short length
taper. Because the metal is removed by the
entire cutting edge, and only increase in the
length of the taper will necessitate the use of a
wider cutting edge. This will require excessive
cutting pressure, which may distort the work due
to vibration and spoil the work piece.
Taper turning by swiveling the compound rest
• The compound rest has a circular base graduated in
degrees, which can be swiveled at any angle.
• While turning a taper, the base of compound rest is
swiveled through an angle equal to the half taper angle.
The tool is then fed by hand.
• 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.
• 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.
1. calculate the compound rest angle for turning short
taper of 1:16.
sol.
Let α be the angle at which the compound rest will be set
Dd 1
tan α =
2l 2 16
1
tan 1.91 Ans.
1
0
32
3. Calculate the compound rest angle to turn a
short taper of 1mm per 12mm.
Dd 1
tan 0.04167
2l 2 12
2.3860 Ans
4. Determine 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.
Solution
Given data: D1 = 80 mm, D2 = 50 mm, Lj = 80 mm (with usual
notations)
tan = (80-50) / 280 or = 10.620
1 1
tan
2 25 50
set over, S = L
tanα
1
300 6 mm
50
Taper turning by a taper attachment
• The principle of turning taper by a taper
attachment is to guide the tool in a straight path
set at an angle to the axis of rotation of the work
piece, while the work is being revolved between
centers or by a chuck aligned to the lathe axis.
• A taper turning attachment consists essentially of
a bracket or frame which is attached to the rear
end of the lathe bed and supports a guide bar
pivoted at the centers. The bar having
graduations in degrees may be swiveled on either
side of the zero graduation and is set at the
desired angle with the lathe axis.
• When the taper turning attachment is used, the
cross slide is first made free from the lead screw
by removing the binder screw. The rear end the
cross slide is then tightened with the guide block
by means of a bolt.
• When the longitudinal feed is engaged, the tool
mounted on the cross slide will follow the angular
path, as the guide block will slide on the gear bar
at an angle to the lathe axis.
• The required depth of cut is given by the
compound slide which is placed at right angles to
the lathe axis.
• The guide bar must be set at half taper angle and
the taper on the work must be converted in
degrees. The maximum angle through which the
guide bar may be swiveled is 10 degree to 12
degree on either side of the centre line.
• If the diameters D,d and the length L of the taper
are specified, the angle of swiveling the guide bar
can be determined from equation
tanα=
The advantage of using a taper turning attachment
are-
1-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.
2-once the taper is set, any length of a piece of work may
be turned with in its limit.
3-very steep taper on a long work piece may be turned,
which cannot be done by any other method.
4-accurate taper on a large number of work pieces may
be turned.
5-internal tapers can be turned with ease.
Q. A component having 400 mm length in which
central 150 mm length of component can be
taper turned to an angle of 4 Degree. Which of
the Taper turning Method is used for this ?
Ans: Compound and taper attachment method
s
tan 4
400
s 28 offset
,
ELEMENTS OF THREDS
• PITCH(P): It is the distance from one point on the thread to
the corresponding point on the adjacent thread.
• Major Diameter(D): It is the largest diameter of a
screwed part, measured at right angle to the axis of the
piece.
• Minor Diameter(d):It is the smallest diameter of a
screwed part, measured normal to the axis of the piece.
• Pitch Diameter(Pd): It is the Diameter of the imaginary
cylinder of which the surface will intersect the threads at
such points where the widths of the threads is equal to
the adjacent widths of the spaces between them.
• Depth of threads(t): It is the distance, measured normal
to the axis of part , between the crest and root of the
thread.
t=(D-d)/2
•Lead is the axial distance a point moves along the helix in
one revolution.
•In a single start helix, lead=pitch.
•In a multistart helix, lead=pitch x number of starts.
Thread cutting in a Lathe
• For cutting treads – For every revolution of the
spindle(work) the tool should move parallel to the axis of
the job by a distance equal to the LEAD of the screw.
• There will be a definite ratio between longitudinal feed of
the tool and the speed of the spindle.
• The desired ratio is obtained with the help of lead screw
by connecting it to the spindle through a train of gears.
• On engaging the split half nut the movement of the
carriage, and hence the tool is guided by the lead screw.
• Gear ratio= (Driver teeth/ Driven teeth)=(Speed of the
Lead screw)/(Speed of Work )=(Pitch of the screw to be
cut)/(pitch of the lead screw)
Calulate the gears for cutting the following threads on a lathe with a
lead screw of 6mm pitch.
96
Lathe Centers
97
Revolving Tailstock Centers
• Replaced solid dead centers for most
machining operations
• Used to support work held in chuck or
when work is being machined between
centers
• Contains antifriction bearings which allow
center to revolve with workpiece
– No lubrication required between center and
work
98
Revolving Tailstock Centers
99
Work Holding Devices
Three jaw chuck
For holding cylindrical stock centered.
For facing/center drilling the end of your
aluminum stock
Four-Jaw Chuck
102
Collet Chuck
Magnetic Chuck
105
Spring Collet Chucks
• Spring-collet chuck
– One form: Handwheel draws collet into
tapered adapter
– Another form: Uses chuck wrench to
tighten collet on workpiece
• Can hold larger work than draw-in type
106
Spring Collet Chucks
107
Jacobs Collet Chuck
• Jacobs collet chuck
– Utilizes impact-tightening handwheel to
close collets
– Wider range than spring-collet chuck
108
Jacobs Collet Chuck
109
Magnetic Chucks
• Used to hold iron or steel parts that are
too thin or may be damaged if held in
conventional chuck
• Fitted to an adapter mounted on
headstock spindle
• Used only for light cuts and for special
grinding applications
110
Magnetic Chucks
111
Faceplates
112
Faceplates
113
• It is usually a cast iron disc, having a threaded
hole at its centre so that it can be screwed to
the head stock spindle.
• It consists of number of holes and slots to
hold the work piece.
• A number of other things like bolts, nuts,
washers and clamping plates are for holding
the job.
Steadyrest
• Used to support long work held in chuck
or between lathe centers
– Prevent springing
• Located on and aligned by ways of the
lathe
• Positioned at any point along lathe bed
• Three jaws tipped with plastic, bronze or
rollers may be adjusted to support any
work diameter with steadyrest capacity
115
Steadyrest
116
Follower Rest
• Mounted on saddle
• Travels with carriage to prevent work
from springing up and away from
cutting tool
– Cutting tool generally positioned just
ahead of follower rest
– Provide smooth bearing surface for two
jaws of follower rest
117
Follower Rest
118
Lathe Dogs
119
Standard bent-tail lathe dog
120
Standard bent-tail lathe dog
121
Straight-tail lathe dog
122
Safety clamp lathe dog
123
Heavy Duty Lathe Dog
124
Super Quick-Change Toolpost
126
summary