SECTION H: MACHINING

The lathe is used for producing cylindrical work. The work piece is rotated while the
cutting tool movement is controlled by the machine. The lathe is primarily used for cylindrical
work. The lathe may also be used for: Boring, drilling, tapping, turning, facing, threading,
polishing, grooving, knurling etc.
The purpose of a lathe is to rotate a part against a tool whose position it controls. It is
useful for fabricating parts and/or features that have a circular cross section. The spindle is the
part of the lathe that rotates. Various work holding attachments such as three jaw chucks, collets,
and centers can be held in the spindle. The spindle is driven by an electric motor through a
system of belt drives and/or gear trains. Spindle speed is controlled by varying the geometry of
the drive train.
The tailstock can be used to support the end of the work piece with a center, or to hold
tools for drilling, reaming, threading, or cutting tapers. It can be adjusted in position along the
ways to accommodate different length work pieces. The ram can be fed along the axis of rotation
with the tailstock hand wheel.
The carriage controls and supports the cutting tool. It consists of: A saddle that mates
with and slides along the ways, an apron that controls the feed mechanisms, a cross slide that
controls transverse motion of the tool (toward or away from the operator), a tool compound that
adjusts to permit angular tool movement and a tool post T-slot that holds the tool post.

Fig 8.1 Principal components of a central

lathe

Feed, Speed, And Depth of Cut

Cutting speed is defined as the speed at which the work moves with respect to the tool.
Feed rate is defined as the distance the tool travels during one revolution of the part. Cutting
speed and feed determines the surface finish, power requirements, and material removal rate. The
primary factor in choosing feed and speed is the material to be cut. However, one should also
consider material of the tool, rigidity of the work piece, size and condition of the lathe, and depth
of cut. To calculate the proper spindle speed, divide the desired cutting speed by the
circumference of the work.

59
Parts of Lathe
Head Stock
The headstock houses the main spindle , speed change mechanism , and change gears The
headstock is required to be made as robust as possible due to the cutting forces involved, which
can distort a lightly built housing, and induce harmonic vibrations that will transfer through to
the work piece, reducing the quality of the finished work piece
Bed
The bed is a robust base that connects to the headstock and permits the carriage and
tailstock to be aligned parallel with the axis of the spindle. This is facilitated by hardened and
ground ways which restrain the carriage and tailstock in a set track. The carriage travels by
means of a rack and pinion system, leads crew of accurate pitch, or feed screw.
Feed and lead screws
The feed screw is a long driveshaft that allows a series of gears to drive the carriage
mechanisms. These gears are located in the apron of the carriage. Both the feed screw and lead
screw are driven by either the change gears or an intermediate gearbox known as a quick change
gearbox or Norton gearbox. These intermediate gears allow the correct ratio and direction to be
set for cutting threads or worm gears. Tumbler gears are provided between the spindle and gear
train that enables the gear train of the correct ratio and direction to be introduced. This provides a
constant relationship between the number of turns the spindle makes, to the number of turns the
lead screw makes. This ratio allows screw threads to be cut on the work piece without the aid of
a die.
Carriage
In its simplest form the carriage holds the tool bit and moves it longitudinally (turning) or
perpendicularly (facing) under the control of the operator. The operator moves the carriage
manually via the hand wheel or automatically by engaging the feed screw with the carriage feed
mechanism, this provides some relief for the operator as the movement of the carriage becomes
power assisted. The hand wheels on the carriage and its related slides are usually calibrated both
for ease of use and to assist in making reproducible cuts.
Cross-slide
The cross-slide stands atop the carriage and has a lead screw that travels perpendicular to
the main spindle axis, this permit facing operations to be performed. This lead screw can be
engaged with the feed screw (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 is the part of the machine where the tool post is mounted. It provides
a smaller amount of movement along its axis via another lead screw. The compound rest axis can
be adjusted independently of the carriage or cross-slide. It is utilized when turning tapers, when
screw cutting or to obtain finer feeds than the lead screw normally permits.
Tool post
The tool bit is mounted in the tool post which may be of the American lantern style,
traditional
4 sided square styles, or in a quick change style. The advantage of a quick change set-up is to
allow an unlimited number of tools to be used (up to the number of holders available) rather than
being limited to 1 tool with the lantern style, or 3 to 4 tools with the 4 sided type.
Tail Stock
The tailstock is a tool holder directly mounted on the spindle axis, opposite the
headstock. The spindle does not rotate but does travel longitudinally under the action of a lead
screw and hand wheel.

69
The spindle includes a taper to hold drill bits, centers and other tooling. The tailstock can be
positioned along the bed and clamped in position as required. There is also provision to offset the
tailstock from the spindles axis; this is useful for turning small tapers.

