Turning

Operations

Lathe
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Turning
Operations
Machine

Tool LATHE
Job (workpiece) rotary
motion
Tool linear motions
Mother of Machine Tools

Cylindrical and flat

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Some Typical Lathe

Jobs
Turning/Drilling/Grooving/
Threading/Knurling/Facing...

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The Lathe

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The Lathe
Head Stock

Tail Stock
Bed

Feed/Lead
Screw
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Carriage

Types of Lathes
Engine

Lathe
Speed Lathe
Bench Lathe
Tool Room Lathe
Special Purpose Lathe
Gap Bed Lathe

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Size of Lathe
Workpiece Length

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Swing

Size of Lathe ..
Example: 300 - 1500 Lathe
Maximum Diameter of
Workpiece that can be
machined
= SWING (= 300 mm)
Maximum Length of
Workpiece that can be held
between Centers (=1500
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Workholding
Devices
Equipment

used to hold
Workpiece fixtures
Tool - jigs
Securely HOLD or Support
while machining

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Chucks
Workholding
Devices ..

Three jaw
Jaw

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Four

Workholding
Devices ..

Centers

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Workholding
Devices ..

Faceplates

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Workholding
Devices ..

Dogs

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Mandrels
Workholding
Devices ..

Workpiece (job) with a hole

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Rests
Workholding
Devices ..

Steady Rest
Rest

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Follower

Operating/Cutting
Conditions
1.
2.
3.

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Cutting Speed v
Feed f
Depth of Cut d

Operating
Conditions

relative tool travel in 1 rotation D

peripheral speed S D N
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Cutting Speed
Operating
Conditions..

D Diameter (mm)
N Revolutions per Minute
(rpm) D N

1000

m/min

The Peripheral Speed of

Workpiece past the Cutting
Tool

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Feed
Operating
Conditions..

f the distance the tool

advances for every rotation
of workpiece (mm/rev)

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Depth of Cut
Operating
Conditions..

perpendicular distance
between machined surface
and uncut surface of the
Workpiece
d = (D1 D2)/2 (mm)

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3 Operating
Conditions

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Selection of ..
Material
Tool Material
Tool signature
Surface Finish
Accuracy
Capability of Machine Tool

Operating
Conditions..

Workpiece

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Material Removal
Rate

Operations on
Lathe ..

MRR

Volume of material removed in

one revolution MRR = D d f
mm3
Job makes N revolutions/min

MRR = D d f N

(mm3/min)
In terms of v MRR is given by
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Operations on
Lathe ..

MRR
dimensional consistency
by substituting the units
MRR: D d f N (mm)(mm)
(mm/rev)(rev/min)
= mm3/min

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Operations on
Lathe ..

Operations on
Lathe

Turning
Facing
knurling
Grooving
Parting

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Chamfering
Taper

turning
Drilling
Threading

Operations on
Lathe ..

Turning

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Cylindrical job

Operations on
Lathe ..

Turning ..

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Cylindrical job

Operations on
Lathe ..

Turning ..
Excess Material is
removed
to reduce
Diameter
Cutting Tool: Turning Tool

depth of cut of 1 mm
will reduce diameter by 2

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Operations on
Lathe ..

Facing

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Flat Surface/Reduce
length

Facing ..
machine

end of job Flat

Operations on
Lathe ..

surface
or to Reduce Length of Job
Turning Tool
Feed: in direction perpendicular
to workpiece axis
Length of Tool Travel = radius
of workpiece
Depth of Cut: in direction parallel
to workpiece axis
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Operations on
Lathe ..

Facing ..

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Operations on
Lathe ..

Eccentric Turning

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Knurling
Operations on
Lathe ..

Produce

rough textured

surface
For Decorative and/or
Functional Purpose
Knurling Tool
A Forming Process
MRR~0

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Operations on
Lathe ..

Knurling

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Operations on
Lathe ..

Knurling ..

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Grooving
a Groove on
workpiece
Shape of tool shape of
groove
Carried out using
Grooving Tool A form
tool
Also called Form Turning
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Operations on
Lathe ..

Produces

Operations on
Lathe ..

Grooving ..

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Parting
workpiece into Two
Similar to grooving
Parting Tool
Hogging tool rides over
at slow feed
Coolant use

Operations on
Lathe ..

Cutting

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Operations on
Lathe ..

Parting ..

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Operations on
Lathe ..

Chamfering

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Chamfering
Operations on
Lathe ..

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Beveling sharp machined

edges
Similar to form turning
Chamfering tool 45
To

Avoid Sharp Edges

Make Assembly Easier
Improve Aesthetics

Taper Turning
Operations on
Lathe ..

Taper:

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D1 D2
tan
2L

Taper Turning..
Operations on
Lathe ..

Conicity

D1 D2
K
L

Methods

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Form Tool
Swiveling Compound Rest
Taper Turning Attachment
Simultaneous Longitudinal and
Cross Feeds

..
By Form Tool

Operations on
Lathe ..

Taper Turning

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Taper Turning ,,
Operations on
Lathe ..

By Compound Rest

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Drilling
Operations on
Lathe ..

Drill cutting tool held in

TS feed from TS

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Process Sequence
Operations on
Lathe ..

How

to make job from raw

material 45 long x 30 dia.?

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Steps:

Operation
s
Sequence
Tools
Process

Process Sequence ..

Operations on
Lathe ..

Possible Sequences
TURNING - FACING KNURLING
TURNING - KNURLING FACING
FACING - TURNING KNURLING
FACING - KNURLING TURNING
KNURLING - FACING rkm2003

X
X
X
X

Machining Time
Operations on
Lathe ..

Turning Time
Job length Lj mm
Feed

f mm/rev
Job speed N rpm
f N mm/min

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Lj

f N

min

Operations on
Lathe ..

Manufacturing Time
Manufacturing Time

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=
+
+
+

Machining Time
Setup Time
Moving Time
Waiting Time

Example
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.

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Example
Given data: D = 50 mm, Lj = 500
mm v = 30 m/min, f = 0.7
mm/rev
Substituting
the
values
of
v
and
DN
v
m/min
D in
1000

calculate the required spindle

speed as: N = 191 rpm
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Example
Can a machine has speed
of 191 rpm?
Machining time:
t
t

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Lj
f N

min

= 500 / (0.7191)
= 3.74 minutes

Example
Determine

the angle at which

the compound rest would be
swiveled for cutting a taper on
a workpiece 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

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Example
Given

data: D1 = 80 mm, D2 =
50 mm, Lj = 80 mm (with usual
notations)
tan = (80-50) / 280
or
= 10.620
The compound rest should be
swiveled at 10.62o
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Example
A

150 mm long 12 mm
diameter stainless steel rod is
to be reduced in diameter to
10 mm by turning on a lathe in
one pass. The spindle rotates
at 500 rpm, and the tool is
traveling at an axial speed of
200 mm/min. Calculate the
cutting speed, material

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Example
Given

data: Lj = 150 mm, D1 =

12 mm, D2 = 10 mm, N = 500
rpm
Using Equation (1)

v = 12500 / 1000

= 18.85 m/min.
depth of cut = d = (12 10)/2
= 1 mm

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Example
feed

rate = 200 mm/min, we

get the feed f in mm/rev by
dividing feed rate by spindle
rpm. That is

f = 200/500 = 0.4 mm/rev

From Equation (4),
MRR = 3.142120.41500 =
7538.4
mm3/min
from Equation (8),
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Example
Calculate

the time required to

machine a workpiece 170 mm
long, 60 mm diameter to 165
mm long 50 mm diameter. The
workpiece rotates at 440 rpm,
feed is 0.3mm/rev and
maximum depth of cut is 2
mm. Assume total approach
and overtravel distance as 5

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Example
Given

data: Lj = 170 mm, D1

= 60 mm, D2 = 50 mm, N =
440 rpm, f = 0.3 mm/rev, d=
2 mm,

How

to calculate the
machining time when there is
more than one operation?