Fig 8.2 Different parts of engine lathe or central lathe

Lathe Operations
Turning
Turning is the machining operation that produces cylindrical parts. In its basic form, it
can be defined as the machining of an external surface:
 with the work piece rotating,
 with a single-point cutting tool, and
 with the cutting tool feeding parallel to the axis of the work piece and at a distance that will
remove the outer surface of the work.
Taper turning is practically the same, except that the cutter path is at an angle to the work axis.
Similarly, in contour turning, the distance of the cutter from the work axis is varied to produce
the desired shape
Facing
Facing is the producing of a flat surface as the result of a tool's being fed across the end
of the rotating work piece. Unless the work is held on a mandrel, if both ends of the work are to
be faced, it must be turned end for end after the first end is completed and the facing operation
repeated. The cutting speed should be determined from the largest diameter of the surface to be
faced. Facing may be done either from the outside inward or from the center outward. In either
case, the point of the tool must be set exactly at the height of the center of rotation.
Parting
Parting is the operation by which one section of a work piece is severed from the
remainder by means of a cutoff tool. Because cutting tools are quite thin and must have
considerable overhang, this process is less accurate and more difficult. The tool should be set
exactly at the height of the axis of rotation, be kept sharp, have proper clearance angles, and be
fed into the work piece at a proper and uniform feed rate.
Drilling

61
 A lathe can also be used to drill holes accurately concentric with the centerline of a
cylindrical part. First, install a drill chuck into the tail stock. Make certain that the tang on the
back of the drill chuck seats properly in the tail stock. Withdraw the jaws of the chuck and tap
the chuck in place with a soft hammer.
Move the saddle forward to make room for the tailstock. Move the tailstock into position, and
lock the bit in place. Before starting the machine, turn the spindle by hand. Just move the saddle
forward, so it could interfere with the rotation of the lathe chuck. Always use a center drill to
start the hole.
Boring
Boring is an operation in which a hole is enlarged with a single point cutting tool. A
boring bar is used to support the cutting tool as it extends into the hole. Because of the extension
of the boring bar, the tool is supported less rigidly and is more likely to chatter. This can be
corrected by using slower spindle speeds or by grinding a smaller radius on the nose of the tool.

Single Point Thread Turning

External threads can be cut with a die and internal threads can be cut with a tap. But for
some diameters, no die or tap is available. In these cases, threads can be cut on a lathe. A special
cutting tool should be used, typically with a 60 degree nose angle. To form threads with a
specified number of threads per inch, the spindle is mechanically coupled to the carriage lead
screw. Procedures vary for different machines

Fig. 8.3 Types of tool

TURNING, FACING AND CHAMFERING
 TURNING, FACING AND CHAMFERING
Ex no :
Date :

Aim:

To make the turning, facing and chamfering on the given metal work piece to get the required
dimension.

Application:

Mechanical industries

Material Supplied:

Mild steel rod of 25 mm diameter X 75mm length

Tools required:

1. Steel rule 2) Vernier caliper 3) Center lathe M/C

4. Single point cutting tool 5) Chuck key 6) Tool post key
7) Spanner 8) Cleaning brush

Sequence of Operation:

1) Checking 2) Work piece setting 3) Tool setting 4) Facing

5) Turning 6) Chamfering

Working Steps:

1) The given work piece is checked for its given dimensions

2) The work piece is hold in the three jaw chuck. Chuck key is used to tighten the job rigidly
ensuring centering of the work piece.
3) The single point cutting tool is fixed in the tool post of the lathe machine using Tool post key
and spanners. Sometimes the packing material like hacksaw blade pieces, thick sheet paper
materials can be used to set the tool appropriately pointing towards the center of the job.
4) Facing operation is done to obtain the required length of the job.
5) Turning operation is done to obtain the required diameter of the job.
 6) Chamfering is done to remove sharp edges and corners of the work piece by keeping the tool at
an angle of 45 0 to the lathe axis.
7) Finally the work piece dimensions are checked to conform to the specification given in the
drawing.

Result:

Hence the required shape and size are obtained using turning, facing and chamfering operations
on the given work piece.
Pre Lab Question:

1) What is the lathe?

2) List out the types of lathe?

3) Mention the main parts of lathe?

4) Classification of the operation?

5) List out the lathe cutting tools?

Post Lab Question:

1) List out the types of lathe chuck?

2) Mention the tool materials used in lathe?

3) Mention the tool post angle for facing, turning and chamfering process?

4) What is the facing operation?

5) Define turning operation?