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Example
Time for Turning:
Total length of tool travel = job length +
length of approach and overtravel

L = 170 + 5 = 175 mm
Required depth to be cut = (60 50)/2 =
5 mm
Since maximum depth of cut is 2 mm, 5
mm cannot be cut in one pass. Therefore,
we calculate number of cuts or passes
required.
Number of cuts required = 5/2 = 2.5 or 3
(since cuts cannot be a fraction)

time for one cut = L / (fN)

Machining
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Example
Time

for facing:

Now, the diameter of the job

is reduced to 50 mm. Recall
that in case of facing
operations, length of tool
travel is equal to half the
diameter of the job. That is, l =
25 mm. Substituting in
equation 8, we get

t = 25/(0.3440)
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Example
Total

time:

Total time for machining =

Time for Turning + Time for
Facing

= 3.97 +
0.18

= 4.15 min.
The reader should find out the
total machining time if first
facing is done.
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Example
From

a raw material of 100 mm

length and 10 mm diameter, a
component having length 100
mm and diameter 8 mm is to
be produced using a cutting
speed of 31.41 m/min and a
feed rate of 0.7 mm/revolution.
How many times we have to
resharpen or regrind, if 1000
work-pieces are to be
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Example
Given

D =10 mm , N = 1000
rpm, v = 31.41 m/minute
From Taylors tool life
expression, we have vT n = C
Substituting the values we get,
(31.40)(T)1.2

= 180
or T = 4.28 min

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Example
time/piece = L / (fN)

= 100 / (0.71000)

= 0.142 minute.
Machining time for 1000 workpieces = 1000 0.142 =
142.86 min
Number of resharpenings =
142.86/ 4.28

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= 33.37 or 33 resharpenings
Machining

Example
6:
While turning a carbon steel
cylinder bar of length 3 m and
diameter 0.2 m at a feed rate of
0.5 mm/revolution with an HSS
tool, one of the two available
cutting speeds is to be selected.
These two cutting speeds are 100
m/min and 57 m/min. The tool life
corresponding to the speed of 100
m/min is known to be 16 minutes
with n=0.5. The cost of machining
time, setup time and unproductive
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time together is Rs.1/sec. The cost

Example
Given T1 = 16 minute, v1 = 100
m/minute, v2 = 57 m/minute, D =
200mm, l = 300 mm, f = 0.5 mm/rev

Consider Speed of 100 m/minute

N1 = (1000 v) / ( D) =
(1000100) / (200) = 159.2 rpm

t1 = l / (fN) = 3000 / (0.5

159.2) = 37.7 minute

Tool life corresponding to speed of

100 m/minute is 16 minute.
Number of resharpening required =
37.7 / 16 = 2.35

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Example
Total

cost =
Machining cost + Cost of
resharpening Number of
resharpening

= 37.7601+
202

= Rs.2302
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Example
Consider

Speed of 57 m/minute

Using Taylors expression T2 =

T1 (v1 / v2)2 with usual
notations

= 16 (100/57)2
= 49 minute
Repeating the same procedure
we get t2 = 66 minute, number
of reshparpening=1 and total
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Example
Write

the process sequence

to be used for
manufacturing the
component
from
raw material of 175 mm length
and 60 mm diameter

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Example

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Example
To write the process sequence, first
list the operations to be
performed. The raw material is
having size of 175 mm length and
60 mm diameter. The component
shown in Figure 5.23 is having
major diameter of 50 mm, step
diameter of 40 mm, groove of 20
mm and threading for a length of
50 mm. The total length of job is
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160mm. Hence, the list of

Example
A

possible sequence for

producing the component would
be:
Turning (reducing completely to
50 mm)
Facing (to reduce the length to
160 mm)
Step turning (reducing from 50
mm to 40 mm)
Thread cutting.
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